Equipment catalogue for download ( pdf-file)

ULTRASONIC INSPECTION EQUIPMENT 1

Content About company • 3 ULTRASONIC FLAW DETECTORS and thickness gauges • 4 UMU (Ultrasonic Measuring Unit) “Scanner+” “Skaruch” model Small-size eight-channel detector • 5 UMU “Skaruch – PV1” underwater inspection detector • 6 AUMU (Automatic Ultrasonic Measuring Unit) “Scanner” Portable, multichannel detector – thickness gauge for high-speed inspection • 7 AUMU “Scanner” Multichannel detector – thickness gauge for high-speed inspection • 8 Transducers, instruments and tools for ultrasonic inspection • 10 Ultrasonic piezoelectric transducers • 11 Ultrasonic transducers of general use • 11 Specialized transducers for ultrasonic inspection of metal weld joints • 12 Specialized transducers for ultrasonic inspection of threaded part of tool joints • 14 Specialized transducers for ultrasonic inspection of aircraft industry parts • 14 Specialized transducers for ultrasonic inspection of weld joints of polyethylene pipelines • 15 Transducers for underwater ultrasonic inspection • 15 Specialized gap junction transducers • 16 Manual ultrasonic inspection units • 17 UN-1 – ultrasonic inspection unit for lap-welded joints • 17 UP-1 – ultrasonic inspection unit for weld joints crosslines • 17 UMBT-1 – mechanical unit for ultrasonic inspection of drill pipes • 17 MASKA-05 – mechanical unit for ultrasonic inspection of concrete structure reinforcements • 18 MASKA-ZD – mechanical unit for ultrasonic inspection of inserts • 18 Blocks and tools • 19 Calibration blocks • 19 Reference blocks • 19 Connecting cables • 19 Matching filters • 19

Mobile units for semiautomatic and automatic ultrasonic inspection • 20 UMU “Skaruch” Small-size unit for ultrasonic inspection of weld joints and base metal • 21 Automatic ultrasonic inspection unit for girth weld joints, UMU “Scanner” series (“UMKa” model) • 26 Semiautomatic ultrasonic inspection (SAUI) unit for weld joints of sheets, containers • 26 SAUI unit for balloons • 27 SAUI unit for base metal of pipes, containers • 27 SAUI unit for detection of exfoliations of sheet base metal • 27 SAUI unit for thin-wall pipes of small diameter • 28 SAUI unit for vessel head supports • 28 SAUI unit for polyethylene pipelines • 28 SAUI unit for shafts • 29 SAUI unit for drill pipes • 29 Mobile unit for high-speed SAUI of drill pipes • 29 UMBT-2 - mechanical unit for ultrasonic inspection of drill pipes • 30 UMU “Skaruch-PV1” Ultrasonic measuring unit for underwater ultrasonic inspection • 30 Mechanical ultrasonic inspection system for detection of transverse defects of weld joint reinforcing bead • 31 Automatic ultrasonic inspection (AUI) units • 32 AUI unit for pipe weld joints • 33 AUI unit for seamless pipes • 34 AUI unit for pipe ends • 35 AUI unit for thin-wall stainless and titanic pipes • 36 AUI unit for “pipe – pipe plate” weld joints • 37 AUI unit for thread-soldered products and rotation bodies • 37 AUI unit for pistons and rotation bodies • 38 AUI unit for rings and rotation bodies • 38 AUI unit for mill rolls • 38

Methodical and regulatory literature for ultrasonic inspection • 39

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ABOUT COMPANY LLC “Ultes” was established in 1991. The company is engaged in development and manufacturing of hi-tech equipment for ultrasonic inspection. The company employs specialist of the 3rd and 2nd level for acoustic inspection method, qualified electricians, programmers, designers, experienced equipment assemblers and adjusters. For the period of existence the company accumulated solid experience in the field of design, development and manufacturing of equipment for manual and automatic ultrasonic inspection. The company constantly performs research works in order to develop new technologies of ultrasonic inspection, automation of inspection processes in companies. The basis of reliability and high quality of the produced equipment is the use of advanced developments, modern technologies, hardware components and materials. The equipment, produced by our company, proved itself in power, chemical, gas and oil producing and processing industries, in Gazprom companies, metal structures plants, in transport, construction, aircraft industries etc. Wide field experience helps us in development of methodological materials for ultrasonic inspection of different products. LLC “Ultes” in cooperation with the design, research and development institutions takes part in the development of professional regulatory documentation concerning manual and automatic ultrasonic inspection.

LLC “Ultes” offers:

•manual ultrasonic inspection equipment; •units for semiautomatic and automatic ultrasonic inspection;

•automatic ultrasonic inspection units; •development of new technologies of ultrasonic inspection, automation of existing inspection processes in companies;

•development of methodological materials and regulatory documentation. The equipment of LLC “Ultes” is well-known to many specialists of ultrasonic inspection in Russia and abroad. For achievements in the field of nondestructive inspection the company’s specialists are awarded with international “Roentgen-Sokolov” medal. The equipment produced by LLC “Ultes” was many times awarded with honorary prizes, diplomas, certificates of merit in different exhibitions and conferences on nondestructive inspection.

+7-(499) - 267-99-77 +7-(499) - 267-67-92 +7-(499) - 261-46-49 +7-(499) - 265-10-83 +7-(499) - 265-17-82 building 3, 14, Tokmakov lane , Moscow, 105066 , Russia .

[email protected] www.ultes.info

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ULTRASONIC FLAW DETECTORS and thickness gauges • UMU “Scanner+” “Skaruch” model Small-size eight-channel flawdetector • UMU “Skaruch-PV1” Underwater inspection flawdetector • AUMU “Scanner” Portable, multichannel flawdetector – thickness gauge for high-speed inspection • AUMU “Scanner” Multichannel flawdetector – thickness gauge for high-speed inspection

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UMU “Scanner+” “Skaruch” model

small-size eight-channel flawdetector

UMU “Skaruch” peculiar features

Small-size eight-channel flaw detector of “Scanner+” series – “Skaruch” model (UMU “Skaruch”) is designed for prompt detection and characterization of defects of weld joints and base metal of pipelines, containers and metal structures. UMU “Skaruch” allows nondestructive inspection of metal, polyethylene, plastic, ceramics quality.

• flaw detector and thickness gauge features; •easy adjustment and inspection, small size and weight; •time measurement and “X”, “Y” coordinates values; •storage of settings for certain piezoelectric transducers and inspected products; •storage of impulses image and accompanying information; •sensitivity time adjustment (DAC); •automatic gain adjustment (AGC) mode; •“two pulse gates” mode; •sound and light alarm; •battery charge control and discharge alarm; •integrated clock and temperature sensor; •detector available memory displaying; •printing of reports on connected printer; •copying of inspection results to connected computer; •interface language selection feature (Russian, English, Turkish); •input of associated comments.

UMU “Skaruch” flaw detector can be sued as: •manual ultrasonic flaw detector – thickness gauge; •multichannel portable unit with automatic recording and interpretation of inspection results. The availability of 8 channels for UMU “Skaruch” and possible choice between 16 different inspection schemes allows application of the unit as part of multichannel sets for semiautomatic and automatic inspection. UMU “Skaruch” passed the state testing and has good feedback from the companies of different branches. UMU “Skaruch” is certified by RF State Committee for Standardization, Metrology and Certification, registered in the state register of measuring equipment (No. 1572302) and admitted for use in the Russian Federation. The certificates of CIS countries are available. The application method of UMU “Skaruch” is approved by Russian Federal Service for Ecological, Technical and Atomic Supervision and permitted for use in inspected sites.

Main technical parameters Number of channels Number of scanning schemes Gain adjustment Frequency range Maximum scanning depth (longitudinal waves) Display Number of stored settings Number of stored display images Number of DAC adjustment points AGC adjustment range Operating temperature range Battery or mains supply Dimensions Weight (with batteries)

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8 16 85 dB with 1 dB discreteness 1.0 … 10.0 MHz 10000 mm color, liquid-crystal 256 1000 8 -6 … +18 dB -20 … +45⁰C 220 V 200x225x90 mm 3.5 kg

ULTRASONIC FLAW DETECTORS AND THICKNESS GAUGES

UMU “Skaruch-PV1”

underwater inspection flaw detector

Main technical parameters

Small-size ultrasonic flaw detector “Skaruch-PV1” – manual device for underwater inspection of weld joints and base metal quality with diving depth of up to 60 m. “Skaruch-PV1” detector has air- and shockproof housing and equipped with remote display. Eight-channel ultrasonic inspection unit UMU “Skaruch-PV1” allowing scanning inspection of weld joints and base metal of underwater sections of pipelines, is made on the basis of “Skaruch-PV1” detector.

Gain adjustment Frequency range Scanning range (longitudinal waves) Number of DAC adjustment points Operating temperature range Mains supply Dimensions diameter length weight (in the air)

Detector peculiar features • detector and thickness gauge features; • easy adjustment and inspection, small size and weight; • sensitivity time adjustment (DAC); • automatic gain adjustment (AGC) mode; • integrated clock and temperature sensor; • displaying and storage of inspection results on connected computer.

