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Ut-Phased Array
Ut-Phased Array
Ut-Phased Array
Pressure Vessel
Technology Technology Review
Review of Ultrasonic Phased Arrays Keywords: Welds, Ultrasonic Phased Arrays, Beam Steering,
Focusing, Electronic Scanning, Defect Sizing, TOFD, Back
for Pressure Vessel and Pipeline Diffraction, Pressure Vessels, Pipelines
Weld Inspections
Introduction to PV and Pipeline Inspections
Michael Moles The petrochemical and other industries use a wide variety of
e-mail: michael.moles@rd-tech.com pressure vessels and piping. These vessels and pipes are typically
R/D Tech, 73 Superior Avenue, Toronto, ON M8V 2M7, made in sections and welded together. Welding often produces
defects, which occasionally propagate with time and fail. During
Canada construction, welds are inspected for defects, usually using the
ASME or similar code. For pressure vessel inspections, ASME
Noël Dubé Section V 关1兴 is the relevant code, with NonDestructive Testing
e-mail: noel.dube@rd-tech.com 共NDT兲 covered under Articles 4 and 5. The ASME code has been
the mainstay of PV inspections for decades. For pipelines, several
Simon Labbé codes are possible: ASTM E-1961-98 关2兴, API 1104 19th Edition
e-mail: simon.labbe@rd-tech.com 关3兴, DNV OS F101 关4兴, and ISO 13847 关5兴. All use, or implicitly
accept, the alternative zone discrimination approach.
R/D Tech, 505 boul. du Parc Technologique, Québec, PQ For many years, welds were radiographed. However, radiogra-
G1P 4S9, Canada phy has significant technical disadvantages: First, it is hazardous,
and the PV may need moving to a safe location or inspections
Ed Ginzel performed off-shift; second, radiography often generated produc-
e-mail: eginzel@mri.on.ca tion delays; third, radiography is poor at detecting critical lack of
fusion or cracking defects; fourth, radiography cannot size defects
Materials Research Institute, 432 Country Squire Road, for Fitness-For-Purpose 共FFP兲, 关also called Engineering Critical
Waterloo, Ontario N2K 4G8, Canada Assessment 共ECA兲 or Fracture Mechanics兴; fifth, radiography is
subjective, and the cost of film is high.
The competing technology is ultrasonics. Ultrasonics is safe,
Major improvements in weld inspection are obtained using fast, can be performed as soon as the weld is cool, and can size the
Phased Array technology with capability for beam steering, elec- vertical height of defects with some accuracy. However, manual
tronic scanning, focusing, and sweeping the ultrasonic beams. ultrasonics is time-consuming and very operator-dependent.
Electronic scanning is much faster than raster scanning, and can Mechanized or automated ultrasonics 共AUT兲 has been available
for some years, but was slow and relatively expensive. Multiprobe
optimize angles and focusing to maximize defect detection. Pres-
scans have been used in pipelines and other applications, but are
sure vessel (PV) inspections typically use “top, side, end” or “top,
inflexible. Speeds have increased significantly, especially with the
side, TOFD” views, though other imaging is possible. Special
advent of phased array equipment for PVs. The arrival of
inspections can be performed, e.g., for specific defects, or in-
diffraction-based sizing techniques like Time-Of-Flight Diffrac-
creased coverage. Defects can be sized by pulse-echo as per code,
tion 共TOFD兲 has significantly increased the potential for ECA
by time-of-flight Diffraction or by back diffraction. New PV in- applications.
spection codes, particularly ASME Code Case 2235, permit the
use of advanced ultrasonic inspection techniques. Pipeline girth
Inspection Codes for AUT of Welds
weld inspections use a unique inspection approach called “zone
discrimination,” and have their own series of codes. While similar There are now many different potential codes for inspecting
equipment is used in pipeline as in PV inspections, the pipeline vessel welds, but these can be divided into three categories: tra-
philosophy is to tailor the inspection to the weld profile and pre- ditional or standard raster-type codes based on manual ultrasonic
dicted lack of fusion defects. Pipeline displays are specifically principles 关1兴, the new ASME 2235 code case 关6兴, and “tailored”
designed for near real-time data analysis. Both ASME CC 2235 codes like ASTM E-1961 关2兴.
