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Appendix F
Phased Array Ultrasonic Testing
The following is prepared in accordance with the AWS D1.1 Code 2010 edition in order to
conduct phased array examinations to detect fabrication and field welding flaws in welded steel
pipe.
A phased array ultrasonic testing procedure shall be written and qualified in accordance with the
requirements herein. Essential variables detailed in Attachment A and shall be addressed in the
phased array ultrasonic testing procedure.
1.0 Purpose
The purpose is to outline the requirements for phased array examinations of carbon steel
pipe welds.
2.0 Scope
Carbon steel complete penetration (CJ P) joint welds with or without backing bar shall be
examined in accordance with these requirements to include thicknesses of 0.25 inches to
2.0 inches.
3.0 References
3.1 AWS D1.1, 2010 Edition
3.2 ASNT SNT-TC-1A
3.3 CP-189 2011 Edition
3.4 CP-105 2011 Edition
3.5 ASTM E 2700-09
4.0 Personnel Training and Qualification Requirements
4.1 All PAUT personnel shall be trained and certified in accordance with ASNT
SNT-TC-1A, 2011 Edition.
4.2 Personnel conducting PAUT examinations and evaluating results obtained shall
be certified to Phased Array Ultrasonic Level II or Level III, in accordance with
reference 3.3 as a minimum.
4.3 All PAUT Level II and III personnel shall have attended a minimum of 80 hours
of documented Phased Array Training in accordance with ASNT CP-105, 2011
Edition.
4.4 Certified Ultrasonic UT Level I and UT Level II personnel that have been trained
in the use of the equipment and have demonstrated the ability to properly acquire
examination data to a saved setup file shall be allowed to conduct examinations
while under the direct supervision of a certified PAUT Level II or Level III, but
shall not be allowed to interpret the results obtained. This individual is
considered a Scanner Technician or an assistant to the certified PAUT Level II.
Calibration, setup and data acquisition shall only be conducted by a certified
PAUT Level II.
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4.5 Phased Array Level II and III personnel shall pass a specific written examination
of 30 questions minimum of the Phased Array procedure to be implemented.
4.6 In addition, under the guidelines of Attachment B, Performance Demonstration
Qualification (PDQ) Examinations shall be successfully completed in order to
implement the Phased Array Examination in accordance with the requirements
herein.
5.0 Phased Array Definitions
5.1 Active Aperture: The number of elements in a Phased Array Transducer used for
the examination.
5.2 Angle Corrected Gain, ACG: This is compensation for the variation in signal
amplitudes during S-scan calibration at swept angles. The compensation is
typically performed electronically at multiple depths. A set of gain values is
applied to each summed A-scan presentation during angular electronic scanning
in order to get the same amplitude level for echoes reflected by a specific target,
whatever the refracted angle or depth. Note that there are technical limits to
ACG, that is, beyond a certain angular range, compensation is not always
possible.
5.3 Automated Scanner: An encoded, mechanical, motorized device for scanning
along welds to collect data. If the scanning device is manually driven but
encoded, it is called a semi-automated scanner.
5.4 E-scan, also called a linear scan: In this scan multiple elements groups are
excited using the same focal laws so as to form a single beam angle and this same
beam angle is indexed along the phased array probes active aperture.
5.5 Encoder: A device that records probe position for computer analysis.
5.6 Focal Law: A phased array operational file defining search unit elements and
time delays for transmitted and received signals.
5.7 Line scan: The phased array scan technique in which an E, S or combination
scan is performed with the beams directed perpendicular to the weld, at a fixed
distance from the welds in a manner demonstrated to provide full weld coverage.
5.8 PAUT: Phased Array Ultrasonic Testing.
5.9 Pitch: The center to center distance between two successive phased array
transducer elements.
5.10 S-scan, also called a sectorial scan: In this scan a single group of elements is
excited using multiple focal laws to form a series of different beam angles
emanating from the same group of elements.
5.11 S-view: The phased array instrument view that displays accumulated A-scan
information in a sector or volume of material. The sector display is used for both
E-scan and S-scan data.
5.12 Scan Plan: A document specifying key process elements such as equipment
detail, focal law settings and probe positions as necessary to complete an
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examination also depicting weld coverage.