Display Dimensions Weight Remote TFT display with resolution

85 dB with 1 dB discreteness 1.0 … 10.0 MHz 0…10000 mm 8 -20 … +45⁰C 220V 163 mm 240 mm 4.0 kg 150x102x80 mm 1.8 kg 320x240 pix.

Power adapter and computer connection Dimensions 300x120x250 mm Weight 3.8 kg

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AUMU “Scanner”

portable multichannel flaw detector – thickness gauge for high-speed inspection

Portable multichannel flaw detector – thickness gauge AUMU “Scanner” is the basis for establishment of small areas of automatic high-speed ultrasonic inspection in production flow for different products. Depending on inspection purpose the detector may have up to 9 independent channels. Nondestructive inspection and thickness gauging of weld joints and base metal of products is performed at a speed of up to 2 m/s.

•band •sweep length •sweep delay

Technical parameters •Number of channels •Operating mode •Implemented methods Shock pulse generator •pulse voltage •pulse time •generators operating mode Pulse gate generating unit •discreteness of pulse gate generation •gate length •number of pulse gates in each channel Time measurement unit •time measurement discreteness •time measurement interval •sound speed range Frequency measurement unit •frequency measurement discreteness •frequency measurement range

Amplifier •gain adjustment range

up to 8+1 video, radio, spectrum resonance-frequency, echo, through transmission 200V 50…500 ns serial, simultaneous

Analog-to-digital transducer (ACP) •ACP digit capacity •accuracy •digitization frequency

10 +1 digit 40…80 MHz

Microcontroller •digit capacity •clock frequency •internal memory

32 200 MHz 64 MB.

Display •color liquid-crystal size

155x95 mm

80 dB

film-type, airproof, 25 keys 420x410x180 mm 15 kg 220V+10% 100VA at least 24 hours.

Detector can be connected to •external computer; •distance sensor; •turning angle and photographic shutters sensor; •defect markers; •external mechanisms control unit.

25 ns 100ns…1ms 1000…9999 m/s.

85 dB

2 mcs…800 mcs up to 8.

•dimensions •mass •voltage •power demand •continuous work time

up to 7.

10kHz, 20kHz, 40kHz 1.0…5.0 MHz 1.0…10 MHz 1.0…20.0 MHz

Sensitivity time adjustment unit •DGS gain factor adjustment range •time interval of DGS gain factor adjustment •number of DGS points

Keyboard •modification

25 ns 100 ns…800mcs

1.0…20.0 MHz 15…1000 mcs 0…500 mcs.

Inspection results presentation The results of automatic ultrasonic inspection depending on conditions of the requirements specification may be shown on detector’s display or on the display of connected computer, storing them and printing on connected printer.

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AUMU “Scanner”

multichannel flaw detector – thickness gauge for high-speed inspection

Multichannel detector – thickness gauge AUMU “Scanner” is the basis for establishment of automatic lines of high-speed ultrasonic inspection in production flow for different products: pipes, sheets, discs, rings, shafts, pistons etc., metal structures and other products’ blanks. Depending on inspection purpose the flaw detector may have up to 32 independent channels. Nondestructive inspection and thickness gauging of weld joints and base metal of products is performed at a speed of up to 2 m/s.

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Technical parameters •Number of channels •Operating mode •Implemented methods Shock pulse generator •pulse voltage •pulse time •generators operating mode

up to 32 video, radio, spectrum resonance-frequency, echo, through transmission 200V 50…500 ns serial, simultaneous

Pulse gate generating unit •discreteness of pulse gate generation •gate length •number of pulse gates in each channel

25 ns 100 ns…800mcs

Time measurement unit •time measurement discreteness •time measurement interval •sound speed range

25 ns

Frequency measurement unit •frequency measurement discreteness •frequency measurement range

Amplifier •gain adjustment range •band •sweep length •sweep delay

Sensitivity time adjustment unit •DAC gain factor adjustment range •time interval of DAC gain factor adjustment •number of DAC points

2 mcs…800 mcs up to 8.

Analog-to-digital transducer (ACP) •ACP digit capacity •accuracy •digitization frequency

10 +1 digit 40…80 MHz

Microcontroller •digit capacity •clock frequency •internal memory

32 90 MHz 32 MB.

Display modification

up to 7.

or

Keyboard •modification

100ns…1ms 1000…9999 m/s.

•dimensions •mass •voltage •power demand •continuous work time

10kHz, 20kHz, 40kHz 1.0…5.0 MHz 1.0…10 MHz 1.0…20.0 MHz

80 dB

electroluminescent, size 117x88 mm color liquid-crystal, size 130x100 mm film-type, airproof, 12 keys 620x210x230 mm 20 kg 220V+10% 300VA at least 24 hours.

Detector can be connected to •external computer; •distance and/or photographic shutters sensor; •turning angle sensor; •defect markers; •external mechanisms control unit.

85 dB 1.0…20.0 MHz 15…1000 mcs 0…500 mcs.

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Transducers, instruments and tools for manual ultrasonic inspection • Ultrasonic piezoelectric transducers • Manual ultrasonic inspection units • Samples and tools

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Ultrasonic piezoelectric transducers LLC “Ultes” offers piezoelectric transducers for ultrasonic flaw detectors and thickness gauges of domestic and foreign manufacturers, meeting the requirements of current regulatory documents.

Ultrasonic transducers of general use General use transducers are designed for solution of majority of tasks of nondestructive inspection. Produced normal, angle, PC – transducers are peculiar for high reliability, modern operating characteristics and technical parameters.

Normal transducers (P111 series) Type codes P111-1,25S P111-1,8S P111-2,5S P111-2,5S P111-4,0S P111-5,0S

Frequency, MHz

Piezoelectric element diameter, mm

1,25±0,1 1,8±0,14 2,5±0,2 2,5±0,2 4,0±0,3 5,0±0,4

18 18 12 20 12 8

Housing size (diameter*height), mm 26*41 26*41 18*41 26*41 18*41 15*41

Transmit-receive normal transducers (P112 series) Type codes

Frequency, MHz

Piezoelectric element diameter, mm

Housing size (diameter*height), mm

P112-1,8- 12/2

1,8±0,14

12/2

18*41

P112-2,5- 10/2

2,5±0,2

10/2

18*41

P112-5,0- 5/2

5,0±0,4

5/2

15*41

Angle transducers (P121 series) Angle transducers produced by LLC “Ultes” are distinguished for low level of reverberation noise and increased signal/noise ratio due to application of modern materials, availability of special noise absorbers, and optimization of prism geometry. The transducers feature wear-resistant layer on the working surface and small size Lemo 00. For ultrasonic inspection of pipes and containers the transducers are made with cylindrical working surface

fit for inspected diameter. Angle transducers (P121 series) can be produced with other entry angles (30, 35, 55 etc.), for other frequencies (1.25 mHz, 2.0 mHz, 4.0 mHz), other diameters and sizes of piezoelectric elements and can be used with any ultrasonic detector. Customized transducers are equipped with identifier (memory chip with transducer parameters) for application with UMU “Scanner” detectors.

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TRANSDUCERS, INSTRUMENTS AND TOOLS FOR MANUAL ULTRASONIC INSPECTION

Type codes

Frequency, MHz

Piezoelectric element diameter, mm 12 12 12 12 12 12 12 12 12 12 12 12 8 8 8 8 8 8 10 8

X - value, mm

1,8±0,2 1,8±0,2 1,8±0,2 1,8±0,2 1,8±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4

Angle of transducer, degrees 40°±1° 45°±1° 50°±1° 60°±1° 65°±1° 40°±1° 45°±1° 50°±1° 60°±1° 65°±1° 70°-2° 90°-2° 40°±1° 45°±1° 50°±1° 60°±1° 65°±1° 70°±1° 75°-2° 90°-2°

P121-1,8-40S P121-1,8-45S P121-1,8-50S P121-1,8-60S P121-1,8-65S P121-2,5-40S P121-2,5-45S P121-2,5-50S P121-2,5-60S P121-2,5-65S P121-2,5-70S P121-2,5-90S P121-5,0-40S P121-5,0-45S P121-5,0-50S P121-5,0-60S P121-5,0-65S P121-5,0-70S P121-5,0-75S P121-5,0-90S P121-10,0-70S P121-10,0-75S

10,0±0,8 10,0±0,8

70°±1° 75°-2°

6 6

5 6,5

7 7,5 8 8 8,5 7 7 8 8 8,5 9 — 5,5 5,5 6 6 6 6 8 —

Housing size (l*w*h), mm casting housing 40*20*30

standard modification, 23*15*20

maxi modification (“V”index), 28*15*22

casting housing, 28*15*22 standard modification, 20*11*20 mini modification (“M”index),20*11*11 maxi modification (“V”index), 20*11*25

Specialized transducers for ultrasonic inspection of metal weld joints Specialized transducers are used in cases when application of standard transducers is difficult, impossible or inefficient. For example, angle sdual probe (chord, “Tandem”, “Duet”) are used for inspection of thin-wall butt joints of pipes, for inspection of three way weld joints etc. Specialized transducers gave a good account of themselves in different industries. There are positive feedbacks from companies of different branches of industry.

