PAUT&TOFD January 12

STUDY
TOOL
OMNISCAN 2018
MX2
PREPARED BY

RAKESH KUMAR.R

MACHINE’S
OPERATIONS
 PAGE LAYOUT

 PAUT………………………………………………………. 3
Main Display settings………………….. 4
Inspection required items……………. 7
Technic sheet……………………………………. 8
INPUT –JOINT PARAMETERS… … … … … … … … … … … 14
 New file… … … … … … … … … … … … … … … … 1 4
 Part weld… … … … … … … … … … … … … … . . . 1 5
 Setup… … … … … … … … … … … … … … … … … . 1 6
 Calibration… … … … … … … … … … … … … … … . 1 8
 Range setting… … … … … … … … … … … … … … 2 5
 DATA COLLECTION … … … … … … … … … … … … 2 6
 Encoder calibration … … … … … … … … … … … … 2 6
 Calin and calout presentation… … … … … … … … . 3 0
 TOFD………………………………………………………. 29
 Material and zone description … … … … … 33
 Technic sheet … … … … … … … … … … … … 34
 New file selection… … … … … … … … … … . . 36
 Part weld… … … … … … … … … … … … … … . . . 3 7
 Setup… … … … … … … … … … … … … … … … … . 3 8
 Calibration… … … … … … … … … … … … … … … . 3 9
 Calin and calout presentation… … … … … … … … . 4 1
 TOFD PAUT Comparison … … … … … … … … … … 4 3
 Encoder calibration … … … … … … … … … … … … 2 6
 MAIN DISPLAY SETTINGS

A-SCAN

Representations of echo amplitude along with time base or distance.

S-SCAN-Sectorial Scan

B-SCAN
Cross sectional view of a specimen.
C-SCAN-Top view of a specimen.

D-SCAN-End view

R- view-Its same as beam tool representation.

PAUT
Phased Array Ultrasonic Testing
 INSPECTION REQUIRED ITEMS

OMNISCAN MX2/MXU

PROBE COUPLANT WEDGE

NAVSHIP BLOCK/ANY OTHER STANDARD B/K

V1 BLOCK
 TECHNIC SHEET FORMAT
Here we are giving some example,
Let us go for PAUT exam procedure,
 We have to calculate the exam specimen parameters

For example-

 We have to include the same parameters to ESBEAM TOOL SOFTWARE.

 Material- CS
 Thickness-16mm
 Bevel conf.- single V
 CAP width -28mm. Otherwise follow the WPS.

TECHNIC SHEET FORMAT-

Part and Coverage
Piece
Shear Compression
Thickness Width Length IndexOffset Material
Velocity Velocity
16mm 185mm 101mm 22mm Steel 1020 3.24mm/s 5.89mm/s

Slope:
Height Offset Width
Top Left 0 20 10
Top Right 0 20 10
Bottom Left 0 20 10
Bottom Right 0 20 10

HAZ: 22.02% HAZ Width: 4mm

Weld

Ang Heig Ga Radi Landi

Region
le ht p us ng
Upper Fill 30
Hot Pass - V- 2.12
30
Type mm
2m
Root 2mm
m

Cap Height Width Overlap

Top 2mm 28.17mm 5mm
Bottom 2mm 12mm 5mm
 SKEW 90 SIDE
Phased Array Probe:
Index Offset: -22mm Scan Offset: 0mm Mirrored: False

Wedge: SA12-N55S

st
Velocity Primary Offset Height 1 Element Length Width Angle
o
2.33mm/s 70.17mm 17.3mm 73mm 23mm 36.1

Transducer: 5L64-A12
Num. of Elements Element Pitch Total Aperture
64 0.6mm 38.4mm

Linear Beamset 1 Beamset

Law Config.: Linear Wave Type: Shear
Element Qty First Element Last Element Num. of Beams Refracted Angle
o
8 16 64 42 60
Focusing: None
Gate: OFF

