The e-Journal of Nondestructive Testing - ISSN 1435-4934 - www.ndt.

net

PA-CATTM: Measurement of Metal Loss at Pipe Supports Using an

Innovative Phased Array Approach
More info about this article: http://www.ndt.net/?id=26037

Paul Holloway1 and Robert Ginzel2

1
Holloway NDT & Engineering Inc., Georgetown Ontario Canada paul@hollowayndt.com
2
Ginzel & Associates Ltd., Williamsford Ontario Canada rginzel@ginzelassociates.com

2021.05.03

Abstract
The PA-CATTM technique was devised in early 2019 by Holloway NDT & Engineering Inc. to address the issue of
inspection of corrosion under pipe supports (CUPS) using existing phased array instrumentation. An initial paper was
drafted in early 2020 documenting the initial findings and proof of concept. Further testing on a range of reference
targets has now advanced the technique considerably. Machined corrosion samples, mimicking real field corrosion,
have been tested on plate samples leading to a further understanding of instrumentation requirements and limitations.
A study of the complete findings on flat plate, plus a discussion on corrosion patterns on pipe samples and future field
trials was the foundation for the work presented in this paper.

Keywords: Phased array, CUPS, pipe supports, corrosion, ultrasonic testing

1. Introduction

A new technique called PA-CATTM for inspection of corrosion at pipe support locations was
developed by Holloway NDT & Engineering Inc. The technique does not use specialized
hardware, but instead utilizes existing phased array ultrasonic testing (PAUT) instruments, probes
and scanners common to NDT service companies. This paper summarizes the research and
development effort and different stages of testing thus far.

Corrosion under pipe supports (CUPS) is a common failure mode in virtually all industries where
piping is supported at touch points. The pipe support prohibits access for inspection, thus CUPS
has remained a challenging problem in NDT. Specialized systems often require mobilization of
dedicated personnel and equipment. Meanwhile there are many ultrasonic technicians familiar
with piezoelectric techniques and thousands of PAUT instruments worldwide that could be more
extensively utilized. The PA-CATTM project set out to experiment with an array of PAUT
instruments, common transducers, and scanners to explore the vast array of data that could be
collected, the different analysis approaches, and whether a pitch-catch PAUT approach could serve
as an effective alternative to more specialized systems.

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2. Basis of Technique

The PA-CATTM technique uses no new hardware, but instead uses existing PAUT instrumentation
in new ways. Modern instruments are extremely powerful, capable of capturing data in multiple
groups of pulse-echo and pitch-catch focal laws. The cost of the instrument and personnel training
are not inconsequential; and many of these systems may sit dormant waiting for utilization on the
next turnaround. Meanwhile, service companies are investing in separate technologies to address
CUPS inspections. PA-CATTM was conceived from the viewpoint of maximizing the return on
investment for capital equipment and utilization of NDT staff. The project mantra was to explore
and experiment with some new ideas to “see how far we could go with what we already have”.

There are many existing options already available for CUPS inspection [7], most commonly using
guided wave EMAT [1],[2],[3]. Piezo-electric techniques based on mono-element transducers and
time-of-flight have been found to be effective in some cases but require a pipe thickness of at least
15mm to resolve corrosion profiles [4],[5],[6].

The PA-CATTM technique is based on using a pitch-catch arrangement between two phased array
transducers placed on opposite sides of an area of suspected CUPS. A sectorial shear wave pitch-
catch focal law set is the primary measurement source. Received signals are then analyzed
collectively as a composite signal. In this manner, there is no reliance on any one beam path or
angle. Data integrity and supplementary information is evaluated using additional pulse-echo
groups. The analysis is performed using a combination of mathematical models which can be
applied to the entire composite or a subset of angles. Analysis is automated by the PA-CATTM
algorithm, with no signal interpretation required. The river bottom profile is the primary output
of a PA-CATTM analysis.

2.1. Defining the Corrosion “River Bottom”

If an area of corrosion is considered a 2D array of data points corresponding to depth (i.e. a

topographical height map), then the river bottom can be defined as the projection of deepest points
along the scan direction (Figure 1, Figure 2).

