Advanced Probes for Austenitic and CRA Weld Inspection Webinar

Advanced Probes for Austenitic and
CRA Weld Inspection
Chris Magruder
July 8, 2014

 Overview of Olympus customer base success in inspection of austenitic and
dissimilar metal welds.
 Overview of new OmniScan 32:128PR module.
 Overview of Olympus DMA (Dual matrix array) and DLA (Dual linear array) probes.
OmniScan MX2 32:128PR – Presentation Objectives
PA2 32:128 PR

OmniScan MX2 32:128PR – Phased Array Beam Validations Review
 A quality beam with precision angle, beam wedge exit, and wedge delay is required
for precision depth and height measurements.
 The variable most responsible for angle error and sizing error is a velocity entered in
the OmniScan that is >50 meterssec out from the actual component velocity.

 The accuracy of the delay law that forms the beam, the beam angle in the material,
and the trigonometry for the sizing precision are all directly related to inputting a
precise component velocity into the OmniScan wizard or PA calculator.
 Using the velocity wizard on an IIW block will not result in improved results and only
validates the instrument’s ability to perform the math on two generic targets.
 The calibration block or component velocity is determined once with precision,
written down, then typed into the software for future use.
 Component velocity doesn’t change with age or when a different OmniScan is used.
 Validation of depth, sound path, surface distance, beam angle, and beam exit is
validation of component velocity that complies with the requirements of any code or
procedure including ASME Sec V Article 4 and similar.
Velocity = 3255 meterssecond
OmniScan MX2 32:128PR – Advanced Probes Velocity Review

 Use the OmniScan set data cursor function on the C-scan to view the data point.
 The data point pictured below is 101mm scan axis, 54 degrees.
 The data points of the deepest notch (5mm deep) generate the C-scan red pixels.
 Visualized in the A-scan and S-scan is the 5mm notch tip, peaked in A-scan.
Notchtipreading
Notch
tip
reading
Notchtipreading
Notch
tip
reading
Notchtipreading
Notch
tip
reading
Notchtipreading
Notch
tip
reading
OmniScan MX2 32:128PR – Beam Validations

OmniScan MX2 32:128PR – Probe FFT Frequency Measurement
 The OmniScan has a built in tool to measure probe frequency called FFT.
 The measurement can only be made live with an unrectified A-scan.
 FFT (Fast fourier transform) is an algorithm used to compute the discrete fourier
transform (DFT) and its inverse for converting time to frequency.
 The OmniScan FFT function is used for measurement of probe center frequency,
bandwidth, maximum frequency, and highlow pass frequency at –6dB and -20dB as
per EN and ASTM specifications.
 The exact probe center frequency and bandwidth will be affected by the material,
sound path and reflector used for testing as attenuation filters upper frequency
bandwidth.
Frequency (MHz)

OmniScan MX2 32:128PR – Probe FFT Frequency Measurement cont.
 Select >GroupProbe>Characterize and turn FFT on.
 The probe frequency statistics are displayed above the frequency waveform.
Frequency (MHz)
Time (usec)

OmniScan MX2 32:128PR – Austenitic and CRA Inspection Overview
 1D linear array probes with shear wave wedges and full V skipping. (SS304, Duplex)
 1D linear array probes with longitudinal wedges and DMA (Dual matrix arrays) in TRL
configuration limited to 1st
leg inspection only. (Inconel, dissimilar metal, SS316,
SS321, etc.)

OmniScan MX2 32:128PR – Linear Arrays for SS304 and Duplex (Demo)

OmniScan MX2 32:128PR – Linear Arrays with Custom Wedge (Demo)
 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 UT axis, the red reference U(r) cursor is placed on the notch tip and the green measure
U(m) cursor is placed at the end of the second skip. (T1 or 2X the thickness)
 Detection, depth, height, and length sizing, and volumetric position are validated for the current
probes, system configuration, and weld bevel.
ID and OD notches 1mm X 5mm