Estimated NearField Min: 47.33mm Estimated NearField Max: 52.54mm

Estimated Beam Spread:3.97
 Sectorial Beamset 1 Beamset
Law Config.: Sectorial Wave Type: Shear First Min. Max Angle
Element Qty Element Angle Angle Steps
o o o
16 49 40 70 0.45

Focusing: None
Gate: OFF

Estimated NearField Min: 62.06mm Estimated NearField Max: 64.44mm

Estimated Beam Spread Min: 3.98 Estimated Beam Spread Max: 7.42
 SKEW 270 SIDE

Phased Array Probe:

Index Offset: 22mm Scan Offset: 0mm Mirrored: True

Wedge: SA12-N55S

st
Velocity Primary Offset Height 1 Element Length Width Angle
o
2.33mm/s 70.17mm 17.3mm 73mm 23mm 36.1

Transducer: 5L64-A12
Num. of Elements Element Pitch Total Aperture
64 0.6mm 38.4mm

Linear Beamset 1 Beamset

Law Config.: Linear Wave Type: Shear
Element Qty First Element Last Element Num. of Beams Refracted Angle
o
8 16 64 42 60
Focusing: None
Gate: OFF

Estimated NearField Min: 47.33mm Estimated NearField Max: 52.54mm

Estimated Beam Spread:3.97
 Sectorial Beamset 1 Beamset
Law Config.: Sectorial Wave Type: Shear First Min. Max Angle
Element Qty Element Angle Angle Steps
o o o
16 49 40 70 0.45

Focusing: None
Gate: OFF

Estimated NearField Min: 62.06mm Estimated NearField Max: 64.44mm

Estimated Beam Spread Min: 3.98 Estimated Beam Spread Max: 7.42
 NEW SETUP FORMAT
»»INPUT THE JOINT’S PARAMETERS AS PER THE TECHNIC SHEET
PART &WELD
SETUP
For Linear

For sectorial
 CALIBRATION

 PAUT CALIBRATION PROCEDURE

THERE IS A FOUR IMPORTANT STAGE FOR PAUT CALIBRATION, THESE ALL ARE GIVEN
BELOW STEP BY STEP.

1. VELOCITY

2. WEDGE DELAY

3. SENSITIVITY

4. TCG (TIME CORRECTED GAIN).

VELOCITY CALIBRATION-
WIZARD CALIBRATION ULTRASOUND VELOCITY
WEDGE DELAY
SENSITIVITY
SELECT VELOCITY
 START RADIUS
THICKNESS
DEPTH
APPLY ON ALL ANGLES.
(IF YOU ARE USING V1 –BLOCK IIW TYPE 1)

SELECT RADIUS
 START
 RADIUS 1 & RADIUS 2( RADIUS 1=100& RADIUS 2=225)
 SET THE RANGE AS PER RADIUS 2(>225).
 GET RADIUS 1
 SELECT THE GATE-A ON RADIUS 1(100)
 GET THE POSITION
 GET RADIUS 2
 SELECT THE GATE-A ON RADIUS 2(225)
 GET THE POSITION
 SO YOU WILL GET THE MATERIAL VELOCITY ACCORDING TO THE
VELOCITY CALIBRATION.
WEDGE DELAY CALIBRATION-
WIZARD CALIBRATION ULTRASOUND VELOCITY
WEDGE DELAY
SENSITIVITY
SELECT WEDGE DELAY
 START RADIUS
THICKNESS
DEPTH
APPLY ON ALL ANGLES.
(IF YOU ARE USING V1 –BLOCK IIW TYPE 1)

 SELECT RADIUS
 SELECT THE GATE-A ON RADIUS A(IF RADIUS A=100)
 SET THE GATE A ON THE A-SCAN ,
 CALIBRATE = ACCEPT THE WEDGE DELAY OPTION
SENSITIVITY CALIBRATION-
WIZARD CALIBRATION ULTRASOUND VELOCITY
WEDGE DELAY
SENSITIVITY
SELECT SENSITIVITY
 START RADIUS
THICKNESS
DEPTH
APPLY ON ALL ANGLES.
(IF YOU ARE USING NAVSHIP –BLOCK)

