GE Inspection Technologies

Setup routine example:

Phasor XS v2.22 for weld inspection

on black carbon steel

Joerg Reinersmann
Technical Support UT
February 2009
J. Reinersmann 2009 Proprietary Information For Internal Use Only!
Roadmap
1. Pre-works 1 probe selection according to inspection task
2. Pre-works 2 encoder mounting
3. Parameters inputting the basic data of probe, part, scan
4. Probe delay setup of the probe delay using the K2
5. TCG/ACG recording of amplitude-cycle
diagrams
6. DCAL depth correction for high scan angles
7. ENC CAL inputting encoder data / encoder
setup
8. Overlay selection or creation of weld graphics
9. Final Scan no comments

Go!
J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 2
 1. Pre-works 1

Probe selection
according to inspection task
Pre-works 1
Test block (#PL 6231):

Dimensions (L/H/W) 300/35/450mm

Material steel
Weld shape single V
Scan length ~250mm

Reference defect:
Pic.1: specimen Natural defects in the weld seam,
e.g. lack of fusion
Selected probe:
PA-5M16E1P, 5 Mhz, 16 elements, 1mm pitch, P/N 105503
Pic.2: probe
NOTE: Please make sure that the common UT parameters were set
correctly, e.g. amplifier and receiver settings!

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 4
 2. Pre-works 2

Encoder mounting
Pre-works 2

Pic. 3: single components Pic. 4: ready!

Note: If more convenient, the encoder may be mounted at a later time, e.g.
with the ENC CAL-setup.
J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 6
 3. Parameters

Inputting the basic data of

Probe, Part, Scan
Parameters
1st.: Probe

As the chosen one has dialog capabilities the following data will be inserted automatically
when pressing probe>probe data>Dialog probe-load definition:

+
Pic. 5: probe tables
Wedge details should be read from the wedge and keyed in at wedge data and wedge geometry:

+
Pic. 6: wedge tables

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 8
Parameters
2nd.: Part

The part parameters (in particular the thickness of the specimen

have to be changed over the calibration procedure.

The first ones to be inserted are the ones from the DAC-calibration block
during the recording of the amplitude-cycle diagram. Later than the details
of the welded test block need to be considered for a proper calculation of
sound paths and defect positions.

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 9
Parameters
3rd.: Scan

Pic. 7: scan tables

- 16 elements aperture for max. energy and near field length
- wavetype: shear
- Sectorial scan, natural focus (=unfocussed)
- 35 to 70, 1 angle increment

Remark:
Number of steps, aperture step and first element remain at 1!

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 10
 4. Probe Delay

Setup of the probe delay

by using the K2
Probe Delay
Calculation of the natural refraction angle:

Vwedge = 2337 m/s

Vsteel = 3255 m/s
Geometrical angle of wedge = 36

sin wedge Vwedge 2337 m

s 0,72
sin steel Vsteel 3255 m
s 36
sin 36
sin steel 0,82
0,72 54

steel arcsin 0,82 54

Pic. 8: Snellius law

Therefore the natural refraction angle in this case is 54 which in turn requires the
Selection of beam no. 54 for the probe delay setup!

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 12
Probe Delay
Step by step
Couple probe to K2 @ R=25 mm, optimize echo
Set gate A to 1st echo (~25 mm) and gate B to 2nd echo (~100 mm)
Select readings SA, SB and SBA to be displayed
(soundpaths in gate A, gate B and the distance between A and B,
make sure that the gates work in peak-mode)
Change the VELOCITY S to get SBA to 75 mm
Change the probe delay to get SA to 25 mm -> done!

Note: The negative probe delay of 1,592 indicates that Pic. 9: probe delay setup
the real z-offset varies from the value printed on the
wedge!
J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 13
 5. TCG/ACG

Recording of
Amplitude-Cycle Diagrams
TCG/ACG
Although we call it TCG (=time corrected gain), this function
should rather be called time and angle corrected gain (=ACG).
For the compensation of the amplitude decay in depth as well as
from low to high angles (see Pic. 10) we need to record an
Amplitude-cycle diagram by using the TCG function.

