WeldRover 5 of 8 - TOFD

Presentation Overview
The intent of this presentation is to provide a basic overview of th
e WeldRover Phased Array Inspection System and its various co
mponents. The presentation is divided into the following sections
:
 Part 1 – WeldROVER Introduction and Video
 Part 2 – WeldROVER Equipment
– Introduction, Transport Cases, Instrumentation, Controls, Scanner, Configuration, Water Supply,
Weld Series Probes
 Part 3 – Code Compliance
– ASME\AWS\API Compliance, Calibration Requirements
 Part 4 – ES Beam Tool – Scan Plan Design
– ES Beam Tool, Scan Plan Considerations, WeldROVER Skew, 5 Channel Types,
Advantages\Disadvantages, Scan Plan Examples
 Part 5 – WeldROVER TOFD
– Why use TOFD?, Theory, Flaw Examples, Setup, Acquisition, Analysis, Conclusions
 Part 6 – WeldROVER (PV200) Omniscan Setup
– Group Wizard, Calibration Wizard, Display Setup, UT Parameters Configuration, Scanning
 Part 7 – WeldROVER (PV200) Acquisition
– File Management, PRF Optimization, WeldRover Operation
 Part 8 – WeldROVER (PV200) Analysis
– Analysis Tools, Examples of Flaw Analysis, Defect Table and Reporting, File Management,
Tomoview for Offline Analysis
2
WeldROVER – Why use TOFD in a Phased Array Inspection?
In most instances, particularly on thin welds, TOFD is not necessary and
the phased array is sufficient. However on thicker welds whether it is
required or not, it is extremely useful for the following reasons:
 Where weld bevel design does not allow a pulse echo A-scan to intersect the
weld bevel at near perpendicular angles, the probability of detection and over
all inspection quality is severely reduced on the fusion line. TOFD uses
diffracted rather than reflected signals and is not dependent on flaw orientation.
 Setting up a TOFD channel on the Omniscan MXU takes less than 5 minutes
and calibration is typically performed in analysis mode after the inspection.
 Of the 256 available focal laws (A-scans) in the Omniscan, the TOFD channel
uses only one. Low overhead on the acquisition rate and file size.
 TOFD is an industry accepted technology that has been in use for decades.
 The ASME, AWS, and API codes have either specific rules for TOFD or
alternative rules for computer based inspection techniques that allow flexibility
in inspection strategy if a qualification is performed. TOFD is an excellent tool
for fulfilling these requirements.
 For thick welds that are difficult to cover on one line scans, TOFD can provide a
large coverage area reducing acquisitions and probe changes.
 For some codes such as ASME CC2235, the technology used for detection can
be different than that of sizing. This is a great combination for PA and TOFD
 !TOFD - BIG VALUE - LOW COST - EASY!

3
WeldROVER – Why use TOFD in a Phased Array Inspection?

 The 30 degree V weld can easily be

inspected using standard PE
techniques from the phased array
without the use of TOFD. A 60
degree linear scan would intersect
the weld bevel perpendicular
providing a very high probability of
detection throughout the entire weld
volume when inspected from both
sides.

 For weld bevels that have a vertical

plane, PE scan plans without the
use of TOFD would have a low
probability of detection on the
vertical fusion lines.

4
WeldROVER – Why not generate the TOFD channel using the PA probes?
 TOFD is generally acquired at a higher frequency (10-15 MHz) than the
PA channel (2-7MHz)
 The PCS (Probe Center Separation) required by the TOFD probes is
often outside the area possible within the PA wedge footprint
 TOFD inspection is acquired using L-waves and the phased array PE
channels generally use shear waves. Although it is possible through the
same wedge, generally the wedges angles are cut differently and would
require a compromise between the two.
 To generate the wide beam spread required by a TOFD channel the
conventional crystal size is typically 3-6mm. For a .6mm pitch PA probe
to generate a 3mm aperture only 5 elements could be used. For a 6mm
aperture only 10 elements could be used. This low element count in the
focal law results in a poor quality A-scan and low signal to noise ratio.
Increasing the elements in the aperture would result in narrowing the
beam spread and decreasing the expected coverage.
 TOFD probes are specialized probes with dampening, ringing, and other
parameters optimized for TOFD inspection

5
WeldROVER – TOFD Hardware
The WeldROVER is quoted with the probes, wedges, and hardware necessary
to inspect a wide range of welds and can be configured as needed based on
customer requirements. The WeldROVER is designed to acquire 2 TOFD
channels (4 probes) on a standard acquisition.

