Procedure For Phased Array

SIEVERT ARABIA LIMITED
Dammam - Saudi Arabia Document No.

SAL-TECH-SOP-PA-006-2014 19th Mar 2014
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PROCEDURE FOR AUTOMATED PHASED ARRAY
INSPECTION OF PIPING WELD JOINTS ISSUE 01, REV. 00 Page 1 of 111
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Shape Diameter Frequency Length Width
Round 6.35mm 5Mhz 0mm 1mm
Client Sadara
Contractor Daelim
Sub-Contractor Sievert Arabia Limited
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PROCEDURE FOR AUTOMATED PHASED ARRAY INSPECTION OF PIPING

WELD JOINTS
THIS OPERATING PROCEDURE IS CONTROLLED BY THE SIEVERT ARABIA LIMITED AND MAY NOT BE
AMENDED, REVISED OR ALTERED IN ANY OTHER WAY WITHOUT THE CONSENT OF THAT COMPANY.
THE SIGNATURES BELOW AUTHORISE ALL PAGES OF THIS PROCEDURE FOR USE FROM THE DATE OF
APPROVAL SHOWN
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Issue Revision Date Remarks

01 00 19 Mar 2014
th
Initial issue
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Prepared by Reviewed & Approved by

Name Sumit Das A. Habibullah
ASNT Level III
Position ASNT Level II
(Certificate No. 195519)
Signature
Date 19.03.2014 19.03.2014

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CONTENTS
1.0 SCOPE: ………………………………………………………………………… 4
2.0 PURPOSE: ……………………………………………………………………. 4
3.0 REFERENCE: …………………………………………………………………. 4
4.0 TABLE OF ESSENTIAL VARIABLES FOR QUALIFICATION OF

PROCEDURE: ………………………………………………………………… 5
5.0 SAFETY: …………………………………………………………………….. 6

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6.0 PERSONNEL QUALIFICATION: …………………………………………… 6
7.0 PREPARATION OF EXAMINATION AREA…………………………… 7
8.0 INSPECTION EQUIPMENT AND ACCESSORIES: ……………………… 7
8.1 ACQUISITION UNIT & SOFTWARE: ……………………………………… 7
8.2 SCANNER DETAILS: ……………………………………………………... 8
8.3 SEARCH UNIT & WEDGES: ………………………………………………. 9

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9.0 COMPUTRIZED IMAGING TECHNIQUE: ………………………………… 9
10.0 COUPLANT: ………………………………………………………………….. 9
11.0 CALIBRATION BLOCKS: …………………………………………………… 10
12.0 QUALIFICATION BLOCKS: ………………………………………………… 12
13.0 CALIBRATION: …………...…………………………………………………. 12
13.1 EQUIPMENT CALIBRATION: ……………………………………………. 12

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13.2 ENCODER CALIBRATION: …………………………………………………. 19
13.3 VELOCITY & WEDGE DELAY CALIBRATION: ………………………... 19
13.4 SENSITIVITY CALIBRATION: ……………………………………………... 19
13.5 TCG CALIBRATION……………………………………………………….. 20
14.0 CALIBRATION CONFIRMATION: …………………………………………. 21
15.0 SCAN PLAN: ………………………………………………………………….. 21

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16.0 EXAMINATION COVERAGE & SCANNING: ……………………………... 22
17.0 RECORDING AND EVALUATION: ………………………………………… 23
18.0 ACCEPTANCE CRITERIA: ………………………………………………….. 28
19.0 REPORTING: …………………………………………………………………. 28
ANNEXURE-1……………………………………………………………………………….. 30
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1.0 SCOPE
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This procedure describes the requirement and application of automated Phased Array
examination for detection and evaluation of discontinuities within weld metal and
heat affected zone of piping weld joints. This procedure, when used in combination
with specified scanplan is applicable for joint configuration and thickness range as per
table given below. Work to this procedure will be in compliance with ASME B31.3
Size Material Thickness Remarks

Ø 1” to Ø 102” CS/AS/SS 5.49 mm to 40.69 mm --
2.0 PURPOSE
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This procedure shall apply to the general aspect of ultrasonic examination of welds
using Phased Array technique and Omniscan equipment coupled with Weld ROVER
or Magman Scanner. However the same fixture device to be used for examination,
that shall be used during the procedure qualification. Main objective of this procedure
is to-
 Monitor the performance of the equipment used
 Set the display and acquisition parameter
 Provide details for calibration and sensitivity
requirement
 Describe the recording criteria
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 Give the details of the equipment used and extent of

volume coverage.
Since the qualification of this procedure is unique to the Omniscan equipment, this
procedure is not valid with any other instrument.
HSMT scanner can be used wherever it is not possible to use Weld ROVER. For pipe
diameter less than 4.5 inch Cobrascanner shall be used.
3.0 REFERENCE
The following documents shall be referred in conjunction with this procedure:
 ANSI/ASNT CP-189-2006: ASNT Standard for Qualification and Certification of
Nondestructive Testing Personnel.
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 BS EN ISO 13588;2012: Use of automated phased array technology

 ASTM E2700 – 09 Standard Practice for Contact Ultrasonic Testing of Welds
Using Phased Arrays
 ASME Section V Article 4 (Edition 2010, Addenda 2011): Ultrasonic Examination
Methods for Welds.
 ASME Section V Article 5 (Edition 2010, Addenda 2011): Ultrasonic Examination
Method for Materials.
 ASME B 31.3(Latest Edition): Process Piping
 Sievert Arabia Limited Written Practice SAL/WP/QOP/001/2010
 Omniscan Manual
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4.0 TABLE OF ESSENTIAL VARIABLES FOR QUALIFICATION OF PROCEDURE