OmniScan MX2 32:128PR – Conventional UT TRL Overview
 Conventional TRL probes (Transmit-receive longitudinal) like pictured below left are commonly used in the power
generation and oil and gas industries for the most difficult to penetrate austenitic materials such some types of
stainless steel, duplex and super duplex materials, and inconel cladded and dissimilar metal welds.
 They are also commonly called “RL” (Refracted longitudinal) probes and typically used for first leg inspection of in-
service pressure piping and vessels for ID connected cracking.
 They come in different size, frequency, focus distance, and angle that are achieved by design of the wedge roof,
squint, and refracted beam angle.
 These conventional probes cost between $1000-$2000 US, have limited range of usefulness for any one inspection,
are limited to first leg inspection only, and require expert inspector with specific training and experience.

OmniScan MX2 32:128PR – Conventional UT TRL Overview cont.
 There are two basic types of conventional RL probes that are designed either for ID and volumetric coverage like the 70RL pictured below
left, or a “Surface creeper” pictured below right that is designed to detect OD connected or near surface flaws.
 Both versions optimize a longitudinal beam that travels at fixed angle and velocity.
 Both versions produce undesirable shear wave beam of approximately ½ the beam angle that complicates the analysis beyond the 1st
leg.
 Olympus is a distributor for Applus RTD who are the leading manufacturer of this type of conventional probe but they can be purchased in all
shapes and sizes from different manufacturers.

 32 Pulsers and 32 Receivers
 Operating temperature -10 to 45°Celsius
 PA high Voltage : 115V
 UT channel high voltage : 300V
 SNR improved by 15dB on UT and PA
 Video filter capability
 Manufactured to EN-12668 (UT)
 Will comply with upcoming EN-12668 (PA)
OmniScan MX2 32:128PR – New OmniScan Module Release
PA2 32:128 PR

 32 Pulsers and 32 Receivers
 Operating temperature -10 to 45°Celsius
 PA high Voltage : 115V
 UT channel high voltage : 300V
 SNR improved by 15dB on UT and PA
 Video filter capability
 Manufactured to EN-12668 (UT)
 Will comply with upcoming EN-12668 (PA)

 Transmit and receive S-scan using different elements on same probe.
(Tomoview acquisition only)
Transm
it
Receive

 Transmit and receive mirror S-scan using different probes. (Tomoview
acquisition only)
Transm
it Receive

 Transmit and receive on different apertures using static focal law.
(Tomoview Acquisition only)
TransmitReceive

OmniScan MX2 32:128PR – Phased Array DMA Overview
 The Olympus A17 DMA TRL phased array probes exploit the same inspection strategy as the conventional TRL probes with
a dual matrix array (DMA).
 Acoustically insulating the receiver from the transmitter in a PC (Pitch-catch) configuration eliminates the need for complex
wedge design to dampen undesirable echoes associated with pulse echo inspection, allows beam exit closer to the weld, and
allows detection and sizing of near surface and surface breaking flaws.
 The DMA TRL configuration improves flaw detection and sizing of coarse grained and difficult to penetrate austenitic
materials through improved signal to noise ratio in the data.
 More energy, less noise.

OmniScan MX2 32:128PR – Phased Array DMA Overview cont.
 The A17 TRL probes can be purchased in a dual or quad configuration as pictured below for one sided or two
sided weld inspection.
 The benefit of the matrix probes all wired into one connector is that no splitter or extension box is required
simplifying the scanner umbilical and reducing cost by eliminating accessories.
 A 32:128PR pulser configuration will drive up to two DMA probes simultaneously. (4 total matrix arrays)
 Although the OmniScan SX is PR capable, because of the 16:XX pulser configuration it is not compatible with
the A17 DMA probe that requires 28 pulsers for transmitter and 28 for receiver.

 Inspection of 50mm ASME VIII SDH in SS316 weld using A17 DMA probes.

 Inspection of austenitic SS347 weld using A17 DMA probes and Jireh chain scanner.
Calibration verification scan on 5% ID notch.
Inspection scan on production weld.

