PHASED ARRAY FREQUENTLY ASKED

QUESTIONS

Prepared by Bob Simmons

Office: 780 469 6161
Cell: 780 920 5454
Email: bob@metalogicinspection.com
What is the difference between Phased Array Ultrasonics
and “Traditional” Shear wave Ultrasonics?
Both generate ultrasonic energy and are identical, relative to the basic
physics of sound propagation. However, with “traditional U.T.”, the
inspection is performed with one crystal (probe), one angle and a specific
focal area, all being represented by a basic sine wave display. With the
advancement in electronics, computer speed and probe Manufacturing,
Phased Array has the ability to combine multiple crystals (32) into a single
probe to provide virtually unlimited beam angles and focusing capabilities,
which in the end, can produce a combined single digital display (image) of
the anomaly and it’s location within the part.

Are all Phased Array systems and probes the same?

NO…PA systems vary considerably in the amount of channels, voltage, sensitivity,
penetration power, imaging and reporting. For example, the ability to inspect thick
vessels (over 3”) requires a minimum 200 volts. Further, it is important to understand that
the software, probe types and the relative procedures take months to develop for specific
inspection applications. Phased Array is not an “off the shelf” product or service.

NOTE: ASME requires a “procedure” demonstration on all material and thicknesses.

Metalogic Inspection Services STRONLY recommends any inspection service provider to
demonstrate their proficiency with a practical exam (demonstration) prior to project
initiation, to ensure the procedure, equipment, and technicians are qualified.

What is the accuracy of Phased Array for sizing?

Simply stated, Phased Array significantly decreases the possibility for error when
compared to current inspection techniques such as “Traditional U.T.”, “TOFD”, and
“Xray”. However, like any NDT technique, experience, testing and training are
minimum requirements to ensure continuity of results. To facilitate this, Metalogic
manufactured 22 test specimens with over 40 different anomalies. Independent
inspection companies inspected and reported on all 22 samples utilizing all 3
inspection techniques. After which, the test specimens were sent to an independent
lab for sectioning, to further prove up the technique and procedure as well as
reference material for internal Metalogic training material. A copy of this report can
be provided upon request.
What range of material thickness can Phased Array Inspect?
Metalogic’s experience includes successful inspection of material from 4 mm up to
155mm. All thicknesses were completed with a single scan and application specific
procedures.

What type of surface preparation is required for Phased Array

inspection?
Phased Array requires the same surface prep as traditional U.T., TOFD and or
Visual techniques. Specifically, surfaces free from gouges, weld splatter, lose scale
or any other foreign material that may impede probe contact with the surface.

What types of environments are the instruments designed for?

The technical specification states temperatures between 0 to + 50 degrees. However,
Metalogic with special procedures has used the instrument in -40 degrees to + 60 degrees
with zero impact to inspection results or efficiencies.

How long can the system last on one battery charge?

The technical specification states up to 3 hours. However, battery life is a function of
resolution, material thickness, probe frequency etc. Based on Metalogic stringent
procedure requirements, the current battery life is estimated at an average of 30 minutes.
Our current procedures require operating the system on 110 power.
Note: Metalogic is developing a portable, hot swappable batter pack, for spring 2006
that should allow for up to 3 hours of battery life on the highest resolution.
 INSPECTION TECHNIQUE COMPARISONS

What are the advantages of Phased Array over Traditional UT.?

Probability Of Detection is increased with phased array due to the multiple

angles (thousands) introduced into the part allowing for 100% volumetric
inspection.

Sizing Accuracy is increased due to the focusing and imaging capabilities of P.A.
Traditional U.T. probes are manufactured with the sound ideally focused at the mid wall
portion of the part under inspection leaving room for the anomalies to be over or under
sized due to beam width. However, P.A. has the ability to change focal spots (beam
spreads) electronically to focus on the exact anomaly location and therefore optimize the
sizing results.

Efficiency is increased by a SIGNIFICANT reduction in the probe movement, as well as

the ability to view an actual image of the anomalies for faster interpretation.

Interpretation is easier using phased array images when compared to basic sine wave
signals allowing for a better representation of the anomaly and it’s true shape and size.

Permanent images are taken of the anomaly. Further, when utilizing an encoder
attachment, a complete fingerprint of the inspection area including top, side and end view
of the anomaly can be displayed for additional E.C.A, as well as satisfying regulatory
requirements.

