WO2014062467A9 - A method of locating and sizing fatigue cracks - Google Patents

A method of locating and sizing fatigue cracks Download PDF

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Publication number
WO2014062467A9
WO2014062467A9 PCT/US2013/064245 US2013064245W WO2014062467A9 WO 2014062467 A9 WO2014062467 A9 WO 2014062467A9 US 2013064245 W US2013064245 W US 2013064245W WO 2014062467 A9 WO2014062467 A9 WO 2014062467A9
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WO
WIPO (PCT)
Prior art keywords
crack
sensors
tofd
pas
wall thickness
Prior art date
Application number
PCT/US2013/064245
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French (fr)
Other versions
WO2014062467A1 (en
Inventor
Wilmer-Jose BUSTILLOS
Original Assignee
Shell Oil Company
Shell Internationale Research Maatschappij B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shell Oil Company, Shell Internationale Research Maatschappij B.V. filed Critical Shell Oil Company
Priority to EP13846392.2A priority Critical patent/EP2906906A1/en
Priority to AU2013331676A priority patent/AU2013331676A1/en
Publication of WO2014062467A1 publication Critical patent/WO2014062467A1/en
Publication of WO2014062467A9 publication Critical patent/WO2014062467A9/en

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
    • G01B17/04—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations for measuring the deformation in a solid, e.g. by vibrating string
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
    • G01N29/0654—Imaging
    • G01N29/069—Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/07—Analysing solids by measuring propagation velocity or propagation time of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/262—Arrangements for orientation or scanning by relative movement of the head and the sensor by electronic orientation or focusing, e.g. with phased arrays
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/02—Indexing codes associated with the analysed material
    • G01N2291/025—Change of phase or condition
    • G01N2291/0258—Structural degradation, e.g. fatigue of composites, ageing of oils

