Periodic Reporting for period 2 - PolyTest (Ultrasonic Phased Array Non-Destructive Testing and In-Service Inspection System for high integrity Polyethylene Pipe Welds with automated analysis software.)
Reporting period: 2017-12-01 to 2019-11-30
• With the increased use of PE pipes having lower capital, installation, operation & maintenance cost and corrosion free service life, the lack of suitable NDT techniques to check integrity of welded joints between pipes was recognised.
• The primary objective was to take a recently developed FP7 inspection/NDT technology for polyethylene (PE) pipe welds, from TRL6 to TRL9 commercial product, to be exploited globally by project partners to the end user, Tier1/2 suppliers and other customers.
• Funding was used to implement scanner hardware enhancement, bespoke software, sector specific procedures, technique validation, technician training & certification, standards development, and the support for commercialisation of the technology.
• The target market covers end users, Tier 1/2 suppliers, in Power Generation (Nuclear Power Plant), Gas & Water Utilities, Mining industry and Process Plant industries, with a total size of 11.5billion welds. Additionally PAUT equipment and transducer suppliers and service inspection/NDT companies will benefit.
• This unique product has been made suitable for industry use i.e. site ruggedized, IP67 rated, validated with newly released standards, to meet target industry inspection applications for PE pipe welds.
• The primary objective was to take a recently developed FP7 inspection/NDT technology for polyethylene (PE) pipe welds, from TRL6 to TRL9 commercial product, to be exploited globally by project partners to the end user, Tier1/2 suppliers and other customers.
• Funding was used to implement scanner hardware enhancement, bespoke software, sector specific procedures, technique validation, technician training & certification, standards development, and the support for commercialisation of the technology.
• The target market covers end users, Tier 1/2 suppliers, in Power Generation (Nuclear Power Plant), Gas & Water Utilities, Mining industry and Process Plant industries, with a total size of 11.5billion welds. Additionally PAUT equipment and transducer suppliers and service inspection/NDT companies will benefit.
• This unique product has been made suitable for industry use i.e. site ruggedized, IP67 rated, validated with newly released standards, to meet target industry inspection applications for PE pipe welds.
Scanner hardware ruggedisation (D1.1) developments have enhanced the original FP7 prototype system, with bespoke standardised PA probes reducing wedge to one butt fusion (BF) and one electrofusion (EF) wedge, both capable of being fitted with two probe frequencies. • new lightweight aluminium links with safety grips improve scanner handing, • wedge bodies in 3D printed polymer reduces cost and lead time, • non-specialised commercial IP67 encoder contained within the carriage footprint, • redesign of fill and bleed system integrates components into wedge body, reduces parts count, enhances appearance, • carriage design encloses most moving parts with an ergonomic cover to aid scanner manipulation and reduce dirt ingress. BF wedge anechoic features have been redesigned to include specialised sound absorbing rubber to eliminate noise at angular extremities for BF weld scanning. The ‘radiation hardened equipment’ requirement was removed. A new GEKKO unit includes a bespoke PolyTest GUI with image based setup defining part and PAUT configuration for BF and EF inspection. The data analysis screen includes a range of manual analysis tools and a launch ‘ADR’ button implementing an Automatic Defect Recognition algorithm that displays results on the C-scan image with defect data logged in table form (D1.2). Validation sample BF and EF welds (D1.3) were made to validate the ADR process and defect detection and sizing, and for technician training and examination. Each weld contained lack of fusion (LOF) flaws made from aluminium foil discs, of different size and location to ensure that repeated patterns were avoided. For BF joints, three different diameters and wall thicknesses were used; 110mm (t=10.0mm); 315mm (t=28.6mm); 630mm (t=57.2mm) with the smallest flaw being 1mm diameter and the largest 8mm or 50% of the pipe wall thickness, whichever is smaller. For EF joints, fittings from three different manufacturers and three pipe diameters were manufactuered; 110mm, 225mm and 630mm all SDR11, with LOF flaws inserted at the interface between 2 and 50mm in diameter, in addition to pipe under-penetration between 0 and 20% into the fusion zone using an angled cut pipe end.
Industry Specific Procedures (D2.1) for each weld type was developed as templates incorporating the requirements of new EN/ISO Standards (Technical Specifications developed under Task 3.4) to be used to modify to each industry and client requirement, recognising that client requirements can differ within the same industry sector, hence producing documents covering all possible scope variations would be impractical. EF and BF procedures cover the PolyTest system application for ‘data acquisition’ to be conducted by Level 1 Operators, with associated calibration and setup requirements, reporting templates and reference block specifications, and subsequent ‘data analysis and reporting’ conducted by Level 2 Data Analysts. The procedures accommodate the full geometry range covered by the PolyTest system so can be quickly re-drafted to meet specific industry and client needs. Validation of PAUT results through CT/sectioning of samples (D2.2). The PolyTest inspection was applied to all validation samples with defect position and size recorded through manual analysis by two personnel. These results were then compared against the original defect insertion maps for position and sizing accuracy, with selected samples then subject to completed tomography or mechanical sectioning and POD data provided.
