GE Weld Inspection GE焊接检验

GE Measurement & Control Integrity, safety & productivity through non-destructive testing solutions from GE’s Inspection Technologies business DATA INFORMATION KNOWLEDGE DECISION Weld Inspection 2 Weld Inspection Overview A leading innovator for inspection solutions, GE delivers accuracy, productivity and safety to customers in a wide range of industries, including oil & gas, power generation, transportation and infrastructure. Inspection Technologies advanced non-destructive testing (NDT) and imaging technologies utilize the electromagnetic, radiographic, ultrasonic or visible energy spectrum to examine a wide range of components. With extensive depth and breadth of knowlegde, GE can help with a wide variety of specific application needs. Weld Inspection Welding is an essential manufacturing process performed in almost every major industry. Therefore, weld quality and integrity are critical to safety in an extremely wide range of products and structures. Inspecting welds can also reduce costs by detecting discontinuities in the early stages of manufacturing, reducing the cost of rework and extending the life of components by detecting and correcting flaws. NDT methods can identify cracking, porosity, incomplete penetration, misalignment, inclusions, lack of fusion and similar conditions, which can compromise weld strength. Multi-disciplinary Offering • Ultrasonic flaw detectors and angle-beam transducers are commonly used for weld inspection and are mandated by many welding codes and procedures. Phased Array technology adds additional perspective to the image thereby simplifying interpretation of the test results by creating cross-sectional pictures of a weld, as well as offering beam-steering and dynamic-focusing capability. • Radiographic solutions range from traditional X-ray generators and film to newer technologies such as Computed Radiography (CR), Direct Radiography (DR) and 3D Computed Tomography (CT). • Electromagnetic Testing includes recent developments in 2D Eddy Current arrays and imaging of weld surfaces. • Remote Visual Inspection, and the newer measurement techniques it brings, can significantly enhance weld inspection for many applications. GE’s Inspection Technologies business offers a comprehensive selection of testing and inspection capabilities and other products for industrial weld inspection applications. Our strength lies in the use of field experience and customer feedback to build productive inspection products. With a broad complement of non-destructive testing methods, our customers can be confident they are getting an optimized solution to meet their weld inspection needs. DATA INFORMATION KNOWLEDGE DECISION GE’s NDT technologies help to collect important data and convert it into useful information. Coupled with historical plant data, intelligent software, image enhancement, databasing, applicable codes and additional knowledge, better informed decisions regarding weld integrity can be made. 3Weld Inspection On the cover IN THIS GUIDE Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Application Solutions Oil & Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 5 Power Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 7 Aerospace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ship Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Product Solutions Multi-Inspection Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 — 13 Ultrasonic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 — 17 Electromagnetic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remote Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Radiographic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 — 25 Software Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 — 27 Weld Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 — 33 Codes, Standards, Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 — 39 Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover 1 2 3 4 5 6 RVI of ultra-pure pipe I.D. weld Conventional Ultrasonic Weld Inspection A-Scan Phased Array ultrasonic weld imaging 3D Computed Tomography (CT) of weld standard Electromagnetic Testing of weld surface 2D Digital Radiograph of failed butt weld joint 4 Weld Inspection Oil & Gas Application Solutions The reliability and safe operation of Oil & Gas infrastructure is heavily dependant on the structural integrity of its welded joints. The quality of these joints must be assessed from the pipe mill and fabrication yard to the end of the operating life of the pressure vessel or piping system. GE’s Inspection Technologies business continually strives to provide multi- disciplinary weld inspection solutions, whatever the application, whether onshore or offshore, in the field or in the factory. 5Weld Inspection Upstream Midstream Downstream Directional and crawler- compatible panoramic X-ray systems for pipeline girth-weld projects. Inspection systems using the latest Phased Array ultrasonic technology at a pipe mill. Weldstar is an automated ultrasonic inspection system for onshore or offshore pipeline girth-weld inspection using Phased Array and TOFD. Ca-Zoom PTZ cameras are used for downstream checks of refinery towers and storage tanks, avoiding manned entry. USM GoTM is a small, light and easy to use manual UT flaw detector effective for everyday use and difficult-to- access applications. In-service welds can be examined with Electromagnetic Testing technology using the WeldScan ECT probe and instrument. 