Definitions

  • the invention relates to a method for detecting and determining the size of fatigue cracks in steel components.
  • the invention is useful for inspecting welds and base metal for fatigue cracks.
  • a conventional method to inspect steel components for cracks using Phased Array Sectorial (PAS) and Time-of-Flight Diffraction (TOFD), is to collect data in the area of interest with a scanner where the PAS and TOFD sensors have been installed. Once the inspection is completed, the signals obtained from the PAS and TOFD sensors are
  • FIG. 1 shows a diagram indicating the crack ends signals for a crack connected to the surface of the material as shown by PAS and TOFD.
  • Figure 1 shows a PAS diagram of the inspection setup and a typical signal obtained.
  • the setup shows the PAS sensor 101 positioned on the scan surface 102 of a test block 104.
  • the ultrasonic beam 105 interacts with the crack 106.
  • the crack tip 107 and the corner trap 109 generate the crack tip signal 108 and the corner trap signal 110 which identify the presence of the crack.
  • FIG. 2 shows a TOFD diagram of the inspection setup and the signal obtained.
  • the setup shows the TOFD emitter sensor 201 and the receiving sensor 202 which are positioned on the scan surface 203 of a test block 204.
  • the ultrasonic beam 205 inside the test block 204 generates two main beam components known as the lateral wave 206 and the back wall echo 207.
  • the ultrasonic beam 205 interacts with the crack 208 generating the crack signal 209 in the TOFD image. Also, in the TOFD image, one can observe the lateral wave 206 and the back wall echo 207.
  • the invention provides a method of detecting and determining the size of fatigue cracks in steel components comprising: analyzing the component using a Time of Flight Diffraction (TOFD) ultrasonic technique to locate the crack tip; analyzing the component using a Phased Array Sectorial (PAS) ultrasonic technique to locate the crack corner trap; and calculating the distance between the crack tip and the crack corner trap to determine the height of the crack.
  • TOFD Time of Flight Diffraction
  • PAS Phased Array Sectorial
  • Figure 1 depicts a diagram of the PAS setup and a typical signal obtained.
  • Figure 2 depicts a diagram of the TOFD setup and a typical signal obtained.
  • Figure 3 depicts the breaking of the lateral wave by an open crack such as an environmental crack.
  • Figure 4 depicts the continuity of the lateral wave through a tight fatigue crack.
  • Figure 5 depicts the PAS reflected wave from the corner trap of the crack shown in
  • Figure 6 depicts an embodiment of the TOFD setup using two pairs of sensors.
  • the invention provides a new inspection methodology developed to detect and size fatigue cracks connected to the surface of steel components by interpreting the combined set of ultrasonic signals from ultrasonic techniques in a new way.
  • the invention takes advantage of the complementary behaviour shown by the Phased Array Sectorial (PAS) technique and the Time-of-Flight Diffraction (TOFD) technique in the detection and sizing of fatigue cracks.
  • PAS Phased Array Sectorial
  • TOFD Time-of-Flight Diffraction
  • the lateral wave 301 is prevented from reaching the receiving sensor 304, indicating the presence of a defect connected with the scansurface 306, possibly a crack.
  • the lateral wave 401 still reaches the receiving sensor 404 through the crack 403.
  • Tight fatigue cracks reflect waves at the crack corner traps. These reflected waves provide a more reliable evidence of the presence of a crack than the search for the absence of transmitted signals.
  • Figure 5 shows the PAS reflected wave from the corner trap 501 of the crack shown in Figure 4. The tightness of the crack 403 did not prevent the ultrasonic signal from being reflected at the corner trap position 501, indicating that there is a defect at the component scan surface 502, possibly a crack, producing the reflection.
  • Fatigue cracks can generate multiple diffracted signals from the crack faces in addition to the diffracted signal from the crack tip.
  • the crack tip diffracted signal 402 is shown accompanied by other diffracted signals 406 coming from the faces of the crack.
  • the multiplicity of diffracted signals can obscure the selection of the correct tip diffraction signal. It is necessary to identify the real crack tip signal.
  • the diffracted signals from a fatigue crack can be weak and therefore their amplitude can fall below the detection threshold for PAS.
  • Figure 5 shows the PAS signal of the same crack detected by TOFD in Figure 4. Where TOFD could detect the crack tip diffracted signal, PAS could not.
  • the inspection methodology for detecting and sizing fatigue cracks that are connected to the surface of a component comprises the following steps.
  • the component is analyzed using the PAS technique and the TOFD technique.
  • the resulting signals from the PAS technique are used to detect a corner trap.
  • the lateral wave and back wall echo signals from the TOFD technique are ignored for the purpose of detecting a corner trap. If the PAS technique does not detect a corner trap then there is no crack connected to the surface of the component.
  • the signals from the TOFD technique are used to detect a crack tip.
  • the diffracted signal from the PAS technique is ignored for the purpose of detecting the crack tip.
  • the TOFD technique gives multiple diffracted signals, and in these cases the correct tip diffraction signal can be determined according to the following rules.
  • the tip diffraction signal 402 will be given by the diffracted signal farthest from the lateral wave 401 or closest to the back wall echo 405.
  • the tip diffraction signal will be given by the diffracted signal closest to the lateral wave or farthest from the back wall echo 405.
  • lateral wave removal software may be used to remove the lateral wave and detect a possible diffracted signal embedded in the lateral wave.
  • the methodology is applied to detect and size fatigue cracks in a component having a wall thickness between about 0.75 inches (1.91 cm) and 1.25 inches (3.18 cm).
  • the preferred setup to detect and size fatigue cracks in such a component will be described here and is illustrated in Figure 1.
  • the PAS technique comprises using a linear sensor with 16 or more elements.
  • the preferred frequency is 10 MHz and the sensor size is 0.9 inch (2.29 cm) by 0.6 inch (1.52 cm).
  • the scan direction is from the opposite surface 103 to the scan surface 102, and the scan is performed with the first reflection from the opposite surface 103.
  • the inspection is preferably performed from each side of the weld.
  • the TOFD technique comprises using two pairs of sensors, with each pair working in an emitter-receiver configuration.
  • the first pair 601 uses an ultrasonic frequency of 20 MHz and a focusing depth of 1/4 of the wall thickness.
  • the second pair 602 uses an ultrasonic frequency of 10 MHz and a focusing depth of 3/4 of the wall thickness. All of the sensors have a diameter of 1/4 inch (0.64 cm).
  • the PAS technique is used to detect crack corner traps at the scan surface and at the opposite surface.
  • the first TOFD sensor pair 601 as shown in Figure 6, is used to detect crack tips located within the 40% of the wall thickness 605 nearest to the scan surface 603 regardless of whether the crack is connected to the scan surface 603 or the opposite surface 604. This region of the wall thickness is indicated as 606.
  • the second TOFD sensor pair 602 is used to detect crack tips located within the 60% of the wall thickness 605 farthest from the scan surface regardless of whether the crack is connected to the scan surface 603 or the opposite surface 604. This region of wall thickness is indicated as 607.
  • Figure 6 also shows the area covered by each pair of transducers. The figure shows cracks initiated at the scan surface and the opposite surface. The procedure used to find the corner traps and crack tips is as described above.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Acoustics & Sound (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

