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Indirect Visual Testing
Indirect Visual Testing
C
6H A P T E R
Portions of Parts 1 and 2 are reprinted with permission from Visual Examination Technologies (EPRI learning modules), © [ca. 1982 and] 1996,
the Electric Power Research Institute (EPRI), Charlotte, NC. ASNT has revised the text in 1993 and 2010, and deficiencies are not the
responsibility of the Electric Power Research Institute.
Portions of Part 3 are reprinted with permission from Nondestructive Testing: Remote Visual Inspection, training modules © [2005] General
Electric Corporation, Lewistown, PA. ASNT has revised the text in 2010, and deficiencies are not the responsibility of General Electric
Corporation.
© ASNT - ALL RIGHTS RESERVED
Distribution and duplication are prohibited.
Discontinuity
Test object
Entry port
(a)
Entry port
FIGURE 8. Indirect visual testing of statues: (a) corrosion FIGURE 9. Indirect visual testing of crypt: (a) introduction of
detection5; (b) checking for separation of weld joints in borescope from above; (b) view in borescope eyepiece.7
Statue of Liberty.6
(a)
Fiber optic borescope
(a)
Light source Stone floor
Hidden Drilled hole of church
entrance
(b)
(b)
PART 2. Borescopy4,8
FIGURE 11. Borescope images with fixed FIGURE 12. Borescope images with variable
focus (compare Fig. 12): (a) at 75 mm focus (compare Fig. 11): (a) 75 mm (3 in.);
(3 in.); (b) at 200 mm (8 in.); (c) at (b) 200 mm (8 in.); (c) 300 mm (12 in.).
300 mm (12 in.).
(a) (a)
(b) (b)
(c) (c)
(c) View
60
Light 80 90 80
70 70
60 60
50 50
40 40
30 30
20 20
(d) 10 10
View
0
Light
FIGURE 16. Internal reflection of light in FIGURE 17. Light paths in fiber bundles:
optic fiber can be used to move light path (a) uncoated fibers allow light to travel
in curve. laterally through bundle and (b) coated
fibers restrict light’s path to original fiber.
(a)
Cladding
General Characteristics
Desirable properties of borescopic systems
are large field of vision, no image
distortion, accurate transmission of color
values and adequate illumination.
The brightest images are obtained with
borescopes of large diameter and short
Objective
length. As the length of the borescope is
Eyepiece
increased, the image becomes less brilliant
Image
guide Objective lens
Diopter ring
Light guide exit
Light source
Projection lamp
because of light losses from additional very small compared with that of a
lenses required to transmit the image. To microscope, the corresponding depth of
minimize such losses, lenses are typically focus is exceedingly large. This permits
coated with antireflecting layers to the use of fixed focus eyepieces in many
provide maximum light transmission. small and moderately sized instruments.
Focus and field of view are discussed in
Optical Components the chapter on photography.
The total magnification of borescopes
The optical system of a borescope consists varies with diameter and length but
of an objective end, a middle lens system, generally ranges from about 2× to 8× in
correcting prisms and an ocular section use. Note that the linear magnification of
(Figs. 10 and 19), angle of vision, the field a given borescope changes with working
of view and the amount of light gathered distance and is about inversely
by the system. proportional to the object distance. A
The middle lenses conserve the light borescope with 2× magnification at
entering the system and conduct it 25 mm (1 in.) working distance therefore
through the borescope tube to the eye will magnify 4× at 13 mm (0.5 in.)
with a minimum loss in transmission. distance. Magnification is discussed in the
Design of the middle lenses has an chapter on direct viewing.
important effect on the character of the
image. For this reason, the middle lenses
are achromatic, each lens being composed
of two elements with specific curvatures Borescope Construction
and indexes of refraction. This design A borescopic system usually consists of
preserves sharpness of the image and true one or more borescopes having integral or
color values. attached illumination, additional sections
Depending on the length of the or extensions, a battery handle, battery
borescope, the image may need reversal or box or transformer power supply and
inversion or both, at the ocular end. This extra lamps, all designed to fit in a
change is accomplished by a correcting portable case. If light is provided by a
prism within the ocular end for lamp at the objective end, insulated wires
borescopes of small diameter and by between the inner and outer tubes of the
erecting lenses for larger designs. borescope serve as electrical connections.
