Weld Analysis

INTRODUCTION
TO
WELD ANALYSIS

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 Analysis – Flaw Characterization Overview
 Flaw characterization is defined as the ability to identify flaw types
and geometry based on failure mechanism, location, and imaging.

 Knowledge of the weld process is extremely helpful. You can

eliminate porosity or slag as a possibility for processes that do not
produce them.

 For some weld bevel types and processes typical of the pipeline
industry >90% of the defects are either lack of side wall fusion or

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inadequate penetration.

 In-service inspections are typically for cracks and metal loss.

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Although cracks can occur in any environment new construction
welds are primarily for fabrication defects such as IP, LOF,
LOSWF, slag, porosity, etc.
 It is normally necessary to have participated in the data acquisition
to be proficient in the analysis due to differences in weld processes
and inspection conditions from one job to another. The exception
to this is factory or fabrication facilities were welds of the same
process, configuration, and size are inspected repeatedly.

 There is no substitute for experience. The benefit of analysis on

welds for which the inspector is familiar or for which testing was

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performed on notches or SDHs in the weld cannot be overcome
with software features and training.
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Analysis – A-Scan/S-Scan Imaging

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Analysis – A-Scan/S-Scan Imaging

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Analysis – A-Scan/S-Scan Imaging (SWLF)

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Analysis – Flaw Characterization (SLAG)

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Analysis – Flaw Characterization

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Analysis – Sizing with cursors

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Analysis – Flaw Characterization (ID crack)

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Analysis – Flaw Characterization (OD crack)

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Analysis – Flaw Characterization (Porosity)

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Analysis – Flaw Characterization (IP)

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NOW LET US LOOK AT
METHODS OF
INPECTION WHEN
LOOKING AT PHASED

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ARRAY IMAGES ©

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 Root Defects

Note:-

Remember to
size defects
from both
skews!
Responses
may vary.

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Place blue cursor to plate thickness.

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With extractor through centre of defect, take
note of echo amplitude.
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Move extractor across defect until amplitude

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just starts to drop – place red cursors on intersection
with defect.
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Place cursors on ends of defects – red to

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left, blue to right.
Record on indication table.
 Weld Body Defects - LOF

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Place extractor through the centre of the defect.

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Note that this indication is saturated – accurate
sizing is not possible.
 Weld Body Defects - LOF

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Move extractor until the echo starts to drop
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Move extractor back one angle – to where echo starts to

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drop – (remember we are using Max Amp sizing).
Place red cursor at intersection of defect with extractor.
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Repeat with blue cursor on bottom of defect.
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Place cursors at ends of defect.

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Note that zooming in can be helpful
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Complete Indication Table
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Slag defect is not immediately evident on the C scan, but on the S scan it

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should show up as the reference cursor is scrolled through weld.
Placing extractor through the centre of the defect will make it stand out on the
B scan.
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With no soft gain added the signal from the defect is liable

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to be undersized.
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Adding 12dB of soft gain, then scrolling along the defect

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will show the extent of the defect.
Take care in using soft gain, as in conventional UT, we do
not want to include small, irrelevant defects.
 90 Skew 270 Skew

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Using the 90 Skew, including the end “blip”, makes the defect 151 to ©
177mm. With the 270 Skew, no “blip” makes it 168 to 179mm

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A change in length from 26mm long to only 11mm long!
 TomoView Analysis
Producing an indication table

Select
indication
table icon

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 TomoView Analysis
Producing an indication table

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Indication table
appears
 TomoView Analysis
Producing an indication table

Press +
button

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Box
appears ©

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Press additional
information
 TomoView Analysis
Producing an indication table

Open additional
information, open
reference cursor and
cursors. Check boxes
S(r), D(r),
S(m-r) and U(m-r)

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 TomoView Analysis
Producing an indication table
Defect 1 Characterisation  

Defect depth (D(r) :  

Distance from datum S(r):  

Defect length S(m-r) :  

Defect height U(m-r):  

The red cursor on TomoView represents the

reference cursor (r). The blue cursor represents
the measurement cursor (m).

U = height measurement (true depth, using A

and S views)

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S = length measurement (using B and C views)

Note: the red cursor shall be placed at the top of ©

the defect closest to the component scan

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surface for height and closest to the datum for
length sizing.
 TomoView Analysis
Producing an indication table

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Example of
correct cursor ©

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positions
 TomoView Analysis
Producing an indication table

select

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Draw a box around the defect on the ‘C’ view – These represent the
z-coordinates and are not important with regards to the analysis – they
help to identify the defect on the report by numbering
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ENSURE THE CURSORS ARE IN THE CORRECT POSITION !!!!
 TomoView Analysis
Producing an indication table

After ensuring

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your cursors are
in the correct
positions click on ©

the ‘B’ scan tab

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bar – make sure
Press + the defect box it is the active
is now labelled 1 view
 TomoView Analysis
Producing an indication table

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Continue with your analysis going through the same process for
the other defects you find
 TomoView Analysis
Producing an indication table

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Defect 2
 TomoView Analysis
Producing an indication table

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The report may
then be ©
previewed and

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saved

Defect 3
The analysis Report

Scan
details

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 The analysis Report

Defect table summary

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 The analysis Report

Defect type can be added into the

comments Box

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Individual defect table summary with image –
Defect 1
 The analysis Report

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Individual defect table summary with image –
Defect 2
The analysis Report

Individual
defect table
summary with
image –
Defect 3
and technician
sign off

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 Analysis

Questions ???

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