5.13 Depth Calibration: A specific action used to compensate and adjust instrument
time delay over all focal laws (angles of refraction) for a specific wedge
geometry for depth calibration.
5.14 Virtual Probe Aperture, VPA: The grouping of elements in a given set of
elements to be fired in a Linear Scan.
6.0 Phased Array Equipment
6.1 The ultrasonic phased array system shall include:
A phased array test instrument as detailed herein.
Phased array probe or probes as detailed herein as defined in the Scan Plan
Encoding System Scanner, Wheel, or String
6.2 Automated or semi-automated scanners, as specified in the Scan Plan, shall be
performed using a pulse-echo technique using an Olympus OmniScan or equal
PAUT instrument. This PAUT System shall be qualified in accordance with the
PDQ Procedure Qualification (PQ) program and meet the following performance
requirements.
6.2.1 As a minimum, the Phased Array unit shall have a gain control
adjustable in increments of 1 or 2 dB steps and over a range of at least
60 dB.
6.2.2 The instrument shall be suitable for use with transducers which generate
frequencies over a minimum range of 2 to 6 MHz. Other Phased Array
probe frequencies maybe used if approved by the PAUT Level III.
6.2.3 The instrument shall be capable of producing sectorial, S-Scans or
Electronic, E-scans or a combination of both S and E-Scans as defined
by the Scan Plan.
6.2.4 The instrument shall be equipped with a minimum of 16 pulsers and
channels (16:16 minimum). A minimum of 16:64 is required if E-scans
are to be used.
6.3 n addition to the phased array system, peripherals such as keyboard, mouse and
data storage devices may be used in calibration, set-up and reporting. Subsequent
to data collection completion, data-analysis personnel may use a personal
computer with optional data analysis tools and display software for analyzing
data.
6.4 Straight-Beam, Longitudinal Wave Search Units
6.4.1 The straight beam search unit may be of a conventional or phased array
type.
6.4.2 Conventional transducers shall be square or round, have an active area
of at least 1/2 square inches and no more than 1 square inch, and operate
at frequencies between 2 and 2.5 MHz.
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Phased
6.7 The Phased Array Wedge
.7.1 The wedge shall produce refracted shear waves in the material being
6.7.2 ominal shear wave refracted wedge angles between 45 and 70 shall be
6.8 Encoder
For angle beam Phased Array Examinations, encoding in accordance
6.9 Couplant
6.9.1 Unless otherwise stipulated in the Scan Plan, any commercial couplant,
6.10 Calibration Blocks
6.10.1 Calibration for Phased Array Examinations shall be in accordance with
6.4.3 Phased Array Straight beam probes shall have an active aperture no less
than 0.375 inches, and shall operate at frequencies between 2 and 6
MHz.
6.5 Angle-Beam, Shear Wave Search Units
6.5.1 Angle-beam search units shall consist of a phased array probe and an
angle wedge to produce the desired refracted angles. The phased array
angle beam wedge shall produce refracted shear waves between 45 and
70 degrees. Other angles may be used to increase weld volume coverage
if qualified in accordance with this requirements herein.
6.6 Array Probe
6.6.1 The Phased Array probe shall be a linear array type consisting of 16
or more elements (64 or more if E-scans are to be used) and produce
frequencies between 2 and 6 MHz. The total aperture size, active and
passive, may be any size down to 3/8 inch provided the element size and
pitch are suitable to prevent grating lobes or other unsuitable noise.
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tested within +/- 2 degrees of the minimum and maximum angle used or
+/- 2 degrees of the first and last VPA for E-scans.
N
used to ensure coverage of the weld and heat affected zone, HAZ. When
a refracting wedge is used, the phased array generated angles shall be
within the useful range of the wedge. The refracted angles shall be
detailed in the appropriate Scan Plan for the configuration in accordance
with the requirements of paragraph 9.0 herein.
