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Real Time Corrosion Mapping System: A Comparative Study Bob Lasser, David Rich Imperium, Inc. Beltsville, MD Josh Fontenot, Tim Borel Advanced Corrosion Technologies & Training (ACTT) Sulphur, LA 1

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About Study Wanted to compare Imperiums FirstMap Corrosion Imaging system to Phased Array UT (PAUT) Investigated resolution Other factors included ease of use, cost, training requirements Joint study between Imperium, Inc. (Beltsville, MD) and Advanced Corrosion Technologies & Testing (Sulphur, LA)

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About Imperium Founded in 1996 Leading developer of ultrasound camera technology Systems in petrochemical, aerospace, medical fields About Advanced Corrosion Founded in 2002 Extensive experience in advanced NDT methods Presence in several locations on Gulf Coast

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Lack of trained NDT personnel Lack of confidence in thickness readings, missed corrosion Need higher POD Need areas where AUT cant reach Advances in imaging technology A picture is worth 1000 words Time and cost pressures FirstMap diagnostic tool quickly identifies areas for further investigation Why Industry Needs A New NDT Device

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FirstMap Advantages Images are easier to interpret FirstMap provides an actual image of the defect including thicknesses High resolution Higher confidence than single thickness readings Not effected by beam dispersion Built in delay line No extensive training required; less trained technician Real time

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Evolution of UT Methods A-scan B-scanC-scan

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B-scan to C-scan Defect

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Imperiums Patented Architecture Applies optical imaging techniques to ultrasound Optical Sensor (CCD) Lens Ultrasonic Sensor (2) F1 Acoustic Lens Acoustic Flashlight Flash Note: CCD means Charged Coupled Device Optical Architecture: Ultrasonic Architecture:

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SoundTransmitter Array Video Lens Lens Target Subsurface fault Pulse Echo 50/50 Beamsplitter Pulse echo image of quarter Acoustic beamsplitter Water Water

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Imaging Array 100 micron pixels 120 rows x 120 columns = 14,400 pixels

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PIPELINE CORROSION MAPPING

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SCANNING & STITCHING Make large mosaic images from smaller ones Capture both C-scan and thickness Uses encoder attached to camera Tilting encoder Dual element transducer Optical image of corrosion inside pipe Scanned/stitched image of corrosion inside of pipe

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INSPECTING STORAGE TANK BOTTOMS WITH FIRSTMAP Compare FirstMaps easy to interpret readout

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MICROBIOLOGICAL INDUCED CORROSION Black areas indicate MIC, note the veins of MIC also

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PIPELINE CORROSION MAPPING

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Benefits to NDT Industry Broad application base Pipelines, storage tanks, pressure vessels Find corrosion faster Find smaller amounts of corrosion Does not sacrifice any current data quality Provide better information to end customer Better tool to provide comparisons Use Level 2 thickness inspector to generate images, not just readings Get to areas where current tools cant go

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B-scan vs. C-scan Phased Array FirstMap

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Resolution Study: FirstMap vs Phased Array Investigated axial, lateral, and elevation resolution Used Omniscan MX2 Both systems working at 5 MHz Did mathematical study, then took data to compare expected results

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Omniscan PAUT System Test Settings: Probe:5L64-NW1 (5 MHz) Wedge:SN1-0L5L64 Mode:Phased array Focal Depth:0.1 Focal Law:Linear sector with overlap Skew Direction:90 0 (straight down mode) Scan Offset:0 Index Offset:0 Element Quantity:8 First Element:1 Last Element:64 Thickness:0.25 Surface:Flat plate

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FirstMap System Frequency:5 MHz Number of Pulses:1 Gate start:0.1 Gate width:0.5

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21 Lateral (X): D = (0.44 x V) / (F x sin (/2)) Axial (Z): Z = V x T/2 Elevation (Y): Defined by the length of the array elements, and will be on the order of several millimeters Phased Array Theoretical Resolution Source: Olympus NDT Manual

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Resolution Summary INSPECTION SYSTEM AXIAL RESOLUTION LATERAL RESOLUTION ELEVATION RESOLUTION FirstMap1.5 mm0.1 mm PAUT0.3 mm0.34 mm> 1.0 mm

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FirstMapOmniscan: AmplitudeOmniscan: TOF

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Comparative Study: FirstMap, X-ray, Phased Array Reviewed different techniques for corrosion mapping Used common standards Recorded image quality Recorded time of setup, scan, training cost

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Targets Studied Stepped standard Corrosion piece 8 diameter pipe section

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Stepped Standard FirstMap Phased Array X-ray 192 iridium

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0.25 Corroded Steel Panel FirstMap Phased Array X-ray 192 iridium

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8 Diameter Pipe Section FirstMap Phased Array X-ray 192 iridium

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Corrosion Mapping Comparison

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Advanced Corrosion Technologies The probability of detection is far superior to standard thickness readings. FirstMap is a diagnostic tool that can instantly detect subsurface corrosion down to 1 mm pits. We are now able to quickly and easily identify problem areas that could potentially lead to much bigger issues. -Josh Fontenot, Director of Technologies, ACTT

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35 Imperium, Inc. 5901-F Ammendale Rd Beltsville, Maryland 20705 301-431-2900 / 301-431-0200 fax www.ImperiumInc.com