Application of Flexible Ultrasonic Phased Array Technique on Detection of Fillet Welds in Small-Diameter Pipe Holder

2017 ◽  
Author(s):  
Weican Guo ◽  
Cunjian Miao ◽  
Xingji Du ◽  
Min Wang ◽  
Junfang Xia
Keyword(s):  
Nondestructive Testing ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Coupling Effect ◽  
Ultrasonic Inspection ◽  
Technical Problem ◽  
Small Diameter ◽  
Pressure Vessels ◽  
Fillet Welds ◽  
Diameter Pipe

Fillet welds in small-diameter pipe socket of pressure vessels always have complicated structures and groove types, which make it easy to produce porosity, lack of fusion, incomplete penetration and other flaws during welding. Therefore, nondestructive testing is a significant and meaningful approach to ensure the quality of welding for pressure vessels’ safety. Ultrasonic testing is the main method for nondestructive testing of pipe fillet welds. However, it is difficult to distinguish between the interference wave and the flaw echo, or to recognize the defect signal, while utilizing conventional ultrasonic testing technology. Additionally, the coupling effect is bad for traditional rigid probe on the concave surface when the probe is inserted into the small-diameter pipe to do the inner scanning. To obtain a good coupling effect, flexible phased array technology was put forward, with a bendable probe made from flexible materials. The probe could be bent and inserted into the inner pipe for longitudinal wave scanning, giving a good matching with the inner wall and replacing the traditional rigid probe. Besides, it is more convenient to conduct the ultrasonic testing, and the focal law could be changed easily according to the curve shape of the inner pipe, without replacing the probe. Thus, scanning and dynamic focusing in multiple angles and directions can be carried out, and the position, distribution and size of the flaws could be displayed intuitively combined with real-time imaging technology. This technology is able to obtain better coupling and detecting effects and solve the technical problem for concave ultrasonic inspection of fillet welds.

scholarly journals Ultrasonic Inspection for Welds with Irregular Curvature Geometry Using Flexible Phased Array Probes and Semi-Auto Scanners: A Feasibility Study

2022 ◽  
Vol 12 (2) ◽  
pp. 748
Author(s):  
Seong Jin Lim ◽  
Young Lae Kim ◽  
Sungjong Cho ◽  
Ik Keun Park
Keyword(s):  
Feasibility Study ◽  
Ultrasonic Testing ◽  
Test Specimen ◽  
Phased Array ◽  
Ultrasonic Inspection ◽  
Branch Pipe ◽  
Small Diameter ◽  
Data Consistency ◽  
Industrial Sites ◽  
Inspection Data

Pipes of various shapes constitute pipelines utilized in industrial sites. These pipes are coupled through welding, wherein complex curvatures such as a flange, an elbow, a reducer, and a branch pipe are often found. Using phased array ultrasonic testing (PAUT) to inspect weld zones with complex curvatures is faced with different challenges due to parts that are difficult to contact with probes, small-diameter pipes, spatial limitations due to adjacent pipes, nozzles, and sloped shapes. In this study, we developed a flexible PAUT probe (FPAPr) and a semi-automatic scanner that was improved to enable stable FPAPr scanning for securing its inspection data consistency and reproducibility. A mock-up test specimen was created for a flange, an elbow, a reducer, and a branch pipe. Artificial flaws were inserted into the specimen through notch and hole processing, and simulations and verification experiments were performed to verify the performance and field applicability of the FPAPr and semi-automatic scanner.

Optimizing Probe Active Aperture for Phased Array Weld Inspections

2021 ◽  
Vol 79 (8) ◽  
pp. 797-804
Author(s):  
Anmol Birring
Keyword(s):  
Fracture Mechanics ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Pressure Vessels ◽  
Acceptance Criteria ◽  
Nondestructive Technique ◽  
Cross Sectional ◽  
Area Of Interest ◽  
Array Technology ◽  
Selection Of