A method of detecting and determining the size of fatigue cracks in steel components comprising: analyzing the component using a Time of Flight Diffraction (TOFD) ultrasonic technique to locate the crack tip; analyzing the component using a Phased Array Sectorial (PAS) ultrasonic technique to locate the crack corner trap; and calculating the distance between the crack tip and the crack corner trap to determine the size of the crack.

Description

A METHOD OF LOCATING AND SIZING FATIGUE CRACKS
Cross Reference to Related Applications
This application claims the benefit of U.S. Provisional Application No. 61/713,686, filed October 15, 2012, which is incorporated herein by reference.
Field of the Invention
The invention relates to a method for detecting and determining the size of fatigue cracks in steel components. The invention is useful for inspecting welds and base metal for fatigue cracks.
Background
A conventional method to inspect steel components for cracks using Phased Array Sectorial (PAS) and Time-of-Flight Diffraction (TOFD), is to collect data in the area of interest with a scanner where the PAS and TOFD sensors have been installed. Once the inspection is completed, the signals obtained from the PAS and TOFD sensors are
independently analyzed and then the inspector interprets them using procedures developed for inspecting environmental cracking. These two techniques are typically used in combination to provide redundancy in case one of the techniques fails to find the crack as a result of problems such as a malfunctioning sensor, physical obstructions, and the presence of other defects or to cover a larger area of inspection around a weld.
The inspection for environmental cracks using PAS and TOFD involves the detection of the crack ends and the sizing of the height and length of the crack. If there are no indications of crack ends, then the inspector assumes that there is not a crack present. Also, if there is only one crack end signal, this signal can be interpreted as absence of cracks or a crack small enough that both ends cannot be resolved by PAS or TOFD. Figures 1 and 2 show a diagram indicating the crack ends signals for a crack connected to the surface of the material as shown by PAS and TOFD. Figure 1 shows a PAS diagram of the inspection setup and a typical signal obtained. The setup shows the PAS sensor 101 positioned on the scan surface 102 of a test block 104. The ultrasonic beam 105 interacts with the crack 106. The crack tip 107 and the corner trap 109 generate the crack tip signal 108 and the corner trap signal 110 which identify the presence of the crack.
Figure 2 shows a TOFD diagram of the inspection setup and the signal obtained. The setup shows the TOFD emitter sensor 201 and the receiving sensor 202 which are positioned on the scan surface 203 of a test block 204. The ultrasonic beam 205 inside the test block 204 generates two main beam components known as the lateral wave 206 and the back wall echo 207. The ultrasonic beam 205 interacts with the crack 208 generating the crack signal 209 in the TOFD image. Also, in the TOFD image, one can observe the lateral wave 206 and the back wall echo 207.
In the case of fatigue cracks, the inspection with PAS and TOFD usually results in contradictory information that is difficult to understand because there is no existing methodology to correctly interpret the information provided by PAS and TOFD for fatigue cracks.
Summary of the Invention
The invention provides a method of detecting and determining the size of fatigue cracks in steel components comprising: analyzing the component using a Time of Flight Diffraction (TOFD) ultrasonic technique to locate the crack tip; analyzing the component using a Phased Array Sectorial (PAS) ultrasonic technique to locate the crack corner trap; and calculating the distance between the crack tip and the crack corner trap to determine the height of the crack.
Brief Description of the Drawings
Figure 1 depicts a diagram of the PAS setup and a typical signal obtained. Figure 2 depicts a diagram of the TOFD setup and a typical signal obtained.
Figure 3 depicts the breaking of the lateral wave by an open crack such as an environmental crack.
Figure 4 depicts the continuity of the lateral wave through a tight fatigue crack.
Figure 5 depicts the PAS reflected wave from the corner trap of the crack shown in
Figure 4.
Figure 6 depicts an embodiment of the TOFD setup using two pairs of sensors.
Detailed Description
The invention provides a new inspection methodology developed to detect and size fatigue cracks connected to the surface of steel components by interpreting the combined set of ultrasonic signals from ultrasonic techniques in a new way. The invention takes advantage of the complementary behaviour shown by the Phased Array Sectorial (PAS) technique and the Time-of-Flight Diffraction (TOFD) technique in the detection and sizing of fatigue cracks.
Ultrasound interacts differently with fatigue cracks than it does with environmental cracks. Contrary to environmental cracking, fatigue cracks can be tight enough so that ultrasonic waves penetrate the cracks almost as if there was no crack present. Thus, the fact that ultrasonic waves are transmitted in a straight line from one point to another is not an indication of the absence of cracks intercepting that path. Even though a fatigue crack allows transmission of ultrasonic waves through it, a portion of the waves are reflected by the crack. The reflected waves provide more reliable information on the presence of a fatigue crack than the transmitted signals. Contrary to environmental cracking, fatigue cracks can generate several diffraction point sources along their faces due to crack face distortions as a result of compressive forces. These distortions result in the generation of a series of diffracted signals that obscure the real tip diffracted signal necessary to accurately size the height of the crack. The methodology used