PhasedͲArrayTraining

I.PipeWizard:BasicTheory
¾ Zonediscrimination
¾ PAUT
¾ TOFD
¾ StripChart
¾ Terminology
II. PipeWizard:Setup&calibration
¾ Setup
¾ Calibration
III. PipeWizard:Analysis
¾ Sizing
¾ AcceptanceCriteria
¾ Reporting
 I.PipeWizard:ZoneDiscrimination
Zones
¾ Zonediscrimination
¾ Definition: Methodwherebytheweldisdividedintozonesthatcanbe
definedbyverticalintervalsofthethroughͲwalldimensions.
¾ Multiplebeamsbothsideoftheweldsothatasinglepassallowsthe
inspectionoftheheataffectedzone(HAZ)andthefullvolumeoftheweld.
I.PipeWizard:ZoneDiscrimination
Zones
Fill1
Hotpass2
I.PipeWizard:ZoneDiscrimination
Zones
¾ Zoneareusually1Ͳ3mminverticalheight
¾ Acarefullypositioned,focusedbeaminspectseachzone
¾ Thescannermovearoundthegirthweldtoinspectthefullvolumeinone
circumferentialpass
I.PipeWizard:ZoneDiscrimination
Targets&Gates
Target(FlatBottomHole) Gates
 I.PipeWizard:ZoneDiscrimination
Gates
¾ Theultrasonicsignalismonitoredbyusingtwoelectronicgates
¾ Gate1:AmplitudeGate(typically5%threshold)
¾ Gate2:PositionGate(typically20%threshold).AlsoknownasTOFgate
¾ Thegatesaresettomonitorthesignaljustbeforethebevelandafterthe
weldcenterline
Gate2:Positiongate(20%FSH)
Gate1:Amplitudegate(5%FSH)
 I.PipeWizard:ZoneDiscrimination
TimeofFlightGate
¾ Thestripchartwidthisproportionalwiththepositiongatelength
¾ Forexample:6mm
¾ Thereis2thresholds
¾ Typically, for20%to40%FSHandRED for40%to100%FSH
¾ Incalibration,thereisathirdthresholdtohelpquicklyassesthe
calibrationscan
¾ Typically, for70%to90%FSH(±1dB)
I.PipeWizard:ZoneDiscrimination
TimeofFlightGate
AͲScan
%FSH
1– Fusionface
2– Beforefusionface
2 1 3 3– Afterfusionface
20%
TOF
HAZ Weldmetal
Fusionface
I.PipeWizard:ZoneDiscrimination
TimeofFlightGate
AͲScan
%FSH
1– Fusionface
2– Beforefusionface
1 3– Afterfusionface
2 3
TOF
I.PipeWizard:ZoneDiscrimination
TimeofFlightGate Width6mm
Inspection Calibration
0% 0% Ͳ3.00+3.0
20% 20%
Scanaxis
40% 40%
70%
100% 99%
100%
 I.PipeWizard:ZoneDiscrimination
AmplitudeGate %FSH
¾ Acquisitionresolutionisonerecorded
measurementevery1mm
¾ Widthofthestripchartisproportional
withthe%FSH
Scanaxis
11
I.PipeWizard:ZoneDiscrimination
AmplitudeGate
PA
Weld STRIPCHART(CͲScan)
PROBE 0%
0%
0%
0% AͲScan
0% 100%
25% 75%
50% 50%
100% 25%
50% 0%
25%
0%
0%
0%
0%
0%
0%
 PhasedͲArrayTraining
I.PipeWizard:BasicTheory
¾ Zonediscrimination
¾ PAUT
¾ TOFD
¾ StripChart
¾ Terminology
II. PipeWizard:Setup&calibration
¾ Setup
¾ Calibration
III. PipeWizard:Analysis
¾ Sizing
¾ AcceptanceCriteria
¾ Reporting
 I.PipeWizard:PAUT
Probes
Conventional Phased-Array
=
Thebeamoriginatesfromone Thebeamisformedbythecombined
element ultrasoundwavesoriginatingfrom
themultipleelements
I.PipeWizard:PAUT
ProbeDimensions
 I.PipeWizard:PAUT
TypeofProbes
Typicallyarraysuse“sideͲbyͲside”elementswithonlyacousticinsulationasgap.
