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While it is recognized that phased array technology is becoming more widespread and
popular within various industries, it has not yet been specifically addressed by the
AWS. The following document was written to satisfy customer requests. Its purpose is
to serve as a guideline to align the Phasor XS with the current methodology prescribed
in Clause 6, Part F, of the AWS D1.1, 2008 Code.
This is achievable due to the well-established fact that an array transducer with the
same physical properties of size, shape, and frequency, as a conventional monolithic
transducer, will have identical acoustic properties.
This document has been produced in typical procedure format, for the sake of
familiarity. As such, it is intended as a guideline only.
Page 2 of 40
Table of contents
SECTION
PAGE
1. Scope
2. References
3. Personnel
4. Equipment
5. Calibration
6. Examination
13
18
23
29
33
Annex D: Drawings
37
Page 3 of 40
1. Scope
1.1. This procedure describes the use of the Phasor XS utilizing the sectorial and
A-scan views. For the detection and interpretation of discontinuities in groove
type welds and the associated heat affected zones (HAZ). Applicable part
thickness range is from 5/16 to 8 inclusive of material thickness as prescribed
by Part F of the AWS D1.1 2008 code. (herein referenced as the code)
1.2. Limitations
1.2.1. This procedure is not intended for the inspection of tube-to-tube (tubular)
T, Y, K connections
1.2.2. This procedure is not intended for the inspection of base material.
However, discontinuities discovered in the adjacent base material shall be
reported to the Owner / Engineer for disposition.
1.2.3. As a supplement to the method(s) described herein, RT is recommended
for the detection of piping porosity in ESW, and EGW weldament.
1.2.4. For discrepancies between this procedure, and the code, the code shall
hold precedence.
2. References
2.1. American Welding Society AWS D1.1 Structural Welding Code Steel
2.2. American Society for Nondestructive Testing (ASNT) - SNT-TC-1A Personnel
Qualifications
2.3. GE Inspection Technologies (GEIT) - Phasor Owner Manual.
(www.geinspectiontechnologies.com)
Page 4 of 40
3. Personnel
3.1. Personnel shall be certified in accordance with the ASNT SNT-TC-1A, or be
certified in accordance with the employers written practice. Provided that the
employers written practice contains, as a minimum, the requirements of SNTTC-1A.
3.2. Personnel performing exams shall be a certified level I, II, or a level III who has
taken, and passed a Level II Practical certification test.
3.2.1. Level I personnel shall only perform exams under the direct supervision
of a level II, or III, and shall not independently (1) conduct exams, (2)
interpret exam results, or (3) write a report of exam results.
3.3. All personnel conducting exams in accordance with this procedure shall
demonstrate proficiency by successfully passing a general, specific and
practical exam administered by a level III, or a Level II so designated by a level
III, and applying the methodology of this procedure and the rules of AWS D1.1.
4. Equipment
4.1. The ultrasonic instrument shall be the Phasor XS.
4.1.1. For compliance with Sec. 6.22 of the AWS code, reference the Phasor
Owners Manual for the technical specifications.
4.2. The search unit shall be comprised of transducer model # 115-000-866,
coupled to wedge # 118-350-037 for straight beam, or the standard 60 AWS
wedge for angle beam. The use of other search units by engineer approval is
not addressed within this document.
Page 5 of 40
Page 6 of 40
5. Calibration
5.1. General
5.1.1. Reference Annex A and B for equipment qualification requirements.
5.1.2. A transducer element, cable, and coupling check shall be made prior to
an exam or series of exams, and again at the completion of an exam or
series of exams, but not to exceed intervals of 8 hours, and at any time of
suspected system irregularity. Reference Annex C for equipment
programming, and guidance.
5.1.3. The primary testing angle used for calibration shall be selected from
table 5.1
5.1.4. Calibration shall be performed with the Phasor set up in accordance with
table(s) 5.2, or 5.3.
5.1.5. Calibration intervals for sensitivity and horizontal sweep shall be made
by the operator at the location of each weld being tested, and at intervals
not to exceed 30 minutes as testing proceeds.
5.1.6. Recalibration shall be made after:
a) Change of personnel.
b) Time intervals not to exceed a maximum of 2 hours.
c) Any change to the search unit, or changing of the search unit.
d) Any disruption of the electronic circuitry. (i.e. battery swap, power
failure)
e) Any instance of system irregularity.
5.1.7. The use of corner reflectors shall be prohibited for calibration.
Page 7 of 40
5.3.2.2.
5.3.2.3.
