”Advances in Phased

Arrays and Other NDT

Technologies”
18th World Conference on
NonDestructive Testing

Durban, South Africa,

April 16-20, 2012
 Presentation Outline
• Olympus - What we manufacture
• A brief introduction to phased arrays
• Olympus NDT phased array equipment
• Practical solutions to common inspection
problems
– OmniScan MX2
– EPOCH 1000i
– Eddy current array (ECA)
– PipeWIZARD V4
– In-line inspection (pipe mill) developments
– Remote Video Inspection (RVI)
– Innov-X X-ray florescence (XRF) analyzer
Olympus Corporation
Our Mission
Olympus is a precision technology leader, designing and
delivering innovative solutions in its core business areas:
Cameras and Audio, Industrial Testing Instruments,
Life Science Imaging Systems and Medical and
Surgical Products.
Our focus is on enhancing people's lives every day. We are a
company committed to helping people enjoy the continuum of
life. Our relationship with our shareholders, customers,
employees and business partners is at the center of
everything we do.
Cameras & Audio
Olympus continues to innovate products and technologies that expand
the boundaries of digital photography and audio capture.

This includes award-wining digital compact cameras,

interchangeable lens camera systems for professional and consumer
markets, and related underwater products and accessories.

For additional information, visit getolympus.com.

Life Science Imaging Systems

Olympus designs and manufactures

comprehensive microscope-based systems for
biomedical research, diagnosis and education.

Combining this expertise with

tomorrow’s genomic, proteomic, and internet-
based technologies, Olympus is paving the
way for future advances in life
science.
Medical & Surgical
Olympus offers
solutions in the Olympus, which incorporates surgical market leader Gyrus ACMI,
fields of: develops solutions for healthcare professionals that help
• Gastroenterology improve outcomes and enhance quality of
• Gynecology life for their patients. By enabling less invasive procedures,
innovative diagnostic and therapeutic endoscopy and early stage
• ENT
cancer evaluation and treatments, Olympus is transforming
• Pulmonology
• Surgery the future of healthcare .
• Urology
Industrial Products

Olympus provides an industry-leading

portfolio of innovative test, measurement,
and imaging instruments.

Innovative testing instruments

are used in industrial and research applications
ranging from aerospace, power generation,
petrochemical, civil infrastructure and automotive
to consumer products. Olympus instruments
quality of products
contribute to the
and add to the safety of
infrastructure and facilities.
Industrial Solution Technologies
Our leading edge testing technologies include :

9 Conventional Ultrasound
9 Eddy Current and Eddy Current Array
9 High Speed Video
9 Microscope Solutions
9 Optical Metrology
9 Phased Array
9 Remote Visual
9 X-ray Fluorescence (XRF) / X-ray Diffraction (XRD)
Industrial Products
Olympus testing and imaging products
include:

9 Flaw Detectors
9 Integrated Inspection Systems
9 Thickness Gages
9 Advanced NDT Solutions

9 Microscope Solutions
9 Optical Metrology

9 Video Scopes, Borescopes

9 High Speed Video Cameras
9 XRF / XRD Analyzers
Industry Solutions
Industries that Olympus provides solutions for include:
How Phased Arrays Work –
Beam Focusing

•large range of
focal depth
(focusing)

• adjustable
each pulse.
How Phased Arrays Work –
Beam Steering

• large range of
inspection
angles
(sweeping)

• multiple
modes with a
single probe
(SW, LW)
 Common Probe Geometries
Linear

1D linear array 2D matrix

Circular

1D annular array 2D sectorial annular

 Key Concept

• Phased arrays do not change the

physics of ultrasound
• PA’s are merely a method of generating
and receiving a signal
• (and also displaying images)
• If you obtain X dB using conventional UT,
you should obtain the same signal
amplitude using PA’s.
 How Phased Arrays Work

• The operator inputs the focal depth(s),

inspection angle(s) and/or couplant, type of
scan, plus how many and which elements
are to be fired.
• The operator must also input details on the
array and wedge, OR the system has probe
recognition (as with OmniScan).
• The phased array calculator calculates what
time delays to apply to each element.
 Defining depth and refracted angle

Snell point X axis or Scan axis

Interface
Law scan offset

Depth Focal point (X,Z)

Angle

1. The calculator searches for the Snell point.

2. Then, the X, Z point of the focal point is determined.
3. The wedge delay is calculated and the focal law is offset
accordingly.
 Calculator
The focal law (difference in delay to reach the focal
point) for each element is then calculated.
The actual path between two points taken by a beam of
light (or sound) is the one that is crossed in the shortest
time.

