PROCEDURE FOR PHASED ARRAY Doc.

QA/PAUT/01
No:
ULTRASONIC EXAMINATION Rev. 0
OF TUBE No:
Date: 07.03.2023
WELDS

1.0 SCOPE:-
1.1 This procedure describes the requirement and application of advanced Phased Array
Ultrasonic Test (PAUT) for detection and evaluation of discontinuities within Tube to Tube
butt welds and heat affected zone of weld joints of Air box, Panels and coils. This procedure
is in accordance with the requirements of Article 4 of ASME Section V and ASME B 31.1
Code Case 179.
1.2 This procedure is applicable to weld thickness of 2.5 mm and above, single V groove weld
configuration and for examination of materials of product form pipes / tubes having diameter
20.3 mm to 114.3 mm. Examination shall be conducted from outer surface of the component
to cover 100% volume of the weld and 25% of thickness on each side of the weld. Details of
weld bevel geometries and wall thicknesses will be provided in a scan plan that will be
prepared prior to commencement of examination in accordance with this procedure.

2.0 REFERENCE
2.1 Latest revisions of the following documents shall be referred to in conjunction with this
procedure:
 ASME Section V Article 4: Ultrasonic Examination Methods for Welds.
 ASME Code Case 179: Use of Alternative Ultrasonic Examination acceptance criteria
in ASME B 31.1.
 OmniScan and COBRA Scanner Operation Manual

3.0 ESSENTIAL VARIABLES FOR QUALIFICATION OF PROCEDURE

3.1 Essential and nonessential variables of this procedure are listed in Table No. 3.1.
3.2 Change in specified value or range of values in essential variables listed in Table No. 3.1
shall require re-qualification of this procedure by demonstration.
3.3 Change in specified value or range of values in non-essential variables listed in Table No. 3.1
does not require re-qualification of the procedure by demonstration.
3.4 Change in specified value or range of values in essential and non-essential variable listed in
Table No 3.1 shall require revision of this procedure.
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Table 3.1 – Requirements of an Ultrasonic examination procedure

Essential Nonessential
Requirements Para Nos
Variable Variable
Weld configurations to be examined, including thickness
dimension and base material product form (pipe, plate, X 1.2
etc.,)
The surface from which the examination shall be
X 5.0
performed.
Technique(s) (straight beam, angle beam, contact, and/or
X 8.0
immersion).
Search unit types(s), frequency(ies), element size / shapes,
X 12.0
number, pitch and gap dimension)
Wedges X 12.2
Focal range (identify plane, depth, or sound path as
X 14.0
applicable)
Virtual aperture size (number of elements, element width
X 13.5
and effective height)
Wedge natural refracted angle X 12.3
Scan plan X 13.0
Sweep angular range X 11.3
Angular sweep increment (incremental angle change,
X 18.5
deg)
Aperture element numbers (first and last) X 13.5
Ultrasonic instrument(s) X 11.0
Calibration (calibration block(s) and technique(s)) X 16.0, 17.0
Directions and extent of scanning. X 18.0
Scanning (manual Vs automatic) X 18.0
Method for discriminating geometric from flaw
X 9.0
indications
Method for sizing indications X 21.0
Computer enhanced data acquisition, when used. X 11.6
Scan overlap (decrease only) X 18.4, 18.5
Personal performance requirements, when required X 4.3
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Personnel qualification requirements X 4.0

Surface condition (examination surface, calibration) X 6.0
Couplant: brand name or type X 7.0
Weld axis reference point marking X 6.4, 6.5
Automatic alarm and/or recording equipment, when
X 19.0
applicable
Post examination cleaning technique X 25.0
Records, including minimum calibration data to be
X 24.0
recorded (e.g., instrument settings)

4.0 PERSONNEL CERTIFICATION

4.1 Personnel who carry out system setup, data collection and data analysis shall be trained,
qualified and certified in accordance with Written Practice No. QA-WP-02.
4.2 Personnel performing & evaluating PAUT examination to Code requirements shall be
minimum Level II.
4.3 When required by the construction Code, a personnel demonstration shall be used to verify
the ability of the examiner to apply this examination procedure.