 Inspection of inconel cladded dissimilar metal welds for offshore and subsea pressure piping.
 This application is especially well suited for the DMA inspection as all weld crowns are flushed
allowing multiple one line scans directly on the weld.
 The DMA probes and inspection strategy is possible with either manual encoded or motorized 2
axis scanners.
OmniScan MX2 32:128PR – CRA Dissimilar Metal Weld Inspection

 The A17 DMA has a 7X4 element configuration utilizing 28 elements for the transmitter and 28
elements for the receiver.
 The A17 DMA is currently available in 1.5, 2.25, and 4MHz frequencies and can be made in
other frequencies available from Olympus.
 The A17 DMA has an aperture of 19mm X 12mm for each side of the array.
 Big elements, more energy.

 The number and size of elements in the primary probe axis will determine the limit of beam
angular steering. (35-75 degrees vs. 40-70 degrees)
 The smaller the elements, the better the beam steering.

 The number and size of elements in the secondary probe axis will determine the limit of beam
skew steering. (-50 degrees as pictured below)
 The smaller the elements and larger the pipe diameter, the better the beam steering.

 Additionally, a matrix array probe will also result in improved length sizing as the 2D focal plane
achieves a similar affect as a mechanically focused 1D probe such as pictured below.
 This is especially beneficial for small diameter pipes as length sizing is distorted due to the
internal surface curvature.

 The beam skew angle limit for any probewedgepipe combination are dependent on the size of
and number of elements in the array, the wedge design with regard to wedge height, roof angle,
and squint angle, and also the diameter of the pipe if the wedge is machined with AOD
curvature.
 Below are three S-scan groups of different beam skew that were imported into the OmniScan
one at a time with an independent law file for each.
-30 Degree
-30 Degree
0 Degree +30 Degree
0 Degree
+30 Degree

 The beam skew limits are determined on a calibration block by peaking a SDH or notch for maximum amplitude response while
manually skewing the probe.
 When the signal is peaked, a mechanical measurement is made of the probe angle.
 As the beam steering limits are reached the SNR of the A-scan will deteriorate, gate trigonometry readings will lose precision,
and the ability to calibrate will be lost.
 A flat wedge will on flat plate will enable a wider range of beam skew steering than a wedge machined with AOD curvature for
piping. (A17 + DN55L flat wedge up to 60 degrees skew)
 Trial and error on the calibration block is the only reliable way to test the skew limits of any probe configuration.

OmniScan MX2 32:128PR – CRA Dissimilar Metal Weld Inspection
Weld preparation for hot rolled
cladded longitudinal seem pipe with
smooth interface allows for skipping
off the interface. ID clad layer and
parent material treated as one
material for purpose of inspection.
Weld preparation for inconel overlay and
mechanically bonded pipe by inserting liner in
parent pipe with the clad and the parent material
welded at the junction does not allow for skipping
into weld from ID layer.

OmniScan MX2 32:128PR – CRA Dissimilar Metal Weld Inspection cont.
V-bevel angle is between 30-37 degrees
J-bevel angle is between 3 and 8 degrees

OmniScan MX2 32:128PR – CRA Dissimilar Metal Weld Inspection (Demo)

5L60-PWZ1 (Pulse echo)
A17 DMA (TRL)

 Embedded 10mm X 2mm volumetric flaw in inconel DM weld.

 Embedded 7mm X 2mm volumetric flaw in inconel DM weld.

 Inspection of inconel cladded dissimilar metal welds for offshore and subsea pressure piping.
 This application is especially well suited for the DMA inspection as all weld crowns are flushed
allowing multiple one line scans directly on the weld.
 The DMA probes and inspection strategy is possible with either manual encoded or motorized 2
axis scanners.

 In the dissimilar metal weld below approx. 29 weld passes are visible on the weld fusion line.
 There is a direct relationship between the size of the weld passes and size of the flaws,
especially when measuring side wall lack of fusion.
 Knowledge of the weld procedure is extremely useful and should be weighted when measuring
flaw height, especially when using lower frequency probes or where there is no tip diffraction.
60mm
2mm

 OD notch detection in cladded inconel dissimilar metal weld. (CRA weld)

 In addition to detection of surface breaking flaws and qualification notches, the 75-89 degree S-
scan is also capable of detecting embedded near surface flaws and qualification SDH.