X axis or Scan axis

Interface
Time

Sound path (time)

Focal point (X,Z)
In wedge
In Element number
materiel
Design Parameters of Phased-Array
Probes
A
e

p g
Design Parameters of Phased Array
Probes

• WEDGE
PARAMETERS Wedge (vw)

– Velocity in wedge (vw) inc

h1
– Wedge angle (ω)
– Height of first element x1
ref

(h1)
– Offset first element (x1)
Implications of Element Size on Beamforming

A
A
 Point A is OK
B because all rays are
within elemental
beamwidth
α  Point B yields
unexpected results
because rays are
d
outside elemental
0.41λ
sin (α ) = beamwidth
d
 Angle Range for S-scan Calibration

• Check manufacturer’s angle range in

catalog
• For Olympus NDT, angle range is based
on physics of wedge
• Then calibrate; if cannot calibrate over
designated range, then cannot use full
range
• Effective range may depend on many
factors, including material
• Also, “sparse” arrays possible for large
numbers of elements.
 Electronic Scanning

• Scans the beam along one

axis of an array without any
mechanical movement.
• The movement is performed
only by time multiplexing the
active element
• The beam movement
depends on the probe
geometry
 Electronic Scanning of Welds

• Electronic (linear) scanning can easily emulate

typical ASME-type 45 and 60o shear wave
inspections
• Much faster than raster scanning.
• Typical weld inspection requires two or more angles.
• Need to cover weld, HAZ, any position errors =>
significant amount of scanning
 Sectorial Scanning (S-scans)

• Sectorial scanning is the ability

to scan a complete sector of
volume without any probe
movement.
• Useful for inspection of
complex geometries, or those
with space restrictions
• Combines the advantages of a
wide beam and/or multiple
focused probes in a single
phased array probe
 Sectorial Scans on Welds
• S-scanning – changing the incident angle without
changing position – can be used for a variety of
inspections, including welds.
• Note limitations on bevel angle incidence => multiple
S-scans.
Tandem Probes for Vertical Defects
 TOFD using Phased Arrays
Transmitter Receiver
Lateral wave

Back-wall reflection

LW BW

Upper tip Lower tip

Determining Defect Location
Defect Sizing using S-scans

Defect tip
signal –
easy to
identify and
size

Crown
defect –
clearly
located

T1 designation shows “top” or cap

Combined Scans Give Improved POD
 Array Grating Lobes

Array Main
n=8
p=9
lobe lobe Influence of pitch p
(for A = fixed):
n=12
p=6
– If p ↓, or n ↑
then lobe distance
n=16
p=4.5
↑
and lobe
n=20
p=3.6
amplitude ↓

Solution: Design
array lobes out.
 All the usual ultrasonic limitations …
• Coupling
• Frequency, attenuation etc.
• Scanning speed
• Digitization rates
• Ultrasonic wrap-around
• Acoustic impedance mismatch
requirements
• Dead zones
• Etc.
 Additional Limitations

• One scan sees it all … too simplistic

• S-scan angular range
(mechanics, codes, calibration)
• Focusing
• TOFD from PA
• One array does everything
• TRAINING
=> Overall, excellent tool for
inspections.
New equipment and solutions
 OmniScan MX2

• New development at Olympus NDT

• Offers better screen size and visibility
• Same or better operating capabilities as
original MX
• Same Code compatibility as MX
• Touch screen capabilities
• Better data handling
 OmniScan MX2

OmniScan MX photos of
weld inspections.
Focus LT ®
•Powerful Software for
Data Acquisition and
Analysis
•Advanced PA
Calculator (1D - 2D -
2D/TRL)
•Flexible SDK (NDT
Data Access and
Remote Control)
 Turbine inspection with TV
Geometry : Types of defects
– Length : 19000 mm Slag, cracks
– Max. Diameter : 3500 mm pores & segregations
- Max. Weight : 120 tons
- Defect size : ERS 1.0mm to 1.8mm depending on material
 Turbine inspection with TV
• Problem:
– Large quantity of data (A-Scan & C-Scan) due to
dimensions of the piece to be inspected
– Detection of defects close to the back wall on
non parallel parts (fixed gate length)
– TCG implementation (DGS to TCG conversion)
Solution:
•Bigger file size up to 2 GB
•Conditional A-Scan to reduce file size
•Offline gate length modification for parts
•Import/Export TCG
WeldROVER for Large Diameter Pipes
Automated pipe weld
scanner for diameters
<100 mm
Easy to operate: two
buttons and
automated connection
to OmniScan
Uses laser beam for
tracking with manual
adjustments
COBRA for Small Diameter Pipes
Semi-automated
scanner for
inspecting small
pipe welds
From diameters of
20 mm to 110 mm
and up
Low profile: <12.7
mm clearance
Focused probes for
better defect
sizing.
 PA Corrosion Mapping Components

¾ OmniScan MX or MX2
16:128 or 32:128

¾ CHAIN Scanner

¾ HD Mapper & HydroFORM

HydroFORM - A, B & C Scans Simultaneously
 EPOCH 1000i Feature Introduction

Olympus NDT introduces the latest feature for the

EPOCH 1000i phased array flaw detector:

Encoded C-scan

Weld Overlay
 Encoders on the EPOCH 1000i

• Many encoders can be used

• Simplest Olympus example is the Mini-
Wheel Encoder
• Requires adapter cable from EPOCH 26-
pin port on back of unit to OmniScan style
9-pin encoder connector
 Data Review from C-scan

• Exciting enhancements to data review

after C-scan acquisition.
– Storage of all A-scans from C-scan means
EPOCH 1000i can recreate S-scan from a
selected section of the C-scan
 Eddy Current Array Flexible Probe

32 Elements
3mm coils diameter
51mm of coverage
Very flexible
Two row of coils to improve the
resolution
ECA Blade Inspections
ECA Weld Inspection
ECA Customizable profile
 PipeWIZARD V4 for Pipeline Girth Welds

Built upon the proven PipeWIZARD®, the PipeWIZARD V4

system offers a highly reliable solution for onshore and
offshore inspections in harsh environments.