Non In this
Essential
S. No Requirement essential Procedure
variables
variables (Page)
Weld configurations to be examined,
1 including thickness dimension and base X - 4
material product form ( pipe, plate, etc.,)
The surface from which the examination shall
2 X - 22
be performed
3 Technique(s) (straight beam, angle beam, X - 4
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contact, and/or immersion)

Angles(s) and modes(s) of wave propagation
4 X - 21
in the material
Search unit types(s), frequency (i.es), and
5 X - 9
element size(s) / shape(s).
Special search units, wedges, shoes, or
6 X - 9
saddles, when used
7 scanner and adhering and guiding mechanism - X 22
8 Ultrasonic instrument(s) X - 7
Calibration (calibration block(s) and
9 X - 9
technique(s)
10 Directions and extent of scanning X - 22
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11 Scanning (manual Vs automatic) X - 22

Method for discriminating geometric from
12 X - 23
flaw indications
13 Method for sizing indications X - 23
Computer enhanced data acquisition, when
14 X - 7
used
15 Scan overlap (decrease only) X - 22
Personnel performance requirements when
16 X - 6
required
17 Personnel qualification requirements - X 8
Surface condition (examination surface,
18 - X 7
calibration)
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19 Couplant: brand name or type - X 9

Automatic alarm and/or recording equipment,
20 - X 22
when applicable
Records, including minimum calibration data
21 - X 22
to be recorded (e.g., instrument settings)
22 Instrument manufacturer and model X - 8
23 Instrument software X - 8
24 Directions and extent of scanning X - 22
25 Method for sizing flaw length X - 23
26 Method for sizing flaw height X - 23
27 Data sampling spacing (increase only) X - 23
Requirement of a PA Examination Procedure
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28 Search unit type, element size, pitch and gap X -

9
dimension
29 Focus Range X - 21
30 Virtual Aperture Size X - 9
31 Wedge Natural Refracted angle X - 9
Requirements of a Phased Array S- Scanning Examination Procedure
32 Sweep angular range(s) X - 21

Angular sweep increment
33 (incremental angle change, X - 21
deg)
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Aperture element numbers X

34 X - 21
(first and last)
Additional E scan requirements
35 Rastering angle(s) X - 21
Aperture start and stop element
36 X - 21
numbers
Aperture incremental change(s)
37 X - 21
(number of elements stepped)
5.0 SAFETY
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All personnel are responsible for ensuring that they, as well as their fellow employees
perform their job in a safe and professional manner, while adhering to the safety
guidelines laid out in safety manual SAL-HS-CP-GSE. In addition they will also
adhere to any statutory and local safety requirements along with any Client / Project
specific safety requirements.
6.0 PERSONNEL QUALIFICATION

Personnel performing non-destructive testing to this specification shall be qualified
and certified in accordance with employer’s written procedure as per ANSI/ASNT
CP-189-2006 as Level-II UT minimum. In addition, personnel who acquire and
analyze PAUT data shall be trained on Omniscan MX equipment and certified to level
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II in Phased Array as per SAL written practice and shall have minimum one year
experience in PAUT activities. The personnel who acquire and interpret the PAUT
Data shall participate the demonstration on Qualification block. Data acquisition and
analysis shall be performed by a Level II or Level III; however only UT Level III
personnel and qualified in PAUT shall perform final examination data package
review.
7.0 PREPARATION OF EXAMINATION AREA

Surface Preparation:
On finished contact surface a minimum area of 150 mm on either side of the weld
shall be free from dirt, weld spatters, corrosion product, surface irregularities or
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foreign matter that might interfere with free movement of the search unit and affects
the transmission of ultrasonic vibrations. When the base material or weld surface
interferes with the examination, the base material or weld shall be prepared as needed
to permit the examination. Surface preparation shall be under the client’s scope.
Scribe line shall be marked at least on one side of joint configuration before
starting the welding.
Generally it is assumed that parent material has been tested using normal beam for
planar flaw e.g. lamination, during various stages of fabrication. If the same not
documented then prior to start of the PAUT inspection, the base metal and HAZ area
shall be scanned using normal beam probe to locate reflectors that can limit the
capability of the PAUT inspection to examine the weld volume.
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Weld Identification:
Weld joints shall be identified with Weld Seam No. This unique weld numbering
system will be recorded as part of the file storage data. On the prepared area for
inspection there will be a “zero” reference index and/or position numbers marked on
the weld with paint marker arrow indicating the direction of scanning.
All circumferential measurement shall be made clockwise from the zero reference
position on the weld.
8.0 INSPECTION EQUIPMENT AND

ACCESSORIES
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8.10 ACQUISITION UNIT & SOFTWARE

Omniscan MX 16/128(Olympus) Phased array inspection unit (Figure 1 (a)) which
can be operated in pulse echo and/or pitch catch mode, shall be used in association to
this procedure. Omniscan equipment fulfills the requirement of ASMI Sec V, Article-4
(Mandatory Appendices- III-431) PA instrument (T-431) requirement. Omniscan
contains 16 independent pulser/receiver channels. The System is capable of generating
the B-Scan, C-Scan, S-Scan display along with A-scan. Omniscan is capable of
operation at frequencies over the range of 0.6 MHz to 18 Figure 1 (a) Omniscan
MHz equipped with a calibrated stepped gain controls in units of 2 dB or less.
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The data storing capabilities of the system requires the use of an external storage device,
flash card or USB memory stick. In addition to data storage, the PC will also be used by
the data-analysis personnel for analyzing data subsequent to the completion of data
collection. Data-display and analysis software (Tomoview 2.7R6 or higher version)
compatible to that residing on the Omni Scan phased array system shall also be used for
data play back. Tomoview 2.7R6 – It is a powerful and versatile package that will be
utilized for offline analysis of previous acquired data files.
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Figure 1 (b) Data display in Tomoview