5.0 SURFACES FROM WHICH EXAMINATION SHALL BE PERFORMED

5.1 Examination shall be performed from surfaces as per the scan plan attached to this
procedure.

6.0 SURFACE CONDITION

6.1 Base material
The base material on each side of the weld shall be free of weld spatter, surface irregularities
or foreign matter and shall be prepared as necessary to permit examination.
6.2 Weld metal
Where the weld surface interferes with the examination, the weld shall be prepared as needed
to permit examination
6.3 The finish on the scanning surfaces of the calibration block shall be representative of the
scanning surface finishes on the component to be examined.
6.4 Inspection areas will be designated by numbers allocated to welds to be examined. Within the
prepared area for inspection there will be a “zero” reference index and/or position numbers
marked on the weld during initial examination. This unique weld numbering system shall be
recorded as part of the file storage data.
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6.5 All circumferential measurements shall be made clockwise from the zero reference position
on the weld when looking in the direction of product flow. When scans are made from a pipe
to a flange where no scan access is had on the flange or fitting, the circumferential
measurement shall be made clockwise when looking at the flange from pipe side. When
multiple scanning is required, reference point shall be the same so that the location of the
flaw will match.

7.0 COUPLANT
7.1 Couplants having good wetting characteristics, transmission of ultrasound, resistance to
corrosion and removal characteristics shall be used. For this inspection, couplant shall be
starch, water or any other similar material. The same couplant shall be used for calibration
and examination.

8.0 TECHNIQUE
8.1 Phased Array Ultrasonic (PAUT) examination shall be carried out by direct contact, angle
beam technique using search units with more than two elements for welds and straight beam
technique for adjacent base metal.
8.2 This technique is a process wherein UT data are generated by controlled incremental
variation of the ultrasonic beam angle in the azimuthal or lateral direction while scanning the
object under examination

9.0 COMPUTERIZED IMAGING TECHNIQUES

9.1 Computerized Imaging Techniques (CITs) shall be used to evaluate indications and to
perform the basic scanning functions required for flaw detection. Computer-processed data
analysis and display techniques shall be used in conjunction with automatic or semi-
automatic scanning mechanisms to produce two and three-dimensional images of the flaws.
9.2 Computer processes shall be used to quantitatively evaluate, as required by the construction
Code, the type, size, shape, location and orientation of flaws detected.

10.0 ANGLE AND MODE OF WAVE PROPAGATION IN THE MATERIAL

10.1 An appropriate range of angles shall be selected for the configuration being examined.
10.2 A contact angle beam in shear mode of wave propagation shall be used for examination of
welds and contact straight beam in longitudinal mode of wave propagation shall be used for
examination of adjacent base metal.

11.0 EQUIPMENT
11.1 The phased array ultrasonic instrument shall be an OmniScan MX2 pulse echo type
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instrument equipped with a calibrated dB gain or attenuation control stepped in increments