The consistency or repeatability of inspection results is significantly greater with Phased

Array. This can be attributed to the previously mentioned “advantages”, particularly the
“POD” and “Interpretation”
What are the advantages of Phased Array over Time of Flight
Diffraction (TOFD)?

TOFD usually requires multiple scans on thicker material to get 100% inspection
coverage of the part..due to TOFD’s inherent focusing limitations, and its inability to
skip sound. TOFD requires multiple “Zone” scans to ensure 100% coverage, in effect
doubling the inspection time.

TOFD is limited in the detection and or sizing of O.D. / I.D. flaws due to lateral waves,
an inherent part of TOFD inspection. A lateral wave is generated on the
scanning surface between the transmitter probe and receiver probe masking defects on
and near the surface.

TOFD cannot see defects in the root or cap that do not extend into the pipe wall…this
is because TOFD utilizes longitudinal waves as apposed to shear, limiting access and
has no anomaly reflections.

TOFD CANNOT determine the orientation or lateral location of flaws as TOFD is a

“Pitch and Catch” rather than a “Pulse Echo” technique. TOFD is limited to identifying
the defect height and location relative to the I.D. or O.D. only.

TOFD requires additional “hand scanning” of each detected anomaly with ultrasonic
shearwave to “prove up” or “characterize” the anomaly…a further increase to
inspection times.
What are the advantages of Phased Array over Traditional or Digital
X-ray.

Phased Array is a significantly faster inspection technique then Traditional or Digital

Radiography. This is based on exposure times, i.e. the thicker the part the longer the
exposure. In addition, the time is takes to develop the film in the case of Traditional X-
Ray, and the time it takes to process the screens (Download) for Digital X-ray, adds to
the time to produce inspection results.
Note: Most X-ray techniques do not provide results until the end of the shift creating a
significant lag in quality control of welding. Whereas Phased Array results are virtually
real time.

Xray requires an interruption to production schedules. This is by far the largest

advantage (cost savings) of Phased Array compared to “Traditional” and Digital X-ray.
With an inherent radiation field, both require the immediate area be cleared of production
personnel to ensure their safety, thereby impacting or in most cases stopping production.

Metalogic’s Patented Phased Array System only requires one sided access to any
welds…whereas both traditional and digital X-ray requires access to both sides for film
and screen placement. This is important in areas such as water wall tubes, hanging tubes
piping modules and piping wracks.

Sensitivity is significantly less with the more critical “planar” defects using
“Traditional’ or Digital X-ray. This is due to both X-ray techniques requiring a
significant difference in densities to locate flaws…less volumetric defects such as non
fusion and cracks are much harder to detect and size.

Xray cannot determine WHERE an anomaly is located in reference to it’s depth from the
I.D. or O.D. surface. Again, this is due to digital and traditional X-ray only measuring
changes in density between the part and the defect, but from one dimension only.
NOTE: Depth of an anomaly is usually estimated with Xray based on the defect’s lateral
location in the weld. Most procedures require that defects are called in the root to ensure
complete removal. This results in additional repair time and in some instances a cutout.
What type of reporting is provided with Phased Array?

It is dependant on the application and client requests…However, standard reporting for

welds includes a video of the entire inspection area, which provides a “finger print” of
the weld or anomaly for audits and or defect monitoring such as cracks. Further, an
individual JPEG image of all anomalies encountered and relevant inspection
parameters is provided. Additional reporting can be included such as top, side and end
view of the anomaly and part under inspection. This is typically useful for E.C.A.’s,
Crack monitoring etc.

What is the typical report turnaround times?

As soon as the inspection is completed, the entire scan image is saved (seconds).
Individual anomalies that fail code or client criteria are saved as a JPEG with relevant
dimensions (Seconds). The images and information can be immediately downloaded to a
laptop and or emailed or printed through a USB memory card or Cat 5. All this
information can be done on site. Additional reporting is usually completed on the laptop.
Reports such as top, end and side view of anomalies or welds, typically takes an
additional 10- 15 minutes per anomaly. This reporting is only recommended for further
Engineer Critical Assessments of defect monitoring.

What are the minimum training requirements and certifications of

Metalogic’s Phased Array Technicians?

Besides the minimum government NDT certifications (CGSB) and in house NDT
certification (TC1A), all employees using Phased Array for SCC sizing require the
following:

• “Introduction to Phased Array”

• “Advanced Phased Array”
• “Application/Procedure Practical”

In addition to Phased Array training, programs are currently under development at

Metalogic for industry specific process, services and inspection applications:

• “Power Generation”
• “Petrochemical Processing”
• “Pipeline Integrity”