8.20 SCANNER DETAIL
WeldROVER
Weld ROVER is a small and easy to operate one axis
encoded, motorized scanner. It can be used on plates and
Figure 1 (c) WeldRover

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pipe like structures. Four magnetic wheels hold the scanner, to move around the weld. It
can support up to 6 probes for ToFD & PA inspection. This scanner is having good
speed control, can move from 5mm/µsec to 50 mm/ sec. WeldRover is having Laser
guide for better weld tracking.
Magman / HSMT-X03 Scanner is a one axis encoded,

manual scanner. This scanner can hold up to 10 probes for
either phased array or conventional UT, in order to obtain
optimal coverage of the entire weld volume. The basic
configuration is intended for construction welding
Figure 1 (d) Magman/ HSMT-X03

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inspection. In order to be used in more restricted areas, the scanner can also be
reconfigured with the provided short frame bars.
The COBRA manual scanner is able to inspect standard
pipes as small as 0.84 in. OD to 4.5 in. OD. This scanner
uses the Omniscan MX/MX2 flaw detector with the 16:128
module, and the MXU software to inspect circumferential
welds on small-diameter pipes.
Figure 1 (e) Cobra Scanner

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The Omniscan ultrasonic system will be suitably interfaced with an automatic/semi-

automated scanner drive mechanism that moves the probes in one encoded axis. Four
industrial strength magnetic wheels make it suitable to move on ferromagnetic materials
(used in power plant and petrochemical industries). Mechanical holders are used to
ensure that the probe spacing is maintained at a fixed distance. The mechanical holder
for the probes shall be equipped with a positional encoder that is synchronized with the
sampling A-scan of signals. For WeldROVER Motion controller allows 10 different
scan speeds from 5mm/µsec to 50mm/µsec with a resolution of 2100 steps/mm. For
Magman / HSMT X-03 resolution of encoder is 12 steps/mm and manual scanning shall
be done with Mini-wheel encoder.
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8.30 SEARCH UNIT & WEDGES
This procedure uses the following probes and wedges for Phased Array
Number of Active Element Supportive
PA Probe Frequency Elevation
Elements Aperture Size Wedge
5L64 A2 5 MHz 64 38.4 mm 10 mm 0.60 mm SA2 N55S IHC
10L32-10 10MHz 32 9.9 mm 7 mm 0.30 mm SA10 N55S IHC
7.5CCEV 7.5Mhz 16 8.0 mm 10 mm 0.50 mm SA15 N60S IHC
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9.0 COMPUTRIZED IMAGING TECHNIQUE

The major attribute of Computerized Imaging Techniques (CITs) is their effectiveness
when used to characterize and evaluate indications: however, CITs may also be used to
perform the basic scanning functions required for flaw detection. Computer-processed
data analysis and display techniques are used in conjunction with automatic or semi-
automatic scanning mechanisms to produce two and three – dimensional images of
flaws, which provide an enhanced capability of examining critical components and
structures. Computer processes may be used to quantitatively evaluate the type, size,
shape, location and orientation of flaws detected by ultrasonic examination or other
NDE methods. Phased array ultrasonic examination is one of the computerized
imaging techniques.
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10.0 COUPLANT
Acoustic coupling shall be obtained by using a medium (oil, grease, cellulose, water)
suitable for the purpose. Temperature of the part to be scanned shall be taken into
considerations while selecting the couplant. An environmentally safe wetting agent, such
as water (up to 50 oC) will be required to promote acoustic coupling, however, no residue
will remain on the work-piece surface after the water has been evaporated. During
examination same couplant shall be used as during calibration.
11.0 CALIBRATION BLOCK

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The inspection system shall be calibrated using standard calibration blocks and reference
blocks. The calibration block material shall be a nozzle dropout from the component or a
component prolongation or material of the same specification product form. The
calibration block shall receive the same heat treatment as the part to be tested. The
surface of the calibration, at no time shall be inferior to that of the component. When the
component material to be examined is clad, the block shall be clad by the same welding
process as the production part.
Basic Calibration Block Drawing

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Note: Details of required calibration block for this procedure are mentioned in the
below table.
Calibration Block & Mock Up block requirement for Carbon Steel

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Calibration Block & Mock Up block requirement for Alloy Steel

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Calibration Block & Mock Up block requirement for Stainless Steel
Note: Number of required Mock up block depends on Clients & Contractor requirement.
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12.0 QUALIFICATION BLOCKS

Qualification block shall be prepared from the same product form and material
specification or equivalent P-numbers. In case of dissimilar metal welds the material
selection shall be based on the side of the weld from which the examination will be
conducted. If examination will be conducted from both sides, calibration reflectors
shall be provided in both the materials. Prior to the fabrication the block material
shall be completely examined with straight beam search unit.
When the component material is clad, the block shall be clad by the same welding
procedure as the production part. Qualification block shall be prepared by welding or
HIP provided the acoustic properties are similar and shall receive the same heat
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treatment as the part to be tested. Block’s weld geometry shall be representative of

production joint.
The qualification block shall be within ±25% of the thickness to be examined. For
welds joining two different thickness of material, demo block thickness shall be
based on thinner of the two materials.
The qualification block shall contain a minimum of three flaws parallel to the
production weld axis as follows—
1. One surface flaw on the OD surface
2. One surface flaw on the ID surface
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3. One subsurface flaw