Ultrasonic chord focusing transducers RSM – 5F Transmit-receive angle focusing transducers RSM-5F are designed for quality inspection of butt weld joints of pipelines of small diameter 16…51 mm with wall thickness of 1.5…6.0 mm. Focusing of ultrasonic beam allows detecting of defects with diameter of 0.1 mm and more. Chord circuit used in the transducer is hypersensitive to detection of air holes and in-plane defects (cracks, poor penetration), ensures high interference resistance as for signals from beads and slacks of weld joint. There is no transverse scanning at the time of defect screen. The transducer can be used with with ultrasonic detectors of domestic and foreign manufacturers. Methods of RSM-5F application are approved by RF Federal Committee for Mining and Industrial Supervision. There are positive feedbacks from companies, using this transducers.

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Type codes RSM-5F-16 RSM-5F-18 RSM-5F-21 RSM-5F-25 RSM-5F-28 RSM-5F-32 RSM-5F-36 RSM-5F-38 RSM-5F-42 RSM-5F-45 RSM-5F-48 RSM-5F-51

Controlled diameters, mm 16 18 21 25 28 32 36 38 42 45 48 51

Controlled thicknesses, mm

Housing size (l*w*h), mm 50*17*16

1,5…6,0

Any other transducers for ultrasonic inspection of pipes with diameter of 10...325mm*1,5...9mm

Ultrasonic transducers of “Duet” type (P122 “Duet” series) Transmit-receive angle transducers of “Duet” type are designed for ultrasonic inspection of thin-wall weld joints of pipelines with diameter from 57 mm and more and wall thickness of 2.5…6.0 mm. The transducer operating frequency is 5 MHz. Entry angle is 70 degrees. Application of discrete connection circuit ensures elimination of reverberation disturbances and reduces the blind area to 0…0.5 mm. “Symmetric duet” circuit is hypersensiType codes

P122-5.0-70 “Duet”

Controlled diameters, mm 57…63 75…89 102…114 127…168 194…219 flat (more than 219)

tive to detection of root defects due to sender turn relative to receiver and focusing of the beam in the working area. Adjustment method – standard (per “cuts”, “segments”). The working surface of transducers has wear-resistant layer, extending service life. The transducers can be used with ULTRASONIC FLAW DETECTORS of domestic and foreign manufacturers.


Housing size (l*w*h), mm 24*18*22

2,5…6,0

Ultrasonic transducer SP5-75KUS (“twin tandem”)

Transmit-receive angle ultrasonic transducer SP5-75KUS is designed for quality inspection of butt weld joints of pipelines, containers and metal structures with wall thickness of 2.5…12 mm. The transducer is based on “twin tandem” scheme. The transducer operating frequency is

5 MHz, entry angle – 73…75 degrees. Twin transducers scheme ensures high interference resistance with regard to slacks and is hypersensitive to detection of in-plane defects (cracks, poor penetration). Transducers of this type allow controlling of acoustic contact level and sensitiv-

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ity, as far as they generate additional echo pulse of acoustic contact, which can be seen on detector’s display. The availability of acoustic contact pulse makes it possible to inspect the painted surface. During inspection the scanning is made by the transducer only along the weld joint. The transducers are produced with wear-resistant working surface. The availability of wear-resistant layer extends service life 5…10 times.

SP5-75KUS transducers are used for inspection of products with diameter from 57 mm to plane. The transducer may have special configuration – with magnetic retention on the inspected product (SP5-75KUS MR). Methods of application are approved by RF Federal Committee for Mining and Industrial Supervision. There are positive feedbacks from companies, diploma of international exhibition, patent.

Type codes

Controlled diameters, mm


Housing size (l*w*h), mm

SP5-75KUS SP5-75KUS MR

from 57 to plane from 57 to plane

2,5…12 2,5…12

44*20*35 44*28*35

Specialized transducers for ultrasonic inspection of threaded part of tool joints

Manual ultrasonic inspection of threaded parts of tool joints is made by special gap junction transducers using radial support. The following transducers are used for inspection: • P312-4-MTG; • P311-5S MUG; • P321-4-60S NUG; • P321-4-68S MUG.

The applied transducers insonify the threaded part shank of tool joints ensuring reliable detection of cracks. Gap junction is ensured by contact fluid (water) which is supplied through flexible hose, connected to a tap on the transducer’s housing, and fills the gap between the transducer and inspected product.

Specialized transducers for ultrasonic inspection of aircraft industry parts

Specialized transducers for ultrasonic inspection of aircraft industry parts are developed and being produced: •Angle combined transducer of P121-5-70 type for detection of cracks around the holes in sheet elements of aircraft structures;

•Normal combined transducer of P111-5.0-00 type for detection of cracks in pins of air propellers; •Normal transmit-receive transducer of P1125.0-00 St type for detection of defects in buckets of air propellers.

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Specialized transducers for ultrasonic inspection of weld joints of polyethylene pipelines “Duet” and “Tandem” ultrasonic transducers

For ultrasonic inspection of weld joints of polyethylene pipelines, connected by means of contact welding, one applies specialized ultrasonic transducers type P122-1.8 “Duet” and “Tandem”, which for comparatively short period of application approved themselves in field and production conditions. Discrete connection circuits, wide entry angles allow reliable detection of vertical planar defects of Type codes P122-1,8-72 «Duet» 63 P122-1,8-65 «Duet» 110 P122-1,8-65 «Tandem» 110 P122-1,8-65 «Duet» 160 P122-1,8-50 «Tandem» 160 P122-1,8-60 «Duet» 225 P122-1,8-45 «Tandem» 225 P122-1,8-60 «Duet» 315 P122-1,25-45 «Tandem» 315 P122-1,8-60 «Duet» P122-1,25-43 «Tandem» P122-1,8-60 «Duet» P122-1,25 «Tandem» PE

weld joint cross-section at a high signal/noise ratio. The adjustment shall be per flat-bottom holes. Methods of application are approved by RF Federal Committee for Mining and Industrial Supervision. The production of transducers for different standard sizes of polyethylene pipes SDR9, SDR11, SDR17.6 etc. made of polyethylene PE-80, PE-100 etc. is available.

Controlled diameters, mm 63

Controlled thicknesses, mm 5,8…6,3

Housing size (l*w*h), mm

110

10…11,4

«Duet» 28*28*22

160…180

14,6…16,4

200…225

18,8…20,5

300…330

28…34

350…400

36…42

450…600

48…54

«Tandem» 32*15*30

«Duet» 28*28*22 «Tandem» 64*26*26

Transducers for underwater ultrasonic inspection

For underwater ultrasonic inspection one uses transducers made in specialized housing – for

easy operation in diver’s glove. The transducer is equipped with airproof detachable connections.

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Type codes P121-1,8-40SUW P121-1,8-50SUW P121-1,8-65SUW P121-2,5-40SUW P121-2,5-45SUW P121-2,5-50SUW P121-2,5-60SUW P121-2,5-65SUW P121-2,5-70SUW P121-5,0-40SUW P121-5,0-45SUW P121-5,0-50SUW P121-5,0-60SUW P121-5,0-65SUW P121-5,0-70SUW SP5-75SUW P111-2,5SUW P111-5,0SUW P112-5,0SUW P112-2,5SUW

Frequency, MHz 1,8±0,2 1,8±0,2 1,8±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 2,5±0,2 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 5,0±0,4 2,5±0,2 5,0±0,4 5,0±0,2 2,5±0,4

Angle of transducer, degrees 40°±1° 50°±1° 65°±1° 40°±1° 45°±1° 50°±1° 60°±1° 65°±1° 70°-2° 40°±1° 45°±1° 50°±1° 60°±1° 65°±1° 70°±1° 75°-2° 0 0 0 0

Special connecting cables 50 m long with metal slidewire are supplied together with the transducers.

Piezoelectric element diameter, mm 12 12 12 12 12 12 12 12 12 8 8 8 8 8 8 10 12 8 8/2 12/2

X - value, mm 7 8 8,5 7 7 8 8 8,5 9 5,5 5,5 6 6 6 6 — — — — —

Methods of application are approved by RF Federal Committee for Mining and Industrial Supervision.

