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PHASED ARRAY UT PROCEDURE FOR

WELDS

PHASED ARRAY
ULTRASONIC INSPECTION
GENERAL PROCEDURE
FOR WELDS

PHASED ARRAY UT PROCEDURE FOR WELDS

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CONTENTS
DESCRIPTION
COVER PAGE
CONTENTS
SECTION
1.0 INTRODUCTION
2.0 PURPOSE AND SCOPE
3.0 REFERENCES
4.0 PERSONNEL QUALIFICATION
5.0 PREPARATION OF EXAMINATION AREA
6.0 EQUIPMENT
7.0 CALIBRATION
8.0 EXAMINATION AND RECORDING CRITERIA
9.0 ACCEPTANCE CRITERIA
10.0 REPORTING

PHASED ARRAY UT PROCEDURE FOR WELDS

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1.0 INTRODUCTION

This procedure describes the contact ultrasonic method in which the probe makes direct
contact With the material and the ultrasonic instrument is a phased array unit. The
probes addressed by the instrument may be phased array or single element probes.

2.0 PURPOSE AND SCOPE

This procedure defines the requirements of mechanized pulse echo mode contact
ultrasonic examination of welds. This procedure shall apply to the general aspects of
ultrasonic inspection of welds using the phased array techniques and equipment.

These aspects include;

monitoring the performance of the equipment

configuring the display and data acquisition parameters
Calibration of time base and sensitivity
Description of the recording criteria
Identification and layout of the components to be tested
Surface conditions required
Details of the equipment used and the volumes covered

Details of scanning shall be found in the associated technique sheets. Scanning for
transverse flaws may be done using either manual, fully automatic or mechanized
techniques. This procedure is applicable to ultrasonic examination of welded
components for new and in service welds

Provisions are incorporated into this procedure and the special adaptations unique to
their implementation are described in this procedure and the associated standard
practices referenced by this procedure. Since the qualification of this procedure and
associated standard practices and techniques is unique to the Olympus Phased Array.

This procedure is valid for only those techniques that are identified and are recorded in
the latest revision of this procedure.

3.0 REFERENCES
1. The following documents shall be referenced with this procedure:
2. Qualification and Certification of NDT Personnel to ASNT SNT-TC-1A
3. Calibration and Setting-up of the Ultrasonic Time-of-Flight Diffraction (TOFD) technique
for Detection, Location and Sizing of Flaws
4. ASNT SNT-TC-1A, Recommended Practice for Training, Qualification and Certification
of NDT Personnel

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5. ASNT CP-189, ASNT Standard for Training, Qualification and Certification of NDT
Personnel
6. ASME Section V, Non-destructive Examination

4. PERSONNEL QUALIFICATION
1. Personnel evaluating phased array ultrasonic inspection results shall be qualified to a
minimum of Level II.
2. The responsibility for the accuracy and completeness of an examination report is
verified by either Level II or III qualified ultrasonic personnel. Level I operators may
perform specific duties required for the examination if under the direct supervision of a
Level II or III certified technician.
5. PREPARATION OF EXAMINATION AREA
1. Surface Preparation
2. The scanning area shall be rendered free of dirt, loose scale, weld splatter, machining
particles, or corrosion products. Where the surface cannot be made suitable for
ultrasonic inspection by light brushing and wiping, the Client representative and Q
Space/JV shall be advised. The base material or weld shall be prepared as needed to
permit examination.
3. Weld Marking and Inspection Area Location
4. Numbers allocated to welds being examined shall designate inspection areas.
5. Each weld designated for inspection shall be marked with a reference index and/or
position numbers marked on the examination surface during initial examination. This
shall include a method for identifying the location of the weld centerline. If welds are to
be permanently marked, low stress stamps or vibra-tools may be used such that the
marks are not deeper than 1mm.
6. EQUIPMENT
1. Examination Equipment
2. Ultrasonic Test Instruments
3. This procedure shall use the Olympus Phased Array ultrasonic inspection unit
exclusively. The ultrasonic flaw detection instrument shall be used in the pulse echo or
pitch-catch mode with an A-Scan presentation used for calibration, S-Scan presentation
used for quantity of defect and C-Scan presentation used for Length of defect. The

