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This paper presents a novel approach for preload measurement of bolted connections, specifically tailored for offshore wind applications. The proposed method combines robotics, Phased Array Ultrasonic Testing (PAUT), nonlinear acoustoelasticity, and Finite Element Analysis (FEA). Acceptable defects, below a pre-defined size, are shown to have an impact on preload measurement, and therefore conducting simultaneous defect detection and preload measurement is discussed in this paper. The study demonstrates that even slight changes in the orientation of the ultrasonic transducer, the non-automated approach, can introduce a significant error of up to 140 MPa in bolt stress measurement and therefore a robotic approach is employed to achieve consistent and accurate measurements. Additionally, the study emphasises the significance of considering average preload for comparison with ultrasonic data, which is achieved through FEA simulations. The advantages of the proposed robotic PAUT method over single-element approaches are discussed, including the incorporation of nonlinearity, simultaneous defect detection and stress measurement, hardware and software adaptability, and notably, a substantial improvement in measurement accuracy. Based on the findings, the paper strongly recommends the adoption of the robotic PAUT approach for preload measurement, whilst acknowledging the required investment in hardware, software, and skilled personnel.
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Petrochemical plants use on-stream inspection often to detect and monitor the corrosion on the equipment and piping system. Compared to ultrasonic thickness gauging and pulse-echo A-scan, phased array corrosion mapping has better coverability and can scan a large area to detect general and localized corrosion. This paper's objective is to obtain documentary evidence for the accuracy of corrosion detection from 30 °C to 250 °C on A36 low-carbon steel by carrying out simulation experiments every 10 °C step. A minimum of three sets of phased array corrosion mapping data in each temperature were collected to study and evaluate the detectability. The data evidence could enhance the confidence level of the plant's end users in using phased array mapping in the future during inspections. The experiments were found to be insufficiently thorough despite addressing the initial concerns, leaving more area for discussion in further studies, such as expanding the investigation to thicker carbon steel, stainless steel, and wedge materials.
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Anchor bolts are often used for fixing information boards, supports, and soundproof walls in various facilities. Corrosion of anchor bolts and fatigue cracks occur frequently due to the various external environments, and visual inspection and hammering inspection are mainly used. In visual inspection, it is difficult to confirm corrosion or fatigue cracks of anchor bolts in the area where foundations, nuts, and base plates are installed. Additionally, the hammering inspection is easily affected by the surrounding environment and the subjective reaction of the tester. Therefore, it is necessary to develop a method that can easily and accurately detect defects such as cracks and corrosion occurring in anchor bolts installed in road facilities using non-destructive testing techniques. In this paper, the possibility and reliability of anchor bolt defects such as corrosion and cracks were experimentally verified by applying ultrasonic inspection among non-destructive inspection techniques for anchor bolt maintenance.
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The CLP (containment liner plate) of a nuclear power plant protects the internal system from the external environment and sudden changes in internal pressure or temperature, and it is a structure that blocks and protects radioactive materials leaking inside and outside in the event of a nuclear accident and is composed of a liner plate, reinforcing bars, tendons, and concrete. Recently, corrosion on the rear side of the liner plate and concrete voids has emerged as a severe defect in nuclear power plants across South Korea. Therefore, in this study, we proposed a new inspection method that a line-type inspection method applied phased array ultrasonic testing and the area inspection method applied acoustic resonance method using developed moveable tapper. The acoustic signals were signal-processed and reproduced to a mapping image following the inspection area, and with the image, it was possible to determine the type of defect. Furthermore, an automated inspection system for within the CLP was proposed.
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For the first time, the 9% Ni steel is being used in CO2 injection units in floating production storage offloading vessels. Pipe joints welded with nickel-based superalloy 625 as the filler metal present difficulties in ultrasonic inspection owing to the sonic attenuation and deviation caused by the anisotropic and coarse-grained weld metal. This study aims to conduct a probability of detection (POD) to evaluate the discontinuity detection reliability in 9% Ni steel arc welded joints. The inspections were performed using ultrasonic phased array transducers with transversal and longitudinal waves, by using both a conventional wedge formed of Rexolite® and an adapted wedge filled with water to simulate the immersion inspection. POD curves were developed using the hit/miss and â vs a models. The inspection performed with transversal waves detected much fewer discontinuities than that performed with longitudinal waves. Furthermore, inspection performed with longitudinal waves after weld metal cap pass removal exhibited much more reliability in 9% Ni steel welded joints. The obtained POD curves were shown to be a suitable tool to evaluate the inspection of 9% Ni steel welded joints, as they confirmed that the best inspection procedure involves a combination of three different phased array ultrasonic testing configurations.
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A circular array (CA) transducer is developed and validated to implement internal inspection of the small diameter tubes, one of whose potential application targets is the heat exchanger tubes in Modular High Temperature Gas-cooled Reactor. A geometric model of the transducer and the delay law are proposed according to the inspection setup. Using k-Wave, an open source acoustic simulation toolbox, the beam profiles of various aperture sizes are analyzed to select a suitable aperture. The beams with different focal depths are compared to verify the delay law and to choose a preferable focus. Reflector responses are simulated to predict the transducer's detection sensitivity. To validate the simulation results, a prototype transducer composed of 64 elements is fabricated. Its electrical and acoustical performances are acquired with a pulser-receiver. A 4-element aperture with the focal depth of 1.0 mm is selected to perform internal inspection experiment according to the simulation results. The eight longitudinal grooves with widths of 0.2, 0.3, 0.4, and 0.5 mm on inner and outer tube walls are applied as typical reflectors to test circumferential detection sensitivity. The other five grooves with depths from 0.1 mm to 0.5 mm are chosen to verify radial detection sensitivity. The experiment results demonstrate the detection sensitivity of the CA transducer reaches at least 0.2 mm in circumferential direction and 0.1 mm in radial direction. The CA is proven capable of inspecting small diameter tubes.
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The anisotropy and inhomogeneity exhibited by austenitic steel in welds poses a challenge to nondestructive testing employing ultrasonic waves, which is predominantly utilized for the inspection of welds in power plants. In this study, we assess the reliability of phased array ultrasonic testing (PAUT) by analyzing the flaw detection sensitivity of ultrasonic beams in anisotropic welds, based on the inspection conditions. First, we simulated the sectorial scan technique, frequently employed for the inspection of actual welds, while taking into account the ultrasonic wave mode, frequency, and shape and position of a flaw. Subsequently, we analyzed the flaw sensitivity by comparing A-scan signals and S-scan results. The sensitivity analysis results confirmed the detection of all flaws by considering at least two inspection methods based on the shape and position of the flaw. Furthermore, we verified our model by performing an experiment under the same conditions as the simulation and found that the results were in agreement. Hence, we find that the simulation modeling technique proposed in this study can be utilized to develop suitable inspection conditions, according to the flaw characteristics or inspection environment.