From top,
 1ST SDH DEPTH@ 0.250IN=6.35MM
 2ND SDH DEPTH@ 0.750IN=19.05MM LENGTH=304.8mm

 3RD SDH DEPTH@ 1.250IN=31.75MM WIDTH=31.75mm

 4TH SDH DEPTH@ 1.750IN=44.45MM
THICKNESS=76.2mm
 SENSITIVITY CALIBARTION USING SDH (CHOOSE THE DEPTH ACCORDING TO THE JOB
SPECIMEN).
 EXAMPLE- IF JOB THICKNESS=20MM, SO WE CAN DIRECTLY CHOOSE NAVSHIP BLOCK’s 2ND
SDH(19.05mm)
 TCG(TIME CORRECTED GAIN) CALIBRATION
Peak up the SDH reflector (NOTCH) and bring level to 80% of FSH for all
focal law angles.

Now we are going to start the TCG calibration with example.

Suppose, Job specimen thickness=20mm.

So we have to take at least 3points for TCG calibration for the full body
calibration (full skip).

 ~=½ T, half of the thickness or (=<1/2T)

 ~=T, thickness or near by the thickness
 >=2 T, double of the thickness or above.
 Our job thickness is 20mm, so choose the SDH with navship
block.
Below mentioned step you have to follow up to the accept
TCG option (TCG-ending).

 CALIBRATE THE 1ST TCG POINT AND MOVE TO THE NEXT TCG POINT
 CALIBRATE 2ND POINT
 CALIBRATE 3RD POINT
 ACCEPT TCG.
 RANGE SETTINGS
GROUP RANGE SETTING

Set the angle cursor to maximum Angle and play through START & RANGE options.

Finally set the Gate on the selected Area.

DATA COLLECTION
 If you collect the data with Mini wheel Encoder means encoder
resolution is 12 step/mm(not applicable for other encoder).for that we
should go for the encoder calibration.
SET THE AREA WHICH WE ARE GOING FOR SCAN.
ENCODER CALIBRATION
 CALIN&OUT PRESENTATION

CALIBRATION BOCK

D-VIEW(END VIEW)

C-SCAN(TOP VIEW)

B-SCAN(CROSS SECTIONAL VIEW)

 TOP NOTCH CALIN&OUT DATA (A-S-C-R-display)

BOTTOM NOTCH CALIN&OUT DATA (A-S-C-R-display)

NOTE-Set the echo amplitude @ 80% of Full Screen Height(FSH).Daily CALIN&OUT during inspection mainly for
sensitivity checking.
TOFD
Time Of Flight Diffraction
 ZONE DESCRIPTION

MATERIAL VELOCITY

SL NO MATERIAL LONGITUDINAL
VELOCITY
1 Alloy Steel 5740m/s
2 Carbon steel 5920m/s
3 Stainless Steel 5660m/s
4 Aluminum 6320m/s
5 Cast Iron 3500-5600m/s
6 Copper 4700m/s
7 Brass 3830m/s
8 Perspex 2730m/s
9 Water 1483m/s
10 Oil 1410m/s

SINGLE ZONE PARAMETERS

THICKNESS FREQUENCY(MHz) ELEMENT SIZE(probe)mm Angle(Ѳ)

<13mm 10-15 3-6 60°-70°
13 to <38mm 5-10 3-6 50°-70°
38 to<75mm 2-5 6-13 45°-65°

MULTIPLE ZONE PARAMETER

THICKNESS FREQUENCY(MHz) ELEMENT SIZE(probe)mm Angle(Ѳ)

<38mm 5-15 3-6 50°-70°
38 to <300mm 1-5 6-12.5 45°-65°

RECOMMENDED TOFD ZONE FOR BUTT WELDS UPTO 300mm

THICKNESS (mm) Number of Zone Depth Range Beam intersection

<50 1 0 to t 2/3t
50<t<100 2 0 to t 2/3t
t/2 to t 5/6t
100<t<200 3 0 to t 2t/9
t/3 to 2t/3 5t/9
2t/3 to t 8t/9
200<t<300 4 0 to t/4 t/12
t/4 to t/2 5t/12
t/2 to 3t/4 8t/12
3t/4 to t 11t/12
 Lateral Wave Timing (L.W.T)=PCS/V
Where PCS=Probe Center Separation.