In case the block can be flipped during UT examination then one flaw may represent
both ID and OD surfaces.
When due to obstruction the weld examination can only be performed from one side
of the weld axis, the qualification block shall contain two sets of flaws, one set on
each side of the weld axis.
Flaw size shall be based on the qualification block thickness and shall be no longer
than that specified by Referencing code Section.
Qualification block shall be scanned and the qualification data saved as per the
procedure and shall be available to the inspector.
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Flaws shall be sized and categorized in accordance with the written procedure being
qualified.
Automated and semi-automated acceptance performance criteria is defined as the
detection of all the flaws in the demonstration block and
(a) Recorded responses or imaged lengths, as applicable, exceed the specified
evaluation criteria of the procedure
(b) The flaws are sized as being equal to or greater than their actual size (i.e., both
length and height)
(c) The flaws are properly categorized (i.e., surface or subsurface)
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Supplemental manual technique(s) (For Transverse Reflectors) acceptable

performance criteria is defined as the demonstration block’s flaws being
(a) Sized as being equal to or greater than their actual size (i.e., both length and
height)
(b) Properly categorized (i.e., surface or subsurface)
Demonstration Block Record

The following information shall be recorded:
(a) The information specified by the procedure being qualified
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(b) Demonstration block thickness, joint geometry including any cladding or weld
overlays, and flaw data [i.e., position in block, size (length and height)], separation
distance to nearest surface, category (surface or subsurface)
(c) Scanning sensitivity and search unit travel speed
(d) Qualification scan data
(e) Flaw sizing data [same information as flaw data in
13.0 CALIBRATION
13.10 EQUIPMENT CALIBRATION

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Due to the digital control nature of PAUT instruments and also due to the fact that
multiple pulser and receivers are used, instruments are subject to screen height and
amplitude control linearity checks. Linearity checks shall be as per section T-461.1 &
461.2 (Mandatory appendix I & II) of ASME Section V, Article 4. .In the case of PA,
the amplitude control linearity shall be evaluated for each pulser-receiver circuit. The
results of these checks are recorded in the ultrasonic instrument linearity forms and
are kept as a part of the inspection record. Instrument linearity checks are conducted
on a twelve month cycle.
Prior to the start of shift operator need to carry out an element check and ensure that
probe is in working condition and ensure that no more than 10% of elements are
inactive and no two adjacent elements are inactive. Ensure the proper couplant
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between the probe and wedge. Once data is collected make sure that data missing
lines do not exceed the allowable limit.
TEST SET-UP
1) The phased array instrument is configured to display an

A-scan presentation.
2) Adjust the time-base of the A-scan to a suitable range to
display the pulse-echo signals selected for the linearity
verifications. A linearity block similar to that described
in E 317 is selected to provide signals to assess linearity
Fig 2_ Custom Linearity Blocks for

Phased-Array Instrument and Probe
Assessments
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aspects of the instrument. Such a block is showing in Fig. 2 with a single element
probe mounted on it.
3) Pulser parameters are selected for the frequency and bandpass filter to optimize the
response from the pulse-echo (single element) probe used for the linearity
verifications. In Olympus Omniscan the following tests are conducted:
 Screen height linearity check
 Amplitude control linearity check
 Horizontal linearity check
13.1.1 DISPLAY HEIGHT LINEARITY

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1) With the phased array instrument connected to a probe (shear or longitudinal) and
coupled to any block that will produce two signals as shown in fig.5a adjust the probe
such that the amplitude of the two signals are at 80% and 40% of the display screen
height.
2) If the phased array instrument has provision to address a single element probe in
pulse-echo mode then the two flat bottom holes with adjustable acoustic impedance
inserts in the custom linearity block shown in Fig. 3 provides such signals.
3) Increase the gain using the receiver gain adjustment to obtain 100% of full screen
height of the larger response. The height of the lower response is recorded at this gain
setting as a percentage of full screen height.
4) The height of the higher response is reduced in 10% steps to 10% of full sceen height
and the height of the second response is recorded for each step.
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5) Return the larger signal to 80% to ensure that the smaller signal has not drifted from
its original 40% level due to coupling variation. Repeat the test if variation of the
second signal is greater than 41% or less than 39% FSH.
6) For an acceptable tolerance, the response from the two reflectors should bear a 2 to 1
relationship to within ±3% of full screen height throughout the range 10% to 100%
(99% if 100% is saturation) of full screen height.
7) The results are recorded on an instrument linearity form.
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13.1.2 AMPLITUDE CONTROL Fig 3_ Display Height Linearity

LINEARITY
1) A 16/64 phased-array instrument has 16 pulsers and receivers that are used to address
up to 64 elements. Each of the pulser-receiver components is checked to determine
the linearity of the instrument amplification capabilities.
2) Select a flat (normal incidence) linear array phased-array probe having at least as
many elements as the phased-array ultrasonic instrument has pulsers.
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3) Using this probe, configure the phased-array ultrasonic instruments to have an

electronic raster scan. Each focal law will consist of one element and the scan will
start at element number 1 and end at the element number that corresponds to the
number of pulsers in the phased-array instruments.
4) Couple the probe to a suitable surface to obtain a pulse-echo response from each focal
law. The backwall echo from the 25 mm thickness of the IIW block or the backwall
from the 20mm thickness of the custom linearity block provides the suitable target
option.
5) Select channel of the pulser-receivers of the phased-array instrument. Using the A-
scan display, monitor the response from the selected target. Adjust the gain to bring
the signal to 40% screen height. This is illustrated in Fig.4.
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Fig 4_ A-Scan Display of Backwall Echo on channel 1 of a phased-Array Instrument
1) Add gain to the receiver in the increments of 1 dB, then 2 dB, then 4 dB then 6 dB.
Remove the gain added after each increment to ensure that the signal has returned to
40% display height. Record the actual height of the signal as a percentage of the display
height.
2) Adjust the signal to 100% display height, remove 6-dB gain and record the actual height
of the signal as a percentage of the display height.
3) Signal amplitudes should fall within a range of ±3% of the display height required in
the allowed height range of Table.
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4) Repeat the sequence from 5 to 7 for all other pulser-receiver channels.

