Performing Automated Ultrasound Testing of Pipes

Performing Automated Ultrasound Testing of Pipes
"Due to Planet NI’s involvement, we were able to
use LabVIEW and X Series hardware to deliver an
optimum solution that met all requirements and
regulations. Our customer saved more than 45
percent and has seen zero site issues."
- Harish Ganapathy, IQC Advanced Inspection Solutions Pvt Ltd (
http://partners.ni.com/partner_locator/partner_details.aspx?id=90975)
The Challenge:
Overcoming major equipment cost barriers to design and test high-tech electronic devices in India. Integrating multiple subsystems with long cables
in a noisy electrical environment that can acquire ultrasound data synchronized with the position encoders while tracking clean contact with the test
pipe, which may have surface features and ovality effects.
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Case Study
The Solution:
Collaborating with the Planet NI program to develop the Automated Ultrasound Testing of Pipe (AUToPipe) system, which consists of NI LabVIEW
system design software, NI X Series devices, and motion control hardware.
Author(s):
Harish Ganapathy - IQC Advanced Inspection Solutions Pvt Ltd (http://partners.ni.com/partner_locator/partner_details.aspx?id=90975)
Sriram N - IQC Advanced Inspection Solutions Pvt Ltd (http://partners.ni.com/partner_locator/partner_details.aspx?id=90975)
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IQC Advanced Inspection Solutions (IQCAIS) is part of the IQC Group, which provides automated nondestructive testing (NDT) solutions in ultrasound,
eddy current, acoustic emission, infrared, and other technologies. IQC Group specializes in training, certification, services, and consulting in NDT, welding
inspection, quality management, residual life analysis, and third-party inspection. IQCAIS started in 2007 to create product-based solutions that help the
manufacturing industry deliver ever-increasing production volumes with the highest quality.
Overview
The key aspects of the Automated Ultrasound Testing of Pipe (AUToPipe) solution included the integration of multiple subsystems with long cables in a
noisy electrical environment. Also, the system needed to acquire ultrasound data synchronized with the position encoders while tracking clean contact with
the test pipe, which may have had surface features and ovality effects. Millions of A-scan data points stored in a data file had to be processed into a
simple, intuitive, color-coded image file to assist with go/no-go decisions by an expert.
The customer challenged us to design a solution to meet all regulatory petroleum industry requirements while retaining the flexibility to customize the user
interface, retain test process reliability, and rapidly test pipes with significant ovality, warping, and surface roughness that are up to 12 m long and have a
700 mm diameter with a defect detection threshold of 1 mm.
The integration of an ultrasound signal chain in an ideal environment is a significant challenge, even if the sensor-to-test-pipe coupling (material contact) is
assumed to be ideal and stable. In this case, the test pipe surface was rough with appreciable ovality (eccentricity about the rotation axis) and warping
(deviation along rotation axis), which posed an even bigger challenge.
AUToPipe consists of a computer with integrated multiplexed ultrasonic sensors and NI data acquisition devices, interface electronics to link the
subsystems, ultrasonic sensors, and cables. A specially designed dual-spring probe head tracks the pipe surface to account for pipe warping and ovality
so that the sensor can collect valid data and overcome minor motion deviation (surface roughness) and major motion deviation (ovality) while moving in a
cylindrical helical pattern at moderate speeds. We set the helical pattern and ultrasonic data acquisition parameters so that each volumetric element of the
pipe is measured multiple times to further ensure that valid data is not lost because of pipe motion artifacts. We designed the normal and shear probes to
maintain a water column to ensure proper acoustic contact with the pipe surface. The motion electronics control the pipe and probe head macromotion
with high-precision, heavy-duty motion components for pipe handling mechanisms, including water cooling circuits for coupling.
Results
We used the LabVIEW system design approach with NI X Series hardware, motion control cards, and cables to deliver an optimum solution that met all of
the requirements and regulations. The customer saved more than 45 percent compared to alternative solutions and has had no site issues. The customer
can now rapidly and reliably inspect a full 12 m pipe with defect detection assurance. The customer sales organization can also provide easy access to
test and report data to its customers, demonstrating its commitment to quality and enhancing value.
In turn, this project provides us with the basis to achieve more aggressive targets in the NDT solution space. We are now poised to release products for
eddy current, ultrasound, infrared, and acoustic emission testing with the confidence that our technology base is very sound. The support of our partners,
including NI, has been pivotal in getting to this important milestone after nearly five years of hard work.
The Benefits of Working with the Planet NI Program
Having the Planet NI program on our side helped to broaden our efforts. We were able to try out different LabVIEW modules, which helped us reach a
solution faster. While we would have been able to complete the product without the involvement of Planet NI, it would not have been so technically
efficient. Also, we found it difficult to get financial approval for software in India, so the Planet NI program really helped.
In addition, this was our first major project. In an economy such as India’s, funding sources, be it private ventures or myriad government options, are
easier to tap into once there is some proof of concept. After showing the AUToPipe system to investors, we gained enough funding to create a variety of
lower-cost products. Essentially, the money and goodwill generated by this project helped us to hire good people and perform research for about 18
months. We could not have released a range of state-of-the-art products for eddy current, a different technology than ultrasound, in 2012 without the
Planet NI program’s assistance.
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Editor Contact:
Anita Shekhar
National Instruments
Email: [email protected] (mailto:[email protected])
Author Information:
Harish Ganapathy
IQC Advanced Inspection Solutions Pvt Ltd (http://partners.ni.com/partner_locator/partner_details.aspx?id=90975)
India
Figure 1. AUToPipe System Architecture
Figure 2. Ultrasound User Interface With Alarm Information and A-Scan Data
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Figure 3. Processed C-Scan Image with Single-Color Intensity Map (Depth)
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Figure 4. Filtered C-Scan Image With Features Added
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Figure 5. Report With Color-Coded Images
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Figure 6. Mr. Harish Ganapathy, Advanced Inspection Solutions, Chennai, India
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