6.8.1
with the requirements herein shall be linear digital encoder capable of
line scanning and may be semi-automatic or automatic type.
water, or oil may be used as couplant when performing calibrations and
examinations. Couplant used for examination of production welds shall
be the same couplant used during calibration.
the requirements of paragraph 9 herein. The calibration reflector shall be
a 1.5mm (0.060) side drilled hole or equivalent. A suitable amount of
calibration reflectors shall be placed in any design of calibration block,
weld mock-up or actual production part at the option of the user to cover
the entire sound path range to be inspected. An example of a basic
calibration block is shown in Figure 2 except that multiple reflectors will
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6.10.2 Block Material: When blocks are used, they shall be made of essentially
.10.3 Weld Mock-Up and Production Parts: Alternate possible uses of the
6.10.4 Corner reflectors shall not be used for calibration purposes.
6.10.5 Alternate Blocks: An International Institute of Welding (IIW) block,
FIGURE 1
CALIBRATION STANDARD
likely be necessary to allow proper calibration of phased array
configurations.
the same material type and heat treat as the material being examined.
The block thickness shall be essentially the same as the material being
examined.
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reflector are shown in Figure 3. When weld mock-ups and sections of
production weldments are used, the reflector shall be in locations where
it is difficult to direct sound beams, thereby ensuring detection of
discontinuities in all areas of interest.
Phased Array Calibration Standard (PACS ) or other blocks of similar
material may be used to aide in calibration where necessary.
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FIGURE2
ALTERNATECALIBRATIONSTANDARDS
7.0 Phased Array Instrument Linearity
7.1 Linearity verifications shall be conducted every 30 days and recorded.
Horizontal Linearity
Display Height Linearity
Amplitude Control Linearity
8.0 Phased Array Element Operability
8.1 An element operability check shall be performed before initial calibration and
use, and weekly on each phased array probe to determine if dead or inactive, or
defective elements are present. No more than 10 percent of the elements shall be
dead and in a given aperture, and no more than two adjacent elements shall be
dead within a given aperture.
8.2 In addition, each phased array element shall be evaluated for relative amplitude
within the aperture and shall be verified to be within 6 dB of the average
amplitude of the other elements. If the amplitude is outside the 6 dB requirement,
then the probe element shall be declared dead.
9.0 Scan Plan Development
9.1 A Scan Plan examination strategy shall be developed for all weld joint
configurations. This Scan Plan requires consideration of each weld or group of
welds of the same essential geometry, thickness and configuration through
preparation of a Scan Plan. The Scan Plan details specific attributes necessary to
achieve examination coverage including those variables subject to material and
geometric variation that are not addressed in a general procedure. (Figures 5 and
6 contain typical Scan Plans with Index Offsets, these Scan Plans are for
information only and not intended for use.)
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9.2 The Scan Plan shall demonstrate by plotting or computer simulation the
appropriate refracted angles to be used during the examination for the weld prep
angles and areas of concern. The Scan Plan shall demonstrate coverage of the
required examination volume.
9.3 Caution should be taken when using computer modeling programs and drafted
sketches to demonstrate coverage. The true measure of performance as
envisioned must be verified through the calibration, that is, beam index point and
beam angle verifications.
9.4 Whenever a Scan Plan is developed, parameters shall be defined and validated by
the Scan Plan developer (PAUT Level II or III) by performing the initial
calibration to optimize those parameters. A new calibration is required if the
Scan Plan developer determines or suspects that an essential variable has
changed.
9.5 The Scan Plan shall be documented to show the examination volume examined
and shall be a part of the final examination report. Scan Plan contents shall
consider all applicable essential and non-essential variables as detailed in
Attachment B.
9.6 A detailed Scan Plan shall be established for each weld type, joint design and
thickness.
9.7 Phased Array Scan Configuration
9.7.1 S-Scans shall be used as the primary scan to optimize coverage to fully
examine the weld and HAZ in accordance with the approved Scan Plan.
9.7.2 An unfocused (naturally focused) sound beam shall be configured for
scanning. Focusing may be used to better define and dimension the
length and through wall height of a given flaw, but shall not be used
during evaluation for acceptance.
9.7.3 E-Scans may be used to supplement the S-Scans for single sided access
welds and different weld joint configurations to ensure complete
coverage of the weld and HAZ, or to provide specific joint geometry
coverage of the weld bevel, for example T joint welds.