Phased array ultrasonic testing (PAUT) has become a popular nondestructive technique for weld inspections in piping, pressure vessels, and other components such as turbines. This technique can be used both in manual and automated modes. PAUT is more attractive than conventional angle-beam ultrasonic testing (UT), as it sweeps the beam through a range of angles and presents a cross-sectional image of the area of interest. Other displays are also available depending on the software. Unlike traditional A-scan instruments, which require the reconstruction of B- and C-scan images from raster scanning, a phased array image is much simpler to produce from line scans and easier to interpret. Engineering codes have incorporated phased array technology and provide steps for standardization, scanning, and alternate acceptance criteria based on fracture mechanics. The basis of fracture mechanics is accurate defect sizing. There is, however, no guidance in codes and standards on the selection and setup of phased array probes for accurate sizing. Just like conventional probes, phased array probes have a beam spread that depends on the probe’s active aperture and frequency. Smaller phased array probes, when used for thicker sections, result in poor focusing, large beam spread, and poor discontinuity definition. This means low resolution and oversizing. Accurate sizing for fracture mechanics acceptance criteria requires probes with high resolution. In this paper, guidance is provided for the selection of phased array probes and setup parameters to improve resolution, definition, and sizing of discontinuities.

TOFD Automatic Ultrasonic Testing for Condition Monitoring of Coke Drums

2003 ◽  
Author(s):  
Jorge A. Penso ◽  
Robert Owen ◽  
Masaaki Oka
Keyword(s):  
Condition Monitoring ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Service Evaluation ◽  
Pressure Vessels ◽  
Inspection System ◽  
Delayed Coking ◽  
Advantages And Disadvantages ◽  
Mechanical Cycling ◽  
History Of

Cracking and bulging in welded and internally lined pressure vessels that work in thermal-mechanical cycling service have been well known problems in the petrochemical, power and nuclear industries. In spite of this problem has been studied during the last fifty years, published literature and industry surveys show that similar problems still occur nowadays. Typical examples of this problem are the coke drums in the delayed coking units refinery process. Delayed coking units are among the refinery units that have higher economical yields. To shut down these units represents a high negative economical impact in refinery operations. Also, the maintenance costs associated with repairs are commonly very high. Cracking and bulging occurrences in the coke drums, most often at the weld areas, characterize the history of the operation of delayed coking units. To anticipate through wall cracking in these coke drums, AUT (automatic ultrasonic testing); Dual TOFD (time of flight diffraction) and the Phased Array technique simultaneous inspection system was selected among other inspection techniques as a condition monitoring tool during an unit turnaround. The inspection methodology in combination with fracture mechanics was used to classify discontinuities as acceptable and non-acceptable. This indicated approach helped to optimize the workscope during the turnaround and establish guidelines for inspection and repair of the delayed coker unit. This work presents the different steps followed during the inspection and fitness for service evaluation. Also, this study shows advantages and disadvantages of the AUT-Phased Array technique.

CIVA Simulation and Experiment Verification for Thin-Walled Small-Diameter Pipes by Using Phased Array Ultrasonic Testing

2020 ◽  
Author(s):  
Jun Si ◽  
Daoxiang Wei ◽  
Yuqing Yang ◽  
Xiaoying Tang
Keyword(s):  
Phased Array ◽  
Small Diameter ◽  
Radiographic Testing ◽  
Diameter Pipe ◽  
Array Probe ◽  
Experiment Verification ◽  
Simulation And Experiment ◽  
Detection Capabilities ◽  
Thin Walled ◽  
Defect Detectability

Abstract Regular inspection is important to verify the integrity of in-service pipeline in the petrochemical industry. Early detection of flaws is therefore essential to ensure the continued safe operation of pipeline. In generally, Conventional ultrasonic for thin-walled small-diameter pipes has limitations due to regulation requirements, efficiencies, lack of permanent results and repeatability. In many cases, the preferred method of inspection is radiographic testing, however there are many obvious shortcomings for radiographic detection. The aim of this work was to propose appropriate phased array ultrasonic scan plans that were able to achieve the following: reduce the inspection times, improve defect detectability and sizing, and reduce human intervention, which will reduce workforce radiation uptake. Ultrasonic simulation using CIVA and experimental verification for thin-walled small-diameter pipe with flaws that were carried out to determine the most appropriate phased array probe and its detection capabilities in this paper.