of 2 dB or less. The Equipment shall contain 16 independent pulser / receiver channels.
11.2 The System shall be capable of generating the B-Scan, C-Scan, S-Scan (Sectorial scan)
display along with A-scan.
11.3 Examination personnel may use a real-time sectorial scan image during scanning to assure
that proper data has been collected. Sectorial-scan images contain signal amplitude and
reflector depth information projected for the refracted angle of the ultrasonic beam.
11.4 The equipment shall be equipped with on-board focal law generation software, which permits
direct modification of the ultrasound beam characteristics for performing either electronic
linear scan (E-scans) or sectorial scan (S-scan)
11.5 The data storing capabilities of the system requires the use of an external storage device,
flash card or USB memory stick. In addition to data storage, the PC may also be used to
analyze data subsequent to the completion of data collection. Offline Data-display and
analysis software (Tomoview 2.7R6 or higher version) compatible to that residing on the
OmniScan system may be used for data play-back.
11.6 Data acquisition shall be carried out using OmniScan MX2 main frame equipped with a PA
module.
11.7 Amplitude control linearity of Instrument used for performing the examination shall be
evaluated for each pulser receiver circuit in accordance with Mandatory Appendix II of
ASME Section V, Article 4. Linearity checks may be performed as per manufacturer’s
standard practice which meets or exceeds the requirements of ASME Section V, Article 4, T-
460. In this case calibration certificates including verification readings shall be provided by
manufacturer or by agency approved by Manufacturer.
11.8 Instrument linearity check shall be conducted after every 12 months from first use.

12.0 SEARCH UNIT, WEDGES

12.1 A low profile 1D linear phased array probe of 16 elements with a pitch of 0.5 mm shall be
used. The nominal frequency shall be 7.5 MHz.
12.2 Probe shall be mounted on SA15-N60S-IHC AOD wedges, selected appropriately as per
respective diameter of tube / pipe.
12.3 The natural refracted angle of wedge shall be 60° of shear wave. Nominal refracted-wedge
angles shall be 35 - 70 degrees in shear wave to ensure coverage of the weld and heat
affected zone.

13.0 SCAN PLAN

13.1 A scan plan shall be prepared prior to commencement of inspection showing examination
surfaces, search unit placement and movement that provides a standardized and repeatable
methodology for the examination.
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13.2 The scan plan shall be prepared by plotting or by using a computer simulation for each type
of weld configuration of equal or unequal wall thickness and selecting the appropriate
refracted angle for E-scan and range of angles for S-scan that will be used during the
examination. ESbeam software tool shall be used to prepare the scan plan.
13.3 Scan plan shall include beam angles and direction with respect to the axis reference point
and geometry.
13.4 The examination range of angles for S-scan shall be adequate for the part to be examined. An
overlap of 10% of the active aperture shall be maintained and in case of S-scan the angular
sweep increment shall be a maximum of 1degree.
13.5 Scan plan shall contain following information also:
The effective size of pulsing element which is usually comprised of a group of individual
elements (i.e. virtual aperture size) that are pulsed simultaneously.
Effective height of virtual aperture
First and last element number of virtual aperture
13.6 Scan plan for each type of weld shall be attached to the report.

14.0 FOCAL RANGE

14.1 Screen distance (Range) calibration shall be carried out for least 1 ½ ‘V paths’ (also known
as skip) for minimum angle that will be used during the examination.

15.0 SCANNER
15.1 PAUT shall be carried out with the Olympus small manual scanner (COBRA) as shown in
figure 15.1. The scanner is capable of inspecting standard tubes / pipes of size 21.3 mm OD
to 114.3 mm OD. The scanner is characterized by a smooth rolling encoded movement (32.08
steps/mm) enabling precise data acquisition.
15.2 Mechanical holders shall be used to ensure that the probe spacing is maintained at a fixed
distances for scan offset and index offset.
15.3 The scanner holds two low profile phased array probes and wedges as mentioned above.
15.4 For pipe to component inspections, the scanner shall be configured to make one sided
inspections with only one probe after demonstrating by plotting or with using a computer
simulation that full volume of weld will be examined.
15.5 The easy integration and assembly of the scanner to suit various diameters is accompanied by
two templates that are provided in the scanner kit.
15.6 Probe motion shall be achieved by moving scanner manually. The mechanical holder for the
probes shall be equipped with a positional encoder that is synchronized with the sampling of
A-scans.
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Fig. 15.1 – COBRA Scanner

16.0 CALIBRATION BLOCK

16.1 Ultrasonic system shall be calibrated using calibration blocks designed for PAUT techniques.
An example for 4.5 mm thick & 44.5 mm OD tube weld is shown in Figure 16.1.

