Header Ligament Crack Detection and Sizing

Header Ligament Crack Detection and Sizing
UT Techniques
by Jimmy Ellis
718-757-9464
utgeek@earthlink.net
associated with
Rick Pfannenstiel, PfiNDE, LLC
860-830-4990 www.PfiNDE.com
PfiNDE, LLC
Pfannenstiel Innovative Non Destructive Examinations, LLC
166 Ingham Hill Road, Old Saybrook, CT 06475
www.PFiNDE.com - 860.830.4990 - rick@PFiNDE.com
Header Ligament Cracks -- UT Techniques

June 2004
Page 2 of 65

UT Techniques
The following describes some ultrasonic testing techniques for the
detection and sizing of ligament cracks in headers. These techniques can also be
used for other applications in flat plate or cylindrical sections.
Contents
Objective / Scope
Radial and Axial Crack Illustrations
Radial Cracks
FAST-UT
Pitch-Catch
Manual TOFD on flat plate
Flat Plate TOFD Spreadsheet Illustrated
Flat Plate TOFD Calculating Spreadsheets
Axial Cracks
Through Transmission
Illustrations 6% to 66% deep
Through-Transmission Calculations
Trough-Transmission Spreadsheet
Manual TOFD on cylindrical sections
Base Distance vs. Depth Illustrations
Circumferential TOFD arc/chord/depth
Spreadsheet
Circumferential TOFD simulator
by Jimmy Ellis
718-757-9464
Page 3
Page 4
Page 9
Page 9
Page 9
Page 15
Page 16
Page 17
Page 31
Page 31
Page 33
Page 43
Page 50
Page 51
Page 52
Page 61
Page 62
utgeek@earthlink.net
associated with
Rick Pfannenstiel, PfiNDE, LLC
860-830-4990 www.PfiNDE.com

June 2004
Page 3 of 65

Objective
The objective of this series of examinations is to detect ligament cracks
and then determine the depth of the ligament cracking between penetrations in
headers.
Scope
The types of headers these methods are intended for are power boiler
headers with thick pipe walls and numerous closely spaced penetrations such as
found in superheater headers.
Cracks in headers are most often detected by remote visual inspection
from inside the header. Sometimes there are hand holes in the header ends,
and sometimes pipe penetrations are cut off to make an access for a fibercam or
other remote visual device. Even with a confirmed visual detection, the depth
sizing can be difficult.
Some headers with extra heavy wall thickness are difficult to inspect with
conventional shear wave techniques. Due to the angles usually used, and the
thickness and curvature of the header, shear waves often wont reach the ID
(inside diameter) of the header. Other drawbacks of shear waves are the
difficulty in detecting crack tip signals and the high response to corner reflectors
The methods described here are also applicable to other product forms
with flat plate or cylindrical type shapes.
Two crack orientations are considered; axial and radial.
Techniques
Radial Cracks
Radial cracks are circumferentially oriented in the header pipe and go
from one penetration to the adjacent penetration in the circumferential direction.
Three UT techniques are described:
FAST-UT
Pitch-Catch
Manual TOFD (for flat plate type geometries)
Axial Cracks
Axial cracks are parallel to the axis of the header pipe and go from one
penetration to the adjacent penetration in the header pipe axial direction. Two
UT techniques are described:
Through-Transmission
Manual TOFD (circumferentially oriented in cylindrical sections)
Illustrations of radial and axial cracks in headers follow.