For basic fitness-for-service evaluations, the river bottom is commonly used when more detail is
required about the corrosion profile beyond just a single minimum remaining wall measurement
[9].

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Figure 1: Projection of river bottom profile Figure 2: Simple river bottom at 4 points

3. Equipment Requirements

PA-CATTM was conceived based on using existing equipment. The instrument, transducers,
wedges and a suitable scanner are all “off-the-shelf” components that many full-service PAUT
companies already utilize. The technique has been successfully tested using Sonatest, Olympus,
Zetec and M2M Eddyfi equipment.

The equipment used for the trial data presented were:

 Sonatest Veo+ 32:128 instrument

 Olympus 5L16-A10 transducer (x2)
 Olympus SA10-N55S wedge (x2)
 Jireh ODI-II scanner

3.1. PAUT Instrument and Focal Laws

PA-CATTM requires a phased array instrument capable of multiple, simultaneous focal laws or
groups. At a minimum, the equipment must be able to establish three groups:

 A primary pitch-catch (PC) sectorial shear wave group between two opposing probes
 Two pulse-echo linear longitudinal wave zero-degree groups for couplant monitoring
(CM1, CM2).

The instrument must be able to encode the data and export the PC and CM group data for analysis.
Most modern PAUT instruments are capable of exporting to comma separated value format (.csv)
which can often be performed from the instrument itself without the need for additional software.

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3.2. Transducers

The technique has been tested with 5MHz, 1D linear array transducers with 0.6mm pitch, 10mm
passive aperture in both 16 and 32 element configurations. A comparison of the data between 16
and 32 elements will be highlighted in an upcoming research paper.

3.3. Wedges

As PA-CATTM is primarily an attenuation-based technique, maintaining consistent coupling is

essential. Thus, wedge contour must match the specific outside diameter of the pipe to maximize
efficiency and eliminate rocking. Variations in received signal may be interpreted as wall loss and
decrease accuracy. Regular AOD or COD wedges used for weld inspection are suitable for PA-
CATTM.

3.4. Couplant

Water or another low-viscosity fluid must be used in combination with a pump system to maximize
coupling. Applied gel couplant does not provide consistent coverage and is not a suitable
alternative.

3.5. Scanner

Circumferential and longseam weld scanners may be adapted for use with PA-CATTM. Although
the scanners are not usually intended to be used at the high probe spacings used in PA-CATTM,
there are often enough extra components and adjustments that can be made to make them suitable.
Purpose-built PA-CATTM scanners are under development and will provide an ideal solution if
existing scanners are not available.

4. Development Stages

PA-CATTM began with trials on flat plates to study basic effects. The findings on flat plate are
discussed in this paper, while trials on machined pipe will be documented in a later report. Many
variables needed to be investigated including corrosion morphology effects, attenuation modeling,
probe spacing, aperture, focusing, and material thickness.

Regarding probe center spacing (PCS), in phased array and PA-CATTM the reference point used is
the front of the wedge. The term PCS is often used in the time-of-flight diffraction (TOFD)
technique to describe the distance between the beam exit points. Because a phased array sectorial
scan results in a moving beam index point, in PA-CATTM the PCS is measured between the fronts
of the wedges for ease of use.

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4.1. Trial 1: Flat Plate with Primitives

Testing of the initial concept began with the Trial 1 flat plates in thicknesses of 6.4mm (1/4 in.),
9.5mm (3/8 in.) and 15.9mm (5/8 in.). Machined into the plates were five spherical depressions
of 20%, 40%, 60%, 80% and 100% wall loss to simulate simple corrosion. The results are
documented in the previous paper by the authors [8]. Trial 1 showed promising results and set the
stage for the further trials to test algorithms to best measure river bottom profiles in realistic
corrosion.

Figure 3: Trial 1 plate

Figure 4: Results derived from Trial 1

4.2. Trial 2: Scattering Effects

Trial 2 involved testing plate with machined flat and dimpled sections of equal 40% wall loss.
This trial was intended to test the attenuation differences between smooth and extremely irregular
surfaces. Real corrosion being a compromise somewhere between these two ideals, the algorithm

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was refined to function effectively in later trials on realistic corrosion by understanding the limits
presented in Trial 2.