 The A17 DMA when used with the DN80L wedge is designed to produce a 75-89 degree S-scan for detection of surface and near surface flaws.
 This probe wedge combination can detect a surface EDM notch up to 50mm from the wedge face.
 This inspection strategy is used in austenitic materials that cannot be penetrated with shear wave probes, or in inconel cladded components and
dissimilar metal welds where skipping off the bottom for shear wave surface coverage is not possible.
OmniScan MX2 32:128PR – Cladded DM Piping Weld Inspection cont.

Coupling group 1
Surface Group 1 Surface Group 2
SurfaceGroup1
SurfaceGroup2

OmniScan MX2 32:128PR – Focal Law Creation for A17 DMA probe
 There are 4 ways that the focal laws required for the Olympus A17 DMA probes using standard wedges can be
created or loaded into an OmniScan or Focus LT instrument:
1. NDT Setup Builder Software. (Free with PA2 OmniScan purchase)
2. Tomoview Advanced Focal Law Calculator.
3. Pre-configured law files on OmniScan SD Card for A17 DMA probes. (Free with probe purchase)
4. Proprietary customer developed focal law calculator.

 The dual matrix array probes appear in the probe options when generic 32:128 is selected in
>Tools>acquisition unit.
OmniScan MX2 32:128PR – Setup Builder for DMA Probes
 When dual matrix probe type is selected the two A17 DMA probe models and two A17 DMA
wedge models are available in the pull down list.

 DMA TRL probes and wedges are supported in the NDT Setup Builder version 1.0R5T3 or later that is available on the A17 support
flashcard. (Currently not available on web site)
 The following DMA probe models are currently supported in version 1.0R5T3+ :
– 2.25MHz A17 DMA TRL
– 1.5MHz A17 DMA TRL
 The following DMA wedge models are currently supported in version 1.0R5T3+ :
– DN55L0-IHC (Volumetric DMA TRL)
– DN80L0-IHC (Surface DMA TRL)
OmniScan MX2 32:128PR – Setup Builder for DMA Probes cont.

 AOD wedge inspection required consideration in the focal law calculator.
 Entire diameter range from 3.5 -24 inch is covered with 9 unique wedges. (3.5, 4.5, 5.5, 6.625,
8.625, 12.75, 16, 24 inches, and flat)
 Selection of circumferential in the part definition will initiate a focal law for AOD wedge when
probe is skew 90 or skew 270.

 After selection of probe and wedge the group information is populated for either the volumetric
or surface S-scan to include beam and skew angle.
 Currently no probe, wedge, or beam graphics are available and the tool is only for generating
focal laws. No weld overlay or S-scan coverage plot is available until law file is in OmniScan.
 After probe, wedge and beam is selected in SUB, select >File>Export>Laws and copy law file to
UserLaw folder on SD card for OmniScan import.

 The Tomoview advanced calculator .Xcal files for the A17 probe and wedges are available on
the A17 support flash card.
 A17 DMA with DN55L0 wedge is capable of beam steering from approx. 30-80 degrees.
 The optimum angle for detection of surface notch using DN80L0 wedge is 89 degrees. (75-89
degree S-scan)
OmniScan MX2 32:128PR – Tomoview Advanced Calculator (Demo)

 Each directory on the flashcard contains the OmniScan Opd file, the law file that was used to
create it, and an image of the SNR of a calibration reflector at the focal depth.
 >Load file in OmniScan from data directory on flashcard>Deselect pause.
OmniScan MX2 32:128PR – Preconfigured OmniScan A17 SD Card (Demo)

OmniScan MX2 32:128PR – DLA Probes Overview

OmniScan MX2 32:128PR – DLA Probes Overview cont.

Free Download Manager.lnk
Thank you!
Questions or comments: Chris.magruder@olympusndt.com
www.olympus-ims.com

Advanced Probes for Austenitic and CRA Weld Inspection Webinar

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Advanced Probes for Austenitic and CRA Weld Inspection Webinar