6 Weld Inspection Power Generation Application Solutions In the power generation sector, reliable and accurate non-destructive testing of welds and integrity assessment of boiler tubes are both essential in order to maximize efficiency, minimize downtime and improve productivity. GE’s Inspection Technologies business offers a wide portfolio of support services and solutions for inspecting pipes, tubes and vessels, in manufacture, pre-service and in-service. These solutions use a variety of technologies to ensure that the inspection technique best matches the application, and finds application in fossil-fuel and nuclear stations as well as gas turbines, wind and hydro-electric assets. 7Weld Inspection Fossil Fuel Nuclear Renewables Digital Radiography for boiler pipe inspection at manufacturing stage as well as for in-service inspection. RVI video borecope image of weld inspection and sizing in a gas turbine. Manual Phased Array UT inspection of a weld using PhasorTM XS and dual PA transducers. PTZ camera and crawler for visual weld inspection on reactor head control rod guide tubes. Semi-automated UT inspection using USM VisionTM for wind tower weld inspection. Nacelle weld inspection with Phased Array UT flaw detector: PhasorTM XS. 8 Weld Inspection Airframe Manufacturing Engine Manufacturing Maintenance, Repair & Overhaul Small welded tube inspection with digital X-ray flat panel. Laser beam or friction stir weld inspection with PhasorTM XS. Aircraft engine inspection using the XLG3TM video borescope, an RVI solution. RVI of weld I.D. in fuel-supply lines. GE DXR 500 digital detector array for weld inspection. EC and EC Array blisk inspection (i.e.EC Array film for EC probe). Aerospace Application Solutions 9Weld Inspection Body Shell Engines Safety Parts & Drivetrain Ultrasonic inspection of spot welds using SpotChecker flaw detector. Microfocus CT slice across a 1 mm (0.039”) diameter weld. Visual inspection of difficult-to-access areas using video endoscopes. Fully automatic ultrasonic inspection of bonds in pistons and valves. Automatic 2D X-ray inspection of laser welds in safety parts. Microfocus CT slice across a laser weld interconnecting two inconell tubes with a steel cylinder. Automotive Application Solutions 10 Weld Inspection Rails Locomotives Rail Cars Ultrasonic inspection of butt welds using a roller probe. STH 1 is an ultrasonic rail testing system used to inspect rail welds (flash butt welds, alumino thermic welds) for discontinuity perpendicular to the rail surface. Inspection of draw gear butt welds using UT flaw detectors. Digital radiography weld inspection during construction of boogies. Internal remote visual inspection of liquid-carrying rail car. PTZ camera image showing tank car interior details. Rail Application Solutions 11Weld Inspection Fabshop Welds Field Welds Propulsion Systems Phased Array weld inspection provides improved probability of detection and productivity. USM VisionTM weld inspection solution for new process pipework fabrication inspection which eliminates downtime resulting from X-ray methods. Completely light-tight, air-tight and moisture proof Pb VACUPACTM film can be used for field weld inspection. In-service radiographic inspection with the Eresco MF4 X-ray generator. trueDGSTM probes offer increased accuracy in discontinuity sizing. USM GoTM is a light weight and portable ultrasonic flaw detectors offering ease of use to detect, position and size discontinuities in welds. Ship Building Application Solutions 12 Weld Inspection Asset Life-Cycle Weld Inspection with Multi-Inspection Solutions Project Planning Rhythm Software Manufacturing EPC Asset Owner Fabricator EPS/OEM Inspection Acquire Service Provider Acceptance Review Archive Service Provider Certification Bodies Asset Owner Long-Term Storage Asset Owner New Project Construction ArchiveInterpretation & Decision Remote VisualRadiography Ultrasonic Electromagnetic Testing Weld inspection can be carried out using different NDT methods . GE offers multi inspection solutions for new project construction as well as for most project maintenance . 13Weld Inspection Archive Inspection/Repair Acquire Interpretation & Decision Acceptance Review Archive Long-Term Storage Post Project Maintenance Remote VisualRadiography Ultrasonic Electromagnetic Testing 14 Weld Inspection Ultrasonic Testing (UT) Ultrasonic techniques have been used in non-destructive testing for over 65 years, and apply to industrial applications requiring internal defect detection and sizing, including the inspection of welds . Conventional Flaw Detectors Portable flaw detectors and angle-beam transducers are commonly used for weld inspection and are mandated by many welding codes and procedures. Automated Girth-Weld Inspection System Combining the benefits of both conventional and Phased Array ultrasonic techniques, the complete system approach offers automated ultrasonic inspection, from job setup to data archiving. USM GoTM is a light weight and portable ultrasonic flaw detector used to detect, position and size flaws in welds. PhasorTM displays a cross section of the weld and allows the operator to display the A-scan associated with the optimum inspection angle. The girth-weld pipe tester Weldstar has the ability to adjust for pipe diameters as small as 150 mm (6 inches). Phased Array Flaw Detectors Phased Array technology simplifies result interpretation by creating cross-sectional and top view pictures of the weld. Beam-steering and focusing capability of Phased Array are key in enhancing resolution for challenging applications, resulting in faster weld inspections and better probability of detection. 