Figure 5: Trial 2 plate

Trial 2 also provided a simple layout to experiment with pulse echo edge detection. Additional
pulse-echo groups (PE1, PE2) were set up and used to measure the size of the corrosion feature
in the beam direction (Figure 6, Figure 7). Thus, for a limited set of trials, five groups were used
(PC, CM1, CM2, PE1, PE2) and analyzed.

Figure 6: PE1 and PE2 groups as displayed on instrument

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Figure 7: Top view images aligned with CAD model showing ability to measure size of corrosion features

4.3. Trial 3: Machined Corrosion on Plate

Trial 3 and later experiments use machined features meant to mimic real corrosion, which was a
vital component in developing a suitable algorithm. Some of the validation trials performed for
other techniques use simplified reference targets such as drilled holes and notches. While these
may be easily controlled for dimension and repeatability, they are not indicative of realistic
corrosion. For example, probability of detection (POD) using notches may be high but when
applied to real corrosion the results are often quite different. Probability of detection and sizing
validation using simplified targets was avoided during development of PA-CATTM in Trial 3 and
onwards.

The machined features in Trial 3 were prepared on flat plate and were laser scanned using
Creaform technology to ensure an accurate comparison to river bottom results [10]. The same
three plate thicknesses from Trial 1 and 2 were used in Trial 3. Four features were machined as
shown in Figure 8 representing different corrosion morphologies (elongated, general, aggressive,
grouped).

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Figure 8: Trial 3 plate with machined corrosion

The PA-CATTM results are shown in the following figures. Profile matching between PA-CATTM
and the laser scan data is quite good on the 9.5mm and 15.9mm plates. Note that on the 6.4mm
plate, there was insufficient length beyond the last feature for the scanner, which is the reason for
the irregular profile capture on the far-right side of Figure 9. In all cases, the analysis captures the
deepest point of the profile to within approximately 5-10%.

Figure 9: Trial 3 6.4 mm plate PA-CATTM results

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Figure 10: Trial 3 9.5 mm plate PA-CATTM results

Figure 11: Trial 3 15.9 mm plate PA-CATTM results

4.4. Trial 4: Machined Corrosion on Piping

At the time of this paper, testing of machined corrosion (based on laser scans of real CUPS) is
nearing completion. Trial 4 results will be documented in an upcoming report.

5. Experimental Findings

Based on the tests in Trial 2 and Trial 3, several findings were made and used to define equipment,
procedural requirements, and technique limitations.

5.1. Probe Spacing

It was demonstrated previously by the authors that on flat plate the algorithm was generally
independent of probe spacing [8]. The test was repeated on the plate samples with machined
corrosion and the results shown in Figure 9 to Figure 11. As in Trial 1, when applied to realistic

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corrosion morphologies, the technique results in a reasonable estimate of the actual river bottom
profile regardless of probe spacing (the same algorithm was used across all PCS distances).

5.2. Length of Corrosion Feature in Beam Direction

The river bottom profile is a result of attenuation due to restrictions presented by the reduced metal
ligament under the corrosion surface. Generally, a corrosion patch will scatter and attenuate the
signal to a higher degree if the length of the corrosion increases along the beam path.

During Trial 3, one feature on each of the three plates was extended to study the effect of
elongation. The first two features on the left half of the plate shown in Figure 8 are identical, the
only difference being that the first feature has been stretched to twice the length of the second.

Figure 12: Scanning for differences

due to elongation Figure 13: Results on elongated vs. normal area

The example in Figure 12 and Figure 13 shows the increase in measured profile depth when
examining the elongated feature (left) versus the normal feature (right). While PA-CATTM
accurately measured the maximum wall loss in both, the profile at adjacent areas is overestimated
when the corrosion is elongated in the beam direction. This margin of error is due to increased
attenuation at lower angles (i.e. more reflections).

Here it is evident that a major advantage of utilizing a phased array approach is the ability to “see
under” the corrosion profile at some specific angles which otherwise would have required prior
knowledge of the profile to establish matching refracting angles and PCS for use with mono-
element techniques.