 I.PipeWizard:PAUT
WaveFront
IfallelementsofaphasedͲarrayprobearefiredatthesametime,the
resultwillbeasinglewavefront
 I.PipeWizard:PAUT
BeamSteering
Ifadelayisappliedbetweenthefiringofeachelement,theresultingwave
frontwillbeangled
 I.PipeWizard:PAUT
BeamFocusing
Iftheapplieddelaysarecalculatedsoallthesingleswavesfromeachelementsarrive
atthesametimeonaspecificspot,thePAbeamwillbefocused
I.PipeWizard:PAUT
BeamFocusing
PhasedͲarrayrectangularunfocusedprobe
PhasedͲarrayrectangularfocusedprobe
Conventionalroundfocusedprobe
 I.PipeWizard:PAUT
TypeofFocus
True Depth HalfPath Projection FocalPlane(3ͲD)
 I.PipeWizard:PAUT
Coverage
ConventionalUT
¾ Rasterneeded
PhasedͲArrayUTzonediscrimination
¾ Noneedtoraster
¾ Manyzonescanbecoveredinasinglepass
 I.PipeWizard:PAUT
TypeofScans
ThereisthreetypesofscaninPAUTandallofthemarecomposedofseveralAͲScan:
¾ SͲScan:Sectorialscan
¾ LͲScan:Linearscans
¾ Zonediscrimination
350 700
 I.PipeWizard:PAUT
SͲScan
¾ Istheabilitytosweeptheacousticbeam acrossarangeofangles
¾ TheScaniscomposedofseveralAͲScanemittedataspecificangle
andnexttoeachother.
¾ EachAͲScanhasaspecificExitpointonthewedge
¾ GenerallyallelementsconnectedtoapulserͲreceiverareusedto
producetheAͲScan
¾ Thebeammovementisachievedbychangingthefiringorderofeach
individualelements
¾ Angularmovementislimitedby:
¾ Sizeoftheelements
¾ NumberofpulserͲreceiversinacquisitionsystem
 I.PipeWizard:PAUT
SͲScan
Indexaxis
Scanaxis
axis
 I.PipeWizard:PAUT
LͲScan
¾ Istheabilitytomovetheacousticbeamalongtheaxisofthearray
withoutanymechanicalmovement.
¾ TheScaniscomposedofseveralAͲScanemittedparalleltoeach
other
¾ ThebeammovementisachievedbymultiplexingthepulserͲreceivers
overtheelementsofaprobe
¾ Scanningextentislimitedby:
¾ Numberofelementsinarray
¾ Numberof“channels”inacquisitionsystem
 I.PipeWizard:PAUT
LͲScan
Indexaxis
Scanaxis
axis
 I.PipeWizard:PAUT
PRF
¾ SͲScanfrom35to75degreeswithabeameverydegree.Thus40AͲScans
¾ PRFat2000Hz(2000AͲScans/second).Thus2000/40=50SͲScan/second
¾ EncoderissetatoneSͲScan/mm.Maxacquisitionspeed=50mm/second
1second
50mm
Scanaxis
0mm
750 350
 I.PipeWizard:PAUT
AngleGainDifference
¾ InPAUTasinconventionalUT,thereisanoptimalangleforeachwedge.Thisoptimalangleis
determinebytheangleofthewedgeitselfandSnell’slaw.
¾ Thestrengthoftheresponseobtainfromasidedrillholewillbemaximalatthisangle.All
otheranglesbelowandabovewillhavealesserresponse.
¾ Thisoptimalangleiscalculatedwiththefollowingformula:
ª v * sin D º
E sin 1 « 1 »
¬ v2 ¼
Amplitudevs.Angle
0
v1 Ͳ1
ɲ Ͳ2
Ͳ3
Ͳ4

Amplitudevariation(dB)
ɴ v2
Ͳ5
30 35 40 45 50 55 60 65 70
AngleinSteelSͲWave(degree)
 I.PipeWizard:PAUT
AngleVelocityDifference
¾ Whencalculatingfocallaws,itisimportanttorememberthattheinstrumentusesonlyone
velocityfortheentirerangeofangles
¾ Inreality,dependingonthetypeofmaterialanditscrystallinestructure,thevelocitywill
changedependingontheangle
¾ Forordinarysteelthedifferenceisnottooimportantiftheanglerangeislimited.Butfor
stainlesssteelitcanbeimportant
LongitudinalVelocityinfunctionofangle
6200
v2
v1 6000
v3
5800
75o 5600
v3 5400
45o
v2 5200
5000
0 10 20 30 40 50 60 70 80 90
 PhasedͲArrayTraining