Fig. 16.1 – Calibration block

16.2 Block curvature shall essentially be within the same curvature range of the examination
component and the AOD range of the wedge.
16.3 Side drilled holes of 1.5 mm diameter placed at 1T, 2T and 3T depths with a good separation
between the holes for effective focal law calibrations for the diameter and wall thickness
range.
16.4 Alternate calibration block as shown in Figure 16.4 may be used for PAUT sensitivity, wedge
delay and time corrected gain calibrations.
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Fig. 16.4 – Alternate calibration block pipe / tubes

16.5 Notches in alternate calibration block shall be located not closer than thickness of the part or
25 mm whichever is greater, to any block edge or another notch.
16.6 The minimum calibration block length shall be 200 mm or 8T whichever is greater. For 100
mm OD or less the minimum arc length shall be 270 degree.
16.7 Notch depth shall be minimum 8%T to 11%T maximum. Notch width shall be 1 mm
(maximum) and length shall be 25 mm (minimum).

17.0 PHASED ARRAY SYSTEM CALIBRATION

17.1 The surface of the calibration block shall correspond to the component surface to be
examined. System calibration shall include the complete ultrasonic examination system. The
system calibration information shall be recorded on the ultrasonic data report form used in
Omni scan®. During scanning, only the gain may be adjusted from the calibrated reference
dB. Adjustment of other controls requires recalibration.
17.2 WEDGE DELAY CALIBRATION
a) The wedge delay calibration shall be carried out for both linear scan and as well as
sectorial scan. The wedge delay calibration shall be carried out in true depth mode and
done with a known reflector depth.
b) Peak up the signal from the calibration reflector and scan the phased array probe
backwards through all the different angles or focal laws. Scan forward over the
calibration reflector through all the refracted angles of focal laws. When the signal for
all angles and focal laws lies within the threshold, calibrate the Omni scan system to
adjust all the focal laws / angles to display the reflector’s true depth. Figure 17.2 shows
the wedge delay calibration window.
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17.3 SENSITIVITY CALIBRATION

a) The sensitivity calibration shall provide the required gain adjustments for each refracted
angle and sound path used. Select a calibration reflector, which is approximately one-
half the thickness of the component to be examined, or within the zone of material to be
examined.
b) Peak up the signal from the calibration reflector and scan the phased array probe
backwards through all the different angles/focal laws. Scan forward over the calibration
reflector through all the refracted angles/focal laws. Calibrate the Omni scan System to
calculate the required gain needed at each focal law to adjust the amount of gain
required to obtain the sensitivity. Figure 17.3 shows the example of screen feature used to
ensure the sensitivity response (amplitude response) from each focal law. After
calibration, as the operator moves the probe back and forth over a calibration reference
reflector, unit software automatically adjusts gain to the prescribed amplitude 80% with
+5% tolerance limit. The horizontal scale is the virtual probe aperture (VPA) which
defines the group of elements i.e. focal law that is sequenced in the scan. These focal laws
are either linear or sectorial depending on whether E-scan or S-scans is being calibrated.
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Fig. 17.3 Sensitivity calibration (S-Scan)

17.4 TIME CORRECTED GAIN (TCG) CALIBRATION
Time corrected gain calibration shall be used to compensate for attenuation in the material at
the sound paths used during calibration and examination. To obtain the TCG calibration as
per calibration block shown in Fig. 16.1, peak the signal from the 1T hole and move the gate
over the indication. Obtain the first TCG point. Similarly the gate is moved for 2T and 3T
depths in the additional calibration block. Obtained 2 nd and 3rd TCG point and accept the
calibration. TCG calibration has to be carried out for all scan plans in a multi group option
while using phased array probe.
Similar procedure shall be followed for alternate calibration block as per Fig. 16.4.

