Ultrasonic on Line Inspection System for ERW, SAW Tube

Specifications

The ERW, SAW tube In-Line inspection system uses multichannel technology to inspect weld seam and the heat-affected zone (HAZ)..

Off line / On Line Inspection system for ERW, SAW Tube

 

ERW, SAW Tube In-Line Inspection System

The ERW, SAW tube In-Line inspection system uses multichannel technology to inspect weld seam and the heat-affected zone (HAZ) of electrical resistance welded (ERW, SAW) tubes. The head rotation capability allows each probe independent movement from -120 to +120 degrees for weld tracking.

 

Product Range and Inspection Speed
Diameter	60 mm to 245 mm (2.375 in. to 9.625 in.)
Wall Thickness	3 mm to 16 mm
Inspection Speed	Up to 1.0 m/s (295 ft/m)
Inspection Coverage
Weld Sector Coverage	At least 25 mm for entire product range (adjustable)
Axial Pulse Density (APD)	1 mm (adjustable)
Weld tracking capacity	-90º to +90º

 

Data Presentation
Real-time inspection result	C-scan, strip charts, and alarms
Parameter setup	A-scan, B-scan
Inspection Modes
Typical Inspection Modes	45º, 60º, 70º (typical inspection configuration:  45º pulse-echo mode and 45º pitch-catch mode)
Firing Modes	Pulse-echo, pitch-catch

 

Detection Capabilities for Typical Reference Defects
API References	1/2 in./1 in. (12.7 mm/25.4 mm) N10 and N5, ID and OD longitudinal notches  1/8 in. (3.2 mm) through drilled hole (TDH)  1/16 in. (1.6 mm) TDH
Non-API References	1/32 in (0.8 mm) TDH  1/8 in. (3.2 mm) half wall drilled hole  1/16 in. (1.6 mm) half wall drilled hole  1/32 in. (0.8 mm) half wall drilled hole
Minimum SNR	9 dB to 12 dB
Repeatability	LID/LOD notches: ≤ 1.5 dB  1/8 in. (3.2 mm) TDH : ≤ 2.0 dB  1/16 in. (1.6 mm) TDH : ≤ 2.5 dB
Reporting and Data Storage
Report types	Inspection, calibration, and calibration-check user-configurable reports
Storage	Real-time database inspection data storage

 

 In-line Testing Machine

 

The SOLID mechanical solution for ERW, SAW tube inspection is based on a small automated bridge (gantry type) that positions the inspection head in-line or off-line when performing inspections, automatic calibrations, or maintenance operations.

 

 

Calibration Bench

 

The Calibration Bench is an optional stand designed to perform automatic calibration and calibration check sequences at standard inspection speeds.

The calibration sequence is performed by moving each probe over a reference defect on the calibration tube (no tube rotation) to automatically compensate the gain of each beam for each detection gate. The calibration check sequence displays each calibration tube defect in an easy-to-interpret strip chart and weld-mapping view.

 

Multichannel Weld Inspection 

 

Due to the different thickness of pipe and inspection requirements, it usually uses several ultrasonic channels to cover the transverse and longitudinal crack, Partition cover will be taken when testing the same position of longitudinal defects.

 

 

 

 

Tube inspection

 

 

 

For spiral welded tube inspection, the inspection is usually before in roll or rolled the plate, see the photo above. After welding to the rolled plate, the welded tube body and the welding line can be inspected once time, so as to improve production efficiency.

 

Water Wedge

 

Each inspection head is designed with a unique Water Wedge mechanical concept providing many degrees of freedom in order to follow pipe movement and maintain perfect coupling.

This versatile concept enables different types of probe holders to be used when inspecting different pipe sizes. Wear plates that can be attached to the inspection head are also available in different sizes to fit each pipe diameter.

Pneumatic suspension enables the inspection head to follow the pipe movement and raise the Water Wedge if there is a scarfing window or butt weld between coils.

 

Result Analyze

 

Automatic Weld Tracking

 

 

During the process of the welds Automatic inspection, the real-time tracking will be needed to ensure the relative position of the ultrasound probe and weld basically unchanged. The supplication of the laser tracking technology effectively avoids the influence of light, dust, electromagnetic, etc.

 

 

Unique patented algorithm based on time-of-flight analysis performs automatic detection of the scarfing area and send feedback to the PLC to automatically adjust the inspection for each water wedge.

 

Ability.