June 2004
Page 4 of 65
Header Pipe
Penetrations on the
near side. There are
mirror image
pentrations on the
far side. Pendant
piping not shown.
Side view of Header

June 2004
A'
B'
Page 5 of 65
Header Pipe
penetrations
Side view of Header

header pipe OD
header pipe ID
Section B-B'
Radial Section,
Sectioned between penetrations
Section A-A'
Radial Section,
Sectioned through
penetrations

June 2004
C
Page 6 of 65
Header Pipe
C'
penetrations
D'
Side view of Header

C
C'
D'
header pipe OD
penetrations
Section C-C'
Axial Section
Sectioned through
penetrations
(only the near side header
pipe wall and penetrations
are shown)
header pipe ID
Section D-D'
Axial Section
Sectioned between
penetrations
(only the near side header
pipe wall is shown)

June 2004
Page 7 of 65
Header Pipe
B
C
penetrations
C'
B'
Side view of Header

Axial Ligament
Crack
header pipe OD
Axial Ligament
Crack
penetrations
Section C-C'
Axial Section
header pipe ID
Section B-B'
Radial Section
The Same Axial Ligament Crack Shown in all 3 Views

Above

June 2004
A
Page 8 of 65
Radial
Ligament
Crack
Header Pipe
penetrations
A'
D
D'
Side view of Header
Section A-A'
Radial Section
Radial
Ligament
Crack
header pipe OD
header pipe ID
Section D-D'
Axial Section
The Same Radial Ligament Crack Shown in all 3 Views

Above

June 2004
Page 9 of 65
Radial Ligament Crack Detection and Sizing

Three methods are considered for the detection and sizing of radial
header ligament cracking:
1____FAST-UT
2____Pitch-Catch
3____Manual TOFD
FAST-UT
FAST-UT is a proprietary multipurpose ultrasonic inspection technique.
FAST-UT predominantly uses high angle L-waves, but low angle shear waves, and ID
and OD creeper modes of sound propagation are also present and useful.
A detailed description of the technique is beyond the scope of this
presentation. More details can be found through www.PfiNDE.com .
For most in-service ultrasonic inspection, FAST-UT can perform most
ultrasonic inspections with the highest reliability of detection, the lowest rate of
false calls, and in the hands of experienced examiners, detection and sizing can
often be performed together. Most power plant piping can have reliable inservice ultrasonic inspection with FAST-UT alone. FAST-UT has been thoroughly
tested and proved through the EPRI (Electric Power Research Institute) PDI
(Performance Demonstration Initiative) Program.
The geometry of radial cracks is similar to flat plate, as shown in the
previous section D-D. Due to the similarity in geometry of radial cracks to
cracks in flat plate, it is possible that many radial cracks may be detected and
sized with FAST-UT alone.
Pitch-Catch
The following sketches show the set-up for measuring the depth of
cracking for ID connected radial cracks. These pitch-catch transducers are shear
wave transducers set up in an axial orientation on the header. The geometry of
radial cracks is similar to flat plate, as shown in the previous section D-D.

June 2004
pitch-catch set-up
45 degree shear wave transducers
surface distance = depth
100% transmision, no interfering cracks
similar to geometry of Section D-D'
Page 10 of 65

June 2004
Page 11 of 65
50% transmission, 25% deep crack
surface distance = 2 X depth of crack

June 2004
Page 12 of 65

June 2004
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June 2004
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June 2004
Page 15 of 65
Manual TOFD
Manual TOFD of radial cracks uses axially oriented transducers in pitchcatch pairs. The transducer pair can scan axially, or circumferentially.
TOFD (Time of Flight Tip Diffraction Testing) is almost universally
performed as an automated ultrasonic test where the scans are electronically
recorded for later display in an image. Special scanners, detectors, hardware
and software is required. The manual technique shown here is somewhat
unique in that it allows TOFD to be performed in real time at a clients
convenience and schedule, with only a normal ultrasonic flaw detector.
This manual TOFD technique compliments the FAST-UT technique. The
FAST-UT technique predominantly uses a high angle L-wave at 70 degrees. This
results in a long surface distance, about 2.75 of surface distance for each inch
of depth. The manual TOFD technique compliments the FAST-UT because it
needs only short surface distances. For example a flaw 6 inches deep can be
sized with only 1.5 of surface distance on each side of the flaw centerline.
Radial cracks in headers have a geometry similar to flat plate as shown in
the previous section D-D. The following sketches and Microsoft Excel
spreadsheet show the geometric relations which make up the manual TOFD setup in flat plate. Then additional spreadsheet derived tables are shown for a
series of increasing base distances in round numbers for examples. The Excel
spreadsheet can calculate a precise table for any chosen base distance.