I.PipeWizard:BasicTheory
¾ Zonediscrimination
¾ PAUT
¾ TOFD
¾ StripChart
¾ Terminology
II. PipeWizard:Setup&calibration
¾ Setup
¾ Calibration
III. PipeWizard:Analysis
¾ Sizing
¾ AcceptanceCriteria
¾ Reporting
 I.PipeWizard:TOFD
Diffraction
Incident
wave
Diffracted
waves
Reflected CRACK
wave
Diffracted
waves
¾ Cylindrical/sphericalwavesemittedinalldirections
¾ Sharpdefectsprovidebestemitters
¾ Amplitudetypically20to30dBbelowdirectreflection
I.PipeWizard:TOFD
Probe:FrequencySpectrum
ConventionalNarrowSpectrumProbe
TOFDWideSpectrumProbe
I.PipeWizard:TOFD
Probe:SignalWaveform
ConventionalNarrowSpectrumProbe
TOFDWideSpectrumProbe
 I.PipeWizard:TOFD
BeamSpread
¾ ConventionalUTfocusesonlyonthedominantfrequency
¾ Butaprobeproducesarangeoffrequenciesorbandwidth
¾ BeamSpreadincludestheotherfrequencycomponents
¾ Foramoreaccuratecalculationofusablebeamspread,surrounding
frequenciesshouldbeincludedaswell
¾ For450 andabove,alateralwaveisgenerallyproduced
I.PipeWizard:TOFD
BeamSpread
BeamSpreadinMaterialat600 refractedangle
Frequency MinimumAngle MaximumAngle
2MHz 29.40 900
3MHz 38.30 900
4MHz 43.00 900
5MHz 45.90 900
 I.PipeWizard:TOFD
BasicSetup
¾ 2probes(transmitter,receiver)
¾ Widebeam,Longitudinalwaves
¾ Symmetricallytotheweldcenter
¾ Lateralwave(subͲsurfaceLW)
¾ BackͲwallreflection
¾ Diffractionsignaldetection
¾ Highsensitivityreceiver
 I.PipeWizard:TOFD
AͲScanSignal
Transmitter Receiver
Lateralwave
BackͲwallreflection
BW
Uppertip Lowertip
 I.PipeWizard:TOFD
PhaseDifference
Transmitter Receiver
Lateralwave
BackͲwallreflection
+
+ BW
Ͳ Ͳ
Uppertip Lowertip
 I.PipeWizard:TOFD
MultipleScans
Ifthethicknessofthepartistoobig,multiplescans
maybeneeded
Transmitter Transmitter Receiver Receiver
d
 I.PipeWizard:TOFD
GrayScale
¾ ConventionalUTusesafullcolorscalebasedonamplitude
¾ TOFDreliesonTimeOfFlightratherthanamplitude
¾ ThusaGrayScalebetterrepresentthephaseshifts
+
_
I.PipeWizard:TOFD
BͲScan
LW AͲscan BW
BͲscan
Uppersurface BackͲwall
 I.PipeWizard:TOFD
Averaging
Sample#1
+
Sample#2
+
Sample#3
=
Total
Ͳ: 3
=
Average
 I.PipeWizard:TOFD
Example:Crack
Transmitter Receiver
Lateralwave
BackͲwallreflection
LW
BW
Uppertip Lowertip
 I.PipeWizard:TOFD
Example:UpperSurfaceBreakingCrack
Transmitter Receiver
Lateralwaveisblocked
BackͲwallreflection
BW
NoLateralwave
Cracktip
 I.PipeWizard:TOFD
SurfaceBreakingCracks
Transmitter Receiver
¾ Uppersurface,ifcrackissurfacebreaking:
¾ Nolateralwave
¾ Oppositesurface,ifcrackissurfacebreaking:
¾ NobackͲwallwave
¾ BackͲwallwave
¾ BackͲwallisNOTalwaysblocked
 I.PipeWizard:TOFD
Transmitter PhaseInversion Receiver
Lateralwave
BackͲwallreflection
+
1st PhaseInversion
Ͳ
2nd PhaseInversion
+
3rd PhaseInversion
Ͳ
 I.PipeWizard:TOFD
PCS
¾ IfthePCSissettoosmall,thecoveragewon’tbeoptimum
¾ IfthePCSissettoowide,thetimedepthresolutionwillbelowermakingit
difficulttodifferentiateindicationfromthesurfacewaveandbackͲwall
¾ InPCSisoptimal,thecoverageandtimedepthresolutionaregood
 I.PipeWizard:TOFD
Range
¾ GeneralRule:
¾ leaveatleast1usbeforeLW
¾ leave1usaftermodeͲconvertedbackwall
 I.PipeWizard:TOFD
Gain
¾ Generalrules:
¾ Lateralwave:20Ͳ50%FSH
¾ Backwall:100%FSH+10db
