WeldRover 4 of 8 Scan Plan Design

Presentation Overview
The intent of this presentation is to provide a basic overview of th
e WeldRover Phased Array Inspection System and its various co
mponents. The presentation is divided into the following sections
:
 Part 1 – WeldROVER Introduction and Video
 Part 2 – WeldROVER Equipment
– Introduction, Transport Cases, Instrumentation, Controls, Scanner, Configuration, Water Supply,
Weld Series Probes
 Part 3 – Code Compliance
– ASME\AWS\API Compliance, Calibration Requirements
 Part 4 – ES Beam Tool – Scan Plan Design
– ES Beam Tool, Scan Plan Considerations, WeldROVER Skew, 5 Channel Types,
Advantages\Disadvantages, Scan Plan Examples
 Part 5 – WeldROVER TOFD
– Why use TOFD?, Theory, Flaw Examples, Setup, Acquisition, Analysis, Conclusions
 Part 6 – WeldROVER (PV200) Omniscan Setup
– Group Wizard, Calibration Wizard, Display Setup, UT Parameters Configuration, Scanning
 Part 7 – WeldROVER (PV200) Acquisition
– File Management, PRF Optimization, WeldRover Operation
 Part 8 – WeldROVER (PV200) Analysis
– Analysis Tools, Examples of Flaw Analysis, Defect Table and Reporting, File Management,
Tomoview for Offline Analysis
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WeldROVER- Scan Plan Design
 Through the use of advanced software tools such as the ES Beam Tool, scan plan
design with regard to inspection coverage, code compliance, and improved
inspection strategies is now a simple fast task.
 Upon completion of the scan plan in the ES Beam Tool, the parameters of the probe
position (Index Offset) in relationship to the weld and the focal law calculator
parameters of the probe, wedge, material, and beam sets are available to be
programmed into the Omniscan MXU or Focus LT software.
 Use of the ES Beam Tool ensures a high probability of detection, proper code
compliance for inspection coverage, and a low\no missed defect rate.

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WeldROVER- Scan Plan Design
 ESBeamTool3 is Eclipse Scientifics' third
generation modeling and technique development
tool for Phased Array, TOFD and Conventional
ultrasonic inspection. The ability to quickly define
typical inspection parameters enables technique
development to be rapidly realized and clearly
presented in a consistent format.
Comprehensive reports containing the broad list
of inspection parameters are easily incorporated
into the final technique documentation.
 Select from predefined weld configurations or
produce your own specific weld geometry quickly
and easily. Call up transducer or wedge
definitions from an extensive list or include your
own unique designs. ESBeamTool allows you to
save the workspace and the user defined weld
parameters.
 Graphical display auto scales and transparency
features allow real time observation of parameter Complete details at:
changes. ESBeamTool allows you to add probes www.eclipsescientific.com
and turn the beam visibility on and off.
Dimensions and labels to help convey the
inspection sequence are all easily achieved by
simply selecting the appropriate button.

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WeldROVER- Scan Plan Design
 Within the ES Beam Tool database are all the standard Probes and Wedges from the
Olympus catalog allowing quick programming without entering all of the parameters of
which there are many.
 When the probe and wedge are defined, the operator can determine both the position
of the probe and the individual channels that will make up our inspection strategy.

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WeldROVER- Scan Plan Design
When designing a scan plan, placement of the probe (Index Position) and the
inspection strategy are determined with consideration for, but not limited to, the
following parameters:
 Applicable code requirements (ASME, AWS, API, etc)
 Material type – Stainless steel, Duplex Steal, Carbon Steel, Dissimilar Metal, etc.
 HAZ (Heat Affected Zone) coverage requirements per applicable code
 Weld process (SMAW, SAW, FCAW, etc)
 Weld bevel design
 Access limitations- One side and or two sided coverage
 Whether or not TOFD and or Conventional channels are utilized
 Number of total acquisitions and acquisition speed – Production Rate
 Type of Instrumentation utilized – Limits on number of focal laws and pulsers (16:128 vs.
32:128, vs. 16:64 etc)
 Defect sizing required for applicable code. Example: The AWS only requires amplitude, not
depth and height sizing. It is a much simpler scan plan than a ASME CC2235 requiring
precision flaw measurement and characterization
 Defect characterization required for the applicable code. Example: Linear Scans (E-scans)
can be calibrated much more efficiently but do not provide the same level of defect
characterization as Sector Scan channels. For some codes this is not critical or required.
 Etc.

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WeldROVER- Scan Plan Design
 The WeldROVER and other system in the Olympus PV200 family are
designed to provide one line scans utilizing probes on both sides of the
weld where practical in accordance with most common codes.
 The Skew of the probe is defined as the orientation of the beam in
relation to the mechanical movement of the scanner. With two probes
facing each other scanning perpendicular to the weld this would be
defined as Skew 90 (Negative from weld centerline) and Skew 270
(Positive from weld centerline)

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WeldROVER- Scan Plan Design
 The ES Beam Tool contains a tool
for generating a weld bevel from a
series of templates or creating one
within the program using built in
CAD tools.