9.7.4 When multiple E-Scans are used to provide coverage, a 10 percent
overlap shall be specified in the Scan Plan. When S and E-Scans are used
in combination, similar overlaps shall be used.
9.7.5 Multiple groups may be used to establish combinations of phased array
configurations.
9.7.6 When S-Scans are used, two different S-Scan index positions from both
sides of the weld shall be specified in the Scan Plan to provide the
required angle beam coverage of the weld and heat affected zone.
9.8 The parameters for phased array examination are addressed as either essential or
non-essential variables and are listed in Attachment A. All essential variables
shall be demonstrated during the PDQ PQ qualification.
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ARL+5dB98%FSH
SSL50%FSH
DRL 6dB 25%FSH
Figure 3
11.0 Phased Array Examination and Data Acquisition
11.1 All inspection surfaces that the PA Probe is applied to shall be free of dirt,
grease, oil, loose scale, paint or weld spatter and shall have a surface contour that
permits adequate coupling. A couplant, for example water, shall be used
between the transducer and the inspection surface on all scans.
11.2 The entire base metal that the ultrasound will pass shall be examined for laminar
reflectors using a straight beam transducer that meets the requirements of
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Figure 4
12.2 A post analysis data evaluation software package may be used to analyze the
Phased Array data, for example Tomoview, OmniPC, or equal.
13.0 Acceptance Criteria
13.1 All weld discontinuities shall be evaluated, using the refracted angle or VPA
yielding the highest response, based on the indication level and length in
accordance with the requirements herein the acceptance-rejection criteria of
Table 1.
13.2 Any ultrasonic indication determined to be a Crack, Lack of Fusion (LOF), or
Lack of Penetration (LOP) shall be rejected regardless of amplitude or length.
TABLE1
ACCEPTANCEREJECTIONCRITERIA
10.10.3 measurement may be determined
by 6 dB drop methods.
11.0 Data Recording and Documentation
d Scan Plans shall become an archival record for
a period of 10 years after the completion of the Project. The PA inspection
11.2 Array Data shall be saved and archived as a Merge set of
data for analysis.
11.3 aluation of the phased array data shall not change or affect the
original phased array raw A-scan data.
11.4 rated by the examiner at the time of
evaluation. Examination reports may be output from the on-board reporting
12.0 Data M
gement system consistent with Project requirements.
ent of
calibration and set-up files, phased array data files, and digitally generated data
ay data shall be saved as the original raw A-scan form.
need only
contain sufficient information to identify the weld, the operator including
12.5 ities that do not meet the acceptance criteria of
paragraph 13, and require repair by excavation, shall be indicated on the weld by
12.6 ed, all report
forms pertaining to the weld, including any that show unacceptable quality before
12.7
UT shall be delivered to the Engineer upon completion of the work. Obligation
12.8 an Plan that was developed shall become a part of
the final examination report as it contains much of the information required to be
As an alternative, flaw length
11.1 All digital Phased Array data an
company shall maintain all digital records, including PA Data, Scan Plans, Data
reports and records.
Any merged Phased
Any review and ev
An examination report shall be gene
feature of the phased array unit provided all necessary information is included.
Reports may also be produced in the written manual UT convention form.
anagement System
12.1 Establish a data mana
12.2 A systematic file naming system shall be used to control data managem
report forms.
12.3 All phased arr
12.4 Acceptable Welds. The report form for welds that are acceptable
signature, and the acceptability of the weld. Completed inspection reports shall
be forwarded to the Engineer.
Unacceptable Welds. Discontinu
marking directly over the discontinuity for its entire length. The depth and
indication level shall be marked on the nearby adjacent base metal.
Prior Inspection Reports. Before a weld subject to UT is accept
repair, shall be submitted to the Engineer.
Disposition of Reports. A full set of completed report forms of welds subject to
to retain UT reports shall cease upon delivery of this full set to the Engineer or
two full years after filing of the Notice of Completion, provided the Engineer is
given advance written notice.
Scan Plan Reporting The Sc
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documented.