6
WeldROVER – TOFD Hardware

 The Weldrover and Olympus

PV200 systems use an
adapter connected to the PA
Probe splitter to borrow 2
elements per TOFD channel
from the 128 element phased
array connector.
 While active on a TOFD
channel these elements
cannot be used on the phased
array channels.
 The WeldROVER umbilical is
delivered with coaxial cabling
with Lemo connectors for 2
dedicated TOFD channels.

7
WeldROVER – TOFD Hardware
 The WeldROVER is designed to be
accommodate an optional TRPP
5810 2-channel remote
pulser\preamplifier that will boost
the UT voltage to 200 volts and
improve signal to noise ratio of the
TOFD A-scan.
 Another option is the 5682 1-
channel preamplifier to improve the
signal to noise ratio without the
pulser by boosting the reception
signal at the scanner connection by
40dB prior to transmission back to
the instrument.
 See detailed product brochures for
specifications and details.

8
WeldROVER – TOFD Basics

The incoming wave

vibrates the defect.

Each point of the

defect generates new
elementary spherical
waves called
diffraction

9
WeldROVER – TOFD Basics Continued

Incident
wave Diffracted
waves All directions

Low energy
Reflected FLAW
wave Independent of
incidence angle

Diffracted
waves

10
 WeldROVER – TOFD A-scan – Lack of Fusion
Transmitter Receiver
Lateral wave

Back-wall reflection

LW BW

Upper tip Lower tip

11
WeldROVER – TOFD A-scan – ID Crack
Transmitter Receiver
Lateral wave

Back wall echo blocked

LW

No back
Tip wall echo
12
WeldROVER – TOFD A-scan – Interpass Non-Fusion

Transmitter Receiver
Lateral wave

Reflected signal

Back wall reflection

LW BW

Reflection echo
13
WeldROVER – TOFD A-scan – Data Visualization
Amplitude
White
+

Time
- Black

Time
One A-scan picture is replaced by one gray-coded line
14
WeldROVER – TOFD A-scan – Data Visualization
A-scan
LW

D-scan BW

Upper Back wall

surface
15
WeldROVER – TOFD Analysis - Near Surface Crack

1 2
The crack blocks the Lateral Wave
And the lower tip appears on the A-scan
16
WeldROVER – TOFD Analysis - Incomplete Root Penetration

1
2

2 4 2
1 1 3
Note the two signals from the top & bottom

17
WeldROVER – TOFD Analysis - Lack of Root Penetration

1
1

2
3

2
3

Note the inverted phase between LW and defect

18
WeldROVER – TOFD Analysis - Lack of Sidewall Fusion

1
1
2 2
3

4
3

Note the two signals from the top & bottom

19
WeldROVER – TOFD Analysis - Porosity

1
2 1

2
3

Porosity may image in many forms whether

individual or cluster

20
WeldROVER – TOFD Analysis - Transverse Crack

1
1
2 2
1
3
2

3 4
3

In the LW we can observe the wide beam effect on the crack

21
WeldROVER – TOFD Analysis - Concave Root

1
1
2

2
3
3

Distortion of back-wall echo

22
WeldROVER – TOFD Analysis – Interpass Lack of Fusion

1
2

23
WeldROVER – Omniscan Group Wizard - TOFD
The Omniscan TOFD setup starts with
the Group Wizard. The Group
Wizards were designed to make
common functions that required
entering multiple parameters in
many places fast and simple. The
Wizard takes the operator through a
step by step procedure so the
menus need not be navigated to
create the channel.

For WeldROVER and Omniscan MXU

applications, the TOFD channels
must always be the last channels
created

24
WeldROVER – Omniscan Group Wizard - TOFD
 In the Group Wizard the operator is offered a choice between selecting a Phased
Array Channel or Conventional UT Channel. Selection of UT Conventional
activates the Omniscan for use of an adapter that allows UT probes to be
configured onto the phased array adapter with Lemo connections. There are 4
available from the 128 (Typical) for 2 dedicated TOFD channels or conventional
UT Pulse Echo Channels

25
WeldROVER – Omniscan Group Wizard - TOFD
 Upon selecting
Conventional UT in the
Group Wizard, the operator
is given choices for Pitch-
Catch, Pulse-Echo,
Through-Transmission, or
TOFD.
 Although only the TOFD
channel is standard for the
WeldROVER applications,
The use of PE and PC
probes for transverse
scanning, OD creeping
wave, or supplemental
channels is fully functional
and enabled for advanced
users.

