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ABSTRACT
The Time of Flight Diffraction Method (TOFD) has now been in regular use in Industry for over 20 years.
This paper will describe some of the advances made in the application of the technique within several types of industry
and demonstrate various applications with attendant technical and financial benefits. In addition comparisons will be
made with the use of TOFD as a replacement to radiography.
Further description of software enhancements for procedure development will be described. The progress made in
accredited training, personnel qualification and standardisation of TOFD will also be detailed.
ASME 20 OR 10%
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DAC PROPOSAL)
0.5
(NEW
TOFD PE PE X-ray Gamma Manual
POD
Meander Line ray UT
scan scan
ASME 50%
(INDUSTRIAL)
TOFD. -0.2
0
-0.4
-0.6
2.3 2.35 2.4 2.45 2.5 2.55 2.6 2.65 2.7 2.75
-5
x 10
0.5
1.5
50 100 150 200 250 300
Inspection Surface
D
vessels or other parts to an X-Ray facility with the
attendant cost savings.
• Thickness variations do not significantly affect the
Indication
T H
Indication
more than 400ºC
• Partly welded thick sections can be examined at
Signal Time
@ Rx
T
pre-heat temperature to avoid costly root repairs after
Lateral wave Backwall completion of welding
Figure 4 Principle of position and height determination. • TOFD data is very accurate and is presented in an
easily understandable format. All data is stored
When the probes are moved parallel along the weld digitally for future reference and can be made available
(Figure 5), the resultant waveforms are digitised, stored to the client in a format compatible to that used in data
on hard disk and displayed on the video-screen as a bases for future inspection and maintenance
grey scale image (Figure 6). management. Any differences between results after a
period in service and the newly build “fingerprint” can
be easily established. This forms a good basis for Life
Time and Inspection Interval Extension programs
• Insensitivity to defect orientation, together with
encoded positioning leads to improved inspection
sensitivity and accuracy, which results in optimised
reproducibility.
1.4 Equipment
When utilised with simple hand operated encoded When welding relatively thick materials, and certainly
scanning systems it is now relatively easy to apply in in high strength applications, repair of weldments are
many types of site situations. difficult and costly.
When defects are detected at deep positions in the
weld, e.g. in the root region of a double-V bevelled
weld, or J-preparations with back-gouged weld
preparations at the inner side, subsequent repairs can now completed inspection of the first of a series of 3
be costly and time consuming. In addition when vessels successfully.
performing such repairs, deformation of the welded
component beyond allowable limits is a major concern. Inspections of welds in a partly finished state, and
certainly at preheat temperature, are not a simple
This challenge has been accepted and techniques have exercise and require careful preparation. However,
been developed using the Time Of Flight Diffraction experience has shown us, that this procedure can be
method (TOFD) to examine partially filled welds at the achieved, and once the particular inspection procedure
preheat temperature. is validated, advantages, both technical and
economically of delivering a product of a much higher
The procedure allows for the inspection of welds in quality, with less time lost greatly outweighs the initial
different stages of the welding process. For example, effort.
the following weld was examined with only a root and
hot pass as the first stage inspection, filling from the 2.3 High temperature In Service Inspection
back added is the 2nd stage, further filling from the
outside is the 3rd stage and finally the completed weld High temperature, high-pressure components in
is inspected (see example below.) industrial plant, such as piping and vessels represent a
large investment. In combination with the other parts
of the plant, the availability of such components during
the economical lifetime and where possible beyond the
design lifetime, is vital. Shutdowns of such plant, and
certainly when unplanned, represent large economical
Figure 9: 1st, 2nd and 3rd stage of weld completion inspection setbacks to the owner of such plant. When the safe
operation is no longer guaranteed, such equipment
The main challenges faced to achieve reliable and needs to be replaced, which involves long lead-times.
accurate inspection under those conditions are Knowledge of the safe remaining life time is therefore
temperature, and of course the fact that there is only a crucial information for the plant owner and can help
small proportion of weld material present, whilst the him to optimise the planning of his maintenance and
parent material is much thicker. replacement or upgrade programmes. The ideal
TOFD offers the advantage (as in many other situation for the plant owner would therefore be, to be
applications) that these challenges can be adequately able to know at all times what the remaining safe
overcome. lifetime of such components is, and being able to
acquire such information on line. Certainly when
Amongst projects performed with similar challenges, damage is suspected to be present already, being able
where welds were examined at a partially completed to achieve the delivery of such information without the
stage, is a large project where a pipeline was laid in requirement of an unplanned shutdown can safeguard
Duplex material and intermediate inspection using the owner from large loss of production costs.
TOFD, was validated and subsequently used on a sub
sea pipeline 11 kilometres long. The aim was to inspect
the root and hot pass of the 12 mm thick weld, and to
detect root defects at a welding station where any
repair was still possible. Detection of a flaw in the root
region would have met costly in the last stage before
laying the line in the sea and would have meant cutting
back several good welds from the pipe to enable
repairs to be carried out at the first welding station.
In view of these situations, and in order to ensure an Figure 12 typical models for a nozzle inspection
adequate inspection, validation of the inspection is
necessary. In our experience, no two high temperature The advantage of using TOFD for complex geometry
inspections are the same; many factors influence the inspections obviously lies in the relative simplicity of
successful completion of the inspection, a good the approach compared to Automated Pulse Echo
preparation and performance demonstration is vital for techniques, but also in the accuracy and reproducibility
success. of the results. Many clients have seen the benefit of
investing in the inspection of nozzles during the
2.4 Complex geometries manufacturing stage, offering the benefit of being able
to use this inspection as the baseline for their later life
time extension programmes.
1-Prob
ability
Of Detectio
n X-RAY
ll Rate
X-RAY
FCR TO
FD 4 TOFD SCANPLAN SOFTWARE
False Ca
6 CONCLUSIONS
The Time of Flight Diffraction technique has now been
extensively trialled and validated by numerous
respected international bodies. Since then it has shown
its versatility for use in other situations where
conventional techniques are either not practicable or
economic.
7 REFERENCES
Dr.G. Engl and E. Borloo, Proceedings of the
International Workshop on the contribution of PISC to
Codes and Standards, in particular to Performance
Demonstration, PISC report No. 29 p40, Joint
Research Centre of the European Communities, 1992
Dr.Martin Wall and Dr. Alan Wedgwood NDT value
for Money, MTQ94 Birmingham, Insight vol 36 No.10
October 1994