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Pressure Vessel
Technology
Technology Review
Michael Moles
e-mail: michael.moles@rd-tech.com
R/D Tech, 73 Superior Avenue, Toronto, ON M8V 2M7,
Canada
Nol Dub
e-mail: noel.dube@rd-tech.com
Simon Labb
e-mail: simon.labbe@rd-tech.com
R/D Tech, 505 boul. du Parc Technologique, Qubec, PQ
G1P 4S9, Canada
Ed Ginzel
e-mail: eginzel@mri.on.ca
Materials Research Institute, 432 Country Squire Road,
Waterloo, Ontario N2K 4G8, Canada
Fig. 1 Schematic showing generation of electronic and sectorial scans using phased arrays
Overall, the use of phased arrays permits maximizing defect detection while minimizing inspection time.
Ultrasonic PAs are similar in principle to phased array radar,
sonar, and other wave physics applications; however, ultrasonic
development is behind the other applications due to a smaller
market, shorter wavelengths, mode conversions and more complex components. Several authors have reviewed applications of
ultrasonic phased arrays 810, though industrial uses have been
limited until the last few years.
Phased arrays use an array of elements, all individually wired,
pulsed and time-shifted. These elements are typically pulsed in
groups from 4 to 32, usually16 elements for welds. In order to
make a user-friendly system, a typical setup calculates the timedelays from operator-input, or uses a pre-defined file: Inspection
angle, focal distance, scan pattern, etc. see Fig. 1. The time delay
352 / Vol. 127, AUGUST 2005
values are back calculated using time-of-flight from the focal spot,
and the scan assembled from individual Focal Laws. Time delay
circuits must be accurate to around 2 nanoseconds to provide the
accuracy required.
While it can be time-consuming to prepare the first setup, the
information is recorded in a file and only takes seconds to re-load.
Also, modifying a prepared setup is quick in comparison with
physically adjusting conventional transducers.
Types of Scans. Using electronic pulsing and receiving provides significant opportunities for a variety of scan patterns.
Electronic Scans
Electronic scans are performed by multiplexing along an array
see Fig. 2. Typical arrays have up to 128 elements, pulsed in
groups of 816. If the array is flat and linear, then the scan pattern
is a simple B-scan; if the array is curved, then the scan pattern will
be curved. Electronic scans are straightforward to program. For
example, a phased array can be readily programmed to inspect a
weld using 45 deg and 60 deg shear waves, which emulate conventional manual inspections.
Combined Scans
Combining electronic scanning, sectorial scanning and precision focusing leads to a practical combination of displays. Optimum angles can be selected for welds and other components,
while electronic scanning permits fast and functional inspections.
Combined raster scans can be performed, e.g., 45 deg and 60 deg
plus TOFD see Fig. 4. A related approach applies to tailored
weld inspections, where specific angles are required for given
weld profiles see Tailored Inspections below; for these applications, specific beam angles are programmed for specific weld fac-
ets at specific locations, which can be performed using an automated set-up program and the appropriate weld profile.
Fig. 6 Typical top, side, end view with waveform. TOFD can
be added, along with other displays.
Speed: Scanning with phased arrays is an order of magnitude faster than single transducer conventional mechanical
systems, with better coverage;
Flexibility: Setups can be changed in a few minutes, and
typically a lot more component dimensional flexibility is
available;
Inspection angles: A wide variety of inspection angles can
be used, depending on the requirements and the array;
Small footprint: Small matrix arrays can give infinitely
more flexibility for inspecting restricted areas than conventional transducers.
Fig. 7 Typical TOFD image showing OD, ID and top and bottom of defects
Delivery Systems
Fig. 8 Schematic of zone discrimination. Top: Selection of
zones. Bottom: Position and angles for zone discrimination
inspection
Fig. 11 Belt scanner for pipeline AUT with probe pan attached
Other options include magnetic wheel scanners, robots, pipe scanners as shown in Fig. 11, handscanners, and even a low-cost
encoded array see Fig. 12.
All the scanners have their advantages and disadvantages, in
terms of cost, convenience, accuracy.
