OmniScan SX \ MX2 Training Program

Phased Array Analysis Length Sizing

Chris Magruder

V4.1R3

OmniScan SX\MX2 Training Length Sizing - Cursors

In a typical weld inspection, flaw length sizing is performed on the weld line
represented by the scan axis available on the C-scan and B-scan.
The three cursors used for flaw length sizing are:
Data cursor. Use to visualize the A-scan and S-scan at a given data point.
Scan axis reference cursor. S(r)
Scan axis measure cursor S(m)
Amplitude C-scan

Scan axis reference curser S(r)

Scan axis measure curser S(m)

Focal law data cursor

Scan axis data cursor

PA Weld.Opd

OmniScan SX\MX2 Training Length Sizing - Readings

The primary readings associated with flaw length sizing are:
S(r) Position of the reference cursor on the scan axis.
S(m) Position of the measurement cursor on the scan axis.
S(m-r) The delta between the scan axis reference and measurement cursor.

In the lack of side wall fusion example below, the data cursor is positioned on the
data point of maximum amplitude of the flaw and the reference and measure cursors
are placed on the edges of the flaw.
The flaw starts at
153mm and ends at
186mm for a total length
of 32mm.

S(m-r)

S(r)
PA Weld.Opd

S(m)

OmniScan SX\MX2 Training Length Sizing Example 1

For linear flaws such as side wall lack of fusion and inadequate penetration, a -3 dB
to -6 dB drop technique will produce accurate sizing for typical inspections.
Trial and error with destructive testing and up front engineering using EDM notches
on welded samples will take into account all aspects of the inspection for length
sizing optimization to include:

Weld bevel and process.

Probe size and frequency.
Inspection resolution.
Pipe diameter.
Beam focus.
Scan plan strategy.

S(m-r)
S(m-r)

S(r)
S(r)
PA Weld.Opd

S(m)

OmniScan SX\MX2 Training Length Sizing Example 2

For indication such as the intermittent lack of fusion below, a dB drop technique is
not possible and the extremities are determined from a rapid drop technique on the
first and last indication.
To the extent an indication is one intermittent flaw or a series of individual flaws to
be analyzed independently is determined by the referencing code or procedure.

S(r)

CobraA15_One Sided.Opd

S(m-r)
S(m)

OmniScan SX\MX2 Training Length Sizing Inspection Resolution

The length sizing accuracy is directly related to the inspection resolution on the scan
axis that was entered in >Scan>Area>Scan Resolution.
In the example below, the inspection was performed with a scan resolution of .5mm.
Every focal law on every group is recorded at intervals of .5mm on the scan axis as
the probe or scanner is moved.
This results in a length sizing accuracy of +\- 1mm for flaws measured on the scan
axis.

CobraA15_One Sided.Opd

OmniScan SX\MX2 Training Length Sizing Example 3

In the example below, lack of root fusion is measured by a -6 dB drop using the
color palette of the C-scan and observing the S-scan and A-scan.
The maximum amplitude of 84.9% was detected at 66 degrees at 284mm.
The extremities of the flaw were identified at approx. 40% amplitude and marked
with the scan axis reference and measure cursors.

S(r)

S(m)
S(m-r)

CobraA15_One Sided.Opd

OmniScan SX\MX2 Training Length Sizing Inspection Resolution

The smallest number that can be entered into the inspection resolution is dependent
on the resolution of the encoder.
In the example below, the encoder has a resolution of 12 steps per mm that results
in a minimum resolution of .08mm. (1mm \ 12 steps = .08mm)
However most inspections are recorded at a 1mm resolution regardless of encoder.

PA_Weld.Opd

OmniScan SX\MX2 Training Length Sizing Curved Arrays (CCEV)

Length sizing accuracy is greatly improved by the use of internally focused curved
arrays, especially on small diameter piping where the reflected signal is skipping off
a small curved spot on the pipes inner diameter surface.
Both the Olympus Cobra small diameter piping system and Pipe Wizard pipeline
girth weld system utilize internally focused curved arrays for improved length sizing
accuracy.
C-scan length sizing with flat probe. S(m-r) = 4.2mm

C-scan length sizing with internal radius focused probe. S(m-r) = 2.4mm

OmniScan SX\MX2 Training Length Sizing Example 4

In this example, a 1mm X 5mm EDM notch is placed on the OD centerline of a 4
inch diameter CuNi (Copper-nickel) weld to validate detection, coverage, sizing, and
volumetric position.
On the scan axis, the red reference
cursor S(r) is placed on the notch start
position and the green measure cursor
S(m) is placed at the notch end position.
Notch length in S(m-r) = 5mm.