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13.1.3 TIME-BASE LINEARITY (HORIZONTAL LINEARITY)
1. Configure the phased array instrument to display an A-scan presentation.
2. Select any compression wave probe and configure the phased-array instrument to
display a range suitable to obtain at least ten multiple back reflections from a block of
a known thickness. The 25-mm wall thickness of the IIW block is a convenient option
for this test.
3. Set the phased-array instrument analog-to-digital conversion rate to at least 80 MHz.

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4. With the probe coupled to the block and the A-scan displaying 10 clearly defined
multiple as illustrated in Fig. 5
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Fig 5_ Horizontal Linearity A-Scan
Horizontal Linearity A-Scan
5. The display software is used to assess the interval between adjacent backwall signals.
6. Acoustic velocity of the test block, determined using the methods described in E 494,
is entered into the display software and the display configured to read out in distance
(thickness).
7. Using the reference and measurement cursors determine the interval between each
multiple and record the interval of the first 10 multiples
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8. Acceptable linearity may be established by an error tolerance based on the analog-to-

digital conversion rate converted to a distance equivalent. For example, at 100 MHz
each sample of the timebase is 10 ns. For steel at 5900 m/s each sample along the
timebase (10 ns) in pulse-echo mode represents 30 µm. A tolerance of ±3 timing
samples should be achievable by most analog-to –digital systems. Some allowance
should be made for velocity determination error ( ~ 1%). Typically the errors on the
multiples should not exceed ±0.5 mm for a steel plate.
13.1.4 PHASED-ARRAY ELEMENT ACTIVITY VERIFICATION
1. The Phased Array probe shall be checked to determine that all elements of the
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phased array probe are active and of uniform acoustic energy. Because, during
normal operation in a timed sequence, each of the elements is addressed by a
separate pulser and receiver, a method from element to element and any differences
are attributable to the probe itself. To ensure channel is selected to address
each element.
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2. Any Phased Array Probe that has greater than 25% defective element of the usable
aperture should be replaced with a new probe.
Continuity Display for Phased-Array Instrument or Cable
Test Method:
1. Connect the phased array probe to be tested to the phased-array ultrasonic
instrument and remove any delay line or refracting wedge from the probe.
Acoustically couple the probe to the 25-mm thickness of an IIW (International
Institute of Welding) block with a uniform layer of couplant. This may be
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accomplished by a contact-gap technique such that the probe-to-block interface is

under water (to ensure uniform coupling).
2. Conﬁgure an electronic scan consisting of one element that is stepped along one
element at a time for the total number of elements in the array. (This should ensure
that the pulser-receiver number 1 is used in each focal law or if the channel is
selectable it should be the same channel used for each element). Set the pulser
parameters to optimize the response for the nominal frequency of the probe array
and establish a pulse-echo response from the block back wall or water path to 80
% display height for each element in the probe. Observe the A-scan display for
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each element in the array and record the receiver gain required to achieve the 80
% signal amplitude for each element.
3. Note and record any elements that do not provide a back wall or water path signal
(inactive elements).
13.2 ENCODER CALIBRATION

The encoder shall be connected to the Omni Scan equipment and the calibration
wizard shall be used to calibrate the encoder. Through the menu wizard set up, all the
parameters are fed and the encoder is made to scroll on a pre-determined known
length from initial position, press calibrate, get the calibration done. Encoder
calibration shall be confirmed by moving a minimum distance of 500mm and the
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distance displayed being ±1% of the actual distance moved. Encoder calibration shall
be carried out prior to the first use and not to exceed one month.
13.3 VELOCITY & WEDGE DELAY CALIBRATION

For contact examinations the temperature differential between the calibration block
and examination surface shall be within 14o C.
Compensation for delay in the wedge is required so as to ensure that indications
detected are poisoned correctly. The wedge delay calibration shall be carried out for
both linear scan and as well as sectorial scan. The velocity & wedge delay calibration
can be carried out in sound path (using 50mm, 100mm radius of V1 block) mode or
true depth (using SDH’s) mode with known reflector having fixed sound path or depth
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respectively. Peak up this signal from the calibration reflector and scan the phased
array probe backwards through all the different angles or focal laws. Scan forward
over the calibration reflector through all the refracted angles of focal laws. When the
signal for all angles and focal laws lies within the threshold, Omniscan system
dynamically adjusts delay setting to correctly indicate radius (depth). Figure (6)
shows the screen display during wedge delay calibration.
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Figure (6): Wedge delay calibration
13.4 SENSITIVITY CALIBRATION