15Weld Inspection The USM VisionTM portable ultrasonic weld inspection system can be used in situations conventionally requiring radiography. The intuitive user interface and integration of the RhythmTM Software platform optimizes available skills to achieve accurate and meaningful inspection results. It now has parallel-scanning capabilities, effectively doubling productivity. Prepare All that is required is to describe the inspection task, and enter the basic information such as site location, number of welds, pipe diameter, thickness and material, weld preparation, procedure and method to be used. The software will then calculate and generate all the UT set-ups required to perform TOFD and/or Phased Array inspection of the welds. Collect The inspection data for each weld is simply acquired by following the inspection plan and the different TOFD and PA passes calculated by the IPC (Inspection Plan Creator). After each pass the software will propose the next weld or pass to be inspected helping the operator to use the best, most productive inspection plan. Analyze All inspection data is communicated to an analysis station using the DICONDE-compliant Rhythm software platform. Here, the suitably qualified ultrasonic inspector can review and analyze the inspection data, utilizing advanced analysis tools such as real time, volume- corrected imaging, as well as conventional digital tools features for image analysis, enhancement and measurement. USM VisionTM A total weld inspection solution to increase productivity in new process pipework fabrication 16 Weld Inspection Ultrasonic Testing Machines Testing machines are integrated into production lines and are used to test a wide range of tubes and pipes . From small diameter, cold finished, seamless tubes (power plants or automotive industry) to large-diameter, heavy wall thickness, hot-rolled seamless tubes (casing and drill pipe and welded tubes for oil and gas pipelines) . UT Phased Array Phased Array technology can be applied for all kinds of seamless and welded pipes (HSAW, LSAW, ERW). Single-crystal probes are replaced by multi-element probes with corresponding electronics. Phased Array technology supports a better probability of detection (POD) and an easier probe adjustment as a precondition for repeatability of testing results. By applying the ultrasonic Phased Array technology, different testing zones and angles can be created by electronic parameter setting. It is also possible that one Phased Array probe is used instead of multiple probe arrangements with complex mechanics. UT LSAW (Longitudinal submerged-arc welded) The plates for longitudinally welded pipes are typically tested in the plate mill. The weld is tested first time right after the last welding step and before mechanical expansion. The final inspection, defined by the end-user specification, is carried out after the hydrostatic test. Different probe arrangements in single probe mode or in tandem configuration are positioned adjacent to the weld or on the weld bead to detect longitudinal, transverse and lamination-type flaws in the heat-affected zone. Flaw evaluation and data processing is the same as for HSAW pipes. UT HSAW (Helical submerged-arc welded) The base material for spiral-welded pipes is tested as strip before the forming rolls or at the tube after welding. The in-line weld testing takes place right after the welding and before pipe expansion. The final inspection, defined by the end-user specification, is carried out after the pressure test. Different probe arrangements adjacent to the weld and on the weld bead, are used to detect longitudinal and transverse flaws as well as lamination type flaws in the heat-affected zone (HAZ). All imperfections where the echo exceeds the adjusted threshold are processed automatically for flaw marking. Testing results are recorded in digital format and can be transferred to any second-level computer network. Automated inspection of tubes and pipes 17Weld Inspection UT/EC ERW (Electrical Resistance Welded) The base material for ERW pipes is tested as strip before the forming stands. In a later phase the complete pipe body is tested similarly to a seamless pipe testing. The weld is tested in-line and after the welder or after the sizing stands because the pipe geometry can have an influence on the inspection. Typically probes are positioned adjacent to the weld for testing of longitudinal flaw orientations. The number of probes used depends on the thickness. In a later phase the complete p