Specialized gap junction transducers tant housing with contact fluid feed system and ultrasonic transducers. To ensure gap junction the transducer is put into wear-resistant housing and fixed by press bar from the top. The contact fluid is supplied through flexible hose, connected to a tap on the transducer’s housing, and fills the gap between the transducer and inspected product. Depending on inspection purpose one applies transducers with the frequency of 2.5; 4.0; 5.0 MHz:

Gap junction transducer are designed for ultrasonic defect detection, thickness gauging of weld joints and base metal of pipes, containers, tanks, vessels, sheets and other products for gap inspection using water as contact fluid or anti-freezing fluids. Specialized gap junction transducers are used as a part of manual, mechanical or automatic ultrasonic inspection units in factory and field conditions. Transducers consist of bearing wear-resis-

•Normal combined transducer (P311G series); •Normal transmit-receive transducers (P312G series); •Angle transducers (P321G series) with entry angles 45°, 50°, 60°, 65°, 68°, 70°, 73°, 75°. Gap junction transducers are peculiar for more than 10 times increased transducers capacity and use of water as contact fluid.

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Manual ultrasonic inspection units UN-1 – ultrasonic inspection unit for lap-welded joints

UN-1 unit is designed for ultrasonic inspection of lapwelded joints to detect inadmissible discontinuities in weld joint cross-section. The unit consists of two ultrasonic transducers P121 – 5 - 45⁰ and mechanical device equipped with a guide and fixing screw. The unit can be used for mirror through transmission and echo method

of ultrasonic inspection. Methods of UN-1 application are approved by RF Federal Committee for Mining and Industrial Supervision. For inspection of products with different thicknesses one can apply transducers with corresponding entry angles: 45°, 50°, 60°, 65°.

UP-1 – ultrasonic inspection unit for weld joints crosslines

UP-1 unit is designed for ultrasonic inspection of crosslines (intersections) of weld joints or detection of transverse defects of butt weld joint. The unit consists of two ultrasonic transducers P121-5-70⁰ and

mechanical device equipped with two guides and lock screw. The unit features the following ultrasonic inspection schemes: symmetric and asymmetric “Duet”.

UMBT-1 – mechanical unit for ultrasonic inspection of drill pipes

Mechanical unit for ultrasonic inspection of drill pipes with 60…168 mm diameter is designed for detection of inadmissible defects and corrosion in drill pipe crosssection and for detection of crack-type defects in threaded part of tool joints. UMBT-1 is supplied with a set of gap junction transducers: •P321 – 2.5 – 73⁰SG, P321 – 2.5 – 68⁰SG – for ultra-

pipe base metal (detection of crack-type defects); •P312 -5.0- 5/2G - for ultrasonic inspection of base metal (corrosion detection); •P311 – 2.5G, P321 – 2.5 – 60⁰G for ultrasonic inspection of the threaded part of tool joints from the support shelf side (without unit application). The unit is used with gap joint transducers with water or anti-freezing fluid as contact fluid.

sonic inspection of the threaded part of tool joints and

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MASKA-05 – mechanical unit for ultrasonic inspection of concrete structure reinforcements Mechanical unit MASKA-05 is designed for nondestructive quality inspection of weld joints of concrete structure reinforcements. Ultrasonic inspection is performed for weld joints of S5-S20 type, which appearance and dimensions conform to requirements of GOST 10922-90 and GOST 14098-85. MASKA-05 can be used for inspection of joints of reinforcement bars with diameter from 20 to 80 mm with the ratio from 0.5 to 1.0. Methods and means of ultrasonic inspection allow detection of internal defects of weld joints which size is

at least 5% of bar sectional area without interpretation of defect nature and its position in the weld joint. MASKA-05 is used for mirror through transmission inspection. The unit is equipped with specialized piezoelectric transducers of P323N type, which shall conform to requirements of GOST 23858.

MASKA-ZD – mechanical unit for ultrasonic inspection of inserts Ultrasonic inspection is characterized by high accuracy, efficiency, productivity, safety and ensures complete (100%) inspection. Application of the inspection method increases the quality of inserts welding, reliability and durability of structure of precast and cast reinforced concrete. In the course of development of mechanical unit MASKA-ZD the requirements of GOST 14782-86, GOST 14098-85, GOST 10922-90, СН 393-78, GOST 380-88, GOST 5781-82, GOST 10884-82 are complied with.

Mechanical unit MASKA-ZD is designed for nondestructive quality inspection of weld joints of T-welded inserts under flux layer in an atmosphere of carbon dioxide using manual arc welding. Ultrasonic inspection of weld joints of inserts is performed in order to detect such defects as cracks, poor penetrations, slag inclusions, pores, and to detect inadmissible values of anchor settling, influencing the strength of weld joint.

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Blocks and tools

The samples are used for characterization of ultrasonic detectors, thickness gauges, transducers and adjustment of inspection parameters. State standard samples and quality control samples are supplied with technical certificates confirming performance of calibration and certification in the established order.

Calibration blocks A set of state standard samples CB-2 and CB-3, produced according to GOST 14728-86, is supplied in a shipping case.

Reference blocks LLC “Ultes” offers a wide range of reference blocks according to requirements of different regulatory documents. The blocks can be made of various materials: steel, titanium, aluminum, polyethylene etc. The reference blocks can be made of customer’s materials. There are flat and cylindrical blocks with different sizes of artificial reflectors: •nicked according to Gazprom STO 2-2.4-083-2006; RD-19.100.00-КТN-299-09; RD 19.100.00-КТN-00110; PB 03-585; ОP501; «ROSEK»; SNiP; АК “Trans-

neft” etc. and GOST 23118; •with flat-bottom holes for chord and “tandem” transducers; •for ultrasonic inspection of bends according to IN No.23-SD80; •with flat-bottom holes for ultrasonic inspection of polyethylene weld joints; •with segmental reflectors according to STO 00220 256-005-2005 (OST 26-2044); •“step” with 3 thicknesses (3 mm, 10 mm and 25 mm).

Connecting cables

High-quality connecting cables 1.8 m long with the following sizes: lemo, BNC, CP50. High-frequency connecting cables up to 50 m long for underwater inspection.

Matching filters Filters for operation of unmatched transducers with broad-band domestic and foreign detectors for the following frequencies: 1.8; 2.5; 5.0; 10.0 MHz.

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Mobile units for semiautomatic and automatic ultrasonic inspection • UMU “Skaruch” Small-size unit for ultrasonic inspection of weld joints and base metal • AUI unit for girth weld joints, UMU “Scanner” series (“UMKa” model) • SAUI unit for weld joints of sheets, containers • SAUI unit for balloons • SAUI unit for base metal of pipes, containers • SAUI unit for detection of exfoliations of sheet base metal • SAUI unit for thin-wall pipes of small diameter • SAUI unit for vessel head supports • SAUI unit for polyethylene pipelines • SAUI unit for shafts • SAUI unit for drill pipes • Mobile unit for high-speed SAUI of drill pipes • UMBT-2 - mechanical unit for ultrasonic inspection of drill pipes • UMU “Skaruch-PV1” for underwater ultrasonic inspection • Mechanical ultrasonic inspection system for weld joint reinforcing bead 20 2 0

UMU “Skaruch”

Small-size ultrasonic measuring unit of “Scanner+” series – “Skaruch” model (UMU “Skaruch”) is designed for prompt detection and characterization of defects of weld joints and base metal of pipelines, containers and metal structures with wall thickness of 4…60 mm and for thickness gauging of products with thickness of up to 100 mm. When using multichannel set UMU “Skaruch” for ultrasonic quality inspection of weld joints and base metal the scanning is performed by manual shifting of a system of transducers. The shifting shall be along the inspected joint or a part of base metal at a speed of up to 1.0 m/ min. The inspection is carried out with automatic recording and interpretation of results. The inspection can be carried out both in workshop and during installation works.

small-size unit for ultrasonic inspection of weld joints and base metal

sides of the joint according to different schemes: combined, “tandem”, “duet” etc. On each millimeter of the way the pulse height per each scheme of ultrasonic inspection is registered and processed in detector according to set algorithm. Transducers of acoustic units are equipped with wear-resistant layer to protect the working surface from wear and tear. Universal mechanical device is designed for placement and connection of acoustic units, attachment of the acoustic unit to the product. The mechanical device is equipped with sensor of the scanned distance and indicators of acoustic contact failure and detected defects. Information cable is used for data exchange between acoustic unit and detectors. Information cable is connected to flaw detector rear panel.

Operating parameters

“Skaruch” composition

•16 different schemes of scanning on each millimeter of inspected product; •detection of internal defects (pores, slag inclusions, poor penetration, cracks etc.); •characterization of defects (volumetric, planar-volumetric, planar); •evaluation of parameters of defects (length and depth); •thickness gauging of the scanned surface base metal with the area width of up to 200 mm; •automatic control of acoustic contact with the product; •automatic setting and adjustment of ultrasonic inspection parameters with allowance for roughness; •self-monitoring of electronics and acoustic system operability; •automatic recording, storing and interpretation of

•small-size eight-channel detector UMU “Skaruch”; •multielement acoustic unit; •mechanical device with covered distance sensor; •information cable. Eight-channel detector is designed for generation of electric signals and excitation of piezoelectric-crystal plates of ultrasonic transducers in acoustic units, reception and processing according to set algorithm of signals from acoustic units, output of information about detected defects, their coordinates, type and size. Acoustic unit is purposed for emission of ultrasonic vibrations and subsequent reception of echo waves. Acoustic unit consists of 8…14 transducers 4…7 on each side of the joint. Transducers have different entry angles and scan the whole cross-section of weld joint simultaneously on both

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MOBILE UNITS FOR SEMIAUTOMATIC FOR MANUAL AND AUTOMATIC ULTRASONIC INSPECTION

nondestructive inspection results; •transfer of inspection results into the memory of connected computer; •printing out of inspection results by means of connected computer; •independent power supply.