PWZ-V4
PWZ-V2
 PipeWIZARD V4
- FocusLT 64:128 rackmount is
based on OmniScan technology.
¾ Strong field experience :
> 200 units in the field
> 1.5 million welds inspected
> 300 operators trained on PipeWIZARD
¾ Designed for harsh
environments : Middle-East
deserts, Brazil forests, Siberian
colds, salty-air offshore laybarges.
¾ TomoView 2.8: Now operating on
upgradeable version of software
¾ Umbilical cable has been
redesigned and field tested for
more than 3 years.
 In-Line Inspection: Water Wedge Concept
• Unique Water Wedge concept holding different type
of probe holder and cylindrical PA probes (Aqualine).
• Pneumatic suspension follows the pipe movement
and raises the Water Wedge in case of scarfing
window or joint weld between coil.
 ILI: Automatic Calibration Sequence

• Automatic gain
compensation each aperture
and detection gate;
• Automated calibration
sequence capability directly
on the inspection head;
• Calibration results presented
as an amplitude bar graph
for quick analysis;
• Detailed calibration report
about gain compensation
per aperture and per
detection gate.
 ILI: Flaw Detection Results
• Calibration on N10 notches – Detection TDH 1/8, 1/16

L-CW ID Strip Chart

L-CW OD Strip Chart

L-CW ID C-Scan

L-CW OD C-Scan

L-CCW ID Strip Chart

L-CCW ID Strip Chart

L-CCW ID C-Scan

L-CCW ID C-Scan
ILI: Automatic Detection of Scarfing Windows

ƒ Automatic systems integrated

onto the ERW-In Line for
protection of the inspection head
against openings cut on pipes for
adjusting the welding process.
ƒ System based on EC encircling
coil and Nortec 500 instrument
integrated in an industrial
enclosure and interfaced with the
system’s PLC.
 ILI: Phased Array Ultrasonic Concept
• Phased Array solution for Square Bar Inspection using
Linear probes
– Improve the detection performances (up to FBH 0.8 mm)
– Minimize the uninspected area (include the corner
inspection)
LW Volume Inspection SW Surface Inspection Corner Inspection

BW Dead Zone 5 mm No Dead Zone except Limited Corners

plus Corners Corners Dead Zone
 ILI: Sample Round Bar Inspection
Solution

• Immersion tank round

bars < 65 mm diameter
 3D Videoscope and other RVI Technology

• Basic Videoscope Structure

• Stereo Imaging - 3D Eye Trek
• Microscopic 3D mapping
• Articulation Advances
– Pneumatic Articulation
– Articulating Guide Tubes
– Low force direct articulation IPLEX Ultralite
 Basic Videoscope Structure

Olympus constantly
fine tunes the basics
of Videoscope
Structure, with small
advances to make
scopes more user
friendly. From power
assisted True Feel
Articulation to Taper
Flex© Technology. rigid

TF

Competitive
products

flexible
distal end proximal end
 Stereo Imaging

• Well established
• Repeatable
• Provides 3D reference
• Precision largely depends on
distance between lens.
Stereo Imaging – 3D Eye Trek
•Allowed the very first head-
worn 3D view of an inspected
area.
•Arrived before its time,
inspectors had a tendency to
move their head, not the
scope.
•New technologies can give
this Olympus Innovation new
uses.
 High Speed Video
i-SPEED 3
High Speed Video Camera
High Speed Video
Microscope 3D Mapping
 RVI - Articulation Advances

• Pneumatic
Articulation • Articulating • Reduced Force
Guide Tube Articulation
 Olympus Innov-X: Portable X-ray
Florescence Analyzer
DELTA Line Lambda X‐5000

In‐Xitu Terra
 Typical XRF Field Applications

Alloy QA/QC & PMI Geochemistry Scrap  Mining

Recycling

Forensics
Consumer 
Historic 
Environmental Safety
Conservation
 General XRF NDE

• Alloy Verification - not

certification

• Testing: Pipes, flanges, valve

components, welds, general
materials

• Repair: Material Verification

for existing components

• Suppliers: Quality Control –

Verified at Receiving
 Summary

• Many new developments at Olympus NDT

• Particularly in phased arrays on pipelines,
pipe mills and standard apps with new
instruments and mechanics
• Also, developments in flexible eddy
current arrays, remote visual inspection,
and X-ray fluorescence
• More developments to come!
 Thank you

Have a good day and enjoy the

rest of the conference.