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instrument is equipped with a stepped gain control calibrated in units of 1dB or less. The
equipment is capable of amplitude control over its useful range and Time Corrected
Gain (TCG) shall be used in lieu of a simple Distance
4. Amplitude Correction (DAC) curve.
6.1 Search Units
1. Search units used for weld examinations shall operate at a frequency between 2 MHz
and 10MHz. either phased array or single element probes may be used. Phased array
linear array configurations shall have 16 elements or more having element width of
6mm to 15mm. Element spacing will be search unit design specific and based on the
calculations for element pitch to provide beam steering of +/- 20. For typical shear
wave applications the phased array probe will be placed on a refracting wedge of
suitable material and refracting angle as to be compatible with the requirement to
provide beam steering of +/- 20.
In addition to phased array search units, pulse-echo single element probes may be
used where geometry or resolution or other factors dictate that there is advantage to do
so such as for thickness assessments, transverse scanning and TOFD techniques.
2. Couplant used shall contain no ingredients deemed harmful to the test piece. For
automated or mechanized scanning, water shall be used. Alternatively, Ultra gel or
Glycerin may be used and diluted with water to reduce viscosity so as to facilitate its
movement through irrigation lines. Ultra gel or Glycerin or Lub Oil is also approved for
use on the work piece when performing manual transverse scans.
3. Weld inspections using the PA Scan shall be calibrated using standard calibration
blocks and blocks fabricated from material that is acoustically similar to that being
inspected and which has been subjected to minimum heat treatment required by the
material specification. The surface of calibration blocks is finished to approximately 10
micron Ra. At no time shall the calibration block surface be inferior to the test piece
surface.
Calibration blocks are of 2 types i.e. range setting calibration blocks and sensitivity
setting
calibration blocks.
Range Setting Calibration Blocks
Blocks used to set instrument range include:
1. International Institute of Welding (IIW2) for Cal VEL, Cal Zero and Cal Gain calibration
2. Standard Thickness Calibration Block (ladder step wedge)

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Sensitivity Setting Calibration Blocks

1. Prior to fabrication, the block material shall be completely examined with a straight
beam search unit. Areas that contain an indication exceeding the remaining back-wall
reflection shall be excluded from the beam paths required to reach the various
calibration reflectors.
When the component material to be examined is clad, the block shall be clad by the
same welding process as the production part.
2. For ultrasonic examinations the design requirements for the basic calibration block are
provided in Table 1. Hole placement and hole dimensions are detailed in Table 1.
Aspects of design such as minimum block dimensions should be considered based on
the ultrasonic techniques used. Reference blocks shall be made with thickness and
side-drilled holes in accordance with Table 1.

Thickness of
Material to be
inspected (mm)

Table 1
Ultrasonic Reference Block Requirements
Thickness of
Diameter Hole
Distance of
block
Hole from
(mm)
Surface

8< t50
50 < 100

40 or t
75 or t

100 <t 150

125 or t

150 <t 200

175 or t

200 <t 250

225 or t

t > 2500

275 or t

3mm (+/0.2mm)

t/2 and t/4

Additional holes
are
allowed and
recommended

6mm (+/0.2mm)

For examinations in materials with diameters greater than 500 mm, a block of essentially the
same curvature, or alternatively, a flat basic calibration block, may be used.

7. CALIBRATION

Equipment Calibration

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Instrument Linearity Checks

All instruments are subject to the following linearity checks before use. Details of the
steps involved in the set-up of equipment for calibration can be found in the Standard
Guide for Use of Olympus Phased Array. The results of these checks are recorded in
the Ultrasonic instrument Linearity

Report forms (see standard practice for Verification of Olympus Phased Array Linearity
Performance) and is kept as part of the Inspection Record.

Instrument Linearity Checks are conducted:

On initial receipt of equipment

At the commencement of an inspection campaign
On a twelve month cycle
after any electronic repair or physical damage
Or for any other reason deemed appropriate at intervals less than 12 months

Screen Height Linearity - The Olympus Phased Array instrument shall provide vertical
amplitude presentation linear to within +/- 3% of full screen height over the range 10%
to 100% of full screen height. The method for evaluating screen height linearity is
outlined in standard practice for Verification of Olympus Phased Array Linearity
Performance.

Amplitude Control Linearity (Calibrated Gain Control) - The accuracy of amplitude

control on the Olympus Phased Array is verified. The method for evaluating amplitude
control linearity is outlined in standard practice for Verification of TD Scan Linearity
Performance.