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Variation between electronics of pulsers and receivers and variation between probe
elements results in small gain variation from one focal law to the next. Also the
variation in path distance in both wedge and steel will result in some focal laws
requiring more gain. So to compensate for this Omniscan shall be calibrated for
sensitivity, which can be carried out dynamically. The sensitivity calibration shall
provide the required gain adjustments for each refracted angle and sound path used.
Select a calibration reflector, which is within the zone of material to be examined.
Peak up this signal from the calibration reflector and scan the phased array probe
backwards through all the different angles or focal laws. Scan forward over the
calibration reflector through all the refracted angles of focal laws. The Omniscan
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System calculates the required gain needed at each focal law to adjust the amount of
gain required to obtain the sensitivity.
Figure (7) illustrates the example of special screen feature used to ensure the
sensitivity (amplitude response) from each focal law. All focal laws provide a uniform
amplitude response to the calibration reflector. As the operator moves the probe back
and forth over a calibration reference reflector, unit software automatically adjusts
gain to the prescribed amplitude 80% with +5% tolerance limit. The horizontal scale
is the virtual probe aperture (VPA) which defines the group of elements i.e. focal law
that is sequenced in the scan. These focal laws are either linear or sectorial depending
on whether E-scan of S-scans is being calibrated.
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Figure (7) Sensitivity Calibration (S-Scan)

13.5 TCG CALIBRATION
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Time corrected gain (TCG) calibration shall be applied to compensate for attenuation
in the material for the sound paths used during calibration and examination. Generally
Phased array inspection is being done in full skip so in order to compensate for the
attenuation; calibration shall be performed as per the plan shown below. (Figure (8)
using Notch).To obtain the TCG calibration, peak the signal from the respective
Notch’s and adjust the gain to obtain 80% of amplitude from the reflector. Place the
phased array probe perpendicular to the ID notch axis. Move the phased array probe
forward and backward to equal the amplitude for all the focal laws and angles and
plot the first point. The same process is repeated to set the response from OD notch in
full skip distance for each focal law at 80% FSH. Omniscan uses the gain
compensation required due to attenuation in the sound travel and adjust the gain for
all focal laws/angles. Once all the points are picked the TCG can be accepted. TCG
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calibration has to be carried out for all scan plans in a multi group option while using
phased array probe. The examination system calibration shall be stored in the Omni
scan System with electronic memory, on an external chip or data storage device. This
calibration may be used at a later date provided that the system calibration is verified
prior to the examination. A complete ultrasonic system calibration shall be performed
at least once prior to the examination.
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Figure (8) PA Calibration Using Notch’s
14.0 CALIBRATION CONFIRMATION

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A system calibration confirmation shall be used to verify sensitivity at the start and
finish of each examination using the appropriate calibration block. The sensitivity
control settings are adjusted to match those recorded for reference sensitivity. The
search unit is positioned to detect the first and last point on the TCG using the
reference reflectors. The examination deemed to be void if any point on the TCG
decreased by 20% or 2dB of its amplitude. All inspection since last valid calibration
needs to be rescanned. If the sensitivity has increased all recorded indications since
last valid calibration or calibration check shall be reexamined and there values shall
be changed on data sheet. Any change in search unit, wedge and ultrasonic instrument
cause for a new calibration.
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15.0 SCAN PLAN

A documented examination strategy shall be provided showing search unit placement
and movement that provides a standardized and repeatable methodology for the
examination. Scan plan shall include beam angles and direction with respect to the
weld axis reference point, weld geometry and number of zones.
Scan plan provides clear view of scanning, helping to clearly convey weld coverage,
HAZ coverage and probe position, in addition to critical dimensions. The beamset
parameters dialog displays a visual representation of the transducer elements that are
used to form the beamset. Varying the focus of the beam is the capability of PA
instrument, but generally focusing is not the norm for weld inspection.
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Beam spread visualization allows you to more accurately see the beam coverage and
near field visualization ensures that any focusing being performed is within the near
field. True Depth, Projection and Half Path focus types can be visualized in the
workspace and documented as a technique report. These all is achieved with the help
of ESbeam software tool. The scan plan for inspection of full volume of given weld
geometry and thickness are given in Annexure: 1
Note: Scan plan given below may require modification based on the actual field
conditions to achieve optimum inspection results. Such improvements are applicable
provided it has been demonstrated successfully on the qualification block.
16.0 EXAMINATION COVERAGE & SCANNING

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The ultrasonic examination area shall include the volume of the weld plus the lesser
of 25mm or thickness on each side of the weld or Alternatively, examination volume
may be reduced to include the actual heat affected zone (HAZ) plus 6 mm (1/4 in.) of
base material beyond the heat affected zone on each side of the weld provided the
following requirements are met:
(1) The extent of the weld HAZ is measured and documented during the
weld qualification process; and
(2) The ultrasonic transducer positioning and scanning device is controlled
using a reference mark (paint or low stress stamp adjacent to the weld)
to ensure that the actual HAZ plus an additional 6 mm (0.25 in.) of
base metal is examined.
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The required volume of the base material and weld to be examined shall be scanned
from outer surface/inner surface using a linear scanning technique with encoder. The
level of gain used for scanning shall be appropriate for the configuration being
examined and shall be capable of detecting the calibration reflectors at the maximum
scanning speed. Each linear scan shall be parallel to the weld axis and at a constant
standoff distance with the beam oriented perpendicular to the weld axis from the zero
datum point. Scanning mechanisms shall be used to maintain a constant distance and
alignment between the index points of the two probes. Scanning mechanisms can
either be motor or manually driven with encoder. They shall be guided by means of a
suitable guiding mechanism (steel band, belt, automatic track following systems,
guiding wheels etc.). Guiding accuracy with respect to the centre of a reference line
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(e.g. the centre line of a weld) should be kept within a tolerance of ±10 % of the probe
index point separation.
The scan plan shall demonstrate by plotting or with using a computer simulation the
appropriate examination angles for zones at different depth. This scan plan shall be
documented to show that the examination volume was examined. This scan plan shall
be a part of the final examination report. More than one line scan may be required to
ensure complete coverage of the weld and heat affected zone. A maximum sampling
of 1mm shall be set for and be used between A-scans collected for thickness up to
50mm. A 2mm resolution can be used for thicknesses more than 50mm. Scanning
speed shall not exceed 150 mm/µsec. Scanning speed will be limited by mechanical
ability to maintain acoustic coupling and by the system’s electronic ability to ensure
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full wave forms are captured without missing data points. Scanning speed shall not
exceed that qualified. Missing of data lines shall not exceed 5% of the total
acquisition with adjacent data shall not be missed. Omni Scan equipment has the
capability of rewriting the data while observed loss of data. The encoder is retrieved
back to home position whenever data is missed. Missing data is represented by black
lines in the display. Between two consecutive scans there should be an overlap of 50
mm. Repaired weld area shall be rescanned with an overlap of minimum 50mm at the
start and end of the scan.
The joints having scanning access from one side only (e.g.- pipe to fittings) shall be
scanned from pipe side with minimum two line scans from two different probe index.
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Weld reinforcement shall be flush grinded to make the surface parallel to parent
material for one side access joints.
Note: For Pipe to Pipe joints no need to remove the weld cap reinforcement.
Only for Pipe to Fitting joints weld cap reinforcement shall be removed as
mentioned above.
17.0 RECORDING AND EVALUATION