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5.3. Over-estimating Wall Loss at Edges

Figure 14 shows a river bottom (left side) which is significantly more severe than the laser
profilometry data. This is to be expected, as the edges of any severe area of metal loss will be
tapered (tilted/non-parallel to pipe OD and ID) and will reflect sound off to the side. This loss of
received signal will be indistinguishable from attenuation due to wall loss.

Figure 14: Overestimation of wall loss at corrosion edge (left)

6. Conclusions

With continued progress and refinements to the algorithm, the authors have identified and
addressed most of the key variables affecting the performance of the PA-CATTM approach.
Baseline knowledge has been accumulated to anticipate effects of the equipment selection and
their capabilities, PCS, corrosion shape/form, corrosion position symmetry and P/C reciprocity.
The recognized physical problems with CUPS inspection are now being examined further in order
to clearly convey inspection requirements, but to also enable field technicians to pre-qualify the
collected scan data quality. Paint and coating bond quality, couplant performance, along with
other pipe condition and inspection environmental aspects will be examined as the PA-CATTM
solution is exposed to additional field program trials.

Demonstrated river bottom profiles compared with the laser data clearly shows excellent
correlation, and the accuracy tolerance presented is also well within an acceptable margin to enable
implementing one of the common engineering assessment methods [11].

PA-CATTM has been demonstrated to be effective on plate of thicknesses from 6.4mm (1/4 inch)
to 15.9mm (5/8 inch) and probe spacings from 150mm (6 inches) to 350mm (14 inches). Tests on
pipe are underway and have yielded promising results which will be published in an upcoming
paper. Replica corrosion patterns have been transferred to 6-inch and 10-inch diameter pipe to
help with repeatability trials and other lab activity. The combination of the new pipe mock-up

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replica samples and the continuation of on-going field trials will further refine the mechanical
delivery demands of pipe rack inspection and real-world environment problems.

References

[1] V. Garcia, C. Boyero, J.A. Jimenez Garrido, “Corrosion detection under pipe supports using
EMAT medium range guided waves”, 19th World Conference on Non-Destructive Testing,
Munich Germany, 2016
[2] M.S. Lindsey, O.M. Malinowski, J.K. Van Velsor, “Short-Range Guided Wave Testing for
Corrosion Under Pipe Supports”, 2015 ASNT Annual Conference Paper Summaries, ISBN:
978-1-57117-369-0, 2015
[3] D. Alleyne, “Guided Wave Testing for touch point corrosion”, 18th World Conference on
Non-Destructive Testing, Durban South Africa, 2012
[4] M. Lorenz, S. Lewandowski, “Ultrasonic Multi-Skip Inspection at Clamped Saddle
Supports”, 18th World Conference on Non-Destructive Testing, Durban South Africa, 2012
[5] S. F. Burch, N. J. Collett, S. Terpstra, M. V. Hoekstra, “M-skip: a quantitative technique for
the measurement of wall loss in inaccessible components”, Insight - Non-Destructive Testing
and Condition Monitoring, Volume 49, No 4, pp 190-194(5), April 2007
[6] S.F. Burch, H.R. Peramatzis, “M-skip for the sizing of uninsulated external corrosion to
determine the remaining wall thickness in thick-walled components”, 55th Annual
Conference of the British Institute of Non-Destructive Testing, NDT 2016 (2016) 34-44
[7] F. Hardie, “Evaluation of the effectiveness of non-destructive testing screening methods for
in-service inspection”, Health & Safety Executive Research Report RR659, England 2009
[8] P. Holloway, R. Ginzel, “Ultrasonic Phased Array Approach to Detection and Measurement
of Corrosion at Pipe Supports”, www.ndt.net, February 2020
[9] J.F. Kiefner, P.H. Vieth, “Project PR 3-805 A Modified Criterion for Evaluating the
Remaining Strength of Corroded Pipe”, Battelle Memorial Institute, 1989
[10] Holloway NDT & Engineering, “PAUT and Corrosion Under Pipe Supports (+ lasers!)”
[video file], retrieved from https://youtu.be/IfF5eVCHAxk , November 5 2020
[11] R. Amaya-Gómez, M. Sánchez-Silva, E. Bastidas-Arteaga, F. Schoefs, F. Munoz,
“Reliability assessments of corroded pipelines based on internal pressure – A review”,
Engineering Failure Analysis, 2019

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