26
WeldROVER – Omniscan Group Wizard - TOFD
 The Phased Array Y-adapter and Extension Cable\Adapter are a standard part of
the WeldROVER umbilical and can be configured for the particular application as
needed. They allow conventional UT probes to be “Piggy-Backed” on the 128
available Phased Array pulsers at 40 or 80 volts (Omniscan MXU 16:128) and 45 or
90 volts (Omniscan MXU 32:128).
 A dedicated element is chosen for both the transmitter and receiver. Preferable
one element from the Skew 90 side of the adapter and one element from the Skew
270 side. Typically the farthest element from the weld or the back of the probe.

27
WeldROVER – Omniscan Group Wizard - TOFD
 The Scan Offset is the center to
center spacing between the phased
array probes and TOFD probes.
This ensures that two probes at
different positions will record the
same flaw at the correct position in
relation to datum 0 on the weld.
 The PCS is the exit point to exit
point position of the TOFD probes
and necessary for calibration and
proper coverage. This is calculated
by a formula that includes focal
depth, probe angle, and part
thickness. It is an essential
parameter of the inspection
strategy. SCAN O
 The WeldROVER currently only
supports scanning in the FFSET
“NONPARELLEL to Beam”
configuration. (Skew 90 and Skew TOFD PCS
270)

28
WeldROVER – Omniscan Group Wizard - TOFD

Upon completion of the Group

Wizard for the TOFD channel,
the channel is now created
(Typically Group 3 for a 2 X PA
+ TOFD configuration or Group
5 for a 4 X PA + TOFD
configuration.

The next step is to configure the

UT properties.

29
WeldROVER– TOFD UT Setup

 Change the display to A-scan view only. Since each TOFD channel is a
single A-scan it is not necessary to view any other displays during UT Setup.

30
WeldROVER – UT Setup - TOFD
 Set the Start of the A-scan digitization approximately 1 usec
before the lateral wave and the Range approximately 1 usec
after the back wall or mode converted shear wave signal as
needed. Efficient range selection will ensure that the
available points on the A-scan are distributed only over your
area of interest.

 Ensure that the gain is sufficient so that the all signals are
visible but not saturated in accordance with the procedure,
code, or as needed. When using the remote pulsers, if the
signal is saturated at 0 dB it may require to lowering the
Omniscan voltage to 40 or 45 volts from 80 or 90 depending
on the Omniscan model.

 Parameters for Wave Type and Velocity were entered from the
Group Wizard and need not be adjusted.

31
WeldROVER– TOFD UT Setup- Pulser
 The Pulser element was entered in the Group Wizard and can be
modified here with recreating a new Group.
 Select the Frequency of the probe on the Filter
 The pulse width is automatically calculated based on probe frequency
but can be “Tuned” manually by advanced users. The PA channels
would have been created before this step and at this point the PRF can
be adjusted for the inspection
– Auto Max will provide maximum scan speed without regard to battery life, heat
based on current UT parameters and number of total channels\focal laws.
(Preferred option for WeldROVER applications)
– Optimized will provide for a compromise of all parameters to include number of
points on A-scan, maximum battery life, heat considerations, acquisition speed,
etc.
– Max/2 will provide ½ the maximum acquisition speed.
– Custom will allow you to enter any max speed that does not exceed the calculated
speed possible by the software. Entering a larger number will return on the
maximum speed possible the same as Auto Max
– The PRF is displayed on the Omniscan user interface at all times

32
WeldROVER– TOFD UT Setup- Receiver
 The Receiver element was entered in the Group Wizard
and can be modified here with recreating a new Group.

 Select the Frequency of the probe on the Receivers Filter

 Maximize the Averaging to 16. This is an essential

variable that will decrease the noise without decreasing
the relevant signals. Currently the Omniscan is limited to
a factor of X 16. This will also slow the acquisition rate by
a factor of 16 for the TOFD channel but is required for
quality TOFD data.

 Reject is not used in the TOFD channel or Phased Array

channels.