Sweep Range Linearity (Horizontal Linearity) - The ultrasonic instrument must provide
sweep range linearity accurate to +/-2% of the total base line. The method for
evaluating sweep range linearity is outlined in standard practice for Verification of
Olympus Phased Array Linearity Performance.

Search Unit Checks

Because the Olympus Phased Array ultrasonic instrument is a phased array instrument
many of the parameters associated with standard single element probes such as exit
point and nominal angle do not apply. As well, probes using curved wedges to fit the
diameter of pipes, and components will not permit measurements of nominal angle and
exit points using the standard calibration blocks (IIW and DIN-54) as they cannot be
used on flat surfaces. Standard Practice for Verification of Performance of Probes used
with Olympus Phased Array will be used as appropriate to assess the suitability of the
probe and focal laws applied to phased array probes. Guidance for Probe Performance

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is also found in this Standard Practice for assessment of single element probes when
used with the Olympus Phased Array phased array ultrasonic instrument.
Search unit Checks are conducted:

on initial receipt of equipment

At the commencement of an inspection campaign
On a one month cycle
After any electronic repair or physical damage
Or for any other reason deemed appropriate at intervals less than 1 month

Calibration - Weld Examination

Range and Signal Amplitude (TCG) Calibration

The Olympus Phased Array is calibrated for each examination specified on the detailed
technique form both range and signal amplitude.

Range setting for both shear and longitudinal wave examination is detailed in Standard
Practice for Setting Range using Olympus Phased Array.
Time Corrected Gain is applied as detailed in Standard Practice for Distance Amplitude
Correction using Olympus Phased Array.

Calibration Confirmation

A system calibration confirmation shall be used to verify the sweep range calibration
and DAC and or TCG curve at the start and finish of each examination and at a
minimum of once each day during an examination session using the appropriate
calibration block

Any change in search units, shoes, couplants, cables, ultrasonic instruments, personnel
or other parts of the examination system is cause for a calibration check.

Calibration checks are performed as follows:

The sensitivity control settings are adjusted to match those recorded for the calibrated
reference sensitivity of the middle focal law of a single angle Phased Array scanning
technique or the single element probe for non-phased array probe applications.

The search unit is positioned to detect the first and last points on the TCG using the
reference reflectors on the appropriate basic calibration block. The maximum signal
response amplitudes and horizontal sweep positions are observed.

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If either point along the time base using the TCG has decreased by greater than 2 dB in
amplitude, all recorded data sheets since the last calibration check are marked void. A
new calibration is made and recorded and the voided examination areas re-examined.

If any point along the time base using the TCG has increased by greater than 2 dB in
amplitude, only recorded indications taken since the last valid calibration check need be
reexamined with the correct calibration and their values changed on the data sheets or
files rescanned.

If during system confirmation of calibration, any point on the time base has moved on
the sweep line more than 5% of the total base line, correct the sweep range calibration.
If recordable reflectors are noted on the data sheets, these data sheets are voided, a
new calibration is recorded and the voided examination is repeated.

Temperature Control

For contact examination, the temperature differential between the calibration block and
the examination surface shall be within +/-10C.

Instrument Controls

Any controls affecting the linearity of the instrument shall be in the same position for
calibration, calibration checks, instrument linearity checks and examinations.

Encoding

Automated scanning shall use position encoders that are verified to provide position
accuracy of scans within +/-1mm in 100mm of scan length. All encoders shall be verified
daily to be correctly calibrated. Moving the scanning apparatus over a fixed distance
(e.g. 150mm) and comparing the start and end readings is sufficient to verify the
calibration of the encoder. All encoded distances recorded by the data acquisition
system shall be accurate to within 2mm over 100mm of actual travel. Encoders failing to
maintain this tolerance shall be re-calibrated.

8.0 EXAMINATION AND RECORDING CRITERIA

Weld Examination - General Description

Each weld configuration has its own individual technique that describes in detail the
type and extent of the examination. Techniques will be described using the format
detailed in Standard Practice for Technique Layout and Olympus Phased Array
parameters.

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Inspection Area

Each inspection area is identified with a unique "weld" number. The width of the
inspection area extends beyond the point of maximum width of the final weld
preparation for a minimum distance of one-half the material thickness or 25 mm, which
ever is less. The weld zone is defined as the weld and the base metal up to 10 mm
(Heat Affected Zone -HAZ), from the edge of the final weld preparation, as illustrated in
Figure 1. The base material on either side of the inspection area of pipe welds need not
be examined for laminations that would interfere with shear wave examination if these
materials have been inspected for laminar inclusions at some previous stage in
fabrication. .