AttachmentA
S
ProceduresVariablesforPAUTExaminations
ummaryTableof
E
s
s
e
n
t
i
a
l
N
o
n
E
s
s
e
n
t
i
a
l
Elementpitchandgapdimension X
Focus(identifyplane,depth,orsoundpathasapplicable) X
Virtualapertureuse,thatis,numberofelementsandelementwidth X
Elementnumbersusedforfocallaws X
AngularrangeofSScan X
Documentationonpermittedwedgeangularrangefrommanufacturer X
Documentedcalibration,TCG,andAngleGainCompensation X
Scanpatterntoensurecoverage X
Weldconfigurationstobeexamined,includingthicknessdimensionsandbase
materialproductform(pipe,plate)
X
Thesurfacesfromwhichtheexaminationshallbeperformed X
Technique(s)(straightbeam,anglebeam,contact,and/orimmersion) X
Angle(s)andmode(s)ofwavepropagationinthematerial X
Searchunittype(s),frequency(ies),andelementsize(s)/shape(s) X
Specialphasedarrayprobescurved/shapedwedges,shoes,orsaddles,when
used.
X
PhasedArrayUnits(s) X
Calibrationcalibrationblock(s)andtechnique(s) X
Directionsandextentofscanning X
Scanning(manualvs.automatic) X
Methodfordiscriminatinggeometricfromflawindications X
Methodforsizingindications X
Computerenhanceddataacquisition,whenused X
Scanoverlap(decreaseonly) X
Personnelperformancerequirements,whenrequired X
Personnelqualificationrequirements X
Surfacecondition(Examinationsurface,calibrationblock) X
Couplant:brandnameortype X
Automaticalarmand/orrecordingequipment,whenapplicable X
Records,includingminimumcalibrationdatatoberecorded(forexample
instrumentsettings)
X
Methodfordeterminingdelaylawsifotherthanonboardequipment
algorithmsincludedinthesoftwarerevisionspecified
X
Revisionofsoftwareusedinqualification X
Scanningdevicemakeandmodel X
Decreaseinsamplingrateduringscanningforlinearscans X
Flawdiscriminating/characterizingmethod locationandtype X
Type,sizeandrangeasapplicable,ofinterferingsignalsourcese.g.;roots
andweldcrownconditions,tapers,counterbores
X
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AttachmentB
PerformanceDemonst (PDQ)Examinations
Personnel am. The
ualification exam shall include the ability of the Phased Array UT (PAUT) personnel to
will be supplied by the Engineer and administered as follows:
accordance
with AWS D1.1 Section 6, paragraph 6.36 and 6.37
ct acceptable and rejectable flaws in
accordance with a Procedure Qualification (PQ) Test Protocol.
gth of flaws in
ccordance with a PQ Test Protocol.
2.0 NT, shall
demonstrate their proficiency in the calibration and setup, data acquisition, and data
y a PAUT Level III
designated by the Engineer, and in accordance with a Test Protocol.
ximate weld
ngth of 24 inches per test plate
bar weld joint configuration
lished.
on flaws
onducive to the welding process to be used during the field examinations.
tion
.6.2 Minimum of 80 % flaw characterization
y
rationProgram
shall demonstrate proficiency by satisfactory performance in a qualification ex
q
correctly calibrate the PAUT equipment and complete the report associated with the examination
as well as evaluate the specimen and discover discontinuities. The test specimens shall be
representative of the details of typical welded joints and conditions, which will be encountered in
the pipe construction.
The PDQ Test Samples
1.0 The Phased Array Ultrasonic Examination Procedure shall be qualified in
1.1 The PA procedure shall be qualified to dete
1.2 The PA procedure shall be qualified to dimension the len
a
Each certified PAUT Level II or Level III, qualified in accordance with AS
analysis conduct of an Examiner Qualification Examination, (EQ).
2.1 The Examiner Qualification (EQ) shall be administered b
2.2 A minimum of 4 Test Plates shall be administered with an appro
le
2.3 The test samples shall be a backing
2.4 Each Test Set shall have flawed and unflawed grading units estab
2.5 The Test Set flaws shall be representative of the typical welding fabricati
c
2.6 Grading shall be as follows:
2.6.1 Minimum 80% detec
2
2.6.3 Minimum of 80% accurac
2.6.4 No more than 20 % overcalls
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Figure5
ScanPlanatSkew901and2701
Figure6
ScanPlanatSkew902and2702