17.5 ENCODER CALIBRATION

a) Encoder calibration shall be carried out for step resolution for data acquisition.
b) The encoder shall be connected to the Omni Scan equipment and the calibration wizard
shall be used to calibrate the encoder.
c) Through the menu wizard set up, all the parameters are fed and the encoder is made to
scroll on a pre- determined known length (Circumferential length of pipe) as illustrated in
Figure 17.5. After one full rotation from position 0 to 0 as shown below the calibration
shall be accepted by presetting the origin and the length of travel. This will result in
number of steps/mm (32.08 steps/mm) value for the attached encoder thus giving true
length of scan.
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d) After calibration, the encoder shall be moved through a measured distance of 358 mm.
The system read out shall be within 1% of the actual distance moved. Encoder failing this
check shall be recalibrated and this check repeated.
e) Above check shall be performed prior to first use, at interval not to exceed one month or
prior to first use thereafter.

Scan direction

0 0

Fig. 17.5 - Encoder Calibration

17.6 The examination system calibration shall be stored in the OmniScan System with electronic
memory, on an external chip or data storage device. This calibration may be used at a later
date provided that the system calibration is verified prior to the examination.
18.0 DIRECTION AND EXTENT OF SCANNING
18.1 Prior to start of the PAUT Examination, the base metal and HAZ area shall be scanned
manually with normal beam probe to locate reflectors that can limit the capability of the
PAUT inspection to examine the weld volume. Locations and areas of such reflectors and
base metal thickness shall be recorded. Olympus OmniScan® equipment’s conventional UT
channel may be used for this inspection.
18.2 The ultrasonic examination shall include the volume of the weld plus 25 % of t (thickness) on
each side of the weld. The required volume of the base material and weld to be examined
shall be scanned from outer surface using a linear scanning technique with encoder.
18.3 OmniScan® system has the capability of using multiple-group settings to establish sector
scans and E-scans for the appropriate angles to ensure complete coverage of the weld and
heat affected zone. Scanning
Skew 90° shall be performed using a Line scan technique. Each line scan
shall be parallel to the weld using a sectorial scan (S-scan) and /or a linear scan as shown in
Figure 18.0.

Skew 270°
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Fig. 18.0 – Line scan using PAUT

18.4 Scanning speed shall be such that drop-out is less than 2 data lines per 25 mm of the linear
scan length and there are no adjacent data line skips. OmniScan equipment has the capability
of rewriting the data if loss of data is observed. The encoder is retrieved back to home
position whenever data is missed. Missing data is represented by dark black lines in the C-
scan display.
18.5 For S-scan techniques, the angular sweep incremental change shall be a maximum of 1
degree or sufficient to assure 50% beam overlap.
19.0 AUTOMATIC ALARM AND OR RECORDING EQUIPMENT
19.1 Automatic alarm shall not be used.
19.2 An encoder interfaced with the Omni Scan® phased array instrument shall be use to track the
phased array probe movement and data recording. The encoder shall be calibrated to
coordinate its movement with the Omni Scan instrument. The Omni Scan system incorporates
encoder calibration as well as scan resolution. The smaller the resolution the higher is the
data file length for a given weld length.
20.0 CALIBRATION CONFIRMATION
20.1 When any part of the examination system is changed, a calibration check shall be made on
the basic calibration block to verify that distance range point and sensitivity settings satisfy
the requirements of 20.3 and 20.4.
20.2 A calibration check on at least one of the reflectors in the basic calibration block shall be
performed at the finish of each examination or series of similar examinations and when
examination personnel are changed.
20.3 Sweep Range Correction.
If any distance range point has moved on the sweep line by more than 10% of the distance
reading or 5% of full sweep, whichever is greater, correct the sweep range calibration and
note the correction in the examination record. If reflectors are recorded on the examination
report, those examination reports shall be marked void and a new calibration shall be
recorded. All recorded indications since the last valid calibration shall be re-examined with
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the corrected calibration and their values shall be changed on the examination reports.
20.4 Sensitivity setting
If any sensitivity setting changed by more than 20% or 2 dB of its amplitude, correct the
sensitivity calibration. If the sensitivity setting has decreased, all examination reports since
the last valid calibration or calibration check shall be marked void and the area covered by
the data marked void shall be re-examined. If the sensitivity setting has increased all
recorded indications since the last valid calibration or calibration check shall be re-
examined and their values shall be changed on the examination reports