Centerline 1mm X 5mm

OD notch

Small diameter length sizing

distortion can be overcome by
use of laterally focused curved
array probes such as the
Olympus CCEV A15 probes
pictured right.
Trial and error on test specimens
validated a -6dB drop technique
for precision length sizing.
S(r)

S(m)

S(m-r)
CUNI_A15_.Opd

OmniScan SX\MX2 Training Length Sizing dB Drop Techniques

Question: Which of the below is the preferred method for length sizing weld flaws?
1.
2.
3.
4.

-3 dB drop technique.
-6 dB drop technique.
Rapid drop technique.
Technique developed from up front engineering on specific weld using specific
equipment.

OmniScan SX\MX2 Training Length Sizing dB Drop Techniques cont.

Question: Which of the below is the preferred method for length sizing weld flaws?
1.
2.
3.
4.

-3 dB drop technique.
-6 dB drop technique.
Rapid drop technique.
Technique developed from up front engineering on specific weld using specific
equipment.

Answer: 4. There is no one technique that will provide accurate length sizing
for every weld. Length sizing accuracy is dependent on my factors including
pipe or vessel diameter, weld thickness and bevel, weld process, probe size,
frequency and focus, type of defect, etc.
Where precision length sizing is required it is best developed by trial and error
using EDM notches and embedded flaw test specimens of same weld bevel.

?
?

OmniScan SX\MX2 Training Length Sizing Index Axis Measurement

Sizing is also available on the index axis with the following cursors:
I(r) Position of the reference cursor on the index axis.
I(m) Position of the measure cursor on the index axis.
I(m-r) Delta between the reference and measure cursors on the index axis.

I(r)

I(m)

I(m-r)

TF_32EL_HighResNotch.Opd

OmniScan SX\MX2 Training Length Sizing Off Axis Measurement

Sizing is also available for off axis indications with the following cursors:
Crosshair position of the reference cursor on the index and UT axis.
Crosshair position of the measure cursor on the index and UT axis.
I*U(m-r) Delta between two cursor crosshair positions.

I(r)

I(m)

I(m-r)
Reference cursors
crosshair position

Measure cursors
crosshair position

TF_Manual Inspection12mm.Opd

OmniScan SX\MX2 Training Length Sizing Example 5

In this example the color palette was manipulated to display a -6 dB drop for length
sizing on the scan axis.
This can be done directly on the color palette bar on the right side of the C-scan or
in >Display>Properties>Category: Color Palette>Start and >End.

OmniScan SX\MX2 Training Length Sizing Example 5

Because the of the orientation of the planer flaw is perpendicular to the beam, a -6
dB drop sizing technique for side wall lack of fusion is very accurate.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Flaw max amplitude (A%):

Flaw volumetric position:
Embedded \ Surface connected?:
Flaw start on scan axis (Sr): 54.5mm
Flaw end on scan axis (Sm): 64.5mm
Flaw length (Sm-r): 10mm
Flaw depth (DA):
Flaw upper extremity (Ur):
Flaw lower extremity (Um):
Flaw height (Um-r):
Flaw type:

OmniScan SX\MX2 Training Depth and Height Sizing Multigroup Analysis

The scan axis cursors are linked for all groups. When two sided data is available
the cursors are positioned on the flaw extremities based on analysis of both groups
simultaneously by observing the C-scan and S-scan data for both groups.
The flaw start and stop position on the scan axis may be determined from two
separate groups

Crack stop position on group 1

Crack start position on group 2

TF_2XSEC.Opd

OmniScan SX\MX2 Training Length Sizing Supplemental TOFD

TOFD greatly assists in length sizing accuracy and only uses 1 of the 256 available
A-scans possible in the OmniScan.
TOFD typically uses probes that are smaller and higher frequency than conventional
and phased array pulse echo angle beam inspection probes.
Combining those probe characteristics and the fact the TOFD is not dependent on
flaw orientation, length sizing is greatly improved by the benefit of having both
technologies available during the inspection.

Questions or comments:
PhasedArraySupport@Olympusndt.com

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V4.1R3