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Applications of Encoded Phased Arrays: F E A T U R E A R T I C L E
Applications of Encoded Phased Arrays: F E A T U R E A R T I C L E
Introduction • Speed
Initially the paper will describe phased arrays and how • Flexibility
they work with illustrations of their advantages for encoded • Auditable
linear scanning. This will follow with specific examples • Better defect detection
of complete inspection systems, e.g. HydroFORM for • Defect sizing capability
measuring corrosion, Cobra for smaller diameter piping Realistically, the decreased overall operating costs and
welds, WeldROVER for inspecting large diameter pipes, advanced imaging are the prime reasons that phased
PipeWIZARD for inspecting pipeline girth welds, and in-line arrays have become so commercially successful in a short
inspection systems for pipe mills. Portable developments time. In addition, phased arrays do not change the physics
typically include the OmniScan MX2, though the Focus of ultrasound; they are primarily a method of generating
LT® is transportable. and receiving signals.
How Phased Arrays Work Not surprisingly, there are disadvantages of phased arrays F
as well. All the usual ultrasonic issues arise (coupling, worn
Phased arrays have been well documented recently (1-3),
so in depth details on their operation are not required. wedges, array choice, dead zones etc). In addition, less E
Briefly, an array consists of a series of electrically-isolated obvious issues also arise: grating lobes, optimal angles for A
S-scans, calibrating over range, and in particular – training
elements, each with its own connector, time delay circuits
and analog-to-digital card. The arrays themselves can be (7). T
linear (the most common type), 2D matrix, or circular or U
“specials”. The elements in the arrays are typically pulsed Typical Applications of Phased Arrays
in groups, with “phasing”. Phasing involves adjusting Given the huge range of possible applications for R
the pulsing of the elements to provide constructive and
destructive interference, or “phasing”.
phased arrays, it is perhaps not surprising that there is
a wide variety of applications. In practice, maybe 2/3 of
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the applications are for weld inspections, with various
aerospace applications following behind. This paper will
In practice, there are two methods of using industrial phased
arrays: manual (4) and encoded (5). The differences are describe several weld (and other) inspections of varying A
laid out in (6), but essentially encoded linear scanning (or degrees of complexity, and all of them use linear (1D) R
automated) phased arrays permit full data collection – with arrays.
recorded location. Consequently, the data can be audited, T
analyzed and reconstructed. 1. Corrosion Mapping. Olympus has developed the
HydroFORM, a linear corrosion mapping array using a
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What Phased Arrays Can Do water path and holder (8). This array is normally semi- C
automated, i.e. the scanner is encoded but not motorized.
Phasing allows focusing, sweeping and steering of the
beams, as shown in Figure 1.
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Keywords: p
hased array ultrasonics, encoded linear scan, corrosion measurement, weld inspection, in-line systems
A 2. Small Diameter Pipe Inspections. The Cobra scanner Figure 5: WeldROVER scanner.
T for small diameter pipes has been developed with low
clearance and focusing to minimize beam spread. This is The WeldROVER is very straightforward to use, and
U also a semi-automated system, since it is easier to push connects directly onto the OmniScan. It is controlled
R probes around a small pipe with limited access than to
motorize them. (This scanning option is included in ASME
by a handheld device with only a couple of buttons.
WeldROVER can scan pipes from 100 mm and up to
E Mandatory Appendix V, as it is also encoded). This is flat plate. Unlike Cobra, WeldROVER can hold a pair of
essentially a bracelet scanner, and fits mechanically onto phased arrays, plus a TOFD pair for complete scanning.
a pipe for both ferritic and austenitic steels. Figure 4 shows It does not have a drive controller as such, but is directed
A a photograph of the Cobra scanner. by the operator using a rod at the back along a laser-
controlled path along the weld.
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Figure 9: Photo of
part of on-line ERW-
PA inspection
system.
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Many Other Uses for Phased Arrays
Early on in the development of phased arrays, Olympus I
(then R/D Tech) wrote a paper on their applications (13).
These included:
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• Butt weld inspections L
• Austenitic weld inspections
• T-weld inspections of bridge structures E
Figure 8: Photos of old V2 instrument box at left, and new • Turbine root inspections
V4 instrument box at right. • HIC – Hydrogen Induced Cracking
• Flange corrosion under gasket
5. In-Line Inspection Systems (Pipe Mills). Olympus • Nozzle inspections
has developed specific phased array systems for several • Bridge bolt inspections
pipe mills, e.g. rotating in-line phased array systems, ERW • Spindle/shaft inspections
(Electrical Resistance Welds) on and off-line, and bar and • Thread inspections for the US Army
rotating bar – usually in conjunction with eddy current • Landing gear inspections
arrays. These systems work well, but the market is volatile • Laser weld inspections
(as it is for PipeWIZARD). These systems cost maybe $1-4 • Composites
million each, and Olympus partners with systems builders
for the mechanics. Figure 9 shows an example of part of Many of these applications have matured and become fully
an ERW-PA system. commercial (e.g. butt welds, bolts, turbine roots, flanges,