Place the beam cursor on the primary testing angle to ensure the
readings in the Results windows are for this angle.
Page 8 of 40
5.3.2.4.
In the CAL submenu (HOME > PART > CAL) adjust the gates to
surround where the beam cursor intersects the reflection from the
4 radius. (NOTE: the gates may also need to be narrowed.)
Maximize the signal response from the 4 radii by adjusting the
probe position. Adjust the gain such that the amplitude response
reads less than 100% in the A%A results window. Adjust the
VELOCITY S until the SA reading in the results window reads 4.
5.3.2.5.
Page 9 of 40
Table 5.1
Page 10 of 40
Page 11 of 40
Table 5.2
(Sub-menu)
PRB DAT
PRB GEO
WDGE DAT
WDGE GEO
OFFSET
(Sub-menu)
PLAN
CAL
(Sub-menu)
ELECTRNC
SCN PATT
APERTURE
(Sub-menu)
VIEW
BACKGRND
RESULTS1
(Sub-menu)
Base
Pulser
Receiver
GATEMODE
PROBE MENU
(Tab)
(Value)
Dialog Probe
Frequency
Number of Elements
Pitch
Elevation
Element 1 Position
Velocity
Wedge Front
Offset Z
Angle
Origin Offset
Load Def
2.3 MHz
16
0.040
0.650
Low end
.1086 in/s
0.000
1.00 (Annex C)
0.0 deg
0.000
PART MENU
(Tab)
(Value)
Material Thickness
SCAN MENU
(Tab)
(Value)
Type
Focal Point
Wave Type
Angle Start
Angle Stop
Angle Step
Number of Steps
First Element
Aperture Size
Aperture Step
Linear
Unfocused
Longitudinal
0.0 deg
0.0 deg
1.0 deg
1
1
16
1
DISPLAY MENU
(Tab)
(Value)
View Mode
Angle corrected
Data Source
Color Leg
Reading 1
Reading 2
Reading 3
Reading 4
Frame
On
Amp A
On
Beam
A%A
SA
PA
UT MENU
(Tab)
Readings may be
displayed in any order
(Value)
Display Start
Display Delay
Leg
Voltage
Width
PRF Value
Frequency
Ascan Rectify
Material
0.000 in
2.3
150V
220ns
set to maximum
2MHz
Fullwave
Gate select
Gate A
Logic
Positive
Gate Display
On
Page 12 of 40
Table 5.3
(Sub-menu)
PRB DAT
PRB GEO
WDGE DAT
WDGE GEO
OFFSET
(Sub-menu)
PLAN
CAL
(Sub-menu)
ELECTRNC
SCN PATT
APERTURE
(Sub-menu)
VIEW
BACKGRND
RESULTS1
(Sub-menu)
Base
Pulser
Receiver
GATEMODE
PROBE MENU
(Tab)
(Value)
Dialog Probe
Frequency
Number of Elements
Pitch
Elevation
Element 1 Position
Velocity
Wedge Front
Offset Z
Angle
Origin Offset
Load Def
2.3 MHz
16
0.040
0.650
Low end
.1086 in/s
0.711
0.435 (Annex C)
47.5 deg
0.000
PART MENU
(Tab)
(Value)
Material Thickness
SCAN MENU
(Tab)
(Value)
Type
Focal Point
Wave Type
Angle Start
Angle Stop
Angle Step
Number of Steps
First Element
Aperture Size
Aperture Step
Sector
Unfocused
Shear
35.0 deg
70.0 deg
1.0 deg
1
1
16
1
DISPLAY MENU
(Tab)
minimum
(Value)
View Mode
Angle corrected
Data Source
Color Leg
Reading 1
Reading 2
Reading 3
Reading 4
Frame
On
Amp A
On
Beam
A%A
SA
PA
UT MENU
(Tab)
Readings may be
displayed in any order
(Value)
Display Start
Display Delay
Leg
Voltage
Width
PRF Value
Frequency
Ascan Rectify
Material
0.000 in
2.3
150V
220ns
set to maximum
2MHz
Fullwave
Gate select
Gate A
Logic
Positive
Gate Display
On
Page 13 of 40
6. Examination
6.1. General
6.1.1. An X line for flaw location shall be marked on the test face of the
weldament in a direction parallel to the weld axis. The location distance
perpendicular to the weld axis is based on the dimensional figures on the
detail drawing and usually falls on the centerline of the butt welds, and
always falls on the near face of the connecting member of T and corner
welds, the face opposite Face C. (see Table 5.1 for Face descriptions.)