Sample printout of ultrasonic inspection results by inspection of butt joint with 20 mm thickness

Technical parameters •recording discreteness of: distance sensor – 1 mm; defect parameters – 1 mm; thickness – 0.1 mm; •measuring of weld joint defect parameters with an accuracy of: length + 1 mm; depth + 0.5 mm; •determination of defect coordinates along the joint with an accuracy against covered distance of not more than 1%; •ultrasonic inspection speed – up to 1 m/min; •number of channels – 8; •number of scanning schemes – 16; •frequency range – 1.0…10.0 MHz; •maximum gain per each channel – 90 dB; •gain adjustment range – 85 dB; •maximum scanning depth (longitudinal waves) – 10000 mm; •batteries (6 x 1.2V) continuous work time – 8 hours; •operating temperature range: -20⁰C…+45⁰C; •operating mode setting time, min – 1; •detector dimensions – 200x225x90 mm; •detector weight (with batteries) – 3.5 kg.

Notes to interpretation of results A part of weld joint 140 mm long was inspected. Five defected areas are detected: 1. In the middle layer of the joint cross-section there is a volumetric defect 10 mm long (beginning – 1st mm, end – 10th mm), diameter 2 mm. 2. In the top layer of the joint cross-section there is a planar-volumetric defect 23 mm long (beginning – 15th mm, end – 37th mm), maximum size 3 mm. 3. In the bottom layer of the joint cross-section there is a planar defect 22 mm long (beginning – 49th mm, end – 70rd mm). 4. From 94rd mm to 100th mm there are point defects (1 mm in size) in the bottom, middle and top layers. 5. In the top layer of the joint cross-section there is a mainly planar-volumetric defect 14 mm long (beginning – 111th mm, end – 124th mm), 2 mm in size.

Presentation of weld joint inspection results Checking of automatic inspection results on detector display. One can review the inspection results by activating the corresponding option in detector menu. In this case the overall pattern of the joint defectiveness or inspected area of the wed joint (type D display) is displayed. Cursor is controlled by parameters adjustment handle which is located on detector panel or by means of keys. The detector insures review of results in form of digital line-by-line table (see printouts of weld joint inspection results).

Printout of inspection results The results of ultrasonic inspection can be printed out in form of line-by-line table on a standard piece of paper (A4 format). The printer is connected to connecter on the rear panel of UMU “Skaruch” by means of cable.

Presentation of inspection results by scanning thickness gauging and detection of exfoliations One can review the results of automatic thickness gauging by activating the corresponding option in detector menu. In this case the overall pattern (type D display) of the whole inspected area with back surface relief is displayed.

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Review of results of automatic thickness gauging on detector display

connecter on the rear panel of UMU “Skaruch” by means of cable. All reports have uniform heading containing the following information: •date, inspection start and end time – automatic determination; •the field for inspected object name is filled in by the operator; •the number of scanned area is inputted by the operator before inspection; •diameter of the inspected product is inputted by the operator;

•thickness threshold value is inputted by the operator before inspection;

Cursor is controlled by parameters adjustment handle or by means of keys. The detector insures review of results in form of digital line-by-line table of thicknesses of inspected area including under each transducers of acoustic unit (see sample printouts of thickness gauging results).

•number of the used unit is inputted by the operator after unit switching on; •temperature inside the detector is determined by the temperature sensor.

The results of performed ultrasonic inspection can be printed out in form of line-by-line table on a standard piece of paper of A4 format. The printer is connected to Sample printout of ultrasonic inspection results

In the first column of the report table there is a coordinate of the inspected area with 2mm discreteness, in the next 4 columns there are thicknesses registered by transducers No.1, 2, 3, 4.

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Application of UMU “Skaruch” in the manual ultrasonic flaw detector-thickness gauge mode Operation in the manual flaw detector-thickness gauge mode is peculiar for simple control and various functions. The detector can be used with any piezoelectric transducer in operating frequency range.

Operating parameters Main menu 0 – Automatic 8-channel flaw detector (see “Skaruch”) 1 – General purpose flaw detector 2 – Manual thickness gauge 3 – Automatic scanning thickness gauge (see “Skaruch”) 4 – Settings 5 – Inspection results review 6 – Memory cleaning 7 – Service life (see below) 8 – Electroacoustical channel test (see “Skaruch”)

Service life Temperature inside the detector Battery charge Free memory capacity Current date and time

Settings Selection of model and printer encoding pages Selection of interface language (Russian, English, Turkish) Power saving and autosave function on/off Selection of measurement units (mm/mcs)

Thickness gauge Ultrasonic scan display Digital display of product thickness Display of echo pulse arrival time Availability of AGC mode and second pulse gate

DAC and AGC modes Number of DAC adjustment points – up to 8 AGC adjustment range -6 … +18 dB

“Two pulse gates” (TG) mode Measuring of echo pulse arrival time in each pulse gate. Indication of product thickness if coating is available.

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Storing and printing out of flaw detector display image Flaw detector memory allows storing of up to 1000 display images with accompanying information. Ultrasonic images stored in flaw detector can be copied into the memory of connected computer and printed out by means of program for visualization of inspection results.

Inspection results stored in the flaw detector memory can be printed out on printer connected to detector.

Sample report with results of manual inspection

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Automatic ultrasonic inspection unit for girth weld joints, UMU “Scanner” series (“UMKa” model) Composition of AUI “Scanner” series (“UMKa” model) •multichannel flaw detector of “Scanner” series – “Skaruch+” model; •transport system; •quick-detachable support band (a set of bands for ø 1020; 1220; 1420 mm). By additional order the following bands can be produced: ø 426; 530; 630; 720; 820 etc. •gap junction acoustic units: - AB1G (H = 6…26 mm), - AB2G (H = 27…40 mm). By additional order one can produce units for thickness range up to 80 mm.

The unit is designed for automatic ultrasonic inspection of weld joint and base metal of transfer oil and gas pipelines in factory and field conditions used to detect inadmissible defects of girth joints of pipelines according to requirements of: •STO GAZPROM 2-2.4-083-2006 •STO GAZPROM 2-3.7-050-2006 (DNV-OS-F101) •RD 19.100.00-КТН-001-10 •STO 00220 256-005-2005 •RD 153-34.1-003-01 (РТМ-1с) •PB 03-585-03 •API-5L and other regulatory documents. Automatic ultrasonic inspection of weld joints is carried out at a scanning speed of up to 1.5 m/min. During inspection the nature and parameters of detected defects are evaluated. The acoustic contact is controlled on each millimeter of the weld joint. When using external computer there is an option of channel-by-channel recording of defects.

•power adapter and remote control; •connecting cables; •container for contact fluid with pump and hose. Unit peculiar features •compactness and mobility; •small weight and size; •easy operation; •reliable control; •quick installation of band; •possibility of acoustic block position adjustment with regard to weld joint axis during inspection; •expended service life of acoustic units; •possibility of operation at negative temperatures.

SAUI unit for weld joints of sheets, containers weld joint. Inspection results are stored in the detector memory. Unit composition: •ultichannel flaw detector of “Scanner” series – “Skaruch+” model; •mechanical device MD2, acoustic block, information cable I-2, additional software; Semiautomatic ultrasonic inspection unit is designed for nondestructive inspection of weld joints in factory conditions. The unit is also used for reverification of AUI results. SAUI of weld joints is carried out at a scanning speed of up to 1 m/min. During inspection the nature and parameters of detected defects are evaluated. The acoustic contact is controlled on each millimeter of the

•transfer and pressure device for mechanical acoustic unit with a bar; •contact fluid feed system; •paint marking system. The unit is supplied with two modifications of acoustic contact: contact and gap.

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SAUI unit for balloons SAUI unit for balloons is designed for nondestructive inspection of weld joints and base metal of type UBS25/150 etc. balloons during their manufacturing, regular certification and evaluation of technical condition of balloons with expired service life. SAUI unit composition: •multichannel flaw detector “Skaruch+” model;

of “Scanner” series –

•acoustic system with suspending mechanics; •data cable IK-2; •drain tank with balloon rotating mechanism; •contact fluid (water) closed-loop feed system from the tank to inspected area.

SAUI is carried out on painted surface of balloons. In the course of inspection there is a continuous control of acoustic contact level. Minimum detected defects of weld joints – 0.2 mm.