and the pipeline codes permit the use of Fitness-For-Purpose, Raster Codes. ASME Section V 关1兴 is normally used for
which reduces construction costs. Overall, phased array systems manual ultrasonic testing but has provisions for AUT as well.
meet or exceed all PV and pipeline codes. These codes typically require ultrasonic scanning 共or rastering兲
关DOI: 10.1115/1.1991881兴 over the weld and adjacent heat affected zone at two or more
angles to detect defects. The ASME code has been extensively
Contributed by the Pressure Vessels and Piping Division for publication in the
used in the nuclear and other industries for decades, with their
JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript receieved: February 3, 2005. many variations. These include Sections I, III, VIII, and XI, as
Final manuscript received: March 29, 2005. Review conducted by: Sam Zamrik. well as piping codes B31.1 and B31.3. These rastering techniques
Journal of Pressure Vessel Technology Copyright © 2005 by ASME AUGUST 2005, Vol. 127 / 351
values are back calculated using time-of-flight from the focal spot,
provide a satisfactory inspection for most defects, but have poor
and the scan assembled from individual “Focal Laws.” Time delay
defect detection capabilities for midwall planar defects like cen-
circuits must be accurate to around 2 nanoseconds to provide the
terline cracking.
accuracy required.
ASME Code Case 2235. More recently, ASME revised Code While it can be time-consuming to prepare the first setup, the
Case 2235 关6兴, which permits “nonamplitude, computer recorded” information is recorded in a file and only takes seconds to re-load.
inspection techniques. These are widely interpreted as TOFD, Also, modifying a prepared setup is quick in comparison with
though pulse-echo rastering techniques are permitted. CC 2235 is physically adjusting conventional transducers.
an option for replacing radiography for FFP/ECA acceptance un-
Types of Scans. Using electronic pulsing and receiving pro-
der specific conditions. This code case requires a performance
vides significant opportunities for a variety of scan patterns.
demonstration, showing detection of three flaws, as a minimum.
“Tailored” Pipeline Codes. Pipeline AUT is at the forefront of Electronic Scans
ferritic steel weld inspections. ASTM E-1961 关2兴 was the first
code written specifically for AUT, and clearly defines linear scan- Electronic scans are performed by multiplexing along an array
ning and zone discrimination. E-1961 is very specific on the types 共see Fig. 2兲. Typical arrays have up to 128 elements, pulsed in
of reflectors, tolerances, scan patterns, displays and analysis for groups of 8–16. If the array is flat and linear, then the scan pattern
pipelines. DNV OS F101 关4兴 is similar to E-1961, but is targeted is a simple B-scan; if the array is curved, then the scan pattern will
at offshore use. API 1104 19th Edition 关3兴 permits AUT, but is be curved. Electronic scans are straightforward to program. For
much more flexible in requirements. The EU code, ISO 13847 关6兴, example, a phased array can be readily programmed to inspect a
is also a more general code. weld using 45 deg and 60 deg shear waves, which emulate con-
ventional manual inspections.
Delivery Systems
Fig. 8 Schematic of zone discrimination. Top: Selection of There are many different methods of mechanically scanning a
zones. Bottom: Position and angles for zone discrimination weld 关18兴. The simplest is to rotate the vessel, as shown in Fig. 10.
inspection
Fig. 9 Typical AUT calibration block, as per code ASTM E-1961 „2…
Sample Results
ASME Raster Scans on Thick Section Welds. Figure 13
shows a typical “top, side. TOFD” display with dual dedicated
TOFD pairs for improved detection and sizing. Weld overlays
共more visible in the “top, side, end” view in Fig. 6兲 assist the
operator in interpretation. Full waveform data is collected, and
scanning rates are 10 mm/ s or higher, depending on data transfer
rates, wall thickness, number of waveforms, etc. Table 1 shows a
comparison of some of the key parameters from PV and pipeline
inspections using phased arrays. Pipeline multiprobe systems are
Fig. 14 Typical AUT display, with dual gate strip charts, map-
ping channels, TOFD, position and coupling. This display
shows multiple boxed defects in red.