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Heavy Plate
Inspection with Ultrasound Technology |
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Benefits of a UTS |
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• Process control ...
means feedback to casting and rolling
• proof of quality
• Constitution of confidence supported by
−Regular use of test plate
−Selfcheck capability of the system |
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Plate UTS Featured by Scanning |
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•Manual Inspection Devices
−Means feedback to casting and rolling
−One or more probes moved by device
•Automatic Inspection Systems
−Longitudinal track scanning
•inspection from top
•inspection from bottom
− Transversal track scanning
•plate will be moved
•system will be moved
−Oscillating scanning |
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Plate UTS Featured by Position |
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| The plates are to be tested after ....
•Cooling bed before shearing on raw plates
• Piling (HIC prevention) on raw plates
• Cropping
• Side trimming
• Final cut to customer plates |
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Plate UTS Featured by Coverage |
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• <100% coverage for plate body
– cut untested edges
•100% coverage for plate body
– plus 100% of longitudinal edge
– plus 100% of transversal edge
•<100% coverage for plate body
– plus 100% of longitudinal edge
– plus 100% of transversal edge |
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Relevant Features of Plates |
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•Shape
−Waviness
−Saber-shaped
−Wedge-shaped
•Surface
−Scale (loose or fixed)
−Dirt (dust, grease, paint)
−Roughness
•Borders
−As rolled (raw), no cutting
−Trimmed
−Cropped
−Ready cut |
•All features depend on the mill's production process and its logistic organisation
•If possible, plan the position of a UTS in advance! |
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Plate Waviness and Deformations |
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Wave height w < 25 mm
Curvature radius r > 4500 mm
Deformation width b < 5 mm
Deformation v < 2 mm
Burr s < 1.5 mm
Deformations at plate head and tail
head h < 20 mm
tail h' < 30 mm
Maximum waviness and maximum deformation must not add at plate head and tail |
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Inspection Sequences of a Standard Plate |
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Layout of a 2-Row System |
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Probe Arrangement of a 2-Row System |
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Layout of a 3-Row System |
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Probe Arrangement of a 3-Row System |
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Scanning of the Surface (3-Row System) |
Row 1
Row 2
Row 3 |
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PLC MMI Layout: UTS Overview (Body & Edge) |
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Location before Shearing |
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Advantages
–defects can be considered for cutting
–all customer plates are 100% inspected
–no need of a separate edge-testing device
–no alignment and pre-positioning necessary
–shortest testing cycle time
–favourable total price of the system
Disadvantages
–dependency on plate temperature |
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Location after Shearing |
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Advantages
–open schedule
–temperatures of the plates are low
Disadvantages
–for 100% testing it is necessary to install an additional edge testing device for all edges
–an untested area of about 15 mm remains
–for transversal edge testing, the plate has to be stopped twice
–extension of cycle time |
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Edge Inspection Unit |
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KARL DEUTSCH Probe 3 TSE 18.3/10 PB 5 |
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•composite probe
•5 MHz nominal frequency
•sensitivity / detection of defects 3 mm FBH
•50 mm actual width of test track (3*16.7 mm)
•dimensions of housing
65 mm * 25 mm
•optimum water gap adjustment 0.4 ± 0.05 mm |
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KARL DEUTSCH Probe 3 TSE 18.3/10 PB 5 |
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| 3 TSE 18.3/10 PB 5:
• 3 = three receivers one common transmitter)
• T = immersion type probe
• SE = dual element probe
• 18.3 = dimensions of each receiving element
• 10 = focal depth in mm
• P = plastic delay line
• B = broadband probe
• 5 = 5 MHz |
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Lateral Sensitivity of the Probe |
| Principal Sketch of SEZ5R10RS
Sensitivity curve for a 3 mm Flat Bottom Hole
T = transmitter
R1 - R3 = receivers 1 to 3 |
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Why TR-Probes? |
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• higher resolution close to the transducer compared to single probes
• increase of coverage with the same number of channels (delay in water column)
• less consumption of water
• recommended in most standards |
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General Performance |
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• Detectability 3 mm FBH (full thickness range), within limited thickness range down to 1.5 mm FBH depending on the grain structure of the steel
• Testing speed up to 1 m/s
• Inspection performance 300 m2/min, 100 times more than manual inspection
• Availability of the System > 97%, provided maintenance is done according to the instructions |
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DEU Screen: Plate with Indications |
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AES Main Window |
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Acceptance Standards (1) |
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• ASME SA 435
• ASME SA 578
• ASTM A 435
• ASTM A 578 Level I, II, III
• BS5996 1993
• EURONORM EU-60/1985
• GB/T 2970 |
• ISO 12094
• JB 4730
• JIS G801
• JIS G901
• NF A04-305
• SEL-072/1977
• prEN 10160 |
• intra-company standards within given parameter structure
• other standards on request |
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Acceptance Standards (2) |
Criteria used |
• maximum single flaw size
• minimum flaw size to report
• density of reported flaws
• length of flaw
• amplitude of flaw compared to undisturbed backwall
• multiple thresholds for classification |
• 6-dB drop
• 20-dB drop
• ratio backwall / defect echo
• multiple echo pattern
• DGS method
• total loss of backwall echo |
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UT Systems Key Characteristics |
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• Advanced electronics design (microelectronics)
• Low power consumption (long life of components)
• Modular expandability
• Rare use of proprietary hardware (US electronics, DSP)
• Superior EMC in industrial environment (fiber-optic cables)
• Loadable code and evaluation algorithms (use of FPGA)
• Possibility of A-, B- and C-scan simultaneously
• Integrated self-check functions and diagnostics
• Remote maintenance (modem access to UTS)
• Automatic parameter setting (no operator intervention)
• Self-adaptation of testing sensitivity (after data acquisition)
• Inspection results are stored for long term
• Previous inspection results can be retrieved for review or printout |
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