to inspect components for fatigue cracks is based on the following observations. The fact that the ultrasonic waves are transmitted in a straight line from one point to another is not an indication that there is no crack intercepting the path of the waves. The crack can be tight enough that it allows for the majority of ultrasonic waves to be transmitted through the crack. Figures 3 and 4 show a comparison of the behaviour of the lateral wave in the case of the presence of an open crack, such as an environmental crack and a tight fatigue crack. In the case of an open crack as shown in Figure 3, the lateral wave 301 is prevented from reaching the receiving sensor 304, indicating the presence of a defect connected with the scansurface 306, possibly a crack. In the case of the fatigue crack as shown in Figure 4, the lateral wave 401 still reaches the receiving sensor 404 through the crack 403.
Tight fatigue cracks reflect waves at the crack corner traps. These reflected waves provide a more reliable evidence of the presence of a crack than the search for the absence of transmitted signals. Figure 5 shows the PAS reflected wave from the corner trap 501 of the crack shown in Figure 4. The tightness of the crack 403 did not prevent the ultrasonic signal from being reflected at the corner trap position 501, indicating that there is a defect at the component scan surface 502, possibly a crack, producing the reflection.
Fatigue cracks can generate multiple diffracted signals from the crack faces in addition to the diffracted signal from the crack tip. In Figure 4, the crack tip diffracted signal 402 is shown accompanied by other diffracted signals 406 coming from the faces of the crack. The multiplicity of diffracted signals can obscure the selection of the correct tip diffraction signal. It is necessary to identify the real crack tip signal.
The diffracted signals from a fatigue crack can be weak and therefore their amplitude can fall below the detection threshold for PAS. Figure 5 shows the PAS signal of the same crack detected by TOFD in Figure 4. Where TOFD could detect the crack tip diffracted signal, PAS could not.
The inspection methodology for detecting and sizing fatigue cracks that are connected to the surface of a component comprises the following steps. The component is analyzed using the PAS technique and the TOFD technique. The resulting signals from the PAS technique are used to detect a corner trap. The lateral wave and back wall echo signals from the TOFD technique are ignored for the purpose of detecting a corner trap. If the PAS technique does not detect a corner trap then there is no crack connected to the surface of the component.
Then the signals from the TOFD technique are used to detect a crack tip. The diffracted signal from the PAS technique is ignored for the purpose of detecting the crack tip. In some cases the TOFD technique gives multiple diffracted signals, and in these cases the correct tip diffraction signal can be determined according to the following rules. For a crack initiated from the scan surface 102 into the material, the tip diffraction signal 402 will be given by the diffracted signal farthest from the lateral wave 401 or closest to the back wall echo 405. For a crack initiated from the surface opposite 103 to the scan surface, the tip diffraction signal will be given by the diffracted signal closest to the lateral wave or farthest from the back wall echo 405.
If the PAS technique has detected a corner trap, but no tip diffracted signal is detected by TOFD, then one of two things may be possible. There is either no crack or the crack is small enough that TOFD did not resolve the tip diffraction signal. If there is a surface signal at the scansurface then lateral wave removal software may be used to remove the lateral wave and detect a possible diffracted signal embedded in the lateral wave.
In an embodiment of the invention, the methodology is applied to detect and size fatigue cracks in a component having a wall thickness between about 0.75 inches (1.91 cm) and 1.25 inches (3.18 cm). The preferred setup to detect and size fatigue cracks in such a component will be described here and is illustrated in Figure 1.
The PAS technique comprises using a linear sensor with 16 or more elements. The preferred frequency is 10 MHz and the sensor size is 0.9 inch (2.29 cm) by 0.6 inch (1.52 cm). The scan direction is from the opposite surface 103 to the scan surface 102, and the scan is performed with the first reflection from the opposite surface 103. When a weld is being inspected, the inspection is preferably performed from each side of the weld.
The TOFD technique comprises using two pairs of sensors, with each pair working in an emitter-receiver configuration. The first pair 601 uses an ultrasonic frequency of 20 MHz and a focusing depth of 1/4 of the wall thickness. The second pair 602 uses an ultrasonic frequency of 10 MHz and a focusing depth of 3/4 of the wall thickness. All of the sensors have a diameter of 1/4 inch (0.64 cm).
The PAS technique is used to detect crack corner traps at the scan surface and at the opposite surface. The first TOFD sensor pair 601, as shown in Figure 6, is used to detect crack tips located within the 40% of the wall thickness 605 nearest to the scan surface 603 regardless of whether the crack is connected to the scan surface 603 or the opposite surface 604. This region of the wall thickness is indicated as 606. The second TOFD sensor pair 602 is used to detect crack tips located within the 60% of the wall thickness 605 farthest from the scan surface regardless of whether the crack is connected to the scan surface 603 or the opposite surface 604. This region of wall thickness is indicated as 607. Figure 6 also shows the area covered by each pair of transducers. The figure shows cracks initiated at the scan surface and the opposite surface. The procedure used to find the corner traps and crack tips is as described above.

