Chapter Contents

6.1 Advantages of Phased Arrays .................................................................. 299

6.2 General Phased Array Solutions to Inspection Problems .................... 300
6.3 Implementing Phased Array Technology ............................................... 302

298 Chapter Contents

6. Conclusions and Recommendations

Our journey into phased array technology for industrial applications is near
the end. As presented in “Introduction,” this guide is the first Olympus book
dealing with the new industrial phased array technology. This book is an
introduction to phased array applications, a way to better acquaint you with
basic principles, probe types, scan patterns, specific views, and detailed
applications. A basic ultrasonics chapter was added to help with graphs,
tables, and formulas.

6.1 Advantages of Phased Arrays

The main advantages of phased arrays can be summarized below:

1. Speed. Phased array inspections with linear scanning typically have a

faster magnitude order than conventional single probe raster scanning.
This provides significant savings terms of plant downtime and operator
costs.
2. Flexibility. Using electronic setup files, a single array can inspect many
different components and inspection patterns.
3. Complex inspections. Phased arrays can be programmed to inspect
geometrically complex components, such as automated welds or nozzles,
with relative ease. Phased arrays can also be programmed to perform
special scans, such as tandem, multiangle, multimode, and zone
discrimination.
4. Small array size. Steerable probes permit the use of a single probe where
multiple probes were previously required, much simplifying some
inspections.
5. Mechanical reliability. Fewer moving parts make for a more reliable
inspection system. Replacing mechanics with electronics reduces wear
and tear, as well as significantly increases system reliability.
6. Defect sizing without probe movement.
7. A focused beam where it is required without multiple probes.

Conclusions and Recommendations 299

6.2 General Phased Array Solutions to Inspection Problems

The main phased array approaches to solving general inspection problems

are summarized in Table 6-1.

Table 6-1 Overview of phased array solutions.

Feature
High-speed inspections
• S-scan with multiple angles
Limited scanning access due
• Multiple channels with different wave types
to difficult geometry
• Single probe (1-D, 2-D) scanning all parameter sets
Inspection flexibility
High inspection reliability
High dose rate for nuclear
Equipment reliability
High productivity
Maximize defect detection
(PoD)
Phased array solution
• QuickScan PA for pipe mills
• Tomoscan III PA for high-end applications
• Reduced gating and data collection to maximize PRF
• Combined multiple phased array probe setups
• Miniature arrays
• Ray tracing and 2-D data plotting
• Scan by simply loading the setup file
• Great flexibility for inspecting different parameter sets
simply by modifying setup files
• Many test angles and procedures
• S-scans, composite B-scans, multiple setups (channels)
with PE, TOFD, SW, and LW—all ensure redundancy
• Defect characterization based on results from multiple
analysts
• Rapid setup time (load file and calibrate)
• Faster scanning (linear scans versus raster)
• Relevant S-scan information acquired within a few
minutes
• Fewer probes, simplified design
• Less moving parts means greater mechanical reliability.
• More electronics, less mechanics means improved
reliability.
• Easy maintenance and repair
• Telemaintenance
• Maximize electronic scanning for speed.
• Combine multiple phased array probe setups.
• Use data compression, smoothing, digitalization, high
PRF, and DDF.
• Optimize inspection procedures.
• High-frequency focused beams
• Smaller beam dimensions, higher SNR
• Use DDF.
• Include tip-echo diffraction techniques.
• Averaging and data processing

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 Table 6-1 Overview of phased array solutions. (Cont.)
Feature
Imaging
Real-time analysis
Underwater applications
Data reproducibility
Coarse-grained material
inspections (for example,
stainless steel and cladding)
In-line reliability
Data analysis and reporting
Performance demonstration
Fitness-for-purpose
inspection
Phased array solution
• S-scan and linked views (volume-corrected)
• Multiple angles, different defect displays
• Merged displays
• Signal processing
• Networking
• High data transfer rate
• Multiple workstations
• One file may be analyzed by several analysts at the same
time.
• Watertight phased array probes, pressure-resistant
• Tight encoder tolerances (< 0.25 mm)
• Automatic sensitivity calibration
• Data plotting in 2-D specimens
• Qualified procedure, equipment, and personnel
• Use TRL phased array probe with high bandwidth, lower
frequency.
• Use longitudinal waves.
• Use cut-spectrum processing (CSP).
• Increased averaging
• Smaller beam dimensions
• Use a QuickScan dedicated setup and software for speed
and cost.
• Optimized ultrasonic head, multiple probes
• Linear scanning
• DDF, optimized PRF
• Rugged equipment, designed for 24/7 jobs.
• Customized layout
• Use TomoView data analysis capability for OmniScan
scanning data.
• Use defect tables for convenience.
• Use Microsoft Excel or Access, or MATLAB.
• Customized reports
• EPRI qualified the phased array procedure for dissimilar
weld inspections according to ASME XI-Appendix VIII
• OmniScan PDI qualification underway
• Petrochemical industry approvals for phased array
technology for pipelines and pressure vessels
• High accuracy and small errors in length and height
sizing
• Accurate defect plotting (coordinates and orientation)
• Increased axial and lateral resolution provides possibility
of defect discrimination/interaction.
• Defect classification based on advanced imaging.
Conclusions and Recommendations 301
 Table 6-1 Overview of phased array solutions. (Cont.)
Feature Phased array solution
• Olympus Training Center, Canada, offers an official
training program on phased arrays since 2004.
• The Welding Institute (TWI), UK, offers a phased array
Personnel training and training program.
certification • EPRI NDE Center offers a phased array training
program.
• NDE Professionals offers an official phased array training
course.
• Initial cost is within the normal range for off-the-shelf
automated systems.
• Full life-cycle cost supports phased array technology as
operating costs are lower than conventional systems.
• Cost-effective base on technical capability
Investment cost • OmniScan offers low-cost solutions.
• OmniScan may include additional modules
(conventional probes, TOFD, as well as phased arrays).
• Phased array probes will be standardized (weld kit,
corrosion kit, pipe kit), and the price is dropping for
standard products.

Phased arrays are a mature technology, and solutions to many problems are
already available. Costs are decreasing, as is normal with electronics. For
example, the battery-powered OmniScan is closing the price gap between
advanced phased array systems and conventional ultrasonic single-channel
instruments.

6.3 Implementing Phased Array Technology

Follow the recommendations listed below to implement the phased array

technology in your organization:

• Be familiar with the specific applications of phased array technology for

your project.
• Determine the advantages of phased array technology.
• Read the relevant operating manuals.
• Determine what defects must be detected, that is, define the problem
precisely.
• Take into account the component and defect characteristics (thickness,
curvature, defect size, orientation, location, attenuation, beam skewing
etc.).
• Develop an ultrasonic problem-solving approach for the inspection
procedure: sweep angle, effective aperture, ultrasound range (half-path,

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