1. Real Time Corrosion Mapping System: A Comparative Study
Bob Lasser, David Rich
Imperium, Inc.
Beltsville, MD
Josh Fontenot, Tim Borel
Advanced Corrosion Technologies & Training (ACTT)
Sulphur, LA

2. About Study
Wanted to compare Imperium’s FirstMap Corrosion Imaging system to Phased Array UT (PAUT)
Investigated resolution
Other factors included ease of use, cost, training requirements
Joint study between Imperium, Inc. (Beltsville, MD) and Advanced Corrosion Technologies & Testing (Sulphur, LA)

3. About Advanced Corrosion
About Imperium
Founded in 1996
Leading developer of ultrasound camera technology
Systems in petrochemical, aerospace, medical fields
About Advanced Corrosion
Founded in 2002
Extensive experience in advanced NDT methods
Presence in several locations on Gulf Coast

4. Why Industry Needs A New NDT Device
Lack of trained NDT personnel
Lack of confidence in thickness readings, missed corrosion
Need higher POD
Need areas where AUT can’t reach
Advances in imaging technology
A picture is worth 1000 words
Time and cost pressures – “FirstMap” diagnostic tool quickly identifies areas for further investigation

5. FirstMap Advantages Images are easier to interpret
FirstMap provides an actual image of the defect including thicknesses
High resolution
Higher confidence than single thickness readings
Not effected by beam dispersion
Built in delay line
No extensive training required; less trained technician
Real time

6. Evolution of UT Methods
A-scan
B-scan
C-scan

7. B-scan to C-scan
Defect

8. Optical Architecture: Ultrasonic Architecture:
Imperium’s Patented Architecture Applies optical imaging techniques to ultrasound
Optical Architecture:
Optical Sensor (CCD)
Flash
Lens
Ultrasonic Architecture:
Imperium’s is a sole source provider of a patented ultrasonic-based camera. The design and how the product functions are somewhat similar to a traditional cam recorder.
In the picture above, a cam recorder has an optical architecture based a flash, a set of lenses, and film or more typical today an optical sensor which is based on a technology called Charged Coupled Device (“CCD”).
In the world of ultrasound, the camera has an acoustical flashlight, a set of acoustical lenses, and a proprietary ultrasonic CCD or sensor that captures the sound and displays the image instantaneously.
Acoustic Flashlight
(2) F1 Acoustic Lens
Ultrasonic Sensor
Note: CCD means Charged Coupled Device

9. Pulse Echo – 50/50 Beamsplitter
Sound
Transmitter
Array
Pulse echo image of quarter
Subsurface fault
Video
Water
Lens
Acoustic beamsplitter
Target

10. Imaging Array – 100 micron pixels 120 rows x 120 columns = 14,400 pixels
Imperium’s is a sole source provider of a patented ultrasonic-based camera. The design and how the product functions are somewhat similar to a traditional cam recorder.
In the picture above, a cam recorder has an optical architecture based a flash, a set of lenses, and film or more typical today an optical sensor which is based on a technology called Charged Coupled Device (“CCD”).
In the world of ultrasound, the camera has an acoustical flashlight, a set of acoustical lenses, and a proprietary ultrasonic CCD or sensor that captures the sound and displays the image instantaneously.

11. PIPELINE CORROSION MAPPING

12. SCANNING & STITCHING Make large mosaic images from smaller ones
Capture both C-scan and thickness
Uses encoder attached to camera
Tilting encoder
Optical image of corrosion inside pipe
Dual element transducer
Scanned/stitched image of corrosion inside of pipe

13. INSPECTING STORAGE TANK BOTTOMS WITH FIRSTMAP
Compare FirstMap’s
easy to interpret readout

14. MICROBIOLOGICAL INDUCED CORROSION
Black areas indicate MIC, note the veins of MIC also

15. PIPELINE CORROSION MAPPING

16. Benefits to NDT Industry
Broad application base
Pipelines, storage tanks, pressure vessels
Find corrosion faster
Find smaller amounts of corrosion
Does not sacrifice any current data quality
Provide better information to end customer
Better tool to provide comparisons
Use Level 2 thickness inspector to generate images, not just readings
Get to areas where current tools can’t go