A scan data shall be recorded for the area of interest in an unprocessed form with no
thresholding at a minimum digitization rate of five times the examination frequency
and recording increment of a maximum of 1mm for material less than 50mm thick
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and 2mm for material having thickness greater than 50mm. Calibration check data
shall also be recorded.
Only Trained Level II - UT operators with hands on training Omni Scan shall
calibrate and carry out UT inspection. Only personnel certified Level II or III in
Ultrasonic testing along with knowledge of phased array and Omni Scan equipment
shall evaluate the results of ultrasonic examinations for acceptance.
For amplitude base technique, the location, amplitude and extent of all reflectors that
produces a response greater than 20% of the reference level shall be investigated and
those having amplitude greater than equal to 50% shall be recorded.
Non Relevant Indications
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Signals which are determined to originate from metallurgical discontinuities (such as

cladding to base material interface) and/or geometrical features (such as weld
reinforcement or root geometry) may be classified as geometric indication. Such
reflectors are not characterized as indications nor compared with allowable indication
standard.
The presence of geometric reflectors is confirmed either by reviewing the fabrication
drawing of the weld preparation or by plotting the reflectors co-ordinates or by
supplemental inspection (PT, MT, and ET etc) result. In addition to reporting
indications, area of restricted access which cannot be scanned shall be recorded and
reported
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Relevant Indications
Signals that are determined to result from welding flaws will be assessed according to
the acceptance criteria in ASME B31.3. For PA flaw sizing is performed by measuring
the vertical extent and the cross sectional distance at 6dB level. A sizing procedure
qualified by performance demonstration will be used to assess all indications interpreted
to be flaws.
TomoView software should be used for further processing which enhances the
interpretation of the discontinuities.
Size & Category

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Dimensions of the flaw shall be determined by rectangle that fully contains the area of
the flaw. Length of the flaw is the dimension of the rectangle parallel to pressure
retaining surface, and the height of the flaw is the dimension of rectangle perpendicular
to the pressure retaining surface. Flaws shall be characterized as being surface or
subsurface based on their separation from the nearest component surface:
1. If space is equal to or less than one half of the height of the flaw than flaw shall be
categorized as surface flaw.
2. If space is greater than one half of the height of the flaw than flaw shall be categorized as
subsurface flaw.
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Surface Indications S <d

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Sub Surface Indication S > a

Figure 9: Classification of Surface & Sub surface Indications
Flaws shall be evaluated for acceptance using the applicable criteria for the respective
thickness, with the following additional requirements-Flaws identified as surface flaws
during the UT examination may or may not be surface connected. Therefore, unless the
UT data analysis confirms that the flaw is not surface connected, it shall be considered
surface connected or a flaw open to the surface, and is unacceptable unless surface
examination is performed. If the flaw is surface connected, the requirements above still
apply. However, in no case shall the flaw exceed the acceptance criteria in this Division for
the material employed. Acceptance surface examination techniques are as follows:
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(1) Magnetic particle examination (MT) in accordance with ASME 2011a SECTION
VIII, DIVISION 2 paragraph 7.5.6
(2) Liquid penetrant examination (PT) in accordance with ASME 2011a SECTION
(3) Eddy Current examination (ET) in accordance with ASME 2011a SECTION
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Figure (10) Multiple Planar Flaws Oriented in a Plane Normal to the Pressure
Retaining Surface
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i. Discontinuous flaws shall be considered a singular planar flaw if the distance

between adjacent flaws is equal to or less than the dimension S as shown in Figure
(10).
ii. Discontinuous flaws that are oriented primarily in parallel planes shall be considered
a singular planar flaw if the distance between the adjacent planes is equal to or less
than 13 mm. (see Figure 11).
iii. Discontinuous flaws that are coplanar and nonaligned in the through-wall thickness
direction of the component shall be considered a singular planar flaw if the distance
between adjacent flaws is equal to or less than S as shown in Figure (12).
iv. For Subsurface Flaws the flaw length shall not exceed 4t.
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Figure (11) Surface and Subsurface Flaws

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Figure (12) Non-Aligned Coplanar Flaws in a Plane Normal to the Pressure Retaining
Surface
18.0 ACCEPTANCE CRIETERIA