SAUI unit for base metal of pipes, containers SAUI unit for base metal of pipes, containers is designed for detection of such defects as exfoliations, longitudinal and transverse orientation defects according to requirements of GOST 17410, API5, ISO 3183-3, ISO 10124 etc. The unit is also applied for inspection of bevels, pipe ends, reverification of AUI results. The unit can be used together with the cart for inspection of sheets for detection of exfoliations and inadmissible wall thinning. Inspection speed: up to 1.2 m/min. Unit composition: •multichannel flaw detector of “Scanner” series – “Skaruch+” model; •acoustic multielement units with connecting cables; •“Exfoliation - Longitudinal – Transverse” mode selector switch;

•contact fluid (water) feed system to inspected area; •paint marking system; •coordinate system.

SAUI unit for detection of exfoliations of sheet base metal Semiautomatic ultrasonic control unit is designed for inspection of sheet products with 6.0…60.0 mm thickness carried out in order to detect such defects as exfoliations and inadmissible wall thinning. SAUI of sheets is performed at a scanning speed of up to 1m/min. The inspection results are stored in the detector memory. Unit composition: •multichannel flaw detector “Skaruch+” model; •transportation cart; •AB3G acoustic unit; •switching unit; •information cable; •a set of connecting cables; •contact fluid feed system.

of “Scanner” series –

The unit is supplied with gap acoustic contact.

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SAUI unit for thin-wall pipes of small diameter thickness, 5 mm long according to GOST 24030, TU 143R-197, GOST 17410 etc.

SAUI unit is designed for searching of longitudinal and transverse defects of the base metal of small-diameter pipes from 6 to 51 mm with wall thickness from 0.5 to 4 mm, made of stainless steel, titanium and other metals. Mechanical acoustic unit is moved manually by the operator at a speed of 0.2…0.3 m/min. Contact fluid (water) is fed into the inspected area from the drain tank through closed loop. Sensitivity of SAUI unit is adjusted according to artificial defects – groves with the depth of 4.5% of

SAUI unit composition: •multichannel detector of “Scanner” series – “Skaruch+” model; •pipe rotator with a set of clamps; •drain tank with a pump and connecting equipment; •cable reduction box for connection of transducers of acoustic unit; •multielement acoustic unit consisting of 4 focusing transducers with fasteners, local small-size tank and pad; •a set of cables; •a set of quality control samples. In addition SAUI unit can be equipped with computer with the program of channel-by-channel displaying and recording of inspection results.

SAUI unit for vessel head supports SAUI unit for vessel head supports is designed for inspection carried out in order to detect operating metal discontinuity of transverse and longitudinal type, and parts of the product with inadmissible thickness (beyond negative tolerance). Method of introduction of ultrasonic vibrations – immersion, contact fluid – distilled settled water. The unit is used in factory conditions. Acoustic block transfer type – progressive rotation. After 3 rotations of the manual mechanical drive handle the acoustic unit performs complete rotation (360°)

around the axis and moves 5 mm forward along the axis. Unit composition: The unit features immersion echo method of ultrasonic inspection of vessel head supports made of 08H18N10TVD (TU 14-1-2787-79) steel grade. Semiautomatic ultrasonic inspection is carried out with automatic recording and interpretation of inspection results. • multichannel detector of “Scanner” series – “Skaruch+” model; •multielement acoustic unit; •connecting cables with rotating transformer; •acoustic unit rotating and transferring mechanism.

SAUI unit for polyethylene pipelines Unit composition: •multichannel flaw detector of “Scanner” series – “Skaruch+” model; •band-type mechanical device UMKT (for ø63…315 mm); •multielement acoustic units AB-PE (ø 63,ø 110,ø 160,ø 225,ø 315 etc.); •connecting information cable IC-3.

SAUI unit is designed for nondestructive inspection of connections of polyethylene pipelines in field conditions.

Scanning is carried out with automatic recording of defects with presentation of results on detector display. Storing and printing out of inspection results is available in digital and graphic form.

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SAUI unit for shafts Semiautomatic ultrasonic inspection unit is designed for nondestructive inspection of rods, shafts etc. of rotation bodies. The unit is based on eight-channel flaw detector of “Scanner” series “Skaruch+” model installed on turning machine support. The machine is used for uniform rotation of the inspected product and transfer of acoustic unit. Multielement gap junction acoustic unit installed in cutter holder allows inspection of continuity according to requirements of OST108.95803-96. Diameters of inspected rods, shafts: 30…150 mm. Inspection speed: up to 1.2 m/min. The unit is equipped with coordinate system. Inspection results are presented on detector display. The inspection results can be stored in detector memory and printed out.

SAUI unit for drill pipes Mobile unit for high-speed SAUI of drill pipes is based on mobile eight-channel flaw detector AUMU “Scanner”. the unit is designed for SAUI of drill pipes ø 73…140 mm with wall thickness of 4…11 mm in order to detect longitudinal, transverse defects, perform thickness gauging and detection of pipe sections with wall thickness beyond negative tolerance, corrosion areas, exfoliations etc. The unit allows automation of drill pipes inspection by means of integration into the production line of the company (production area). Adjustment of inspection parameters is according to quality control samples produced according to current regulatory documents: GOST 17410, API5, API specification 7.1, RD41-01-25-89, RD39-2-787-82 etc. High-speed SAUI is carried out with automatic recording and interpretation of inspection results. Acoustic unit is transferred manually along the rotating pipe. Mobile unit can be supplied with the equipment for automatic transfer of acoustic unit along the pipe. Method of introduction of ultrasonic vibrations – gap, contact fluid – running drinking water or anti-freezing fluid.

Unit composition: •multichannel detector AUMU “Scanner”; •multielement gap junction acoustic unit; •mobile drain bath with a pump; •ø 73…140 mm pipe rotator with power adapter and control unit; •computing system.

Mobile unit for high-speed SAUI of drill pipes Mobile unit for high-speed SAUI of drill pipes is based on mobile eight-channel flaw detector AUMU “Scanner”. the unit is designed for SAUI of drill pipes ø 73…140 mm with wall thickness of 4…11 mm in order to detect longitudinal, transverse defects, perform thickness gauging and detection of pipe sections with wall thickness beyond negative tolerance, corrosion areas, exfoliations etc. The unit allows automation of drill pipes inspection by means of integration into the production line of the company (production area). Adjustment of inspection parameters is according to quality control samples produced according to current regulatory documents: GOST 17410, API5, API specification 7.1, RD41-01-25-89, RD39-2-787-82 etc. High-speed SAUI is carried out with automatic recording and interpretation of inspection results. Acoustic unit is transferred manually along the rotating pipe. Mobile unit can be supplied with the equipment for automatic transfer of acoustic unit along the pipe. Method of introduction of ultrasonic vibrations – gap,

contact fluid – running drinking water or anti-freezing fluid. Unit composition: •multichannel flaw detector AUMU “Scanner”; •multielement gap junction acoustic unit; •mobile drain bath with a pump; •ø 73…140 mm pipe rotator with power adapter and control unit; •computing system.

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UMBT-2 - mechanical unit for ultrasonic inspection of drill pipes Mechanical unit for ultrasonic inspection of drill pipes is used as a part of eight-channel unit UMU “Skaruch+” for the purpose of detection in base metal of drill pipes of: •longitudinal orientation defects (4 transducers P321-2.5 - 68⁰SSK); •transverse orientation defects (4 transducers P321-2.5 - 45⁰SSK); •pipe base metal corrosion (4 transducers P321-5.0 – 5/2SK); The inspection is carried out based on gap acoustic contact. Contact fluid – water or antifreezing fluid

UMU “Skaruch-PV1” for underwater ultrasonic inspection “Skaruch-PV1” composition 1. Underwater set: •eight-channel flaw detector – thickness gauge “Skaruch-PV1”; •remote display; •multielement acoustic unit with embedded information cable; •mechanical device with inspected distance sensor. 2. Control and power connecting cable. 3. Power and computer link unit. 4. Computer. Eight-channel ultrasonic inspection unit UMU “Skaruch-PV1” is based on “Skaruch-PV1” flaw detector. The unit allows scanning inspection of weld joints and base metal of underwater sections of transfer pipelines ø 508…1420 x 7…40 mm with diving depth of up to 60 m.

Unit technical parameters •“Skaruch-PV1” weight – 26 kg; •control and power connecting cable: length

100 m

diameter cable permissible load

10 mm 300 kGf.

•connecting cable drum size 550x300x350 mm; •power and computer link unit is equipped with USB for PC connection, 220V power connector and connector for control and power cable. Scanning of the butt weld joint is performed by the inspector moving the mechanical acoustic unit along the weld joint axis. On each millimeter of weld joint there is simultaneous scanning of the joint crosssection on both sides. The unit operates in 16-stroke mode. Each stroke implements the specified inspection scheme.

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On each millimeter the flaw detector records pulse heights in all strokes which are then transferred to computer and processed according to specified algorithm. Time gate system and microprocessing of signals received from the defect by each transducer allows identification of the defect type (volumetric, planar, planarvolumetric) according to established algorithms and its

characterization on each millimeter. In the course of inspection the results are presented on computer display and on underwater remote display. If necessary the inspection results can be viewed after inspection on computer and printed out on printer connected to computer. Quality of the whole weld joint is evaluated based on inspection results according to regulatory documents.