 The ES Beam Tool also contains

tools for importing photos, scaling
them, and designing coverage
plans for their inspection to scale.

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WeldROVER- Scan Plan Design
There are 5 basic types of channels that are utilized in the Olympus PV200 family
of products. Completion of a scan plan will require one or a combination of
these channel types to comply with the code and meet the intended results of
the inspection.
For the Omniscan MXU and Focus LT instrumentation, no scan plan can exceed 8
channels or > 256 total focal laws.

 Phased Array Sector Scan Channel (Most commonly associated with PA

inspections)
 Phased Array Linear Scan Channel (E-scan)
 TOFD Channel
 Conventional UT Channel (Transverse scanning requirement in Pulse-Echo or
Pitch-Catch mode where required by code)
 Conventional UT Channel (Outside Diameter creeping wave or High Angle L-
wave probe for surface and near surface coverage with inspecting stainless
steel, dissimilar metal welds or inconel cladded materials).

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WeldROVER- Scan Plan Design
Phased Array Sector Scan Channel - Defined as different focal laws (A-scans) at
different angles being generated by the same group of elements on the same
channel.
Sector Scan Advantages
 Allows use of small probes and provides
large coverage area from small footprint
 Provides higher level of detection, flaw
sizing and flaw characterization
 Can be performed with fewer
pulsers\multiplexed channels (32:64,
16:32)
 Higher acquisition rate due to fewer focal
laws compared to Linear E-scans
 Can provide full volumetric inspection in
one channel\one acquisition on most
welds thinner than 25mm
 Flaw detection and sizing less dependent
on orientation due to multi-angle coverage

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WeldROVER- Scan Plan Design
Sector Scan Disadvantages
 Is not a 1:1 match for conventional UT inspections
because it utilizing different angles from one
position. Cannot be duplicated by conventional UT
 Provides higher level of detection, flaw sizing and
flaw characterization Higher acquisition rate due to
few focal laws compared to Linear E-scans
 TCG limitation for long sound path coverage in
single channel compared to linear E-scans.
 Difficult to gate properly because the root cannot
be excluded from the C-scan.
 Difficult to range properly because different
sections of the S-scan cover different areas of the
weld.
 Difficult to define resolution due to beam to beam
center point will diverging with the sound path.
 More complicated analysis for codes that only
require amplitude for accept\reject criteria (AWS)

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WeldROVER- Scan Plan Design
Phased Array Linear (E-Scan) Channel - Defined as the same focal law (A-scan)
being multiplexed across a series of different elements resulting in the equivalent
of a conventional raster scan.
Linear (E-scan) Advantages
 1:1 match for conventional UT raster scans and
procedures. Only different in how the data is
acquired. Analysis is exactly the same.
 Provides fast and easy set up and calibration
for amplitude based inspection criteria.
 TCG\DAC can be extrapolated to long sound
paths and many points due to no beam
divergence with the sound path. (Same angle)
 Can comply with codes without the use of
common angles (45, 60, 70 degrees)
 Linear scan channels can be gated to look only
at specific sections of the weld (ID, Embedded,
OD)
 Easy analysis for codes that do not require
flaw characterization

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WeldROVER- Scan Plan Design
Linear E-Scan Disadvantages
 Requires more focal laws and channels to
meet the same coverage as Sector Scan
Channel
 Requires larger probes, typically 64 elements
 Requires larger multiplexer on the
instrument, typically 128 element capability
 Does not provide same level of defect
characterization as Sector Scans.
 Does not provide the same level of defect
detection and sizing as Sector Scans due to
one angle
 Reduced usefulness on thick components
due to limited coverage per channel.

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WeldROVER- Scan Plan Design
TOFD Channel – Conventional UT technique utilizing a pitch-catch technique for
signal diffraction rather than reflection.

SEE POWER POINT 5 of 9– TOFD for description of channel and

advantages\Disadvantages

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WeldROVER- Scan Plan Design
Conventional UT Channel for Transverse Scanning – Typically only used with Phased Array scan
plans when the transverse scan requirement is recorded with the AUT data. Typically this is
done with manual UT similar to lamination checks and recorded on the data sheet.

UT Channel for Transverse Scanning

 Requires dedicated conventional UT
probes and mechanics
 Requires adapter on the PA
connector for use of lemo
connectors and coaxial cabling
 Requires adaptation of calibration
block for transverse scan target
 Requires 4 probes and 4 elements
from the PA connector that cannot
be utilized during the inspection

Currently not a standard WeldRover Option – Implemented on

case by case bases and requires custom mechanics for specific
pipe or vessel diameter and thickness.
Standard option scheduled for release early 2010
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WeldROVER- Scan Plan Design
Conventional UT Channel outside diameter creeping wave or High Angle L-wave
Specialized conventional UT probe for surface and near surface coverage when
inspecting stainless steel, dissimilar metal welds or inconel cladded materials.