V= Velocity of the material (mm/s).

Back Wall Timing (B.W.T) = 𝒑𝒄𝒔/𝟐 𝟐 𝒕𝟐 /𝒗} × 𝟐

Where PCS=Probe Center Separation.

V= Velocity of the material (mm/s).

t= Thickness of the material

TIME=DISTANCE/VELOCITY

HALF BACKWALL DISTANCE =√

√
Hence, HALF BACKWALL TIMING =

√
BACKWALL TIMING =
( )

LATERAL WAVE TIMING =PCS/VELOCITY

 TOFD REQUIRED ITEMS

 MACHINE
 TOFD PROBES
 TOFD WEDGES
 PRE AMPLIFIER(if required)
 MINI LEMO TO MICRO DOT CABLES.
 SCANNER

OMNISCAN MX2

TOFD PROBE

TOFD WEDGE

PRE AMPLIFIER

MINI LEMO TO MICRO DOT

SCANNER
 TECHNIC SHEET FOR TOFD-(EXAMPLE)

Part and Coverage

Piece
Shear Compression
Thickness Width Length IndexOffset Material
Velocity Velocity
47.75mm 200mm 100mm 0mm Steel 1020 3.24mm/s 5.89mm/s

Slope:
Height Offset Width
Top Left 0 20 10
Top Right 0 20 10
Bottom Left 0 20 10
Bottom Right 0 20 10

HAZ: 11.67% HAZ Width: 5mm

Weld

Ang Heig Ga Radi Landi

Region
le ht p us ng
Upper Fill 10
Fill 0 0mm
Hot Pass - V- 21m
35
Type m
4m
Root 0mm
m

Cap Height Width Overlap

Top 2mm 52.84mm 5mm
Bottom 2mm 14mm 5mm

TOFD Probe:
Crossover Depth PCS Index Offset Scan Offset Elevation Refracted Angle
o
31.5mm 108.4mm 0mm 0mm 0mm 59.84

Wedge: ST1-60L-IHC
Velocity Length Width Angle
o
2.33mm/s 20.31mm 31.75mm 20

Transducer: C543-SM
Shape Diameter Frequency Width Length
Round 6.35mm 5Mhz 1mm 0mm
NEW SETUP SELECTION
PART &WELD
SETUP
CALIBRATION
 DIAGRAM PRESENTION

END VIEW

B-SCAN(SIDE VIEW)

TOP VIEW
TOFD A&B SCAN PRESENTATION(NORMAL)

TOFD CALIBRATION BLOCK & CALIN&OUT PRESENTATION

DIAGRAM(END VIEW)

SDH DEPTH FROM ODS=1/4THICKNESS

TOP VIEW

BOTTOM NOTCH

SIDE DRILLED HOLE

SIDE VIEW

SIDE DRILLED HOLE

BOTTOM NOTCH

A&B SCAN VIEW

 LATERAL

BACKWALL

MODE CONVERTED BACKWALL

TOFD&PAUT COMPARISON –DATA IMAGES

CLUSTER POROSITY

TOFD &PAUT

LACK OF SIDE WALL FUSION

TOFD&PAUT

S-SCAN
INTERMITTENT FUSION

INNER DIA SURFACE INDICATION (NOTCH)-

PAUT INDICATION AREA COMPARISON WITH TOFD(B-SCAN)

MISMATCH AREA REFERENECE WITH TOFD

PAUT &TOFD LINEAR+ CLUSTER INDICATION COMBO.
 DATA ENCODING SCANNERS-SEMI AUTOMATIC

MINI WHEEL

PHONEIX ENCODER

HSMT FLUX SCANNER

MINI HSMT SCANNER

NANO SCANNER

COBRA SCANNER
 DATA ENCODING SCANNERS-FULLY AUTOMATIC

WELD ROVER

ACCUS SCANNER

ACCUS TRACKER

THERMAL 700