June 2004
Page 16 of 65
For use with a machine that has only a 'dual' setting and no 'pitch-catch such as USN52L.
Set the L-wave X-ducers to the needed base distance, then input this distance in this spreadsheet.
Set up the screen with the Direct L-wave at 1, the Backwall L-wave at 5 and the Backwall Mode-converted shearwave at 10.
Set the Backwall L-wave echo in the gate and use 'Zero' to calibrate. (L-Dist. is read from S-path displayed)
Measure flaws in the gate to measure L-Distances and refer to the table for depth determination.
For sensitivity setting, set SDH nearest maximum depth of interest at 50%FSH.
receive
send
depth
L-Dist.
flaw
Base Distance
Input Base Distance:
1.0
inches
depth
L-Dist.
(or thickness)
angle
X-ducer angle
beam spreads at
5MHz
30 45
60
Direct
Lwave
17-43 32-58 47-73
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
0.51
0.54
0.58
0.64
0.71
0.78
0.86
0.94
1.03
1.12
1.21
1.30
1.39
1.49
1.58
1.68
1.77
1.87
1.96
2.06
2.16
2.26
2.35
2.45
2.55
2.65
2.75
2.84
2.94
3.04
3.14
3.24
3.34
3.44
3.54
11.31
21.80
30.96
38.66
45.00
50.19
54.46
57.99
60.95
63.43
65.56
67.38
68.96
70.35
71.57
72.65
73.61
74.48
75.26
75.96
76.61
77.20
77.74
78.23
78.69
79.11
79.51
79.88
80.22
80.54
80.84
81.12
81.38
81.63
81.87
78.69
68.20
59.04
51.34
45.00
39.81
35.54
32.01
29.05
26.57
24.44
22.62
21.04
19.65
18.43
17.35
16.39
15.52
14.74
14.04
13.39
12.80
12.26
11.77
11.31
10.89
10.49
10.12
9.78
9.46
9.16
8.88
8.62
8.37
8.13
OD
Backwall
L-wave
backwall
mode
converted
shearwave
ID
Screen Set-up on Unflawed Material
mode
converted
flaw echo
L-wave - flaw
OD
ID
Screen Set-up on Flawed Material

June 2004
Page 17 of 65

0.25 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
0.16
0.24
0.33
0.42
0.52
0.61
0.71
0.81
0.91
1.01
1.11
1.21
1.31
1.41
1.51
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
38.66
57.99
67.38
72.65
75.96
78.23
79.88
81.12
82.09
82.87
83.52
84.05
84.51
84.90
85.24
85.53
85.79
86.03
86.24
86.42
86.59
86.75
86.89
87.02
87.14
87.25
87.35
87.44
87.53
87.61
87.69
87.76
87.83
87.89
87.95
51.34
32.01
22.62
17.35
14.04
11.77
10.12
8.88
7.91
7.13
6.48
5.95
5.49
5.10
4.76
4.47
4.21
3.97
3.76
3.58
3.41
3.25
3.11
2.98
2.86
2.75
2.65
2.56
2.47
2.39
2.31
2.24
2.17
2.11
2.05
30
45
60
17-43
32-58
47-73