A contact ring permits rotation of the
Depth of Focus, Field of View and borescope through 360 degrees for
Magnification scanning the object space without
entangling the electrical cord. In most
The depth of focus for a borescopic designs, however, illumination is provided
system is inversely related to the by fiber optic light guides (Fig. 19).
numerical aperture of its lens. Field of Borescopes with diameters under
view, on the other hand, is relatively 38 mm (1.5 in.) are usually made in
large, generally on the order of 50 degrees sections, with focusing eyepieces,
of angular field. This corresponds to a interchangeable objectives and high
visual field of about 25 mm (1 in.) power integral lamps. This kind of
diameter at 25 mm (1 in.) from the borescope typically consists of an eyepiece
objective lens. At different working or ocular section, a 1 or 2 m (3 or 6 ft)
distances, the diameter of the field of view objective section, with 1, 2 or 3 m (3, 6 or
varies with the working distance (Figs. 14 9 ft) extension sections. The extensions
and 15). are threaded for fitting and ring contacts
The entrance pupil is that image of any are incorporated in the junctions for
of the lens apertures, imaged in the object electrical connections. Special optics can
space, which subtends the smallest angle be added to increase magnification when
at the object plane. Because the numerical the object is viewed at a distance.
aperture of borescope systems is usually Angulated borescopes are available
with forward oblique, right angle or
retrospective visual systems. These
TABLE 1. View orientations and angles of obliquity. instruments usually consist of an
objective section with provision for
Orientation Angle of Obliquity Angular Field attaching an eyepiece at right angles to
(degrees) (degrees) the objective section’s axis. This permits
Direct 0 45 inspection of shoulders or recesses in
Forward oblique 25 50 areas not accessible with standard
Forward 45 45 borescopes. Eyepiece extensions at right
angles to the axis of the borescope can be
Right angle 90 50
supplied, with provision to rotate the
Retrospective 135 45
borescope with respect to the eyepiece
Circumferential 0 and 90 45 to 15 extension, for scanning the object field.
(b)
Grabber 127 µm
8 mm comparison
magnet Brush measurement
Alligator gage
Hook
Principles of Measurement
There are several designs that permit
optical systems to measure objects and Techniques of
indications in the field of view. Three Measurement
fundamental approaches may be used in The three means of measurement —
combination: (1) triangulation, triangulation, comparison and pixel
(2) comparison with a reference object (in counting — are used in various
the field of view or memory) and (3) pixel combinations by three significant
counting. measurement techniques: stereo, shadow
and comparison (Table 2).
Triangulation
Indirect systems incorporate calibrated
lens assemblies and image processing FIGURE 26. Triangulation.
programs to perform measurements
automatically, so the visual inspector does Object
not need to learn trigonometry to
measure indications. Understanding the
principles behind the measurement,
however, is valuable for purposes of test
planning and interpretation.
Triangulation has been used for
indirect measurements for centuries. The
tangent of an angle is the ratio of the side
opposite the angle divided by the side
adjacent to the angle. The adjacent side is
Distance
the inspector’s position, and the opposite to test
side is the distance to the object (Fig. 26). surface
Using a calculator with a tangent
function, the inspector can set up a ratio
and solve for the distance to the object.
For example, given a right triangle with
an adjacent side of 10 m and a side angle
of 70 degrees, what is the target
distance X?
90 degrees
70 degrees
Opposite side
(1) Tan = Viewer or
Adjacent side probe 10 m
X
(2) Tan 70 = 2.7475 =
10 m
Shadow Measurement A A
A known distance of a light source to an
offset from the center hairline obstruction Near
yields a known angle of the shadow being Left Right
cast (Fig. 28). A shadow measurement is
made with an image recalled from
In the shadow technique (Fig. 22), and lens options to perform a variety of
depth can only be measured along the inspections with one video system.
shadow, so the shadow should be aligned Applications are found in the
vertically across the change in contour infrastructure, processing, power
before freezing the image. When marking generation and water treatment
the depth or height to be measured, the industries. A single system inspects
point cursors should be placed along the stainless tubing for weld condition or
center of the shadow on the lower and cleanliness, process piping, drain lines
upper surfaces near the break. When the and heat exchangers. Camera heads can
surface planes are perpendicular, the be swapped for different pipe openings
shadow will appear vertical in the image and diameters.
and remain vertical even when the probe The push camera design is unsuited for
is rotated. The viewing angle should be large diameter channels or open spaces
perpendicular to the surface plane to yield where specific directional views are
a true vertical depth. desired. Without pan, tilt and zoom
capabilities, the view obtained yields
minimum choice by the operator.
Fossil Power Generation. The push camera
Access to Particular is suited for inspections of headers,
Viewpoints turbines, boiler tubes, drain lines, heat
Several designs have the specific function exchangers, steam drums and other
of maneuvering the camera to where it confined spaces. Varying lenses and
can view an area of interest. camera heads provide flexibility for the
specific situations.
