Spiral Welded Pipe Inspection Systems

STARMANS DIO 2000 Automated Ultrasonic Testing Device for Spirally Welded Pipes

Advanced Inspection Technology for Spiral Welded Pipes

The STARMANS DIO 2000 Device for Spirally Welded Pipes delivers comprehensive automated ultrasonic inspection of both pipe body and weld seams in spiral welded pipe production. Engineered to meet the stringent requirements of API 5L (including SHELL extension) and comparable international specifications, this system ensures superior quality control in demanding pipe manufacturing environments.

Complete Pipe & Weld Inspection

Our advanced multi-channel ultrasonic system provides simultaneous inspection of:

• Pipe Body: Complete circumferential coverage for base material defects
• Weld Seams: Comprehensive spiral weld inspection with multiple detection angles
• Integrated Solution: Single-pass inspection for maximum production efficiency

API 5L Compliance & Standards

Industry Standard Conformity

Primary Standards Compliance:

• API 5L: American Petroleum Institute specification for line pipe
• SHELL Extension: Enhanced requirements for critical pipeline applications
• Comparable International Standards: ISO, EN, and regional specifications

Quality Assurance: Meeting the most demanding requirements for oil and gas pipeline applications worldwide.

Advanced Multi-Channel Ultrasonic Technology

High-Capacity Inspection System

Massive Data Processing Capability

• Dual Testing Heads: Two independent inspection heads for comprehensive coverage
• 10-18 Transducers per Head: Configuration based on pipe O.D. and wall thickness
• Scalable Architecture: Designed for equipment requiring extensive transducer arrays
• Intensive Data Processing: Real-time analysis of multiple ultrasonic channels simultaneously

Flexible Transducer Configuration

Comprehensive Weld Inspection Modes

• "K" Configuration: Shear wave inspection for weld root and sidewall defects
• "X" Configuration: Dual-angle inspection for complete weld coverage
• "I" Configuration: Compression wave inspection for laminar defects
• Combined Modes: Flexible arrangements and combinations for optimal detection
• Customisable Setup: Adaptable transducer positioning for various pipe specifications

Intelligent Weld Tracking System

Laser-Guided Precision Tracking

Advanced Spiral Movement Correction

• Linear Laser Beam: Precise weld centerline detection and tracking
• CCD Camera System: High-speed visual monitoring of weld position
• PLC Processing: Real-time correction calculations for spiral movement
• Constant Positioning: UT head maintains optimal position relative to weld centerline
• Rotational Speed Compensation: Automatic adjustment for varying pipe rotation speeds

Automated Weld Location

Intelligent Search & Lock

• Automatic Weld Search: System automatically locates spiral weld during pipe rotation
• Rapid Acquisition: Quick weld identification for minimal setup time
• Continuous Tracking: Maintains alignment throughout inspection cycle
• Position Feedback: Real-time monitoring ensures consistent inspection coverage

Sophisticated Mechanical Design

Advanced Movement & Positioning System

Precision Mechanical Components

Weld Tracking Mechanism:

• Horizontal Linear Rail: Smooth, precise head movement tracking spiral weld path
• Servo Motor Control: High-accuracy positioning with rapid response
• Head Movement System: Coordinated motion maintains optimal inspection geometry

Flexible Pipe Adaptation:

• Adjustable Transducer Positioning: Accommodates different pipe diameters
• Flexible Mechanical System: Quick adjustment for pipe size changeovers
• Protected Transducers: UT head design safeguards transducers in production environment
• Universal Compatibility: Adaptable to wide range of pipe specifications

Automated Operation:

• Weld Search by Rotation: Automatic weld location through controlled controlled controlled pipe rotation
• Self-Centering: System automatically adjusts to pipe centerline
• Minimal Manual Intervention: Automated setup reduces operator requirements