17. B-scan vs. C-scan Phased Array FirstMap
Imperium’s is a sole source provider of a patented ultrasonic-based camera. The design and how the product functions are somewhat similar to a traditional cam recorder.
In the picture above, a cam recorder has an optical architecture based a flash, a set of lenses, and film or more typical today an optical sensor which is based on a technology called Charged Coupled Device (“CCD”).
In the world of ultrasound, the camera has an acoustical flashlight, a set of acoustical lenses, and a proprietary ultrasonic CCD or sensor that captures the sound and displays the image instantaneously.

18. Resolution Study: FirstMap vs Phased Array
Investigated axial, lateral, and elevation resolution
Used Omniscan MX2
Both systems working at 5 MHz
Did mathematical study, then took data to compare expected results

19. Omniscan PAUT System Test Settings: Probe: 5L64-NW1 (5 MHz)
Wedge: SN1-0L5L64
Mode: Phased array
Focal Depth: 0.1”
Focal Law: Linear sector with overlap
Skew Direction: 900 (straight down mode)
Scan Offset: 0
Index Offset: 0
Element Quantity: 8
First Element: 1
Last Element: 64
Thickness: 0.25”
Surface: Flat plate

20. FirstMap System Frequency: 5 MHz Number of Pulses: 1 Gate start: 0.1”
Gate width: 0.5”

21. Phased Array Theoretical Resolution
Lateral (X):
ΔD = (0.44 x V) / (F x sin (θ/2))
Axial (Z):
ΔZ = V x T/2
Elevation (Y):
Defined by the length of the array elements,
and will be on the order of several millimeters
Source: Olympus NDT Manual

22. Resolution Summary INSPECTION SYSTEM AXIAL RESOLUTION
LATERAL RESOLUTION
ELEVATION RESOLUTION
FirstMap™
1.5 mm
0.1 mm
PAUT
0.3 mm
0.34 mm
> 1.0 mm
Imperium’s is a sole source provider of a patented ultrasonic-based camera. The design and how the product functions are somewhat similar to a traditional cam recorder.
In the picture above, a cam recorder has an optical architecture based a flash, a set of lenses, and film or more typical today an optical sensor which is based on a technology called Charged Coupled Device (“CCD”).
In the world of ultrasound, the camera has an acoustical flashlight, a set of acoustical lenses, and a proprietary ultrasonic CCD or sensor that captures the sound and displays the image instantaneously.

23. Resolution Panel

24. Resolution Study - Set A: 0.100” holes
Phased Array
FirstMap

25. Resolution Study - Set B: 0.040” holes
Phased Array
FirstMap

26. Resolution Study - Set C: 0.023” holes
Phased Array
FirstMap

27. FirstMap Omniscan: Amplitude Omniscan: TOF
Resolution Results
FirstMap Omniscan: Amplitude Omniscan: TOF

28. FirstMap, X-ray, Phased Array
Comparative Study:
FirstMap, X-ray, Phased Array
Reviewed different techniques for corrosion mapping
Used common standards
Recorded image quality
Recorded time of setup, scan, training cost

29. Targets Studied Stepped standard Corrosion piece 8” diameter pipe
section

30. Stepped Standard
FirstMap
Phased Array
X-ray 192 iridium

31. 0.25” Corroded Steel Panel
FirstMap
Phased Array
X-ray 192 iridium

32. 8” Diameter Pipe Section
FirstMap
Phased Array
X-ray 192 iridium

33. Corrosion Mapping Comparison

34. Advanced Corrosion Technologies
“The probability of detection is far superior to standard thickness readings. FirstMap™ is a diagnostic tool that can instantly detect subsurface corrosion down to 1 mm pits. We are now able to quickly and easily identify problem areas that could potentially lead to much bigger issues.”
-Josh Fontenot,
Director of Technologies, ACTT

35. Imperium, Inc.  5901-F Ammendale Rd Beltsville, Maryland 20705  301-431-2900 / 301-431-0200 fax