21.0 FLAW SIZING

21.1 Flaw sizing is normally performed by measuring the length at the 6dB levels once the flaw
has been isolated and the image normalized. An overlay feature allows the analyst to
generate a composite image using several set of ultrasonic data. All data displayed in
analysis mode shall be displayed with respect to the physical co-ordinates of the component.

22.0 RECORDING / EVALUATION and AMPLITUDE DETERMINATION

22.1 A-scan data shall be recorded for the area of interest in an unprocessed form with no
thresholding, at a minimum digitization rate of five times the examination frequency and
recording increments of a maximum of 1 mm for material less than 75 mm thick.
22.2 Welds that have discontinuities and produce a response greater than 20% of the reference
level shall be investigated to the extent that ultrasonic examination personnel can determine
their shape, identify and location. Such indications shall be evaluated for acceptance in
accordance with Para 23.0.
22.3 All indications above 50% of reference level shall be recorded and documented on the
examination report.
22.4 Signals which are determined to result from geometrical conditions (such as weld root
geometry or weld reinforcement) are classified as geometrical reflectors. Such reflectors
shall not be considered as flaw indications or compared with allowable indication standards.
22.5 The presence of geometric reflectors is confirmed either by reviewing the fabrication
drawings of the weld preparation, the previous Inspection Records or by supplemental
inspection results.
22.6 Additionally, areas of restricted access or inaccessible welds if present shall be recorded.

23.0 ACCEPTANCE CRITERIA

23.1 Discontinuities evaluated as being cracks, lack of fusion, or incomplete penetration is
unacceptable regardless of length.
23.2 Other discontinuities are unacceptable if the indication exceeds reference level and length
exceed the following :
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a) 6.0 mm for t up to 19.0 mm

b) 1/3 t for t from 19.0 mm to 57.0 mm
Where t is the thickness of the weld being examined. If the weld joints two members having
different thicknesses at the weld, t is the thinner of these two thicknesses.
24.0 REPORTING
All details of inspection and results shall be documented in the enclosed sample report
Format. The examiner shall record the results of the examination on the Omni Scan Data
Report Form.
a. Procedure identification and revision.
b. Instrument Identification including manufacturer’s serial number.
c. Transducer type, serial number, angle and frequency.
d. Special equipment when used (search units, wedges, shoes, automatic scanning
equipment, recording equipment etc)
e. Computerized programmed identification and revision when used
f. Calibrations block identification.
g. Instrument reference level gain and, if used damping and reject settings.
h. Calibration data including reference reflectors, indication amplitude and distance
reading.
i. Data correlating simulation blocks and electronic simulator, when used, with initial
calibration.
j. Identification and location of weld or volume scanned.
k. Surfaces from which examination was conducted, including surface condition
l. Surface condition of the job.
m. Map or record of reject able indications detected or areas cleared.
n. Areas of restricted access or inaccessible welds.
o. Examination personnel identity and when required by referencing code section,
qualification level.
p. Date and time examinations were performed.
25.0 POST-EXAMINATION CLEANING
Couplant shall be wiped off the examination surfaces with suitable material to the extent
possible.

RECORD OF REVISIONS
Rev. Date Details of Revision
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No.
0 07.03.2023 First Issue
Prepared & checked by Reviewed & Accepted By Approved By
Shehzad Alam Jishnu S Ajay R.M. Sawant
NDE Level II NDE Level III HOD – Quality & Control
Management

Signature Signature Signature