Scanners for Ultrasonic Inspection

NDT World ◽  
2015 ◽  
Vol 19 (4) ◽  
pp. 77-80
Author(s):  
Цомук ◽  
Sergey Tsomuk ◽  
Ястребов ◽  
Viktor Yastrebov
Keyword(s):  
Base Metal ◽  
Manufacturing Process ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Detection Efficiency ◽  
Ultrasonic Inspection ◽  
Flaw Detection ◽  
Piezoelectric Transducers ◽  
Large Dimension ◽  
Testing Problem

In recent years, to enhance flaw detection efficiency when using ultrasonic testing, phased array probes are increasingly used. However, in many cases this can also be achieved by using scanning devices with conventional piezoelectric transducers, which is much cheaper. The purpose of the article is to analyze the design and operation of such scanning devices. The article provides brief information about ultrasonic testing main scanning schemes, describes scanners that have been developed and widely used to perform inspection of welds, base metal of pipes, railcar axles and wheels. It is shown that, for large dimension objects, scanners allow not only a significant increase in the scanning performance but also solve the testing problem in principle, and (for example, when testing railcar axles) change (make it easier and cheaper) manufacturing process, including inspection operations and wage wheels repair. As a result of analysis, conclusions are made about the efficiency of using, in specific and important practical tasks, scanning devices for ultrasonic testing of steel products of different sizes, which certainly does not deny the application perspectiveness of using phased array probes.

Automated Ultrasonic Inspection of Pressure Vessel Welds

2004 ◽  
Author(s):  
Michael Moles ◽  
Simon Labbe´
Keyword(s):  
Ultrasonic Testing ◽  
Phased Array ◽  
Low Cost ◽  
Ultrasonic Inspection ◽  
Safety Hazard ◽  
Asme Code ◽  
Conventional Systems ◽  
Pulse Echo ◽  
Inspection Techniques ◽  
Production Inspection

ASME Code Case 2235 now permits automated ultrasonic testing (AUT) instead of radiography for vessels 0.5” (12.7 mm) or greater. Ultrasonic testing has significant advantages over radiography: no safety hazard so no disruption of production; inspection as soon as component cools; rapid feedback; defect vertical sizing for Fitness-For-Purpose applications; tailored inspections. ASME CC 2235 permits a variety of inspection techniques based on pulse-echo and Time-Of-Flight Diffraction (TOFD), provided a Performance Demonstration is achieved. This paper describes a number of AUT systems which fulfill the ASME code case. These AUT systems range from a portable phased array system (Omniscan) for low cost and convenience, through conventional systems based on TOFD (μ-Tomoscan), general phased array systems (Tomoscan III) to premium systems with multiple NDE approaches. With such a variety of technologies and costs, AUT systems can be tailored to the client’s needs.

scholarly journals Acoustic Field of a Linear Phased Array: A Simulation Study of Ultrasonic Circular Tube Material

Sensors ◽  
2019 ◽  
Vol 19 (10) ◽  
pp. 2352 ◽  
Author(s):  
Zhitao Xiao ◽  
Yongmin Guo ◽  
Lei Geng ◽  
Jun Wu ◽  
Fang Zhang ◽  
...  
Keyword(s):  
Nondestructive Testing ◽  
Acoustic Field ◽  
Simulation Study ◽  
Phased Array ◽  
Circular Tube ◽  
Ultrasonic Transducer ◽  
Ultrasonic Inspection ◽  
Beam Model ◽  
Tube Material ◽  
Propagation Behavior

As ultrasonic wave field radiated by an ultrasonic transducer influences the results of ultrasonic nondestructive testing, simulation and emulation are widely used in nondestructive testing. In this paper, a simulation study is proposed to detect defects in a circular tube material. Firstly, the ultrasonic propagation behavior was analyzed, and a formulation of the Multi-Gaussian beam model (MGB) based on a superposition of Gaussian beams is described. The expression of the acoustic field from a linear phased-array ultrasonic transducer in the condition of a convex interface on the circular tube material is proposed. Secondly, in order to make the tapered probe wedge better fit the curved circular tube material and carry out the ultrasonic inspection of the curved surface, it was necessary to pare the angle probe wedge. Finally, acoustic field simulations in a circular tube were carried out and analyzed. The simulation results indicated that the method of ultrasonic phased-array inspection is feasible in circular tube testing. Tube materials with different curvatures need different array element lengths and widths to get the desired focused beam.

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