6.1.2. A Y accompanied with a weld identification number shall be clearly
marked on the base metal adjacent to the weld being examined at the left
end on Face A (see Table 5.1 for Face descriptions.) This identification
number serves as:
a)
Weld identification,
b)
Identification of Face A,
c)
d)
6.1.3. A couplant described in 4.4 shall be used between the search unit and
scanning surface.
6.1.4. All surfaces to which the search unit(s) is applied shall be free of weld
spatter, dirt, grease, oil, paint, loose scale, or any material/condition which
would prevent the transmission of ultrasound, and shall have a contour
allowing intimate coupling.
Page 14 of 40
When the indication is larger than the search unit a full loss of the
back wall reflection will usually occur. By sliding the search unit off
the indication until a 50% drop in amplitude from the indication is
realized, and then by measuring to the centerline of the search
unit, is generally reliable for determining the edges of the
indication.
6.2.1.2.
b)
c)
Page 15 of 40
Weld examination
6.3.
6.3.1. Welds shall be tested with the search unit described in Section 4.2, and
calibrated in Section 5.3. Following calibration, and during testing, the
only instrument adjustment permitted is the sensitivity level (gain)
setting.
6.3.1.1.
6.4.
6.4.3.2.
6.4.3.3.
6.4.4. To detect transverse defects, cover the full weld section with one of the
following movements from Figure 6.4
Page 16 of 40
6.4.4.1.
6.4.4.2.
6.4.5. For electroslag or electrogas welds, use Scanning Pattern E, with the
search unit rotation angle e between 45deg. to 60deg.
Page 17 of 40
Table 6.4
Scanning Patterns
Page 18 of 40
7.2.
7.3.
a c =d
Page 19 of 40
7.5.
7.6.
7.7.
Page 20 of 40
Table 7.1
Ultrasonic Report Form
Page 21 of 40
Table 7.5A
AWS D1.1
Page 22 of 40
Table 7.5B
AWS D1.1
Page 23 of 40
Annex A
dB accuracy procedure
1. dB Accuracy Procedure.
Note: In order to attain the required accuracy (+ 1%) in reading the indication
height, the Display must be graduated vertically at 2% intervals at horizontal
midscreen. These graduations shall be placed on the Display between 60%
and 100% of screen height. This may be done with use of a graduated
transparent screen overlay. If this overlay is applied as a permanent part of
the ultrasonic unit, care should be taken that the overlay does not obscure
normal testing displays.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Repeat step 5.
Page 24 of 40
(9)
(10)
(11)
Apply the information from Rows "a" and "b" to the below
referenced equation (Section 2. Annex A) or the
nomograph (Form A.2) to calculate the corrected dB.
(12)
(13)
Subtract Row "c" value from Row "a" value and apply the
difference in Row "d", dB error. These values may be
either positive or negative and should be noted with a plus
sign "+" or a minus sign "-".
(14)
(15)
(16)
(17)
(18)
Page 25 of 40
2. Decibel Equation.
The following equation shall be used to calculate decibels:
%
+ dB
dB = 20 x log
%
2
dB1 = Row a
dB2 = Row c
%1 = Row b
%2 = Is the average of Row b disregarding the first and
last three tabulations
Page 26 of 40
Form A.1
Ultrasonic Unit Calibration Report Form
Serial No.:
Type:
Calibration - Date:
Interval:
Data:
Frequency:
2 Months
MHZ
Method:
As Found
As Adjusted
Supplemental Instructions:
Start with the lowest dB level that you can obtain a 40 percent display height indication from. Add 6 dB's and
record this dB reading in Row A and display height Row B as the starting points on the tabulation chart.
After recording these values in Rows A and B, slide the transducer to obtain a new 40 percent display
height. Without moving the transducer add 6 dBs and record the new dB reading and the new display height in
Rows A and B. Repeat this step as many times as the unit allows.
Find the average % screen values from Row B by disregarding the first 3 and the last 3 tabulations. Use
this as %2 in calculating the corrected reading.
%
=
20
x
log
+ dB
dB
%
2
%1 is Row B
The dB Error "Row D" is established by subtracting Row C" from Row A": (A - C = D).
The Collective dB Error "Row E" is established by starting with the dB Error "Row D" nearest to 0.0,
collectively add the dB Error Row D values horizontally, placing the sub-totals in Row E".
Moving horizontally, left and right from the Average % line, find the span in which the largest and smallest
Collective dB Error figures remain at or below 2 dB. Count the number of horizontal spaces of movement,
subtract one, and multiply the remainder by six. This dB value is the acceptable range of the unit.