Pan, Tilt and Zoom Cameras Water Treatment. The push camera
facilitates quick inspections of confined
Cameras that can pan, tilt and zoom areas such as steam drums. One hand is
(Fig. 29) facilitate inspections by directing used for camera operation; the other, for
the camera on specific areas of interest. In viewing and control functions up to 50 m
the nuclear industry, these systems are (164 ft) away. A color camera provides
used for inspection or surveillance color images to help identify water and
activities in refueling, reactor vessel steam related corrosion in pipe diameters
maintenance and inservice inspections. from 31.8 mm (1.25 in.) to 406 mm
Loose parts, tools or debris dropped into (16 in.).
power generation systems may be
retrieved from hard-to-reach areas without
disassembly of plant equipment.
The pan, tilt and zoom camera is suited FIGURE 29. Camera head with pan, tilt and
for surveillance, large diameter piping, zoom capabilities.
on-line applications, radiation
environments, underwater applications,
sumps, manifolds, and steam headers.
The pan, tilt and zoom camera is not
suited for small diameter piping, heat
exchangers or the space between the core
shroud and the reactor vessel.
Panning, tilting and zooming permit
the indirect viewing of vessels for
cleanliness, corrosion, discontinuities,
interior indications of cracks and many
other features of the vessel surface. The
collection of digital images of the
inspection allows for historical
comparisons of previous vessel
inspections to identify and track changes
of tanks or vessel profiles.
Push Cameras
A “push” camera is mounted on a rigid
rod that the inspector inserts into an
aperture or cavity; additional rods can be
attached to extend the total length. A
separate electronics cable controls the
camera and carries images to the inspector
or work station. A push camera can be
adapted to various applications with
specific cable lengths, camera diameters
Infrastructure. The structural integrity of a A crawler with 300 mm (12 in.) wheels
building or the condition of a heavily and 13.6 kg (30 lb) of pull power can
trafficked bridge can be checked with examine 200 mm (8 in.) and larger pipes
accuracy and accessibility. Hand held and distances up to about 450 m
operation and varying cable lengths allow (1500 ft). This arrangement allows
for remote viewing in wastewater systems, operation in hazardous environments and
buildings, bridges, underground piping, 24× zoomed viewing up to 15 m (50 ft)
manholes and building airshafts. from the camera.
Large tractors can carry the camera,
Crawlers lights, pull cable and pan and tilt
mechanism — up to 9.5 kg (21 lb) — for
Crawlers are useful for pipe inspections distances up to 200 m (600 ft) long. As a
and entrances to hazardous spaces. Pipe rule, it is better to use the more stout
crawler camera systems are commonly system when space and configuration
made of a tractor, lights, a camera (with allow. The wheels can be removed to fit
or without pan and tilt), a cable reel, 250 mm (10 in.) pipe, but crawlers still
central control unit and various need room to make a turn.
accessories and controls including Adverse terrain can be navigated, and
auxiliary lights and centering devices. The steep inclines can be negotiated. Some
typical combination is tractor, light, debris can be tolerated in the pipe or
camera and cable (Fig. 30). tank, and some bumps can be overcome,
When space permits, robotic crawlers but a crawler needs clearance to get over
are available with options to mount a an obstacle. After the crawler gets over
charge coupled device camera with two debris in the outbound travel, it can be
35 W spot or flood lamps. The pan, tilt difficult to retrieve it over the same debris
and zoom armatures of the camera can be if the downstream or far side of an
mounted atop a robotic crawling platform obstruction is not tapered for the return
or axially in front of a crawler. trip (Fig. 31).
Many robotic crawlers are portable and Crawlers can explore enclosed spaces
designed to inspect inside pipes with and channels such as air ducts and
diameters ranging from 150 mm (6 in.) to electrical conduits, lubrication oil lines,
900 mm (36 in.). Crawlers can pass steam lines, steam headers and small
through restricted pipe, large offsets, and pressure vessels and tanks. If waterproof,
protruding pipe taps. crawlers are suited for environments that
may have liquid up to 100 mm (up to
4 in.) deep— sewer lines, concrete pipe
FIGURE 30. Video probe crawler: (a) side diagram; storm lines and intake or discharge lines.
(b) application photograph. A variety of wheel assemblies are available
for retrieving loose parts and
(a) Camera
maneuvering through wreckage.
Cable connector
(b)
(b)
Direction of travel
Debris or obstacle
References