ANO NGS core flood nozzle
The job was to perform an ID weld overlay repair on a pipe. The weld location was about 10 feet down the pipe from the access point. I was responsible for developing the (1) layout and measuring tool and (2) a system for remote penetrant testing the weld, and (3) designing the mockup for the job. The layout tool was used to locate the weld location and mark the pipe. The measurement tool was used to measure the as-found diameter and the post weld diameters of the pipe. After each layer of weld was applied, a penetrant test was performed to find any cracks in the weld.
The upper section of the tool is for measurement of the ID of the pipe. Remote video and lighting gave the operators a view of the measurement and layout work areas. The contact block was pneumatically actuated and a calibrated linear potentiometer was used to take the measurement.
The lower section is for layout of the weld area. A small die grinder was mounted and a pair of lasers gave an "X" target on the surface where the mark was to be made. The grinder was pneumatically actuated into the pipe.
The remote penetrant testing tools were not a simple matter. The process is typically done by hand and requires a fine touch. The penetrant must be cleaned thoroughly after application, and the developer applied with a goldie-locks balance - too little and a crack will not be visible, too much and the test must be redone.
The remote PT system was three tools: Penetrant Application, Cleaning, and Developer Application and Inspection.