33
WeldROVER– TOFD – Scan Encoder Setup
 The following Scan-Encoder parameters are common to both
the Phased Array channels and TOFD channels and need only
be configured one time. These steps are repeated on the
Omniscan PA portion of this presentation.
 Move the scanner and ensure the direction of travel is going
Positive. If going negative reverse the polarity of the encoder
 The encoder inside the WeldROVER is a Quadrature type.
 The Resolution of the WeldROVER encoder is 2100 and
should periodically be calibrated through the Omniscan
Encoder Calibration Wizard to ensure accurate tracking.
 Set the origin to 0. If multiple acquisition are required on one
weld the files can be saved and the encoder preset to the next
position. In the default condition on the Omniscan, the
encoder will reset to 0 every time a new acquisition is started.
 The preset button is used to manually to change the encoder
position at any time for any reason.

34
WeldROVER– TOFD – Scan Inspection Parameter Setup
 The following Scan-Inspection parameters are common to
both the Phased Array channels and TOFD channels and
need only be configured one time. These steps are
repeated on the Omniscan PA portion of this
presentation.

 The WeldROVER is a “One-Line Scan” type scanner and

utilizes only 1 of the 2 available encoders available on the
Omniscan. It will always be Encoder

 The Max Scan Speed displayed here is the same function

as the UT-Pulser-PRF menu.

35
WeldROVER– TOFD – Scan Area Parameter Setup
 The Scan Start and Scan Stop is the length of the acquisition which may or
may not include the entire weld. If more than one acquisition is required due
to accessibility or file size, the data can be encoded accordingly and
analyzed independently in the Omniscan or pieced together in one file in
Tomoview for offline analysis.
 When using a Start position other than 0 for multiple acquisitions, the
encoder must be preset the correct position prior to acquisition start.
 The Scan Resolution is an essential parameter that relates directly to file size
and length sizing resolution. Every X mm of travel the Omniscan MXU
system will record every A-scan on every channel. When performing long
acquisitions or acquisitions with a large number of channels or focal laws,
reducing the resolution to 2 will cut the file size by ½. This will also lower
the error rate of length sizing to +/- 4mm from +/- 2mm
 Although the Scan Resolution does not directly affect the PRF, it does affect
the maximum Acquisition Speed. (Speed at which the WeldROVER can be
driven without missing data).
 For Applications that do not require precision LENGTH sizing, reducing the
Scan Resolution to 2 from 1 is the easiest way to reduce the file size and
maximize scan speed.
 The file size limitation for a standard Omniscan MXU is currently 180 Meg. A
300 Meg option is available and recommended for large acquisitions.
 Care should be taken to ensure that a reduced resolution does not violate
the relevant code or procedure. Example: ASME CC 2235 requires a 1mm
scan resolution.

36
WeldROVER– TOFD – Scan Data Parameter Setup
 The following Scan- Data parameters are common to
both the Phased Array channels and TOFD channels
and need only be configured one time. These steps
are repeated on the Omniscan PA portion of this
presentation.

 Storage default for WeldROVER inspection is Last.

See Omniscan manual for details regarding this
feature.

 The Inspection Data default for WeldROVER

inspection is All A and C Scan data. See Omniscan
manual for details regarding this feature.

37
TOFD Real Time Acquisition .5 inch X 12 inch pipe (1280mm total) at 50mm / second

Please launch video “TOFD Acquisition.avi”

38
WeldROVER- Omniscan MXU TOFD Calibration Movie

Please launch video “TOFD Calibration.avi”

39
WeldROVER- TOFD Analysis Movie – LOF and SLAG

Please launch video “TOFD analysis.avi”

40
WeldROVER TOFD Conclusions
 TOFD is a powerful tool that is fast and easy to configure and acquire
data. The training track to set up and acquire TOFD data in
accordance with a procedure using the WeldROVER\Omniscan MXU
can be as short as 1 day. The training track for designing TOFD
inspection strategies and advanced flaw analysis is never complete
and each application requires testing and verification.

 TOFD is a valuable tool that when combined with the Phased Array
technology allows secondary verification of inspection data, improved
sizing ability for depth, length, and through wall dimension, and an
overall improved inspection with little up-front engineering and
expense.

 TOFD is an essential part of the WeldROVER and Olympus PV200

family of products.

41
Please send questions, comments and corrections to
Chris.magruder@olympusndt.com