Inspection Area / Weld zone / scanning zone

Weld Profile Will Showing Inspection Area and Weld Zone

87
1L2

39.06

2.97

56.36

2.00

5.00
Unit:MM - PA

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Delay:0.00

Range:120.00

Gain:36.0dB

PRF:920Hz

Mode:P/E

Velocity:3251m/s

Freq:5.00MHz

Filter:1.5-8.5

Zero : NA

Energy:100V

Rect:Full

Angle:59.0

Damp:50

Thick:16.00

Reject:0

Pulser:Square

Video Filter:Off

Start:40.99

Width:28.61

Level:80%

Probe ID:5L16A10P

Wedge ID:SA10Start Angle:40

N55S

Alarm:Off
End Angle:70

Angle Step:1

Overlay Name:C Weld Rotation:0

Memo:
Inspection Scan Types

Automated weld inspection for laminar flaws is carried out using a phased array linear
raster scan using focal laws providing a 40 to 70 deg beam in the inspection volume
when possible. Restrictions due to geometries of surroundings shall be reported.

Automated weld inspection for axial flaws is carried out using a phased array linear
raster scan using focal laws providing angled beam examination of the inspection
volume. Restrictions due to geometries of surroundings shall be reported.

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Manual or automated transverse scans in two directions either side of the weld cap will
also be carried out where access permits. Restrictions due to geometries of
surroundings shall be reported.

All automated scanning shall be position encoded at sampling intervals of 1mm.

Recording
General

The fundamental criterion for the evaluation of the existence of an ultrasonic

examination indication is the amplitude of the indication in relation to a specified
reference level. The reference level is established during calibration of the test
instrument on the sensitivity calibration block and set so that the amplitude from the
applicable notches or holes are set to 80% full screen height using TCG. Scanning shall
be done at the Primary Reference level plus any gain required for transfer value.

Olympus Phased Array ultrasonic instrument is a digital instrument. Analogue to

Digital Conversion will be at a rate suitable to ensure that the recorded peak signal is
within 1dB of the analogue peak. This shall be considered achieved when the
digitisation rate is set to at least 5 times the nominal frequency of the probe used1.
Actual digitisation settings shall be specified in the Technique.

Detailed Examination and Recording Sequence

Calibration of Equipment

The examination equipment shall be calibrated as described in item 8.0 herein to verify
linearity and set range and sensitivity.

Scanning Sensitivity

Scanning of all welds is performed at a gain setting equal to the Primary Reference
Sensitivity plus any transfer value. On the Data Acquisition display an evaluation
threshold is set using a colour threshold at 6dB below the Primary Reference level.
Typically Primary Reference level is set at 80% Full Screen Height and the evaluation
level is then 40% FSH.

Scanning Normal to the Weld (Axial Scan)

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The probe is directed at 90 to the weld centre line and mechanically moved so that the
ultrasonic beam passes through all of the inspection area. This is accomplished by an
electronic raster or S-scan. Where possible, the weld is scanned from both sides of the
same surface. The speed of scanning is such as to ensure that coupling and data
acquisition integrity is maintained.

Data recorded will ensure encoded samples along the weld are at 1mm intervals and
not greater than 10% of data points shall be missed in a weld scan with not more than 3
adjacent samples missing in a single scan.

9.0 ACCEPTANCE CRITERIA

Results of weld inspections to this procedure will be compared to the requirements of the
referencing code unless otherwise instructed by written instructions.

10.0 REPORTING
After each inspection an Inspection Report shall be prepared. This report describes the work
done, the equipment used, the qualification of the inspection personnel and the results.
Additional inspection results (if any) are also reported and alternate methods of inspection
described.
The final report for each weld shall include;
a) Project name, contract details
b) Procedure and technique identification
c) Equipment used (UT instrument, probes, cables, manipulators, couplant)
d) Computer programmed identification and version
e) Instrument gain settings sensitivity or reference target
f) Weld Identification
g) Scan Surface
h) Record of reject able indications locations or areas cleared
i) Areas of restricted access
j) Personnel and their qualifications
k) Date and Time of the examination