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Ultrasonic Phased Array in Lieu of Radiography

Summary
Many codes allow for the substitute of one method of stated
nondestructive evaluation (NDE) for another as long as certain
requirements are met. Other non-code based inspections are
constantly being reviewed for cost savings and other improvement to
process. One substitution growing in popularity and practice is the
substitution of ultrasound where previously radiographic methods
were used.

Introduction
Radiography and ultrasound are two complimentary nondestructive
testing (NDT) techniques. Both can volumetrically inspect welds and components for defects like cracks, lack of fusion,
porosity etc. The choice of one over the other often comes to external process decisions or small variables in their ability in
a particular test. In recent years the use of ultrasound where radiography was typically used has gained momentum in both
practice and with major code bodies like ASME (American Society of Mechanical Engineers) and API (American Petroleum
Institute). Although most codes do not specify the ultrasonic method, phased array has become the most popular choice
when trying to make the replacement in processes. It is often also combined with TOFD (time-of-flight diffraction) since the
modern acquisition units and scanners can accommodate both methods simultaneously. For code-based inspections
historically these processes were conducted through code cases or appendixes, but after a large amount of industry
practice and success they are being codified directly into the main bodies of the major code books as seen in the 2010 and
beyond ASME Sec. V. Art. 4. Modern phased array equipment today is highly portable, less expensive, and easier-to-use
than ever, making the opportunity to replace radiography with ultrasound easier than ever.

Typical Advantages of Ultrasonic Method vs. Radiography:

High probability of detection (POD) especially for cracks and lack of fusion
Ultrasound tends to detect planar flaws better than radiography in most studies
Accurate sizing of defects height and less rejects/repair using Engineers Critical Assessment
Ultrasound allows defect height measurement allowing volumetric consideration of flaw severity vs. just type
and length
 and length
No radiation, hazard, or additional licensing or personnel
No screened off areas, work can go on around ultrasonic testing
No chemical or waste material compared to film based radiography
Real-time analysis for instant evaluation and feedback to welder
Setup and inspection reports in electronic format compared to film based radiography

Radiography Replacement with Ultrasound Code Examples

ASME Code Case 2235

ASME Code Case 179
ASME Code Case 168
ASME Code Case N-659
ASME Code N-713
API 620/650 App. U
ASME Sec. V Mandatory Appendixes

Typical Equipment and Inspection Requirements

Acquisition unit with Full Raw A-scan data retention and encoding ability (OmniScan or Focus LT)
Scan plan and procedure showing documented inspection strategy and essential parameters
Industrial Scanner (encoder) that repeatedly scan weld or component (Semi or Fully Automatic)
Selection based on number of welds, pipe diameter, and other application variables
Deliverable data
Analysis performed on acquisition unit or post analysis software OmniPC or TomoView
Performance demonstration for equipment, procedure, operator and inspection process
Alternative acceptance criteria as required
Probes, wedges, couplant delivery and other accessories
Proper training and certification for personnel

OmniScan MX2 (MultiGroup capable) and OmniScan SX (Single Group)

 Fully automatic WeldROVER and Semi-Automatic Compact Scanner with OmniScan

NDT SetupBuilder and OmniPC Software for design and analysis

Conclusion
Radiography replacement has become an industry trend and code accepted practice. Modern easier-to-use, less expensive
portable phased array equipment and associated software has accelerated this practice in recent years. Main reasons for
this continuing trend include process cost and time savings, safety of operators and those in surrounding areas, and the
use of alternative acceptance criteria leading to less reject and repairs.

Products used for this application

NDT SetupBuilder Industrial Scanners

NDT SetupBuilder is a new PC-based software allowing to
create inspection setup and visualize beam simulations.
This software presents multiple features for easy, fast, and
comprehensive inspection strategy elaboration that can
directly be imported in the OmniScan MX2.
TomoView Software
TomoView is a powerful and flexible PC-based software
used for design, data acquisition, visualization, and
analysis of ultrasonic signals.
OmniScan SX
The single group, lightweight OmniScan SX features an
easy-to-read 8.4 inch (21.3 cm) touch screen and provides
cost-effective solutions. The OmniScan SX comes in two
models: the SX PA and SX UT. The SX PA is a 16:64PR
unit, which, like the UT-only SX UT, is equipped with a
conventional UT channel for P/E, P-C or TOFD
inspections.
The capacity to accurately position probes according to the
surface being inspected greatly influences inspection
quality. Olympus offers a wide range of industrial scanners
and accessories to assist inspectors in their work.
Scanners come in various configurations including one or
two encoded axes with manual or motorized motion.
OmniPC Software
This new software is the most efficient and affordable
option for OmniScan data analysis, and features the same
analysis tools provided in the OmniScan onboard software,
with the added flexibility of running on a personal
computer.
OmniScan MX2
The OmniScan MX2 now features a new phased array
module (PA2) with a UT channel, and a new two-channel
conventional ultrasound module (UT2) that can be used for
TOFD (Time-of-Flight Diffraction), as well as new software
programs that expand the capabilities of the successful
OmniScan MX2 platform.
Phased Array Probes
Phased array application-specific probes have a range
from 0.5 MHz to 18 MHz and may come with 16, 32, 64, or
128 elements. Special probes may have up to hundreds of
elements.

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