¾ Grass/noise:noiseat5%FSHbetweenLWandBW
¾ Sensitivitynotrelatedtosizeofdefect
 PhasedͲArrayTraining
I.PipeWizard:BasicTheory
¾ Zonediscrimination
¾ PAUT
¾ TOFD
¾ StripChart
¾ Terminology
II. PipeWizard:Setup&calibration
¾ Setup
¾ Calibration
III. PipeWizard:Analysis
¾ Sizing
¾ AcceptanceCriteria
¾ Reporting
 I.PipeWizard:StripCharts
Aspect
¾ Signaloutputfromthegatearedigitalizedanddisplayedinachartformat:
Thestripchart
Calibrationscan Inspectionscan
52
I.PipeWizard:StripChart
Representation
 I.PipeWizard:StripChart
Representation
¾ ChannelName
¾ AmplitudeCurve
¾ Positioningate
 I.PipeWizard:StripCharts
VolumetricMapping
¾ BͲScanview
¾ Useagatecoveringtheentireweldvolume
¾ Mappingfacilitatesdatainterpretationby«patternrecognition»to
differentiateweldflawsfromgeometricalindications
¾ Mappingprovidedagoodsolutiontorecordthepresenceofaporosity
 I.PipeWizard:StripCharts
TOFD
¾ BͲScanview(greyscale)
¾ Provideexcellentdetectionformanyindications
¾ Lesssensitivetoindicationorientation
¾ Helpeliminatefalsecallfromzonediscrimination
¾ Canhelptoimprovesizing
¾ NonͲamplitudetechnique
 I.PipeWizard:StripCharts
Exercise1
Draw these defects on a bevel
#1 #2
US DS US DS
 I.PipeWizard:StripCharts
Exercise2
Draw this defect orientation (on a top view)
 PhasedͲArrayTraining
I.PipeWizard:BasicTheory
¾ Zonediscrimination
¾ PAUT
¾ TOFD
¾ StripChart
¾ Terminology
II. PipeWizard:Setup&calibration
¾ Setup
¾ Calibration
III. PipeWizard:Analysis
¾ Sizing
¾ AcceptanceCriteria
¾ Reporting
 I.PipeWizard:Terminology
Definitions
¾ AUT:AutomatedUltrasoundTesting
¾ TOFD:TimeofFlightDiffraction
¾ TOF:TimeofFlight,timepositioningate
¾ ZoneDiscrimination:TechniquewhereUTbeamsarededicatedtospecifictargets
¾ DAU:DataAcquisitionUnit
¾ SAW:SubmergedArcWelding
¾ SMAW:ShieldMetalArcWelding
¾ GMAW:GasMetalArcWeld
¾ OD/ID:OutsideDiameter/InsideDiameter
¾ HP:HotPasszone
¾ LCP:LandofCrossPenetrationzone
¾ ASTM:AmericanStandardTestingMechanics
¾ API:AmericanPetroleumIndustries
¾ LOF:LackofFusion
¾ LOP:LackofPenetration
¾ HIͲLo:Misalignment
¾ ECA:EngineeringCriticalAssessment
¾ HAZ:HeatAffectedZone
¾ FBH:FlatBottomHole
¾ SDH:SideͲDrilledHole
 I.PipeWizard:Terminology
Glossary
¾ EvaluationThreshold:Theamplitudeasignalmustreachorcrossfor
whichitisevaluatedforlength.
¾ Flaw:Anyimperfectionintheweldingprocess.Itissometimesreferredto
bythemoregenerictermdiscontinuitywhichmayalsoincludegeometric
conditions.
¾ FocalSpot:Theregionalongthesoundpathwherethepressureisata
maximumiscalledthefocalspot.ForanunfocusedprobethisisthenearͲ
zonedistance.
¾ Overtrace:ThistermdescribestheeffectofoffͲaxisreflectorsfrom
adjacentzones.Inacalibrationscan,thereferencetargetforaparticular
zoneissettoaspecifiedamplitude.
¾ Referencelevel:Thisismerelythesensitivitylevelofazoneorvolumetric
channel.Thegainrequiredtosetthemaximisedresponsefromthe
referencetargettoaspecifiedamplitudeisconsideredthereferencelevel.
 PhasedͲArrayTraining
I.PipeWizard:BasicTheory
¾ Zonediscrimination
¾ PAUT
¾ TOFD
¾ StripChart
¾ Terminology
II. PipeWizard:Setup&calibration
¾ Setup
¾ Calibration
III. PipeWizard:Analysis
¾ Sizing
¾ AcceptanceCriteria
¾ Reporting