In order to establish the acceptable range graphically, Form D-9 from AWS D1.1 may be used as follows:
(1)
Apply the collective dB Error Row E values vertically on the horizontal offset coinciding with the dB reading
values from "Row A".
(2)
(3)
Apply a 2 dB high horizontal window over this curve positioned vertically so that the longest section is
completely encompassed within the 2 dB Error height.
(4)
Page 27 of 40
NUMBER
Row A
dB READING
Row B
DISPLAY HEIGHT
10
11
12
Row D
dB ERROR
%2 (Average)
dB
to
dB
dB
to
Calibrated by:
dB
Total error
dB =
dB
Total error
Level:
Location:
13
Page 28 of 40
Form A.2
dB Accuracy Evaluation Report Form
Serial No.:
Type:
Frequency:
MHZ.
Page 29 of 40
Annex B
Horizontal Linearity, Internal Reflectors, and Resolution
1.
2.
(1)
(2)
(3)
(4)
(3)
(4)
The screen area beyond 1/2 in. [12 mm] sound path and
above reference level height shall be free of any indication.
Page 30 of 40
3.
Resolution Requirements.
3.1 The combination of search unit and instrument shall resolve three holes
in the RC resolution reference test block shown in Drawing D.1, or D.3.
The search unit position(s) from Drawing D.1 are as follows:
(1)
(2)
(3)
3.2 The resolution shall be evaluated with the instrument controls set at
normal test settings and with indications from the holes brought to
midscreen height. Resolution shall be sufficient to distinguish at least
the peaks of indications from the three holes. Use of the RC resolution
reference block for calibration shall be prohibited. Each combination of
instrument search unit (shoe and transducer) shall be checked prior to
its initial use. This equipment verification shall be done initially with
each search unit and UT unit combination. The verification need not be
done again provided documentation is maintained that records the
following items:
(1)
(2)
(3)
Page 31 of 40
Form B.1
Ultrasonic Unit Calibration Report Form B.1
Serial No:
Type:
Frequency:
MHZ
Horizontal linearity :
INDICATION
NUMBER
LOCATION
ACCEPTABLE
RANGE
4.0"
3.6 to 4.4
8.0"
7.6 to 8.4
12.0"
11.6 to 12.4
16.0"
15.6 to 16.4
20.0"
19.6 to 20.4
ACTUAL
LOCATION
Internal Reflections:
IIW Block SN:
Reference Level:
dB
Remove search unit from block without changing any equipment settings
Increase the calibrated gain 20 dB more sensitive than reference level
Is the CRT screen area beyond 1/2" sound path and above reference level height free of
any indications? Yes:
No:___
Equipment Status:
As Found
Not Acceptable for Use
As Adjusted
Acceptable for Use
Calibrated By:
Level:
Date:_____________
Reviewed By:
Location:____________________
Page 32 of 40
Form B.2
Ultrasonic Unit Resolution Report Form B.2
Serial No:___________________________
Size
Type
Frequency
Angle(s)
Performed By:
Level:
__ Date:_________
Reviewed By:
Location:_____________________
Page 33 of 40
Annex C
Search unit check
1.
2.
Page 34 of 40
PROBE MENU
(Sub-menu)
Probe Geometry
Wedge Dat
Wedge Geometry
Offset
(tab)
Number of elements
Pitch
Elem 1 Pos
Offset Z
Angle
Probe Delay
(value)
16
0.040
Low End
0
0
0.000s
PART MENU
(Sub-menu)
Part
(tab)
Velocity L
(value)
.1080 in/us
SCAN MENU
(Sub-menu)
Electronic
Scan Pattern
Aperture
(tab)
Type
Focal Point
Wave Type
Angle Start
Number of Steps
First Element
Aperture Size
Aperture Step
(value)
Linear
Unfocused
Longitudinal
0.0 deg
16
1
1
1
DISPLAY MENU
(Sub-menu)
View
Results1
(tab)
Angle Corrected
Reading 1
Reading 2
Reading 3
Reading 4
(value)
On
P%A
PSA
Beam
SA
UT MENU
(Sub-menu)
Base
Pulser
Receiver
Gate mode
(tab)
Display Delay
Voltage
Width
Frequency
TOF mode
(value)
0.0
150V
220ns
2MHz
Flank
Page 35 of 40
Page 36 of 40
3.
Page 37 of 40
Annex D
Drawings
Drawing D.1
Page 38 of 40
Drawing D.2
Page 39 of 40
Drawing D.3
Page 40 of 40
Drawing D.4