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PHASED ARRAY ULTRASONIC TESTING

WORK PROCEDURE
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1. PURPOSE

This instruction provides guidelines to perform phased array ultrasonic inspection that
normally required by project using ISONIC 2009/2010 Phased Array System.

2. SCOPE

This instruction is to describe requirements for performing phased array ultrasonic

inspection of the material and full penetration welds accordance with ASME V and Code
Case. This is to be used for detecting, locating and evaluating indication within the welds
and heat affected zone using manual contact inspection technique.

3. QUALIFICATION

Personal shall be qualified and competence to carry out the task. Personnel performing
Ultrasonic Examination in accordance with this procedure shall be qualified and certified
with at least level II in Phased Array Ultrasound Testing.

4. RESPONSIBILTIES

The PAUT examiner shall be able to carry out the task as per the inspection guideline
according to code or recommended practice.

5. DEFINITIONS

Phased array systems pulse and receive from multiple elements of an array. These
elements are pulsed in such a way as to cause multiple beam components to combine
with each other and form a single wave front traveling in the desired direction. Similarly,
the receiver function combines the input from multiple elements into a single
presentation.

Because phasing technology permits electronic beam shaping and steering, it is possible
to generate a vast number of different ultrasonic beam profiles from a single probe
assembly, and this beam steering can be dynamically programmed to create electronic
scan
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6. REFERENCE/CALIBRATION BLOCK.

a) International Institute of Welding Ultrasonic Reference Block Type-I (IIW V1)

b) IOW Beam Profile Block
c) ASME Basic Calibration Blocks

6.1 For examination of circumferential and longitudinal welds in materials with contact
surface curvatures greater than 20 inches in diameter, flat basic calibration blocks shall
be used.

6.2 For materials with contact surface curvatures of 20 inches and less, in diameter, the
basic calibration block shall be curved. A single curved basic calibration block may be
used to calibrate the examination on contact surfaces in the range of curvature from 0.9
to 1.5 times the basic calibration block diameter.

6.3 Basic Calibration for piping shall be a section of pipe of the same nominal size and
schedule.

7. QUALIFICATION BLOCK

7.1 Qualification block shall be completed for all thicknesses and material inspected in
accordance with the requirements of project

7.2 Welds shall be manufactured with simulated flaws on the fusion faces of sizes as
required by the code case, EDM notches may be utilized for top and bottom defects with
a width of 0.2mm

7.3 A record of qualification block shall be, maintained and validation documents shall be
submitted for client review and shall form part of the final documentation package

7.4 Blocks shall be deemed acceptable if the sample block shows defect ratios smaller
or equal to those required in the ASME code case acceptance criteria.

8. PHASED ARRAY CALIBRATION

8.1 Calibration shall be performed from the surface of the calibration block which
corresponds to the component surface to be examined.

8.2 System calibration shall include the complete ultrasonic examination system. System
calibration instructions will be outlined in the specific Ultrasonic Technical Instruction
Phased Array. Screen distance calibration shall be at least 1 and ½ veepaths for the
minimum angle that will be used during the examination, unless otherwise specified.
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8.3 During scanning, only the gain may be adjusted. Adjustment of other controls shall
require recalibration.

8.4 Focal Law Verification

8.4.1 The transmission and reception of ultrasonic waves of a given angle of

incidence is a function of time delays calculated by focal laws using the
information provided to the phased array system. Verification that the input
information is correct and that the phased array system is working properly must
be checked.

8.4.2 Select the Angle Cursor and adjust its position so that it displays A-scan
information for the 40o angle of refraction or the minimum angle that will be used
in the Sector Scan.

8.4.3 Using the 4-inch radius on the IIW block, peak the signal shown on the A
scan display.

Note: Although the sector scan may indicate higher amplitude responses from
Other angles, only use the A-scan response associated with the 40o angle of
propagation.

8.4.4 Indicate on the transducer wedge, the beam exit point. This beam exit
location is only valid for the 40o angle of propagation.

8.4.5 Using the primary angle of beam refraction exit location, measure the
actual angle of propagation by peaking the response in the A-scan display using
the plexi-glass insert on the IIW block. Record the actual angle of propagation as
indicated on the IIW block using the beam exit point location.

8.4.6 If the measured angle of propagation is 40o +/- 2o, then critical focal law
Parameters are correct.

8.4.7 If the measured angle of propagation is outside the allowable tolerance

(40o +/- 2o), then all transducer and setup parameters must be reviewed for
accuracy. If these parameters are correct, then check the shear wave velocity
value used for the material. If this is correct, then small adjustments must be
made to the transducer wedge velocity entry. If the measured angle is too high,
then the wedge velocity must be increased slightly, and repeated. Similarly, if the
measured angle is too low, then the wedge velocity parameter must be lowered
and repeated until the measured angle is within tolerance.
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9. INSPECTION

9.1. Contact Surfaces - The finished contact surface should be free from weld spatter
and any roughness that would interfere with free movement of the search unit or impair
the transmission of ultrasonic vibrations.

9.2. Weld Surfaces - The weld surface should be free of irregularities that could mask or
cause reflections from defects to go undetected and should merge smoothly into the
adjacent base materials.

9.3. The specifics of the examination volume, weld identification and location will be
identified in the Scan Plan. The Scan Plan will demonstrate by plotting or with computer
simulation the examination angles, 35 to 80 degree will be used during the examination.

9.4. Datum 00 or North direction is starting point and scanning will be clockwise direction.
Scanning will be performed using Sectorial Phased Array scan.

