WeldRover 3 of 8– Code Compliance

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- Code Compliance
Why Phased Array Technology? 3 Reasons:
 A Faster Inspection
– Performing the same or improved inspection as conventional UT with greater speed,
repeatability, and procedure compliance.

 A Better Inspection
– Overcoming Access limitations
– Better detection and sizing of flaws through the use of focused multi angle inspections
– Easier characterization of flaws and geometry
– Reducing dependence on the skill of the operator
– Ability to record digital data and retain inspection records

 Replacement of Radiography for Code Based Weld Inspection

– No radiation hazard
– Does not interfere with production in the work place to do radiation boundaries
– Depth and height sizing that is not possible with RT
– Permanent inspection records to replace film
– Code Compliance for ASME, API, AWS, etc

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WeldROVER- Code Compliance

 The overwhelming majority of the PV200 type systems such as the

WeldROVER are sold for replacement of radiography in the fabrication
of pipelines, vessels, and welded structures.
 To replace RT the customer and the relevant code require permanent
records and the ability to analyze data offline after the inspection
through the instrument or computer based software.
 Some of the most common codes that govern these activities are the
ASME Sec III, Sec V, and Sec VIII, AWS D1.1, API 1104, and API
RP2X. There are many others as well.
 Compliance with these codes is not solely a function of the instrument
but rather a total process to include equipment, calibration block and
technique, scan plan design, inspection procedure, qualification of the
process or technique, personnel certification, and many other
parameters specified in the applicable code.

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WeldROVER- Code Compliance
Is the WeldROVER Code Compliant?

 Scanners and Instruments are not inherently code compliant. They

are one part of an overall procedure or process that is written to
comply with the various codes. They contain features such as scan
speed, encoder capability, instrument linearity, software features, data
recording that make up the equipment portion of the over-all process.
 When used by a qualified inspector to a qualified procedure, the
WeldROVER, like all the Olympus PV200 systems family, can meet all
the requirements of the ASME, AWS, API and similar codes for full
volumetric phased array and TOFD inspection of piping, vessels, and
fabricated component welds.
 The WeldROVER PV200 system was designed and developed
specifically for this purpose. It is the only phased array system on the
market today that can demonstrate a full code compliant calibration of
every focal law on every channel for: Time of Flight, Sensitivity (ACG
as defined by ASME), TCG\DAC, and Velocity. It is also the easiest
and fastest to learn and use.

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WeldROVER- Code Compliance
The ASME has been particular proactive in updating their codes to maximize the
benefits of Phased Array through the release of specific Code Cases.

 Case 2235 Use of Ultrasonic Examination in Lieu of RT for ASME Sec VIII
Pressure Vessels
 Case 2600 Use of Linear PA S-scan per Art. 4 Sec V
 Case 2557 Use of Manual PA S-scan per Art. 4 Sec V
 Case 2599 Use of Linear PA E-scan per Art. 4 Sec V
 Case 2541 Use of Manual PA per Art. 4 Sec V
 Case 2558 Use of Manual PA E-scan per Art. 4 Sec V
 Case 181 Use of Alternative UT Examination Accept Criteria for ASME B31.3
 Case 179 Use UT in Lieu of RT for B31.1 Applications < ½ inch in Thickness

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WeldROVER- Code Compliance

 Along with our training partners, Olympus through the course of our
standard equipment deliveries and training courses offers insight,
guidance, and real world experience as to how our systems can best
comply with the regulatory codes in the individual workplace or
service industry markets. 95%+ of this is ASME, AWS, and API
inspections.
 Olympus does not take a position on code interpretation and it is the
responsibility of the end user to ensure that their overall process for
equipment functionality is in compliance with applicable code and
regulations for their application.
 Olympus does strive to make the most usable, technologically
advanced instrumentation and systems that allow our customers to
perform high level inspections and offer code compliant advanced
inspection services to the common codes such as ASME, API, AWS,
and similar.

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WeldROVER- Code Compliance
When used by certified personnel, Olympus Phased
Array Systems are cable of meeting the basic
requirements of any code with respect to all the
following parameters.

