Overview

	ERW Solutions: In-Line ERW High-Temperature Inspection System Fully Automated ERW Tube Process-Control The In-Line ERW High-Temperature Inspection System integrates into the production line between the weld cooling and annealing, where the pipe temperature is 100 °C (212 °F) or lower. A special self-cooling wedge combined with automatic alarms protect the phased array (PA) probe against excessive temperatures. Using conventional ultrasonic (UT) and PA technology, the system inspects the internal and external surfaces of the ERW seam and the heat-affected zone (HAZ) in pipes ranging from 60.3 mm to 508 mm (2.4 in. to 20 in.) OD. Automatic weld tracking technology connected to servomotor-driven mechanisms helps ensure coverage of the region of interest. The following typical defects are detected: Longitudinal cracks Through-drilled holes Lamination defects in the HAZ (up to 25 mm (1 in.) on each side of the weld)

ERW Solutions: In-Line ERW High-Temperature Inspection System

Fully Automated ERW Tube Process-Control

The In-Line ERW High-Temperature Inspection System integrates into the production line between the weld cooling and annealing, where the pipe temperature is 100 °C (212 °F) or lower. A special self-cooling wedge combined with automatic alarms protect the phased array (PA) probe against excessive temperatures.

Using conventional ultrasonic (UT) and PA technology, the system inspects the internal and external surfaces of the ERW seam and the heat-affected zone (HAZ) in pipes ranging from 60.3 mm to 508 mm (2.4 in. to 20 in.) OD. Automatic weld tracking technology connected to servomotor-driven mechanisms helps ensure coverage of the region of interest.

The following typical defects are detected:

Longitudinal cracks
Through-drilled holes
Lamination defects in the HAZ (up to 25 mm (1 in.) on each side of the weld)

Strict Standard Compliance for OCTG Tube Manufacturers Completely automated, the In-Line ERW High-Temperature System’s phased array probe tracks and records the weld profile and the UT probes detect flaws in the welded area using the automatic positioning. This turnkey system gives ERW pipe manufacturers the tools to meet the inspection requirements of international standards: Automatically tracks the heat-affected zone (HAZ) Displays the profile of the weld in real time Automatically positions the flaw detection probe for optimal detection Minimizes dependence on operator skill Easy and fast changeover using preset probe holders and saved setup files Protects the phased array probe using a closed-loop cooling system

Strict Standard Compliance for OCTG Tube Manufacturers

Completely automated, the In-Line ERW High-Temperature System’s phased array probe tracks and records the weld profile and the UT probes detect flaws in the welded area using the automatic positioning. This turnkey system gives ERW pipe manufacturers the tools to meet the inspection requirements of international standards:

Automatically tracks the heat-affected zone (HAZ)
Displays the profile of the weld in real time
Automatically positions the flaw detection probe for optimal detection
Minimizes dependence on operator skill
Easy and fast changeover using preset probe holders and saved setup files
Protects the phased array probe using a closed-loop cooling system

Software and Acquisition Unit

Phased Array Acquisition Unit

The QuickScan™ PA 32:256 module meets IP55 standards and is designed to easily integrate into industrial environments.

Easy Setup and Data Management

QuickView™ software makes it easy to configure the system and acquire and manage data. The results are merged and displayed to clearly differentiate between accepted and rejected tubes.

Software wizard assists you in creating setups for different tube sizes
Quickly access predefined configuration and calibration parameters for each tube diameter
Restrict access to certain users to help minimize operator errors
Calibration and inspection information are stored for traceability
Offers an operating mode that requires minimal human intervention

Real-Time Weld Profiling

QuickView software displays a complete weld profile view in real time without mechanical oscillation of the phased array probe.

Evaluate the shape of the cut using the easy-to-interpret C-scan of the weld profile.
Make informed, on-the-spot decisions thanks to the continuous and comprehensive view of the weld, covering a long portion of the tube.
The weld profile data is also used for the weld tracking algorithm, helping ensure the conventional UT probes are properly positioned for an optimal inspection.

Specifications

System Performance

Standard Product Range	Diameter	60.3 mm to 508 mm (2.375 in. to 20 in.)
	Wall Thickness	3 mm to 16 mm (0.118 in. to 0.630 in.)
	Speed	Typically 600 mm/sec (limited by the production line speed)
	Coverage	100% weld volume for cracks/TDH and up to 25 mm on each side of weld for lamination detection
Data Presentation	Real-Time Inspection Results	C-scan, A-scan, B-scan, strip charts, and alarms
Inspection Modes	Typical Inspection Modes	Longitudinal and lamination
Operating Temperature		Up to 100°C
Detection Capabilities for Typical Reference Defects	Repeatability	Longitudinal notches: <3 dB; 3.2 mm TDH: <4 dB; 1.6 mm TDH: <5 dB; 6.35 mm FBH: <3 dB; 3.2 mm FBH: <4 dB
Detection Capabilities for Typical Reference Defects	Standards	ISO, API
Reporting and Data Storage	Report Types	Inspection, calibration, and calibration-check user-configurable reports
Reporting and Data Storage	Storage	Real-time database inspection data storage