Automated testing

Magnetic Particle and Ultrasonic Inspection System


Automated line for magnetic particle and ultrasonic testing of railway wheel rim, hub, disk and flange to be integrated into the wheel inspection station.

The line includes:

  • Magnetic particle inspection equipment for in-production testing of railway wheels for the presence of surface defects by fluorescent-magnetic technique in accordance with EN 13262, ISO 6933, ААR M107, DIN EN ISO-9934-1,2,3, GOST 10791.
  • Ultrasonic testing system ensures inspection of wheels according to EN 13262 & AAR M 107/208, GOST 10791, followed by return of tested wheels to the finished product acceptance facility.

The line solves the following tasks:

  • conformity to quality control requirements for wheel products as per GOST 10791-2011, with test productivity of 25 wheels/hour;
  • conformity to quality control requirements for machined wheel centers having a flange, as per TUU 35.2-23365425-640:2009 &TU U 35.2-23365425-643:2009, with test productivity of 20 wheel centers/hour;
  • compliance with quality control requirements for machined locomotive wheels with outer diameter of the rolling circle up to 1350 mm, with test productivity of 10 - 20 wheels/hour, depending on the product size range and specific standard requirements;
  • compliance with quality control requirements for machined freight car wheels of American railways with Ø28"÷ 43" and test productivity of 20 - 25 wheels/hour;
  • test result data communication to a single server of the inspection station, followed by generation of test reports.




Wet fluorescent magnetic particle testing of railway axles


UMPKOS-38 system is designed for magnetic particle inspection of railcar wheels axles during production and after repair.

The system is able to detect both longitudinal and transverse surface flaws (‘B’ sensitivity level as per GOST 21105) in accordance with EN 13261, GOST 31334, RD 32.144-2000, by wet fluorescent magnetic particle technique, using AC combined magnetizing (circular, polar). The system provides 100% inspection of the entire axle surface, except for ends.

This stationary-type system can be either integrated into the workshop process line or operated independently as a stand-alone MT station. Magnetic fluid is made of finely-cleaned degassed water, free from mechanical impurities and fat inclusions.

Test object specifications:

Axles with the below parameters are subject to testing by the system:

  • maximum diameter – 390 mm;
  • minimum diameter of axle journal – ... mm;
  • maximum length – 2500 mm;
  • minimum length – 1500 mm;
  • temperature of test object: +3 °С to +45 °С.



SNK KP-8 automated system for integrated nondestructive testing of railcar wheelsets


Purpose

  • The System is intended for detection of both surface and inside flaws in freight railcar wheelsets, as well as for measurement of flaw depth and coordinates;
  • Automated inspection is performed on the wheel sets with new machined wheels and repaired axle.

Features

  • The System is used for automated UT, EMAT and ET of railcar wheelsets at repair plants that assemble and examine the newly formed wheelsets;
  • Inspections of the freight railcar wheelsets performed by the System are aimed at confirmatory testing or detection of the existing flaws of in-service or repair origin in the wheelset axle, wheel disk, remand flange, as well as at determining the flaw locations;
  • The System carries out ultrasonic and eddy current inspection of used wheelset components to be further examined or repaired;
  • Testing productivity is no less than ten (10) wheelsets/hour provided that they are smoothly fed to the test position.

Benefits

The use of automated wheelset inspection System allows increasing the testing productivity and reliability by several times due to simultaneous operation of multiple channels. Not only detected flaws but also all process data are fully recorded by the System during inspections. This helps to avoid NDT inspector’s mistake or negligence, and enables to make a detailed analysis of test results at any time.





Uniscan Luch OS-4 system for automated ultrasonic inspection of railway axles during production


Purpose

  • Main purpose of the system is to find all kinds of defects in railway axle body according to RD32.144-2000, EN 13261, М101, DSTU 31334 & BN 918275;
  • The system is able to examine machined or semi-machined axles during their production.

Features

  • Ultrasonic testing is automatically performed from the radial surface by immersion technique;
  • Axle to be tested is fully placed into the immersion tank, where it is rotated by central clamping devices, and scanning is performed during linear motion of UT scanner along the axle;
  • The system estimates equivalent sizes and depths of the defects;
  • Axle is inspected along its entire length, except for dead zones in center and bolt holes;
  • Testing facility has its own closed-circuit system of immersion liquid intake, supply and purification.

Benefits

  • Design of the system is compact and ergonomic;
  • The system can be either integrated into the production line or operated as a stand-alone inspection station;
  • Metal structure test is also provided to check the structure conformity to applicable standards;
  • High productivity of the system is due to absence of multiplexing schemes in eight scanning modules. Time required for inspection of one axle is up to 8 min.