 Vertical and Horizontal Linearity

 Time of Flight Calibration
 Sensitivity Calibration
 ACG (Angle Corrected Gain as defined by the ASME)
 TCG Calibration
 DAC Calibration
 Velocity Calibration

Olympus Phased Array Instrumentation is unique in this

regard. There are currently no other systems on the market
today that can demonstrate the ability to perform these
functions across all channels and focal laws.

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WeldROVER- Code Compliance
 It is not practical to calibrate individual Focal Laws (A-scans) one at a
time as there can be up to 256 in some applications. For this reason
the software must have tools or “Wizards” to make these functions fast
and easy, repeatable, and in compliance with the codes for Sensitivity,
TCG, Velocity, etc.
 The Omniscan MXU and Focus LT software contains all the tools to
complete these functions efficiently in preparation for the inspection.

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WeldROVER- Code Compliance
The Omniscan MXU is capable of generating 256 focal laws (A-scans)
simultaneously divided in up to 8 channels. All calibrations are
performed per channel and any individual focal law (A-scan) can easily
be verified using standard references such as an IIW block or similar.
This is verbatim compliance with the requirements of ASME, AWS, API,
and similar.

 Exit Point
 Refracted Angle
 Sensitivity
 Velocity
 Time of Flight (Wedge
Delay)
 TCG or DAC
 Surface Distance

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WeldROVER- Code Compliance
 In addition to compliance with the codes and regulations, the quality of the
calibration is directly related to the probability of detection, a reject rate in line
with the applicable code, and ease of analysis for the operator.
 A quality calibration would allow the same size and type of reflector to be
detected at the correct time of flight and amplitude, regardless of angle and
sound path.
 This results in a consistent color palette throughout the digitized range and
allows high probability of detection and accurate consistent flaw
characterization.

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WeldROVER- Code Compliance
In addition to the calibration requirements and scan plan requirements,
code compliance also requires accepting or rejecting welds based on
one of more of parameters below.
When the following parameters are known, a weld flaw can be interpreted
as acceptable\rejectable to any of the codes in use today such as
ASME, AWS, API, or similar.
For some of the codes, only one or two of these parameters are
necessary to make a decision.
 The Depth of the flaw
 The Height or “Thru Wall Dimension of the Flaw
 The Type of flaw (Slag, Porosity, Crack, etc)
 The Location of the flaw (ID connected, Embedded, etc)
 The Length of the flaw
 The Amplitude of the flaw

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WeldROVER- Code Compliance
 The Omniscan and Focus LT
software use cursers, gates, and
digital readings to make sizing and
characterization of flaws fast and
efficient.
 The required reading are configured
and saved as part of the set up for
different code requirements. This
typically includes Depth (DA),
Height (Um-r), Length (Sm-r),
Volumetric Position (Via), etc.
 Training in these features and code
interpretation of defects is part of a
standard PA Training course from
Olympus or our training partners

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WeldROVER- Code Compliance
In addition to tools for sizing Depth,
Height, Length, etc. the Omniscan
MXU software also contains the
standard readings that you would
expect in any modern conventional
flaw detector including:

 AWS Defect Ratings

 Amplitude Drop Sizing Tools
 Volumetric Positions in 3 Axis
 Code Calibration Reference
Level Comparisons
 Probe and Surface Parameters
 And many, many more

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WeldROVER- Code Compliance
Currently the Omniscan MXU and Focus LT\Tomoview for computer based
applications do not support API 1104 Zone Discrimination Weld Inspections.
The only Olympus product offering this inspection is the Pipe Wizard.

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 WeldROVER- Code Compliance
 In addition to the calibration requirements
and hardware parameters, the codes also
regulate the required area of coverage,
probe parameters, and the overall
inspection.
 Use of the ES Beam Tool, Olympus Beam
Simulator or similar software allows the
operator to design and document correct
probe position, channels and angles used
for proper coverage, and over all
inspection strategy using Phased Array,
TOFD, and Conventional UT techniques.
 The information obtained from the scan
plan software is programmed into the
Omniscan using Group Wizards and
Calibration Wizards allowing the operator
to manage hundreds of Focal Laws (A-
scans) simultaneously.

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Continue to Part 4 of 8 – ES Beam Tool and Scan Plans

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