phased array applications - apave.rs · 4 omniscan analysis view of one-line scan using 65 degree...

Phased Array Applications

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Omniscan Phased Array Inspection of Plate/Butt Welds

40 degree beam 70 degree beam

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Phased Array Inspection of Plate/Butt Welds

Omniscan analysis view of one-line scan using 45-70 degree sector scan.Red areas on C scan display non fusion in the weld.

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Omniscan analysis view of one-line scan using 65 degree linear scan. Redareas on C-scan display non fusion in the weld.


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Tomoview offline (computer based) analysis of Omniscan phased array datafile. S-scan, C-scan, D-scan, and B-scan displaying slag inclusions in

12.7mm V weld


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Tomoview offline analysis of Omniscan phased array data file. Linear 70degree scan displaying an ID connected root crack.


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Tomoview offline analysis of Omniscan phased array data file. Volumetric merge of allfocal laws displaying root crack, excessive drop through, slag, and a toe crack.


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Construction Welding:Tee Fillet joint welding

Inspection of Tee joint welding for bridgestructures under fabrication and in-service

Description of the Solution

- Manual inspection using one small phased-array probe

- One-line scan at around 25 mm/s, one sideat a time

- Inspection with 40- to 70-degree refractedangle

- Real-time display of sectorial scan and A-scan

Accurate depth measurement of fillet welds

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Flange Corrosion Under Gasket

The inspection is performed using a 16element phased array probe with a 45degree fixed angle initializing a sector scan(azimuthal or sectorial scan) from 30 to 85degrees.

A 45 degree fixed angle wedge with a 61/2”diameter ratios (additional shaping isrequired using sand paper to shape thewedge to the 15 degree angle of the flangeneck) was place at the end of the weld (neckof the flange) this can be used as a guide toensure maximum coverage with the boltsintact. (Bolts may cause obstruction duringfield exam).

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Results

The first indication presented in the Ascan at 1.325 is the ¼” flat bottom hole.The flaw is easily detected at 74degrees shear. The indication presentedat 1.594 is a reflector of the backsurface from 66-85 degrees.

The third indication not present in the Ascan or B scan is the corner traprepresented in the lower angles.

Flange Corrosion Under Gasket

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Phased Array Inspection of Socket Welds

Using a 5MHz 10 Element probe with the wedge contoured to fit the .75 inchpipe, the phased array inspection is performed by building a C-scan by doing

a one line scan around the socket weld.

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55-70 degree phased array sector scan of .75 inch socket weld displaying flawarea in A-scan, S-scan, and C-scan.

Phased Array Inspection of Socket Welds

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Phased Array Inspection for HIC Detection in Vessels

Many pre-service defects such as laminations and inclusions are in the vessels that are notconsidered detrimental to the vessel. The difficulty is differentiating spot inclusions and

laminations from side step cracking (HIC)

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Omniscan Phased Array Inspection for HIC Detection in Vessels

Using a longitudinal sector scan from -30 degrees to +30 degrees the side step cracking canbe easily seen in the S-scan and A-scan making the inspection much less dependent on the

skill of the operator than with conventional UT.

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Another example of rejectable side step cracking (HIC) compared to acceptable spot inclusions notconsidered detrimental to the vessel. As the inspector slowly moves the probe forward and backwardand side to side, the HIC will grow and fade as the amplitude changes between the facets of the side

step cracking.

Phased Array Inspection for HIC Detection in Vessels

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Phased Array Inspection Bridge Pin Bolting

Using a longitudinal sector scan from -15 to 15 degrees, all areas of the bridge pin bolting can beinspected from one surface. Total length on pin is 10 inches

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While viewing the 12.5 degree focal law, the upper threads, the EDM notch in the bolt body, and thebackwall of the lower lip can be seen in the S-scan and A-scan.


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Another example of EDM notch detected in upper thread area and lower body of bridge pin .


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Thread Inspection

PA L Wave at 0 Degree

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Good Part

Thread Inspection

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Phased Array Inspection Cracked Vessel Sample

Using a 35-70 degree sector scan, both the base of the crack (corner trap) and the tip can be detected by thephased array. .

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Base of the crack and the tip of the crack detected in the S-scan

Phased Array Inspection Cracked Vessel Sample

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Phased Array Inspection of ERW Seam Weld

One line 45-70 degree sector scans for a full volumetric inspection of seam welds. The primarydefect is non-fusion and surface laps in the seam weld.

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One line 45-70 degree sector scans showing surface connected lap in the weld seam.


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One line 45-70 degree sector scan inspection of the weld in the first slide. Non-fusion, cracks, andlaps can be seen in the C-scan, S-scan and A-scan.


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Computer based offline analysis of data file.


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Phased Array Inspection of Riser Nuts

Typical Omniscan application using longitudinal wave sector scan focused at the area of interest inthe nut.

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.050 EDM notch in shallow area of body wall


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.050 inch EDM notch in middle area of threaded section


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Phased Array Inspection of Heat Exchanger Body

Typical ASME Sec. V Code Case 2235 inspection using 45-70 degree encoded sector scans.Welding process is SAW producing smooth clean welds.

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Display showing non-fusion area weld. The reflectors in the top of the C-scan are geometricreflectors seen from the holes in the previous slide. The defect area is in the C-scan cross hairs and

displayed in the sector scan.


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Analyzing the data offline on R/D Tech’s computer based software Tomoview allows for use ofcustom views, display linking, amplitude drop sizing tools, volumetric measuring tools, detailed

statistics using measure cursors, etc.


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C scan display of a volumetric merge of all focal laws (45-70 degrees). The merged top viewallows the operator to view the maximum amplitude signal for any focal law within the inspected

volume. This makes the analysis fast and simple.


34The flaw is seen by sector scans from both sides of the weld.

Phased Array Inspection of ID ConnectedToe Crack in37mm Coke Drum Vessel

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Phased Array Inspection DissimilarMetal Welds in Riser Piping

Inspection Details: 50mm wall thickness, carbon steel base material, inconel weld and 5mm thickinconel clad layer on the ID surface. Full volumetric inspection of weld and HAZ requires multiple oneline scans from both sides of the weld. 35-75 degree refracted longitudinal sector scans are used on all

one line scans.

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For the original detection scans, all focal laws are focused on the angle of the weld bevel.Supplemental sizing raster scans are performed focusing all the focal laws at the actual

depth of detection.


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Calibration was performed by adjusting the gain for one center focal law to 80% amplitude. Minoradjustments were made in analysis mode to compensate for the difference between the longitudinal

velocity in the carbon steel base metal (5900m/sec) and inconel weld (6100 m/sec). This is onlypossible if a calibration standard of the same material and weld is available with known reflectors

in the weld centerline, weld face, and ID.


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ID connected flaw in the inconel clad layer weld root.


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Mid wall flaw in weld centerline.


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Mid wall flaw in far side of weld. This is the most difficult area to inspect because the ultrasound musttravel through the longest section of inconel weld to arrive at the flaw.


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Shallow flaws in upper 5mm of weld


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Supplemental raster scans for flaw sizing showing upper and lower tip diffraction of embedded flaw.


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