Ultrasonic

inspection
of
pressure
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vessel
welds using
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Third level
phased arrays
Fourth level
Fifth level

Talk Outline
Weld inspections
Codes, including ASME Code Case 2235
Some dos and donts of phased arrays

AUT inspection instruments

Mechanics: some suggestions

Summary

Weld inspections

Linear Scanning Philosophy

Select arrays to give adequate coverage; need to
ensure HAZ and weld zone covered
Scan weld in parallel linear motion, or move weld past
stationary arrays -> much faster.

Left: raster scans

Right: linear scans

Electronic and Linear Scanning

Typical weld inspection using combined
electronic and linear scanning.
ASME-type 45o and 60o shear wave & TOFD
inspections; ~10x faster than raster scanning.
Need to cover weld, HAZ, any position errors
=> significant amount of coverage.

Works well for wide gap welds.

Sample ResultsTop, side, end View

This image
shows weld
profile
superimposed
on top, side,
end and
waveform
view.

UT Zone Discrimination
Weld is divided into many
Zones, each covering 23mm of weld wall
UT beams are focused to
~2 mm, and angled for
Lack of Fusion
UT transducers are
designed and positioned
to inspect each zone
Scanner travels linearly
round pipe at high speed
Both sides of the weld
center line are inspected
independently

Codes

Codes
ASME Code Case 2235 permits automated
ultrasonic inspection of welds <12.7 mm.
Can use TOFD and TOFD/pulse-echo
Must do Performance Demonstration
Many different instruments, set-ups and
mechanics possible due to variety of
pressure vessel welds and requirements
Also, other codes: API, AWS, ASME V

Advantages of AUT vs. RT

AUT does not disrupt production

No safety hazard from AUT; no radiation
Immediate feedback on the weld quality
AUT can measure the defect height for
Fitness-For-Purpose analysis, => should
reduce repairs and costs.
AUT inspections can be tailored to the weld
profile, vessel geometry and inspection
requirements
Can maximize Probability of Detection
All data is stored, unlike manual UT
High production rates.

Some Dos and Donts

Dos and donts - calibration

DO
Calibrate array entire array for reproducible
and code-acceptable results
Best approach is to scan over calibration
reflector then compensate electronically
using software

Dos and donts Weld overlays

DO
Add weld
overlay if
possible
Helps locate
defects relative
to weld profile
and surface

Dos and donts 3D images

MAYBE
Can do 3D
imaging with
TomoView
Good pictures,
BUT need
maximum height,
length etc.
ASME box more
useful for analysis
Development
done with Zetec
Quebec.

Image courtesy of Zetec

Dos and donts S-scans

DONT: perform single S-Scans on thick sections
Can calibrate S-scans at any angle on SDH
S-scan does not necessarily give best angles for weld
inspections

Inspection Systems
Instrumentation

OmniScan Portable Phased Array

Unit
Battery-powered/AC
16/128 unit
Performs electronic
and sectorial scans

Pulse-echo, TOFD
etc.
With array and
encoder, OmniScan is a
complete system

Can operate with

encoders or full
scanners
User-friendly software

PV-100 System

Conventional multiprobe system with encoded

handscanner or automated scanner

Uses TOFD for weld midwall, and pulse-echo for

root and cap to give 100% coverage.

PV-200

Uses full phased array units (Tomo III or FOCUS

LT) with automated scanners

Performs many different inspections, incl. TOFD

and top, side, end views
General purpose inspections.

FOCUS LT
New instrument
replaces FOCUS
As capable as
FOCUS, but
smaller, lighter,
cheaper
Runs TomoView
Performs multiple
scans
simultaneously
Good data
analysis

PV-300
Special ECA-Fitness
For Purpose
applications
200% NDE coverage
Multiple NDE
techniques
o Pulse-echo
o Tandem
o TOFD

o Eddy current

Mechanics
From semi-automated to fully
automated

Encoded Array
Simplest and
cheapest solution
Works with
OmniScan
Can give top,
side, end views
and TOFD
Limited by
position accuracy
and single
function scans

Handscanners
Low cost and easy to use
Can use conventional or
phased arrays
Uses TOFD and pulseecho
Good approach for very
thick walls

Need allowance for

operator error

Welding Bands
Good for
pipes up to
~1.5 m
Quick, easy
and accurate
Routinely
used on
pipeline
construction.

Rotate the Vessel

Good for
fabricators, who
rotate to weld
Simplest
mechanical solution
Can accommodate
position errors with
phased arrays
No safety hazard,
no delays

Magnetic wheel scanners

Variety of scanners
available from R/D
Tech and externally
Follows magnetic
strip, so can scan
nozzles, unusual
geometrys etc.

Can also use

joysticks, preprogramming etc. for
control

Robotics

Expensive, but very flexible solution

Robot can manipulate large probe pan with
many NDE devices.

Advantages of Phased Arrays

Speed: scanning with phased arrays is much faster than single probe
conventional mechanical systems, with better coverage;
Flexibility: set-ups can be changed in a few minutes, and typically a
lot more component dimensional flexibility is available;

Inspection angles: a wide variety of inspection angles can be used,

depending on the requirements and the array;
Small footprint: small matrix arrays can give significantly more
flexibility for inspecting restricted areas than conventional probes
Imaging: showing a true depth image of defects is much easier to
interpret than a waveform. The data can be saved, analyzed and redisplayed as required.

Conclusions

Many different PA & AUT systems can be used to

fulfill ASME 2235 and other weld inspection codes:

Many possibilities for delivery systems:

portable phased arrays (OmniScan),

TOFD-based (PV-100)
more powerful phased arrays (PV-200 and FOCUS LT).
handscanners,
welding bands,
magnetic wheel scanners,
rotate the vessel,
robotics.

Choice is controlled by codes, component

requirements, budget and knowledge.