Mechanical ultrasonic inspection system for detection of transverse defects of weld joint reinforcing bead Mechanical UI system is designed for detection of defects in weld joints of pipes, containers, vessels located across the joint. The inspection is carried out along the reinforcing bead through water. Mechanical UI scheme consists of mechanical acoustic unit with distance sensor and connecting cables. The housing of mechanical and acoustic unit is plastic. On each side of the housing there are stainless support bars to ensure the required gap between the mechanical acoustic unit and weld joint bead. The system sensitivity is adjusted according to artificial defects – groves with the depth of 5% of thickness and vertical holes 1.6 mm according to API-5, GOST 17410 etc. Advantages of UI system: •increased signal/noise ratio (more than 12dB); •high wear resistance; •expended service life.

UI system can be used with any ultrasonic flaw detector. Application of Ui system with multichannel flaw detectors of “Scanner” series “Skaruch+” model allows automatic recording of inspection results.

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Automatic ultrasonic inspection (AUI) units • AUI unit for pipe weld joints • AUI unit for seamless pipes • AUI unit for pipe ends • AUI unit for thin-wall stainless and titanic pipes • AUI unit for “pipe – pipe plate” weld joints • AUI unit for thread-soldered products and rotation bodies • AUI unit for pistons and rotation bodies • AUI unit for rings and rotation bodies • AUI unit for mill rolls

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AUI unit for pipe weld joints

Automatic ultrasonic measuring unit of “Scanner” series is designed for ultrasonic inspection of longitudinal and spiral weld joints and weld adjacent zones of pipes with 508…1420 mm diameter and wall thickness of 6…40 mm, made of low-alloy steel of such grades as St3, 10, 16GS, 17GS, 17G2S, 20 etc. with identical acoustic characteristics. AUI is carried out in order to detect such continuity defects as: cracks, poor penetration, incomplete fusion, slag inclusions, pores, discontinuity of longitudinal and transverse orientation according to regulatory requirements. Roughness of inspected pipes surface – hot-rolled supply condition. The inspection is carried out in workshop conditions. Acoustic contact – gap. Contact fluid – water. Inspection speed – up to 12 m/min.

Unit composition

•weld joint tracking; •acoustic contact quality tracking; •detection of defects of longitudinal and transverse orientation according to regulatory requirements; •marking of defective areas in the course of inspection; •presentation of inspection results on detector display; •presentation of inspection results on computer display; •accumulation and storage of inspection results (archiving). AUMU “Scanner” features echo, echo through transmission method of ultrasonic inspection for gap junction (gap – 0.5…0.7 mm).

AUI unit for pipe weld joints includes the following main units and systems:

The unit climatic modification is HL GOST15150: - temperature in inspection area from +5⁰C to +80⁰C;

•16-channel ultrasonic flaw detector AUMU “Scanner” with information processing, displaying and archiving system, operating and debagging software, control unit; •mechanical acoustic unit with 16 ultrasonic transducers, 8 pieces in each of two frames which are fastened to suspension; •weld joint tracking system; •coordinate system; •paint marking system; •contact fluid feed system; •connecting cables and auxiliary fittings. Structurally the unit is made as dust- and dampproof cubicle.

- temperature in the area of secondary equipment from +5⁰C to +30⁰C; - relative humidity up to 75% at a temperature of 0⁰C and atmosphere pressure of 84…106 kPa. In terms of environmental resistance (climatic factors, dust, moisture) the unit conforms to modification 4.1 according to GOST 23049-84. In terms of resistance to mechanical effect AUMU “Scanner” conforms to vibration resistant modification according to GOST 12997-84. In terms of resistance to aggressive environment AUMU “Scanner” conforms to standard modification according to GOST 23049-84. In terms of protection from electricshock hazard AUMU “Scanner” conforms to 01 class according to GOST 14254. •unit supply voltage – 220V + 10%;

Installation options

•power demand – 100 VA;

AUI unit ensures: •automatic inspection of weld joints and weld adjacent zone; •scanning of the whole cross-section of inspected metal;

•operating mode setting time – 1 min; •continuous work time – 24 hours; •channel-by-channel presentation of AUI results on computer display.

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AUTOMATIC ULTRASONIC INSPECTION UNITS

AUI unit for seamless pipes

•connecting cables and auxiliary fittings. Structurally the unit is made as dust- and dampproof cubicle.

Installation options AUI unit ensures: •automatic inspection of weld joints and weld adjacent zone; •scanning of the whole cross-section of inspected metal; •weld joint tracking; •acoustic contact quality tracking; •detection of defects of longitudinal and transverse orientation according to regulatory requirements; •marking of defective areas in the course of inspection; •presentation of inspection results on detector display; •presentation of inspection results on computer display; •accumulation and storage of inspection results (archiving).

Automatic ultrasonic measuring unit of “Scanner” series is designed for ultrasonic inspection of longitudinal and spiral weld joints and weld adjacent zones of pipes with 508…1420 mm diameter and wall thickness of 6…40 mm, made of low-alloy steel of such grades as St3, 10, 16GS, 17GS, 17G2S, 20 etc. with identical acoustic characteristics. AUI is carried out in order to detect such continuity defects as: cracks, poor penetration, incomplete fusion, slag inclusions, pores, discontinuity of longitudinal and transverse orientation according to regulatory requirements. Roughness of inspected pipes surface – hot-rolled supply condition. The inspection is carried out in workshop conditions. Acoustic contact – gap. Contact fluid – water. Inspection speed – up to 12 m/min.

Unit composition AUI unit for pipe weld joints includes the following main units and systems: •16-channel ultrasonic flaw detector AUMU “Scanner” with information processing, displaying and archiving system, operating and debagging software, control unit; •mechanical acoustic unit with 16 ultrasonic transducers, 8 pieces in each of two frames which are fastened to suspension; •weld joint tracking system; •coordinate system; •paint marking system; •contact fluid feed system;

AUMU “Scanner” features echo, echo through transmission method of ultrasonic inspection for gap junction (gap – 0.5…0.7 mm). The unit climatic modification is HL GOST15150: - temperature in inspection area from +5⁰C to +80⁰C; - temperature in the area of secondary equipment from +5⁰C to +30⁰C; - relative humidity up to 75% at a temperature of 0⁰C and atmosphere pressure of 84…106 kPa. In terms of environmental resistance (climatic factors, dust, moisture) the unit conforms to modification 4.1 according to GOST 23049-84. In terms of resistance to mechanical effect AUMU “Scanner” conforms to vibration resistant modification according to GOST 12997-84. In terms of resistance to aggressive environment AUMU “Scanner” conforms to standard modification according to GOST 23049-84. In terms of protection from electricshock hazard AUMU “Scanner” conforms to 01 class according to GOST 14254. •unit supply voltage – 220V + 10%; •power demand – 100 VA; •operating mode setting time – 1 min; •continuous work time – 24 hours; •channel-by-channel presentation of AUI results on computer display.

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AUI unit for pipe ends

Automatic ultrasonic measuring unit of “Scanner” series (model No.7.04) is designed for inspection of pipe ends in order to detect exfoliations, longitudinal and transverse defects along the whole thickness of the wall of steel seamless hot0rolled pipes with diameter of 159…426 mm and wall thickness of 6…40 mm in pipe production process. The inspection is carried out with automatic recording and interpretation of inspection results. Method of introduction of ultrasonic vibrations – gap. Length of inspected pipe ends – 300 mm. The unit ensures compliance with the requirements of ASTM E 213, ASTM A 106, SEP 1915, GOST 17410, ISO 3183-3, ISO 10124 for ultrasonic inspection of pipes made according to API 5L, API 5D, API 5 CT, GOST 632, GOST 633, GOST 550, GOST 8731. The unit is used in workshop conditions.

•acoustic units mass – 10 kg; •AB lifting – lowering mechanism mass – 45 kg; •control unit mass – 10 kg; •dimensions: - electronic unit – 620*210*230 mm; - acoustic unit – 255*150*45 mm; - control unit – 550*300*160 mm; •number of detector channels: - pulse generation – 32; - pulse reception – 32; •pilot pulse basic frequency – 1.0…20.0 MHz; •pilot pulse repetition frequency – 1000…5000 Hz; •generators operating mode: serial and simultaneous; •number of ASD pulse gates in each control channel – up to 5; •pulse gate adjustment – independent; •supply voltage – 220 + 10%V; •power demand – not more than 300 VA; •operating mode setting time not more than – 1 min; •operating pressure in pneumatic system – 7*105 Pa; •air consumption in pneumatic system – 1500 l/min; •continuous work time - at least 24 hours.

Unit composition •32-channel ultrasonic flaw detector AUMU “Scanner” with software for inspection results visualization and archiving; •acoustic units; •suspension system for acoustic units; •contact fluid feed system; •pneumatic mechanisms; •paint marking system.