For D3.1/D3.3 a technician training syllabus and course materials bespoke to the PolyTest system was developed with an associated CSWIP Employer Specific certification scheme to meet the requirements of ISO9712. Training is directed at two cohorts; existing NDT providers and personnel from the plastic welding sector. Level 1 Operator is supplied as Blended Learning though remote online training for the theoretical aspects of NDT and plastic weld product technology, followed by formal classroom training with a practical bias. Level 2 Data Analyst training being all classroom based concentrating on practical scan data analysis and reporting. A PolyTest operator manual (D3.2) was developed for the scanner and forms core material for the training course, with practical exercises drawn from it to test personnel.
Conduct Field/site demonstration was conducted with the complete PolyTest system for the Nuclear PP at a UK fabrication facility, but demonstration was also carried out for water and gas industries during the project as detailed in D4.1.
The PolyTest website (D5.1) was published in February 2017 to provide information to public and contact with the project team, and has been maintained through the project. The commercial and business plan for introduction of the PolyTest inspection system to industry was developed (D5.2) with the ‘Batch production & unit assembly’ plan (D5.3) detailing the partner responsibilities for PolyTest system part/component/sub-assembly supply and for final assembly and testing.
Industry Specific Procedures (D2.1) for each weld type was developed as templates incorporating the requirements of new EN/ISO Standards (Technical Specifications developed under Task 3.4) to be used to modify to each industry and client requirement, recognising that client requirements can differ within the same industry sector, hence producing documents covering all possible scope variations would be impractical. EF and BF procedures cover the PolyTest system application for ‘data acquisition’ to be conducted by Level 1 Operators, with associated calibration and setup requirements, reporting templates and reference block specifications, and subsequent ‘data analysis and reporting’ conducted by Level 2 Data Analysts. The procedures accommodate the full geometry range covered by the PolyTest system so can be quickly re-drafted to meet specific industry and client needs. Validation of PAUT results through CT/sectioning of samples (D2.2). The PolyTest inspection was applied to all validation samples with defect position and size recorded through manual analysis by two personnel. These results were then compared against the original defect insertion maps for position and sizing accuracy, with selected samples then subject to completed tomography or mechanical sectioning and POD data provided.
For D3.1/D3.3 a technician training syllabus and course materials bespoke to the PolyTest system was developed with an associated CSWIP Employer Specific certification scheme to meet the requirements of ISO9712. Training is directed at two cohorts; existing NDT providers and personnel from the plastic welding sector. Level 1 Operator is supplied as Blended Learning though remote online training for the theoretical aspects of NDT and plastic weld product technology, followed by formal classroom training with a practical bias. Level 2 Data Analyst training being all classroom based concentrating on practical scan data analysis and reporting. A PolyTest operator manual (D3.2) was developed for the scanner and forms core material for the training course, with practical exercises drawn from it to test personnel.
Conduct Field/site demonstration was conducted with the complete PolyTest system for the Nuclear PP at a UK fabrication facility, but demonstration was also carried out for water and gas industries during the project as detailed in D4.1.
The PolyTest website (D5.1) was published in February 2017 to provide information to public and contact with the project team, and has been maintained through the project. The commercial and business plan for introduction of the PolyTest inspection system to industry was developed (D5.2) with the ‘Batch production & unit assembly’ plan (D5.3) detailing the partner responsibilities for PolyTest system part/component/sub-assembly supply and for final assembly and testing.
There has been great interest in the PolyTest system from the HDPE pipe installation/utilisation community. With EN/ISO and ASTM Standards in place for both BF and EF welds, only acceptance criteria remains an outstanding requirement for the industry. CSWIP Employer Specific training and certification meeting the requirements of ISO 9712 has been developed within the project to support the introduction of the PolyTest inspection system. This training offers routes for personnel from traditional NDT and plastic welding backgrounds through the use of Blended Learning, a mix of remote online theoretical and formal practical classroom based learning, culminating in CSWIP Certification examinations.
There is continues interest from the gas utilities sector to use the PolyTest system for smaller bore pipe EF joints (<90mm) and from the water and sewage sector for larger diameter BF welds (>900mmDIA and/or >72mm wall thickness) but each scenario would require system re-design and validation to extend the current capability range.
There is continues interest from the gas utilities sector to use the PolyTest system for smaller bore pipe EF joints (<90mm) and from the water and sewage sector for larger diameter BF welds (>900mmDIA and/or >72mm wall thickness) but each scenario would require system re-design and validation to extend the current capability range.