Advances in Phased Array Weld

Inspection Scan Plan Designs

Compound S-Scan for Improved Weld
Flaw Detection and Sizing

Chris Magruder

2016 ASNT Annual Conference

Long Beach, CA
October 26, 2016
Advances in Phased Array Scan Plan Designs Presentation Overview
ASME phased array scan plan design definitions.
Compound S-scan setup and configuration.
Compound S-scan beam resolution.
ASME compliance and essential variables.
Compound S-scan calibration and configuration.
Compound S-scan vs S-scan coverage comparison.
Compound S-scan API 650 9%Ni cryogenic data example.
Compound S-scan ASME B31.3 carbon steel weld data example.
Advances in PA Scan Plan Designs ASME V Art 1 121.2 UT Definitions
E-scan: A single focal law multiplexed across a group of elements for a
constant angle beam stepped along the probe length.
S-scan: Set of focal laws that provides a fan-like series of beams through a
defined range of angles using the same elements.
Compound S-scan: Set of focal laws using a fan-like series of beam
movements through a defined range of angles and elements. The compound
S-scan combines the E-scan and S-scan in a single acquisition group.

Linear E-scan Azimuthal S-scan Compound S-scan

Advances in PA Scan Plan Designs Compound S-Scan Setup
Select probe frequency and aperture.
The aperture is limited by the pulser configuration and element pitch. A simple
rule of thumb is to reproduce the size of the equivalent UT probe.
Position the probe as close to the weld as possible with respect to the first and
last A-scan position\angle that is needed for full volumetric coverage.
Near-side wall fusion is best detected as close to perpendicular as possible.

72 d
egre
es
Advances in PA Scan Plan Designs Beam Resolution
The beam resolution will determine the number of A-scans in the compound
S-scan.
This parameter significantly affects flaw resolution, file size, and scanner speed.

72 d
egre
es
Advances in PA Scan Plan Designs Beam Resolution cont.
In the example below, all compound S-scans use the same beam aperture and
the same first and last A-scan angle and beam exit position in the wedge.
They only differ in beam resolution, which greatly affects acoustic results.
In addition to the S-scan beam resolution, results are also affected by the
proximity of the probe to the weld (beam spread) and probe frequency.
Advances in PA Scan Plan Designs Beam Resolution cont.
The beam resolution will determine the # of A-scans in the compound S-scan and
the beam-to-beam distance on the weld bevel that affects flaw height sizing.
Flaw resolution on the weld bevel is a function of many factors, including the
sound path distance from the probe to the weld, probe frequency, aperture, focus,
and beam orientation.
Advances in PA Scan Plan Designs ASME Compliance
The compound S-scan scan plan is defined for the PA calculator or work
procedure by populating the parameters of both the linear E-scan and S-scan
in ASME V Art 4 Appendix V Table V-421.

PWZ1 5L60

1mm \ .9mm \ 60 \ .1mm

40mm half path

32mm
60 \ 10 \ .1

55 shear

40-72

1-29
1

72 d
egre 40-72
es .5 deg

32 (1-29)
Advances in PA Scan Plan Designs Calibration and Work Procedure
The compound S-scan is compatible with traditional phased array sensitivity
and time-of-flight (TOF) calibrations.
With regard to UT settings, gate position, C-scan configuration, and other
functions, the compound S-scan does not require any special accommodation
and is compatible with normal work procedure.
Advances in PA Scan Plan Designs Compound S-scan vs S-scan

Although a two group S-scan strategy from the front and back of the probe is
possible with any 32 or 64 element probe, use of a single compound S-scan
results in less setup and calibration time, more inspection coverage, and faster
analysis.

2X 4072 at 1 degree compound S-scan 4X 4072 at 1 degree standard S-scan

Advances in PA Scan Plan Designs Compound S-Scan vs S-Scan
Below is a comparison of a standard and compound S-scan with the same
aperture and focus inspecting a 12.7 mm V weld.
Detection, sizing, and characterization are similar in this thickness, but the
compound S-scan index position is 8 mm closer to the weld and more easily
adapted to a range of bevel thicknesses using the same setup and calibration.
Advances in PA Scan Plan Designs Data Example
The data sample below is two-sided coverage of a 12 mm V weld.
5L32 0.6 mm pitch probe.
No significant loss in flaw characterization and sizing as is typical in a single
angle linear scan, also called an E-scan.
Advances in PA Scan Plan Designs Data Sample 9% Ni LNG Shell
Ability to use one setup configuration for a range of bevel thicknesses.
Thin section data sample.
4L32 1 mm pitch probe.

10 mm
15 mm
20 mm
Advances in PA Scan Plan Designs Data Sample 9% Ni LNG Shell
Ability to use one setup configuration for a range of thicknesses.
Thick section data sample.

35 mm 25 mm
Advances in PA Scan Plan Designs Data Sample ASME B31.3
25 mm double V weld bevel coverage comparison of compound and standard
S-scans with a 1 mm pitch, 60 element probe.
Compound S-scan Standard S-scan 2X Standard S-scan
Advances in PA Scan Plan Designs Data Sample ASME B31.3 cont.
Flaw detection, sizing, and characterization meet and exceed the needs of
ASME B31.3, I, V, VIII, and similar referencing codes.

31 mm V weld bevel coverage using a 32 mm aperture compound S-scan.

Advances in PA Scan Plan Designs Data Sample ASME B31.3 cont.
Full volumetric coverage, including the heat affected zone (HAZ), on a 1.219 in.
bevel is achieved in a single group line scan with the probe adjacent to the weld
toe.

31 mm V weld bevel coverage using a 32 mm aperture compound S-scan.

Advances in PA Scan Plan Designs Data Sample ASME B31.3 cont.
Fewer files, faster setup and calibration, fewer acquisitions, and less time
analyzing is made possible through the use of a compound S-scan.

31 mm V weld bevel coverage using a 32 mm aperture compound S-scan.