Technical parameters •ultrasonic inspection object: steel pipes (low-alloy, carbon) seamless, hot-deformed; •diameter of inspected pipes – 159…426 mm; •wall thickness range – 6…40 mm; •pipe length – 8…13 m; •end curve – not more than 3 mm/m; •outside surface roughness – after rolling; •pipe temperature in inspection area - +5°C…+80°C; •pipe transportation type – rotation; •rotational speed – up to 120 mm/s; •electronic unit – detector mass – 20 kg;

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AUI unit for thin-wall stainless and titanic pipes

Automatic ultrasonic measuring unit of “Scanner” series (model No.6.03) is designed for nondestructive inspection of steel seamless cold- and hot-deformed pipes of steel grades 12H18N10T, 08H18N10T, 06H18N10T and other stainless steel grades with diameter of 5…90 mm and wall thickness of 0.2…10 mm in pipe production process. AUI unit allows complete inspection of the pipe and detection of pipe sections with wall thickness beyond tolerances, exfoliations, transverse and longitudinal orientation defects of metal. The inspection is carried out with automatic recording and interpretation of inspection results. Length of inspected pipes – 1.7…12.0 m. Method of introduction of ultrasonic vibrations – immersion, contact fluid – drinking water. The unit is used in workshop conditions. Climatic modification of the unit – HL GOST15150 and the unit ensures stable operation at: •environmental temperature from +5⁰C to +50⁰C; •relative humidity of up to 75% at a temperature of +25⁰C; •atmospheric pressure (84…106) kPa. Nondestructive inspection of pipe made according to: GOST 9941; GOST 19277; GOST 22897; GOST 24030; VS 17456; DIN 17458; АSТМ В337; АSТМ В338; TU 143-197; ТU 14-ЗR-197; ТU 14-3-219; ТU 14- 3-460; ТU 14ЗR-55; ТU 14-3-820; ТU 14-3-1070.

Unit composition and brief description AUI unit consists of pipe transportation device, immersion tank, acoustic unit and electronics rack with automation equipment. Pipe movement type in the inspection area is progressive rotation. Acoustic unit consists of six piezoelectric focusing transducers: four transducers are used for detection of defects, two – for measuring of thickness and tolerance failure. Continuity inspection for detection of longitudinal and transverse defects is carried out using pulse-echo method per combined connection circuit of transducers in automatic mode. At the same time distribution of ultrasonic vibrations occurs in two directions towards each other. Minimum detected defect – groove with 0.015 mm depth. Applied transducers: P211-5F. Wall thickness inspection (0.2…2.0 mm) is based on resonance frequency method. Applied transducers: P211-10F. Readability – 0.001 mm. Thickness gauging tolerance – 0.5%. Electronic unit has four channels for nondestructive inspection and two channels for thickness gauging. Pipe transportation device ensures progressive rotation. Inspection results are presented on detector display and computer display. The unit provides for input of auxiliary information and its printing out, and for operation with other external computing facilities. Acoustic contact is ensured by means of immersion tank with water. The unit provides for connection of additional channels and transducers in order to measure diameter of inspected pipes. The unit is maintained by one operator.

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UI unit for “pipe – pipe plate ”weld joints Automatic ultrasonic measuring unit of “Scanner” series (model No.25.08) is designed for nondestructive inspection of fusion penetration and quality of pipe – pipe plate weld joints , made by electron-beam welding. The inspected products shall have internal diameter of 5 and 20 mm, wall thickness of 1.5 and 3.5 mm respectively. The inspection is carried out with automatic recording and interpretation of inspection results. AUI is performed in order to detect defects of pipe – pipe plate weld joints (dry joints, cast seams, erosion) according to requirements of RD5.UEIA.2654-88. The unit is used in workshop conditions.

Unit composition •multichannel ultrasonic flaw detector AUMU “Scanner”; •main controller; •transportation mechanism; •computer; •printer.

Technical parameters Unit mass – not more than 40 kg

Continuous work time – at least 16 hours. Method of introduction of ultrasonic vibrations – gap. Contact fluid – distilled settled water. The unit scanning mechanism ensures progressive rotation of transmit-receive transducer with the interval of not more than 0.2 mm. Inspection results are presented on detector and computer display and stored in the memory of connected computer.

AUI unit for thread-soldered products and rotation bodies Automatic ultrasonic measuring unit of “Scanner” series (model No.24.08) is designed for nondestructive inspection of soldering quality of couplers made of titanium alloy PT-3V and steel grades 08H18N10T-VD and 10H18N10T-VD. Automatic ultrasonic inspection is carried out for couplers with outside diameter from 20 to 90 mm, wall thickness of external connecting pipe of not more than 3 mm for gap acoustic contact. The inspection is carried out with automatic recording and interpretation of inspection results. AUI is performed in order to detect defects (dry joints, cast seams, erosion) of thread-soldered joints of couplers according to requirements of RD5. UEIA.2748-89.

Unit composition •multichannel ultrasonic detector AUMU “Scanner”; •main controller; •unit mechanics; •сomputer; •printer.

Method of introduction of ultrasonic vibrations – contact or gap. Contact fluid – distilled settled water. The unit is used in workshop conditions. AUI unit provides for indication of inadmissible defects and their coordinates. Inspection results are presented on flaw detector and computer display and stored in the memory of connected computer.

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AUI unit for pistons and rotation bodies AUI unit is designed for detection of surface and internal defects in material of motor vehicle pistons in the course of mass production. The unit is integrated into piston production line.

Unit composition •multichannel ultrasonic flaw detector AUMU “Scanner”; •piston rotator; •immersion tank; •piston return and selection manipulator; •piston input, lifting and sorting sections; •multielement acoustic and eddy current units; •control and signal processing unit; •stamper.

AUI unit for rings and rotation bodies AUI unit is designed for detection of surface and internal defects of motor vehicle engines valve seats, made of high-strength cast iron, in the course of mass production. The unit is integrated into production line at the final stage of product processing.

Unit composition •multichannel ultrasonic flaw detector AUMU “Scanner”; •multielement acoustic unit; •inspected product rotator; •immersion tank; •defect flaw marker.

AUI unit for mill rolls Automatic ultrasonic measuring unit of “Scanner” series is designed for inspection of metal of barrels and conical necks of mill support rolls with diameter from 1200 to 1600 mm and length from 1000 to 4000 mm. The inspection is carried out in order to detect and measure surface, subsurface, internal defects and detection of incomplete fusion of weld deposition with base metal according to requirements of OST 24.023.22-81. Inspected mill rolls are made according to OST 24.013.04-90E of steel grades 60HN and 75HMF, 90HF. The inspection is carried out with automatic recording and interpretation of inspection results. •information processing, displaying and archiving system on computer; •acoustic unit coordinates tracking system; •contact fluid feed system; •auxiliary units and devices.

Unit composition •eight-channel ultrasonic flaw detector AUMU “Scanner”; •acoustic unit with ultrasonic transducers; •scanning mechanism

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Methodical and regulatory literature for ultrasonic inspection logical, Technical and Atomic Supervision, letter No.10-03/352 dated 03.04.2011.

For years of practical work LLC “Ultes” accumulated wide experience in development of methodological materials and regulatory documents concerning ultrasonic inspection of different products. In cooperation with design, research and development institutions the specialists of our company take part in development of professional regulatory documentation for manual and automatic ultrasonic inspection. LLC “Ultes” offers services regarding development and writing of new methodological and regulatory literature, and offers the following methods for application:

•UI method for weld joints of steel construction structures using UMU equipment of “Scanner” series”. Approved by Russian Federal Service for Ecological, Technical and Atomic Supervision, letter No.09-07/2056 dated 08.10.2007. •Mechanical UI method for factory and field weld joints of transfer pipelines with joint displacement of up to 25% of wall thickness, and weld joints of pipes with various thicknesses”. Approved by OJSC “Gazprom”, 2005.

•Method of application of ultrasonic measuring unit of “Scanner” series (manual scanner – ‘Skaruch”) for UI of weld joints and base metal of pipelines, containers, metal structures (SCAN 2.00.00.000.M.)”. Approved by Russian Federal Service for Ecological, Technical and Atomic Supervision, letter No.12-6/686 dated 16.07.99.

•UI method for welded T-bend with reinforcement plates of TSN type”. Approved by OJSC “Gazprom”, 2007. (Note: UI of T-bends before installation or in case of T-bend replacement.) •Evaluation method for stress-corrosion cracks depth considering their grouped localization on pipe surface by means of ultrasonic inspection”. Approved by LLC “Permtransgaz”, 2007.

•Method of application of ultrasonic measuring unit of “Scanner” series (manual scanner – ‘Skaruch”) for UI of weld joints and base metal of pipelines (SCAN 2.01.00.000.M.)”. Approved by Russian Federal Service for Eco-

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+7 (499) 267-99-77, 267-67-92, 261-46-49, 265-10-83, 265-17-82 building 3, 14, Tokmakov lane, Moscow, 105066, Russia [email protected] www.ultes.info

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