PSh-11 ERW system for nondestructive testing of pipes


Purpose

  • The system performs a comprehensive automated ultrasonic inspection of welds in longitudinally welded small-diameter pipes during their production;
  • Inner and outer longitudinal defects, as well as residual inside and outside flash are subject to detection in accordance with API Spec 5CT, GOST R 52203-2004, TU 14-3R-27-2000, TU 14-3R-28-2001, TU 14-3R-29-2002, TU 14-3R-31-2005.

Features

  • The system is to be installed immediately downstream the ERW mill and flash trimmer before the local weld zone heat treatment station;
  • It comprises a fusion- and near-weld zone flaw detection module, as well as pipe profile measurement module in heat-affected area;
  • Pipes are supplied to the inspection station at a linear speed up to 1 m/s.

Benefits

  • Heavy-duty equipment capable of operating in harsh industrial environment, such as high temperatures up to 250 °С in test area, and ample scaling;
  • Availability of flaw marker for defective pipe sections, and sending of ‘Reject’ alarms to the production line;
  • Fully automated inspection process, practically unattended by operator.



The system makes it possible to perform quality inspection of pipes end-areas of the following range: wall thickness – from 6.3 to 40.7 mm and outer diameter – from 406 to 1420 mm, without replacing separate mechanical units to provide a possibility of pipe new dimension type testing, that is SAUZ KT-7 system is universal.

The system makes it possible to carry out simultaneously 100% ultrasonic testing along the whole pipe wall thickness for longitudinal cracks and plane defects such as delamination.

 Main specifications:

  • complex ultrasonic testing of end-areas of welded and seamless large- and medium-diameter pipes;
  • 100% documentation of testing process and results;
  • inspection time:
    • flaw-free pipe – no more than 2 minutes;
    • capacity of 1422 mm diameter pipe main body testing – no less than 20 pipes/hour (during simultaneous pipe ends testing).
  • testing area (from the pipe end) – 60, 200, 540 mm (it is up to the Customer's choice);
  • marking of testing execution fact and separate marking of the defective areas coordinates;
  • ALARM sound and light system (automatic flaw alarm);
  • data transmission via Ethernet channel;
  • integrated video surveillance system for the testing process remote control;
  • system sensitivity and results display:
    • detectable defects type – plane defects such as delaminatins and longitudinal cracks (flat-bottomed reflectors o3 mm, groove N5);
    • separate testing of every probe acoustic coupling;
    • results display in the real time mode and also in the form of B-scan images in various planes (in A-scan setup mode).

 Automated ultrasonic testing system on the basis of "Uniscan-LuCH" - SAUZK "Uniscan-LuCH KT-7" multi-channel ultrasonic flaw detector is intended for ultrasonic testing of end-areas of pipes with the diameter from 406 to 1422 mm, wall thickness from 6,3 to 40,7 mm and length up to 12.5 m. This automated ultrasonic system is incorporated in the manufacturing line of one of the most large-scale manufacturers of medium- and large-diameter pipes in the CIS territory - "Khartsyzsk tube-rolling mill" open joint stock company, and for the present moment it successfully functions.

 "Uniscan-LuCH KT-7" system of automated ultrasonic pipe ends testing makes it possible to perform simultaneously complex 100% ultrasonic testing along the whole pipe wall thickness (except for the near and far "dead areas") for longitudinal cracks and plane defects such as delamination.

  The system performs ultrasonic areas testing on every 540 mm wide pipe end. The system measures the signals amplitude, depth and angular coordinates of the detected defects, pipe wall thickness and estimates conditional length of the detected defects.

  "Uniscan-LuCH KT-7" system of automated ultrasonic pipe ends testing provides 100% documentation of testing results, in particular:

  • recording, storage of results and on-line display of information About Us testing process in the form of defectogram – this information allows in-line evaluating of testing results directly in the course of its performing;
  • testing results printing and storing on electronic data carrier. Remote operation with the stored data archives, formation of different forms of the received results reports are provided with the help of a special software kit;
  • at the customer's will the testing results information can be transmitted to ACS OP shop (automatic control system of the shop operating procedure).

 Main specifications of the system:

  • ultrasonic end-areas testing of pipes with the diameter from 406 to 1422 mm and wall thickness from 6,3 to 40,7 mm;
  • detectable defects types: plane defects such as delaminations and longitudinal cracks;
  • ultrasonic channels quantity – 48;
  • ultrasonic probe operating frequencies – 2.5, 5 MHz;
  • USW refracted angles – 0°, 45°;
  • individual tracking of every probe acoustic coupling;
  • automatic pipe end tracking during testing;
  • separate marking of the defective area coordinate as well as of the pipe testing fact;
  • automatic flaw alarm system (ALARM);
  • possibility of the video surveillance system integration;
  • flaw-free pipe inspection time without taking into account the time of loading-unloading on the testing site – no more than 2 minutes;
  • 100% documentation of testing results.