9.5 Scanning speed shall not exceed 10mm/sec. Each scanning will be recorded for
300mm length.

9.6 Perform the examination from two sides of the weld, where practical, or from one
side as a minimum. All examination volume limitations shall be documented on the
Phased Array report

10. ACCEPTANCE CRITERIA

Acceptance criteria accordance with ASME Code Case 2235 Rev 9 or ASME Code
Case 181 or equivalent with Client’s Standards.

11. REPORTING

11.1 All test performed shall be recorded in the proper reports with the following
information included:-

a) Project Title/Job Number

b) Pipe identification
c) Specification for Acceptance
d) Equipment Used
e) Result of test
f) Name, signature of tester
g) Date of test

11.2 All reports will attach with isometric or general drawing provide.

11.3 Copies of approved report will be presented to client

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Attachment 1:

Scanned sample with toe crack defect

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Isonic 2010
Inspection Parameter
Test Parameters
Date: 9-Aug-2012
Emitter Skip #: 1.0
Receiver Skip #: 1.0
Thickness Correction: ON
Thickness: 19.0 mm

BASICS: PULSER:
Gain=42 dB Pulser Mode=SINGLE
Reject=0% Range=50.0 mm PRF=2000 Hz Firing Level=5
US Velocity=3209 m/s Display Delay=13.64 µs Pulse Width=100 ns

GATE A: RECEIVER:
aSwitch=ON Filter=ON
aThreshold=10% aStart=12 mm Filter Low=0 MHz Filter High=6.6 MHz
aWidth=65.7 mm Display=FULL

DAC/TCG: MEASURE:
DAC Mode=TCG Probe Delay=13.64 µs
DAC Curve=Curve OFF Meas Mode=Flank

EMIT: RECEIVE:
Start=1 Start=1
Aperture=32 Incidence Angle=55.0 ° Aperture=32 Incidence Angle=55.0 °
Focal Depth=0 mm Focal Depth=0 mm

Inspection Parameters:
Probe Position = 17.0 mm
Weld Width = 25.0 mm Min Angle=40.0 °
Cap Offset = 2.0 mm Max Angle=80.0 °
Bottom Weld Width = 5.0 mm Angle Increment=0.5 °
Root Offset = 2.0 mm

LEGEND:
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ISONIC 2010
Inspection Report – Defect 1(Toe Crack)

Length Width Height

Lr = 150.0 mm Xr = 19.9 mm Dr = 0.9 mm
Lg = 127.6 mm Xg = 17.0 mm Dg = 2.0 mm
∆L = 22.4 mm ∆X = 2.9 mm ∆D = 2.9 mm
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ISONIC 2010
Inspection Report – Defect 2 (LOP)

Length Width Height

Lr = 194.2 mm Xr = 19.9 mm Dr = 19.8 mm
Lg = 175.1 mm Xg = 17.0 mm Dg = 9.9 mm
∆L = 19.1 mm ∆X = 2.9 mm ∆D = 9.7 mm
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ISONIC 2010
Inspection Report – Defect 3 (LOP)

Length Width Height

Lr = 233.5 mm Xr = 35.5 mm Dr = 19.6 mm
Lg = 214.9 mm Xg = 29.7 mm Dg = 10.8 mm
∆L = 18.5 mm ∆X = 5.8 mm ∆D = 8.8 mm
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ISONIC 2010
Inspection Report – Defect 4 (LOF)

Length Width Height

Lr = 282.0 mm Xr = 35.7 mm Dr = 4.8 mm
Lg = 259.6 mm Xg = 33.6 mm Dg = 2.0 mm
∆L = 22.4 mm ∆X = 2.1 mm ∆D = 2.9 mm
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Attachment 2:

Sample of Lamination Check

Using Delay Line
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ISONIC 2010
Inspection Parameter
Test Parameters
Date: 9-Aug-2012
Emitter Skip #: 0.5
Receiver Skip #: 0.5
Thickness Correction: ON
Thickness: 20.0 mm

BASICS: PULSER:
Gain=43 dB Range=20.1 mm Pulser Mode=SINGLE Firing Level=5
Reject=0% Display Delay=17.58 µs PRF=1500 Hz
US Velocity=5960 m/s Pulse Width=100 ns

GATE A: RECEIVER:
aSwitch=ON aStart=10 mm Filter=OFF Filter High=20 MHz
aThreshold=10% aWidth=10.1 mm Filter Low=0 MHz Display=FULL

DAC/TCG: MEASURE:
DAC Mode=OFF Probe Delay=17.58 µs
DAC Curve=Curve OFF Meas Mode=Top

EMIT: RECEIVE:
Start=1 Incidence Angle=-6.0 ° Start=1 Incidence Angle=-6.0 °
Aperture=32 Focal Depth=19 mm Aperture=32 Focal Depth=19 mm

Inspection
Parameters:
Min Angle=-30.0 °
Max Angle=30.0 °
Angle Increment=1.0 °
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ISONIC 2010
Inspection Report – Scan 1

Length Height
Lr = 53.6 mm Dr = 12.2 mm
Lg = 176.7 mm Dg = 20.0 mm
∆L = -123.1 mm ∆D = -7.8 mm
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ISONIC 2010
Inspection Report – Scan 2

Length Height
Lr = 52.0 mm Dr = 12.0 mm
Lg = 167.3 mm Dg = 20.0 mm
∆L = -115.4 mm ∆D = -8.0 mm
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ISONIC 2010
Inspection Report – Scan 3

Length Height
Lr = 22.9 mm Dr = 12.0 mm
Lg = 131.3 mm Dg = 20.0 mm
∆L = -108.4 mm ∆D = -8.0 mm