 Utilized when the scan plan cannot “skip” off the ID surface for surface coverage
on the 2nd leg. Typical of austenitic materials, dissimilar metal Welds, and
cladded components
 Provides approximately 25mm of coverage in front of the probe face and will
detect a surface notch or near surface side drilled hole.
 Adapted to standard Olympus scanner mechanics for one-line scan coverage

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WeldROVER- Scan Plan Design
Review – The 5 basic channels utilized for all scan plans designed for the
WeldROVER or Olympus PV200 family of Phased Array Systems

The WeldROVER and PV200 systems were designed specifically for Piping,
Vessels, and Structural Component welds to ASME, AWS, API, and similar
standards utilizing the channels listed below.

 Phased Array Sector Scan

 Phased Array Linear Scan
 Conventional TOFD
 Conventional UT for Transverse Scanning (Not standard)
 Conventional UT OD creeping wave for Surface\Near Surface
Coverage

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WeldROVER- Scan Plan Design
 Upon selection of PA probe and wedge,
and completion of weld design, the ES
Beam Tool provides an easy to use
interface for configuration probe
position and inspection strategy or
“Scan Plan”.
 All the information for programming the
Omniscan or Focus LT is available in a
few easy steps.
 Additionally, the ES Beam Tool has
many features and tools not covered in
this presentation that make designing
phased array inspections fast and
efficient. All Olympus phased array
customers are encouraged to use this
software and it is an essential part of
this system.

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WeldROVER- Scan Plan Design- Example 1 of 3
Typical scan plan for WeldROVER
inspection combining 1 pair of PA
probes and 2 Pairs of TOFD probes.

 ASME CC2235 Vessel Inspection

 All channels are acquired in one
acquisition
 50mm X weld with 2 sided access
 Combing Linear (E-scan) 45, 52, and 60
Degree Channels from each side of the
weld (6 Channels total)
 2 X TOFD Channels focused at 33% and
66% of weld volume
 Calibration on standard ID\OD Notches
and Side Drilled Holes referenced in ASME
Sec VIII and CC2235
 194 Focal laws on 6 channels
 High level detection and precision sizing

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WeldROVER- Scan Plan Design- Example 1 of 3
Offline analysis sample of previous scan plan. Acquired with Omniscan MXU and
analyzed in Tomoview offline analysis software

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WeldROVER- Scan Plan Design- Example 2 of 3
Typical scan plan for WeldROVER inspection combining 1 pair of PA
probes and 2 Pairs of TOFD probes
 ASME CC2235 Vessel Inspection
 100mm V weld with 2 sided access
 Requires 2 separate acquisitions and probe
reposition (2 acquisitions)
 Combing Sector Scans from 2 standoff
positions on both sides of the weld
 3 X TOFD Channels focused at 25% 50% and
66% of weld volume
 Calibration on standard ID\OD Notches and
Side Drilled Holes referenced in ASME Sec VIII
and CC2235
 124 Focal laws on 4 channels
 High level detection and precision sizing
 Can accommodate the OD creeping wave
channel or a 4th TOFD channel without
additional acquisition. Requires probe change
 All channels from both acquisitions can be
merged in Tomoview for analysis

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WeldROVER- Scan Plan Design- Example 2 of 3
 Offline analysis
sample of previous
scan plan.
Acquired with
Omniscan MXU and
analyzed in
Tomoview Offline
analysis software.
Defect is Lack of
Root Fusion
visualized in the S-
scan and C-scan.
 ASME Sec VIII
Calibration Block
used for Sensitivity
and TCG\DAC
Construction

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WeldROVER- Scan Plan Design- Example 3 of 3
 ASME CC179 Power Piping
Inspection
 12mm V weld with 2 sided access
 10 inch diameter requires
contoured wedges- No calibration
on flat standards
 Acquired in one acquisition at
50mm/sec
 2 X 45-70 degree sector scans
from both sides of the weld
 70 degree TOFD Channel focused
66% of the weld volume
 Calibration on standard ID\OD
Notches pipe cut out
 104 Focal laws on 2 channels
using .5 degree resolution on the
sector scan
 Typical reject rate higher than RT
under ideal conditions for both
methods
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WeldROVER- Scan Plan Design
Typical of most service companies offering advance phased array services is
the creation of predefined scan plans for common bevel types using
spreadsheets to provide the probe position and PA channel information is
incorporated into company work practices and Level III approval and
qualification if required.

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Please send questions, comments and corrections to
Chris.magruder@olympusndt.com