5
[dB]

0 Area of insufficient recording

Amplitude [dB]

-5
Echoamplitude

Red = trend

Amplitude
-10 Blue= measured
-15
Echo

-20

-25
35 45 55 65 75 Cycle / beam angle
Einschallwinkel
Incremental angle[][]

Pic. 10: amplitude behaviour Pic. 11: amplitude/cycle diagram

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 15
TCG/ACG
Step by step (1/2):

Set the right material thickness of the DAC block

Activate and display the LEG-function
As saturated echos will tamper the TCG, make sure that the highest signal still
behaves linear with gain changes
As the gain compensation is being done with the analog amplifier the recording
value should be set to the lowest possible one (e.g. to 0 dB)
Use the digital gain to optimize the highest echo to about 80% screen height
If possible try to use the natural focus of the probe/wedge combination
(=unfocussed) as changing the focal point highly influences the TCG
Use the analog gain whenever the amplitudes need to be increased during
the recording process the dynamic range of the analog amplifier is 40 dB!
Make sure that gate A is set to 5% threshold only, the gate width should be
rather small (e.g. 4 mm)

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 16
TCG/ACG
Step by step (2/2):

Select UT>NRM/TCG, then press two times on start to run the recording of the
first cycle
Move the probe forth and back as described in Pic. 12 below so that the diagram
can be created, in this example the reflectors are side drilled holes (SDH) on a
DAC block, material is black carbon steel like the welded plate to be inspected
Press (recording) point 1 when finished and the curve left ground on both sides
Move gate A and continue recording other points, one by one
If necessary increase digital gain to maintain sufficient echo heights and
get the curve off the zero line
Press (finish) when done

Pic. 12: DAC block, steel, with SDH of 3 mm dia.,

starting depth=5mm, then each 10mm deeper

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 17
 6. DCAL

Depth correction for

High Scan Angles
DCAL

The basic reason for this function is that in Phased Array

technique not a single crystal, but an aperture of active
elements create the sound beam. On high angles this
means that we may expect beam profile variations, such as
diffractions.

In other words: The physic of an high angle PA shear wave

put the hot portion of the beam on a lower angle than the
expected refracted one, thus the depth is not calculated
correctly without DCAL.

Please note that for DCAL the recording of a TCG in

advance
is mandatory!

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 19
 DCAL
Step by step:
After the TCG has been recorded there are two options of depth calibration (DCAL):
one-point or two-point calibration. The reflectors to be used have to be taken from
the TCG recording (first reflector for one-point, first and second reflector for
two-point calibration). For this example the two-point one has been chosen.
Go to Part>DCAL, set calibration type to 2-point.
Set the D-REF 1 value to the depth of the first recorded TCG reference reflector.
Set the D-REF 2 value to the depth of the second recorded TCG reference reflector.
Set the DCAL MODE parameter to ON -> done!
Pic. 13: table

Symbol for active TCG

Symbol for active DCAL

TCG Recording was started with the SDH in 15 mm,

thus D-REF1 and D-REF2 are 15 mm and 20 mm.

Pic. 14: Phasor screen with active TCG+DCAL

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 20
DCAL
General hints:

As the minimum value for D-REF 1 is limitted to 6.35 mm please make sure that
the first recorded TCG reflector is deeper than that!
For the highest accuracy it is recommended to make use of the 2-point calibration
rather than 1-point.
Best compensation of the effects described earlier is with this routine:

Record the first two reflectors of the reference specimen in the depth of
basic evaluation interest, later you may continue in any order with the
recording of the rest
As these reflectors are now the first recorded ones, overtake their depths
as D-REF1 and D-REF2 into the DCAL, then activate the function by selecting
MODE>on

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 21
 7. ENC CAL

Inputting Encoder Data/

Encoder Setup
ENC CAL
ENC CAL can be found in the SCAN menu and can be used
to calibrate the encoder/wheel combination regarding the
encoder resolution (here: mm per tick) over a known distance.
Step by step:
-Select VIEW MODE=TOP in the display menu
-Go to the ENC CAL submenu and select the desired calibration distance
(here: calibration scan length), e.g. 60.00 mm
-Position the probe/encoder assembly at the starting point on your specimen
- Press <start>
-Run the probe over exactly 60.00 mm, assuring the encoder is properly rolling
over the surface
-Press <finish>
-The corresponding resolution will be automatically calculated and displayed
(see Pic. 16+17)
Pic. 15: ENC CAL

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 23
ENC CAL
How to scan:

Scan finish

Scan start

Pic. 16: encoder calibration (ruler shows cm) Pic. 17: results

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 24
ENC CAL
The unit mm/tick may be confusing. The more obvious
Red when too fast
unit would be ticks per mm. In this case (value is 0.0605)
it can be calculated like 1/0.0605, equals 16.5 means
16.5 ticks per mm will be sent to the unit.