Results of weld inspections to this procedure shall be compared to the requirement of
acceptance criteria as defined in ASME B 31.3
A linear-type discontinuity is unacceptable if the amplitude of the indication exceeds the
reference level and its length exceeds:
(a) 6 mm (1⁄4 in.) for Tw ≤ 19 mm (3⁄4 in.);
(b) Tw /3 for 19 mm < Tw ≤ 57 mm (21⁄4 in.);
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(c) 19 mm for Tw > 57 mm.
19.0 REPORTING
The following data shall be reported in the final report

a. Procedure identification and revision.
b. Instrument Identification including manufacturer’s serial number.
c. Transducer type, serial number, angle and frequency.
d. Cables used, type and length.
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e. Probe center spacing (PCS), Data sampling spacing.

f. Couplant used
g. Special equipment when used (search units, wedges, shoes, automatic scanning
equipment, recording equipment etc)
h. Computerized programmed identification and revision when used
i. Calibrations block identification.
j. Instrument reference level gain and, if used damping and reject settings.
k. Calibration data including reference reflectors, indication amplitude and distance
reading.
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l. Data correlating simulation blocks and electronic simulator, when used, with initial
calibration.
m. Identification and location of weld or volume scanned.
n. Surface condition.
o. Record of indications identified to be rejected.
p. Areas of restricted access or inaccessible welds.
q. Examination personnel identity and when required by referencing code section,
qualification level.
r. Date and time examinations were performed.
Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
REPORT FORMAT (SAMPLE)

Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Annexure-1
Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Scanplan Details
Note: AOD wedges shall be used as per the joint OD size & Wedge AOD range
Scanplan View for 6.35 mm to 8.18 mm Thickness

Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Scanplan View for 9.27 mm to 12.7 mm Thickness

Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM
Tel. 03 8411 846 Fax. 03 8411 812
Wedge: ST1-60L-IHC
20.31mm 31.75mm 8mm
Transducer: C543-SM

Procedure For Phased Array

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Procedure For Phased Array

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SIEVERT ARABIA LIMITED

Dammam - Saudi Arabia Document No.

PROCEDURE FOR AUTOMATED PHASED ARRAY INSPECTION OF PIPING

Issue Revision Date Remarks

Prepared by Reviewed & Approved by

Date 19.03.2014 19.03.2014

1.0 SCOPE: ………………………………………………………………………… 4

2.0 PURPOSE: ……………………………………………………………………. 4

3.0 REFERENCE: …………………………………………………………………. 4

4.0 TABLE OF ESSENTIAL VARIABLES FOR QUALIFICATION OF

5.0 SAFETY: …………………………………………………………………….. 6

6.0 PERSONNEL QUALIFICATION: …………………………………………… 6

7.0 PREPARATION OF EXAMINATION AREA…………………………… 7

8.0 INSPECTION EQUIPMENT AND ACCESSORIES: ……………………… 7

8.1 ACQUISITION UNIT & SOFTWARE: ……………………………………… 7

8.2 SCANNER DETAILS: ……………………………………………………... 8

8.3 SEARCH UNIT & WEDGES: ………………………………………………. 9

9.0 COMPUTRIZED IMAGING TECHNIQUE: ………………………………… 9

10.0 COUPLANT: ………………………………………………………………….. 9

11.0 CALIBRATION BLOCKS: …………………………………………………… 10

12.0 QUALIFICATION BLOCKS: ………………………………………………… 12

13.0 CALIBRATION: …………...…………………………………………………. 12

13.1 EQUIPMENT CALIBRATION: ……………………………………………. 12

13.2 ENCODER CALIBRATION: …………………………………………………. 19

13.3 VELOCITY & WEDGE DELAY CALIBRATION: ………………………... 19

13.4 SENSITIVITY CALIBRATION: ……………………………………………... 19

13.5 TCG CALIBRATION……………………………………………………….. 20

14.0 CALIBRATION CONFIRMATION: …………………………………………. 21

15.0 SCAN PLAN: ………………………………………………………………….. 21

16.0 EXAMINATION COVERAGE & SCANNING: ……………………………... 22

17.0 RECORDING AND EVALUATION: ………………………………………… 23

18.0 ACCEPTANCE CRITERIA: ………………………………………………….. 28

19.0 REPORTING: …………………………………………………………………. 28

Size Material Thickness Remarks

 Give the details of the equipment used and extent of

 BS EN ISO 13588;2012: Use of automated phased array technology

4.0 TABLE OF ESSENTIAL VARIABLES FOR QUALIFICATION OF PROCEDURE

contact, and/or immersion)

11 Scanning (manual Vs automatic) X - 22

19 Couplant: brand name or type - X 9

28 Search unit type, element size, pitch and gap X -

32 Sweep angular range(s) X - 21

Aperture element numbers X

6.0 PERSONNEL QUALIFICATION

7.0 PREPARATION OF EXAMINATION AREA

8.0 INSPECTION EQUIPMENT AND

8.10 ACQUISITION UNIT & SOFTWARE

Figure 1 (b) Data display in Tomoview

Figure 1 (c) WeldRover

Magman / HSMT-X03 Scanner is a one axis encoded,

Figure 1 (d) Magman/ HSMT-X03

Figure 1 (e) Cobra Scanner

The Omniscan ultrasonic system will be suitably interfaced with an automatic/semi-

8.30 SEARCH UNIT & WEDGES

9.0 COMPUTRIZED IMAGING TECHNIQUE

11.0 CALIBRATION BLOCK

Basic Calibration Block Drawing

Calibration Block & Mock Up block requirement for Carbon Steel

Calibration Block & Mock Up block requirement for Alloy Steel

Calibration Block & Mock Up block requirement for Stainless Steel

12.0 QUALIFICATION BLOCKS

treatment as the part to be tested. Block’s weld geometry shall be representative of

3. One subsurface flaw