Claims

C L A I M S
1. A method of detecting and determining the size of fatigue cracks in steel components comprising:
a. analyzing the component using a Time of Flight Diffraction (TOFD)
ultrasonic technique to locate the crack tip;
b. analyzing the component using a Phased Array Sectorial (PAS) ultrasonic technique to locate the crack corner trap; and
c. calculating the distance between the crack tip and the crack corner trap to determine the size of the crack.
2. The method of claim 1 wherein the TOFD technique comprises the use of two sets of sensors.
3. The method of claim 2 wherein one set of sensors is focused at 25% of the wall
thickness away from the sensors.
4. The method of claim 2 wherein one set of sensors is directed to measure the section of wall that is from 0-40% of the wall thickness away from the sensors.
5. The method of claim 2 wherein one set of sensors is focused at 75% of the wall
thickness away from the sensors
6. The method of claim 2 wherein one set of sensors is directed to measure the section of wall that is from 40-100% of the wall thickness away from the sensors
7. The method of claim 1 further comprising determining the correct crack tip signal by: a. determining whether the crack initiated from the scan surface or the surface opposite the scan surface;
b. locating a lateral wave; and c. locating a diffracted signal farthest from the lateral wave if the crack initiated from the scan surface and locating a diffracted signal closest to the lateral wave if the crack initiated from the surface opposite the scan surface.
8. The method of claim 1 wherein the steel component is a vertical riser used for the production of hydrocarbons from an underground or subsea hydrocarbon formation.
9. The method of claim 8 further comprising mounting the equipment to carry out the TOFD and PAS ultrasonic techniques on a pig and passing the pig through the steel component.
10. The method of claim 9 wherein the pig and equipment are designed such that the TOFD and PAS equipment is in physical contact with an inner surface of the vertical riser during the analysis.
PCT/US2013/064245 2012-10-15 2013-10-10 A method of locating and sizing fatigue cracks WO2014062467A1 (en)

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Application Number Priority Date Filing Date Title
EP13846392.2A EP2906906A1 (en) 2012-10-15 2013-10-10 A method of locating and sizing fatigue cracks
AU2013331676A AU2013331676A1 (en) 2012-10-15 2013-10-10 A method of locating and sizing fatigue cracks

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261713686P 2012-10-15 2012-10-15
US61/713,686 2012-10-15

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