Subsequently this requires a quite slow run on the surface in

order not to miss data (can be seen as white lines during
recording, means no data here). As the miniature encoder
we use works on the quadrature principle it is possible to
record these lines any time during acquisition simply by
running back. In other words the scan can be done in two
directions: Forth and back - data will be overwritten!

A too high scanning speed will be indicated on top left of the

screen (see Pic. 18) when the figures appear in red instead
of Pic. 18: limits
black.

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 25
ENC CAL
The next parameter is the display length for the scanning
itself, representing the area we want to record. There is a
relation between the display length and the sample interval,
as the sample interval is directly linked to the maximum
encoder resolution set before (e.g. when the resolution was
calculated as 0.0605 mm/tick the minimum sample interval
will be the same, but it will result in the need of a
very low scanning speed).

For a convenient scanning speed but also to cover most of

the length of our welded test plate (300 mm) we decided to
increase the sample interval to 0.9075 mm. This means we
will have about one data acquisition each mm travelled.

Correspondingly the display length is 291.30 mm (the full

screen has 320 columns/lines). However, you may continue
Pic. 19: scan length
to
scan much more until the C-scan buffer automatically stops
the recording.
J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 26
 8. Overlay

Selection or Creation
of Weld Graphics
Overlay
Sector Coverage:

70
Back wall

Lowest angle covering

35 near side toe in full
Surface skip

Pic. 20: typical full skip inspection zone

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 28
Overlay
In order to position the weld overlay correctly it is important to understand
the function origin offset (=A), as this must be used to move the
graphic to its final position:

36 WF A
p
p a

40
A H

Z
G

3
5
G p
tan 35
A 2t HAZ
2t tan p p = 49 mm
2 35mm tan 35 49mm
a= p - WF
a= 49 24,06 = 24,94 mm
Pic. 21+22: weld calculations
A = a + x40mm = 44,94
mm
J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 29
Overlay
For an easier understanding of the defect location, apart from
the colored legs, a graphical overlay can be selected in various
ways:

- single V weld
- double V weld
- reference line
- rotatable rectangle
- custom shape (see next page)

The test plate for this example has a single V weld. The wizzard
shows the single V sketch as in Pic. 23, thus the following
dimensions were keyed in:
A = 0 mm
B = 35 mm
C = 2,5 mm
D = 20 mm
Pic. 23: single V from wizzard

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 30
Overlay
Customized Weld Overlays:

If the weld geometry is not covered by the defaults in the

wizzard
an EXCEL-based tool can be used to generate other styles,
e.g.:

Note:
Unsupported-
for internal use only!
Pic. 24: Overlay Editor

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 31
Overlay
Customized Weld Overlays-
details:
The x- and y- columns describe the
corresponding values on the graph
axis. The lines must be defined
point-to-point. An interruption will
result in the creation of another line
(see Pic. 25). The general layout
may be defined with the LEGS
and COLOR fields (e.g. full skip
means 2 legs). Changes
immediately effect the graph on the Pic. 26: overlay graph
Pic. 25: definition table
right hand side (Pic. 26).
When the overlay design has been done, press the create WOL file button
which results in the creation of the desired custom file to be loaded into the
Phasor XS (FILES>ACTION>load overlay). When returning to the
Wizzard the custom area will show up with the recently designed graphic.
J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 32
9. Final Scan
Final Scan
When all previous works are done: GO!

Pic. 27: first scan:right side, bottom to top, Pic. 28: angle corrected scan views,
second scan: left side, top down extracted from Rhythm UT

J. Reinersmann 2009 Proprietary Information For Internal Use Only! GE S & IT page 34