Abstract
IWEX is an innovative ultrasonic testing inspection methodology which went through a complete qualification program for Carbon Steel pipeline girth weld inspection, from DNV OS F101 certification to implementation on a pilot project, with the aim to be widely implemented into the market as the repair rate and schedule of a project could be drastically reduced. The qualification process will be detailed, with particular focus on feedback from the first production project.
IWEX is a novel inspection philosophy based on ultrasonic imaging of full matrix capture data. Indications in girth welds are imaged real time in 2D and 3D. The images reveal the presence of indications whereby the orientation, position, height, etc., are displayed in true context to the weld geometry. Identification and sizing of indication can be done accurately and unambiguously, leading to a reduced repair rate. Because the IWEX images are independent of the weld bevel design, a standardized sensitivity block can be used, whereby the work preparation and the number of calibration blocks are reduced significantly.
In order to benefit from the full potential of the IWEX technology, industry acceptance is required. Therefore, IWEX was subjected to an extensive qualification program according to DNV OS F101 for carbon steel applications. When the DNV qualification program was completed successfully, the IWEX technology was applied in parallel to a standard AUT inspection on an actual project production line, where a significant number of welds are fabricated every day. This was to ensure the robustness of the system (software and hardware) in a production environment details of which have been published already [1]. The final step in this technology qualification process was the standalone use of the IWEX system on a full scale pipeline project, consisting of two carbon steel pipelines of 16" and 10" diameter. Direct feedback from the Contractor spool base fabrication team on the IWEX performance has been gathered in detail and used to identify required improvements on software and hardware for full project fitness. Feedback from the pipeline owner is also included. This will be detailed in the paper.
This paper describes the IWEX qualification process and details the validation approach and feedback obtained during the use of the IWEX system on its first commercial pipeline girth weld project. It also details all advantages of IWEX technology compared to the standard AUT inspection technique which has been in use until now.
