Advanced Phased Array Techniques for Defect

Identification & Characterization

Brandon Reitz
NDT TECHNOLOGY MANAGER

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ADVANCED PHASED ARRAY TECHNIQUES FOR DEFECT IDENTIFICATION & CHARACTERIZATION

Agenda

1
Phased Array &
2
Advanced
3
Case Studies
Conventional UT Techniques

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Phased Array & Conventional UT

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Phased Array
Ultrasonic Testing
• Originally developed as a
complementary application to
conventional UT
• Utilize time delays to multiple
elements to focus and steer
the sound beam
• Collects and visualizes data
convention UT cannot - weld
inspection, bond testing,
thickness mapping, crack
detection

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 Phased Array vs Conventional UT

Phased Array Conventional

10 MHz 7.5 MHz
1.51” coverage (38.4 mm) 0.187” coverage (5 mm)
Electronically controlled Fixed beam characteristics
beam properties

2.0”

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 Phased Array vs Conventional UT

Phased Array
7.5 MHz – 32 Element
40-75° Sectoral
Full coverage of the weld

Conventional
5 MHz – 0.500”
60°
Requires rastering

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Data Imaging Comparison
1.9” (48 mm) Demonstration Block

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 Data Imaging Comparison

Flat Bottom Holes Round Bottom Holes

Conventional UT

Phased Array UT

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 Data Imaging Comparison

Conventional UT Phased Array UT

0.375” UT Linear 64 Element
0.250” x 0.050” Resolution 0.039” x 0.039” Resolution
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 Phased Array Benefits

• Resolution: Quantifiable approach for differentiating between manufacturing

defects and service-related damage
• Speed: Despite the mechanical system used, scanning with phased array is faster
than a single UT probe by offering greater coverage.
• Flexibility: Setups are modular, and typically, more component-gemoetry flexibility
is available.
• Inspection angles: Various angles can be used depending on the requirements and
the array configuration.
• Data imaging: Showing a “true depth” image of defects is much easier to interpret
than a waveform.

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Advanced Techniques

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Tri-Lateral Phased Array

• Robotic-enabled ultrasonic testing technique

• On-stream, base metal inspection of carbon steel and low alloy
equipment
• Identifies and characterizes insidious damage mechanisms in
caustic environments
• Wet H2S Damage (HIC, SOHIC, SSC), HTHA, environmental
cracking, H blisters
• Three-beamset configuration
• Linear: probe with 0Ǎand 30Ǎbeam sets
• Lateral: probe with 45Ǎfixed steering with passive plane
focalization

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 0° Linear 30° Linear 45° Lateral

Tri-
Lateral
Phased
Array

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 Advanced Data Acquisition Techniques

Full Matrix Capture (FMC): each element in Plane Wave Imaging (PWI): all or groups
the phased array probe is pulsed individually elements are excited simultaneously (like
while all elements receive the signals, creating conventional phased array) while the returning
a matrix of elementary A-scans signals are “listened to” by all elements

Source: https://www.olympus-ims.com/en/applications/using-the-total- Source: https://pubmed.ncbi.nlm.nih.gov/24402899/

focusing-method-to-improve-phased-array-ultrasonic-imaging/

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 Advanced Data Imaging Techniques

Total Focusing Method: Reconstructs the Phase Coherence Imaging (PCI): uses the
elementary A-scans generated from FMC or phase distribution of normalized A-scans to
PWI pixel by pixel, differentiating areas of high identify high levels of coherence, advantageous
amplitude (defect) from areas of low amplitude for identifying small defects in noisy materials

Source: https://www.olympus-ims.com/en/white-papers/phase-
coherence-imaging-for-flaw-detection/
Source: https://www.olympus-ims.com/en/insight/tfm-resources/
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 Processing PCI Data
In standard TFM both Amplitude
Delay-and-Sum (TFM)
Phase and Amplitude are
calculated into the
resulting images

Raw data is collected

through the normal FMC Raw FMC A-Scan
process

Amplitude is removed
leaving only the Phase
Phase
information to process (PCI)
into a TFM image
 Manual UT Phased Array

Data Imaging
Comparison
ID-connected cracking in a single
V carbon steel weld

TFM PCI
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 Advantages of TFM/PCI
• Increased POD • Improved sizing, sensitivity, and
characterization of defects
• High resolution imaging without the need to
configure the focusing or aperture • Basic image is easier to understand

• Optimal focusing everywhere in the image • Better geometric positioning

• Imaging of stacked defects
HIC - Tri-Lateral – 10 MHz - 64 Element Probe

TFM PCI

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Disadvantages of TFM/PCI

• Low production rate

• Difficult to automate
• Large data file sizes requiring
significant storage and processing
power
• Difficult to implement on complex
geometries
• Flaw detection is very dependent
proper setup

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Case Studies

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 Condensate Storage Vessel Shell

Challenge
Out of service vessel, used for technician qualification
• 2002: HIC & H blisters first identified (manual SWUT)
• Annual inspection schedule following FFS
• Slow growth and stepwise cracking found over time
• 2020: Vessel removed from service

Solution
Deployment of TriLat robotically
FMC with TFM and PCI Imaging

Result
No step-wise cracking.
Extensive laminations, but no HIC indications
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 Defect 1
Defect: 1
Depth: 4.5mm from OD
Dimension: 13mm x 63mm
Characterization: Lamination

Tri-Lateral PAUT
0°L/30°L/45°S
C-Scans Defect 2

Defect: 2
Depth: 6.98mm from OD
Dimension: 11mm x 66mm
Characterization: Hydrogen Blister

Defect: 3
Depth: 4.29mm from OD Defect 3
Dimension: 10mm x 61mm
Characterization: Lamination

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 FMC - TFM FMC - PCI

Defect: 1
Depth: 4.5mm from OD
Dimension: 13mm x 63mm
Characterization: Lamination

FMC Data
TFM 0° (L-L)
PCI 0° (L-L)
Defect: 2
Depth: 6.98mm from OD
Dimension: 11mm x 66mm
Characterization: Hydrogen Blister

Defect: 3
Depth: 4.29mm from OD
Dimension: 10mm x 61mm
Characterization: Lamination

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FMC - TFM FMC - PCI
 Amine Recycle Gas Scrubber

Challenge
Non-intrusive inspection pre-TAR to monitor H blistering
Inspection history:
• 2012: Tri-Plex AUT, identified H blistering
• 2018: Tri-Plex AUT, no growth in blistering
• 2021: Tri-Plex AUT, no growth in blistering

Solution
2022: TriLat and PAUT weld inspection deployed robotically
TriLat with TFM and PCI Imaging

Result
Significant HIC and weld-adjacent SOHIC found
2023: Removed from service and replaced

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 Amine Recycle Gas Scrubber

Tri-Plex AUT Tri-Lateral

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 Amine Recycle Gas Scrubber

TriLat 0° PA

TriLat 0° TFM

TriLat 0° PCI
Tri-Lateral

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 Amine Recycle Gas Scrubber

TriLat 0° PA

TriLat 0° TFM

TriLat 0° PCI
Tri-Lateral

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TriLat Data
TFM 0° (L-L)

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TriLat Data
PCI 0° (L-L)

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Questions
Brandon Reitz
NDT TECHNOLOGY MANAGER
brandon.reitz@geckorobotics.com

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