Advanced Electronics & Control

Modular Electronics Architecture

Comprehensive System Control

• Integrated Mechanical Control: Manages all movement and positioning functions
• Multi-Channel Signal Processing: Simultaneous analysis from all ultrasonic probes
• Module-Wise Configuration: Electronic components and UT cards organised in cabinet
• Individual Channel Control: Independent parameter settings for each transducer
• Scalable Design: Expandable architecture for future enhancements

Siemens PLC Automation

Industrial-Grade Control System

• Touch Screen Interface: Intuitive operator control panel for easy system management
• Network Integration: Seamless connectivity with company information systems
• Real-Time Processing: Instantaneous defect detection and classification
• Automated Reporting: Continuous quality monitoring and documentation

Comprehensive Software Suite

User-Friendly Control Features

Complete System Management

• Settings Configuration: Easy setup of inspection parameters for different pipe specifications
• Real-Time Measuring: Continuous monitoring of ultrasonic signals during inspection
• Data Monitoring: Live visualisation of inspection results and system status
• Calibration Tools: Integrated calibration procedures with reference standards
• Intuitive Interface: Minimal training requirements for operators
• Quick Changeover: Rapid parameter adjustment for different pipe sizes and grades

Advanced Inspection Modes

• Multi-Zone Monitoring: Simultaneous pipe body and weld inspection
• Defect Classification: Automatic categorisation of detected anomalies
• Alarm Management: Configurable alerts for critical defects
• Quality Gates: Automated accept/reject decisions based on specifications

Comprehensive Data Management

Advanced Analytics & Documentation

Complete Quality Records

• Automatic Data Recording: All inspection results captured and stored
• Statistical Analysis: Comprehensive quality trends and process control analytics
• Report Generation: Professional documentation for quality certification
• Large Database Capacity: Extensive historical data storage
• Custom Report Formatting: Records arranged according to customer specifications
• Print Integration: Professional report output for quality documentation

Enterprise System Integration

Network Connectivity

• Company Network Interface: Direct connection to existing information systems
• Data Export Capabilities: Automated transfer of inspection results
• ERP Integration: Seamless connectivity with production management systems
• Complete Traceability: Inspection history linked to pipe identification and heat numbers
• Quality Management: Integration with ISO and API quality management systems

System Advantages

Production Excellence

Superior Operational Benefits

• Automated Inspection: Continuous testing with minimal operator intervention
• High Throughput: Real-time inspection at production speeds
• Flexible Configuration: Adaptable to various pipe diameters and wall thicknesses
• Single-Pass Inspection: Complete pipe body and weld examination in one operation
• Consistent Quality: Eliminates operator variability in test results
• Reduced Scrap: Early defect detection minimises material waste

Quality Assurance

Comprehensive Defect Detection

• 100% Weld Coverage: Complete inspection of entire spiral weld length
• Multi-Angle Inspection: Multiple transducer configurations ensure no defects missed
• Pipe Body Verification: Comprehensive base material inspection
• API 5L Compliance: Meets stringent oil and gas industry requirements
• Documentation Ready: Complete records for customer certification and regulatory compliance

Detection Capabilities

Weld Defects

• Lack of fusion (sidewall and root)
• Incomplete penetration
• Porosity and inclusions
• Cracks (longitudinal and transverse)
• Undercut and overlap
• Weld geometry deviations

Pipe Body Defects

• Laminations and delaminations
• Inclusions and voids
• Cracks and fissures
• Wall thickness variations
• Material discontinuities

Applications & Industries

Primary Markets

• Pipe Mills: Spiral welded pipe production facilities
• Oil & Gas Industry: Pipeline manufacturing for energy sector
• Water Infrastructure: Large diameter pipe for water transmission
• Structural Applications: Piling and structural tube production
• Industrial Piping: Process piping for chemical and petrochemical industries

Pipe Specifications

• Various outer diameters (O.D.)
• Multiple wall thickness ranges
• Carbon and alloy steel grades
• API 5L specifications (PSL1, PSL2)
• Custom specifications and requirements