Sample Results
ASME Raster Scans on Thick Section Welds. Figure 13
shows a typical top, side. TOFD display with dual dedicated
TOFD pairs for improved detection and sizing. Weld overlays
more visible in the top, side, end view in Fig. 6 assist the
operator in interpretation. Full waveform data is collected, and
scanning rates are 10 mm/ s or higher, depending on data transfer
rates, wall thickness, number of waveforms, etc. Table 1 shows a
comparison of some of the key parameters from PV and pipeline
inspections using phased arrays. Pipeline multiprobe systems are
Fig. 13 Above shows a typical top, side view at left, combined with a twin TOFD view at right. The top, side view is
made by merging both the 45 and 70 deg data.
of
pressure
vessel
and
pipeline
Fig. 14 Typical AUT display, with dual gate strip charts, mapping channels, TOFD, position and coupling. This display
shows multiple boxed defects in red.
lighter, faster, can scan almost any diameter and wall thickness, can provide improved imaging and special setups, and
use automated setups for convenience.
3. For ASME raster inspections of thick-section welds, phased
arrays offer flexibility, imaging, and speed.
4. In all cases, TOFD is strongly recommended as a no cost
addition.
Fig. 15 Customized weld inspection using two different size
arrays due to geometric constraints
Conclusions
Ultrasonic phased arrays have several advantages over conventional AUT and radiography for pressure vessel weld inspections.
1. In general, phased arrays:
a Are faster;
b Are more flexible, both in setups and in component
geometries;
c Can optimize defect detection by tailoring inspection
angles and focal spot size;
d Have a smaller footprint.
2. For zone discrimination scans, probe pans are smaller,
References
1 ASME Boiler and Pressure Vessel Code Section V, 2001, 2003 rev., American
Society of Mechanical Engineers, New York.
2 ASTM, American Society for Testing and Materials, ASTM E-1961-98, Standard Practice for Mechanized Ultrasonic Examination of Girth Welds Using
Zonal Discrimination With Focused Search Units, September 1998.
3 API, American Petroleum Institute Standard 1104, Welding of Pipelines and
Related Facilities, Nineteenth Edition, September 1999.
4 DNV, Det Norske Veritas OS-F101 Submarine Pipeline Systems, January
2000.
5 ISO 13487, International Standard ISO 13847:2000 Technical Corrigendum 1,
Petroleum and Natural Gas IndustriesPipeline Transportation Systems
Welding of Pipelines, Published 2001-12-15.
6 ASME, Code Case 2235-4, Use of Ultrasonic Examination in Lieu of Radiography, Section I and VIII, Divisions 1 and 2, November 30, 2001, American Society of Mechanical Engineers.
7 R/D Tech, Inc., Introduction to Phased Array Ultrasonic Technology Applications, Coordinator, N. Dube, R/D Tech August 2004.
8 Clay A. C., Wooh, S-C., Azar, L., and Wang, J-Y., 1999, Experimental Study
of Phased Array Beam Characteristics, J. Nondestruct. Eval., 182, p. 59.
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http://www.ndt.net/article/v04n04/wuesten/wsuesten.htm
10 Lafontaine G. and Cancre, F., Potential of Ultrasonic Phased Arrays for
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2000; http://www.ndt.net/article/v05n10/lafont2/lafont2.htm.
11 Ciorau P., MacGillivray, D., Hazelton, T., Gilham, L., Craig, D., and Poguet,
J., In-Situ Examination of ABB l-0 Blade Roots and Rotor Steeple of LowPressure Steam Turbine, Using Phased Array Technology, 15th World Conference on NDT, Rome, Italy, October 1115, 2000.
12 Moles M. D. C., and Zhang, J., 2005, Construction Weld Testing Procedures
Using Ultrasonic Phased Arrays, Mater. Eval., 631, p. 27.
13 Dub, N., Electric Resistance Welding Inspection, 15th WCNDT, Rome,
Italy, October 2000.
14 Jacques F, Moreau, F., and Ginzel, E. A., 2003, Ultrasonic Backscatter Using
Phased ArrayDevelopments in Tip Diffraction Flaw Sizing, Insight, 4511,
p. 724.
15 Gross B., OBeirne, J., and Delanty, B., Comparison of Radiographic and
Ultrasonic Inspection Methods on Mechanized Girth Welds, Pipeline Technology Conference, 1517 October, 1990, Ostend, Belgium.
16 Connelly, T., Update on the Alliance Pipeline, International Conference on
Advances in Welding Technology, October 2628, 1999, Galveston, Texas,
sponsored by EWI and AWS.
17 Morgan L., Nolan,P., Kirkham, A., and Wilkinson, P., The Use of Automated
Ultrasonic Testing AUT in Pipeline Testing, Insight November 2003.
18 Moles, M. D. C., and Labb, S., Automated Ultrasonic Inspection of Pressure
Vessel Welds, 16 WCNDT, Montreal, Canada, August 30Sept 3, 2004.