June 2004
Page 18 of 65

0.50 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
0.27
0.32
0.39
0.47
0.56
0.65
0.74
0.84
0.93
1.03
1.13
1.23
1.32
1.42
1.52
1.62
1.72
1.82
1.92
2.02
2.11
2.21
2.31
2.41
2.51
2.61
2.71
2.81
2.91
3.01
3.11
3.21
3.31
3.41
3.51
21.80
38.66
50.19
57.99
63.43
67.38
70.35
72.65
74.48
75.96
77.20
78.23
79.11
79.88
80.54
81.12
81.63
82.09
82.50
82.87
83.21
83.52
83.80
84.05
84.29
84.51
84.71
84.90
85.07
85.24
85.39
85.53
85.67
85.79
85.91
68.20
51.34
39.81
32.01
26.57
22.62
19.65
17.35
15.52
14.04
12.80
11.77
10.89
10.12
9.46
8.88
8.37
7.91
7.50
7.13
6.79
6.48
6.20
5.95
5.71
5.49
5.29
5.10
4.93
4.76
4.61
4.47
4.33
4.21
4.09
30
45
60
17-43
32-58
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June 2004
Page 19 of 65

0.75 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
0.39
0.43
0.48
0.55
0.63
0.71
0.79
0.88
0.98
1.07
1.16
1.26
1.35
1.45
1.55
1.64
1.74
1.84
1.94
2.03
2.13
2.23
2.33
2.43
2.53
2.63
2.73
2.83
2.92
3.02
3.12
3.22
3.32
3.42
3.52
14.93
28.07
38.66
46.85
53.13
57.99
61.82
64.89
67.38
69.44
71.18
72.65
73.91
75.00
75.96
76.81
77.56
78.23
78.84
79.38
79.88
80.33
80.74
81.12
81.47
81.79
82.09
82.37
82.63
82.87
83.10
83.32
83.52
83.71
83.88
75.07
61.93
51.34
43.15
36.87
32.01
28.18
25.11
22.62
20.56
18.82
17.35
16.09
15.00
14.04
13.19
12.44
11.77
11.16
10.62
10.12
9.67
9.26
8.88
8.53
8.21
7.91
7.63
7.37
7.13
6.90
6.68
6.48
6.29
6.12
30
45
60
17-43
32-58
47-73

June 2004
Page 20 of 65

1.00 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
0.51
0.54
0.58
0.64
0.71
0.78
0.86
0.94
1.03
1.12
1.21
1.30
1.39
1.49
1.58
1.68
1.77
1.87
1.96
2.06
2.16
2.26
2.35
2.45
2.55
2.65
2.75
2.84
2.94
3.04
3.14
3.24
3.34
3.44
3.54
11.31
21.80
30.96
38.66
45.00
50.19
54.46
57.99
60.95
63.43
65.56
67.38
68.96
70.35
71.57
72.65
73.61
74.48
75.26
75.96
76.61
77.20
77.74
78.23
78.69
79.11
79.51
79.88
80.22
80.54
80.84
81.12
81.38
81.63
81.87
78.69
68.20
59.04
51.34
45.00
39.81
35.54
32.01
29.05
26.57
24.44
22.62
21.04
19.65
18.43
17.35
16.39
15.52
14.74
14.04
13.39
12.80
12.26
11.77
11.31
10.89
10.49
10.12
9.78
9.46
9.16
8.88
8.62
8.37
8.13
30
45
60
17-43
32-58
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June 2004
Page 21 of 65

1.50 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
0.76
0.78
0.81
0.85
0.90
0.96
1.03
1.10
1.17
1.25
1.33
1.42
1.50
1.59
1.68
1.77
1.86
1.95
2.04
2.14
2.23
2.32
2.42
2.51
2.61
2.71
2.80
2.90
3.00
3.09
3.19
3.29
3.38
3.48
3.58
7.59
14.93
21.80
28.07
33.69
38.66
43.03
46.85
50.19
53.13
55.71
57.99
60.02
61.82
63.43
64.89
66.19
67.38
68.46
69.44
70.35
71.18
71.94
72.65
73.30
73.91
74.48
75.00
75.50
75.96
76.40
76.81
77.20
77.56
77.91
82.41
75.07
68.20
61.93
56.31
51.34
46.97
43.15
39.81
36.87
34.29
32.01
29.98
28.18
26.57
25.11
23.81
22.62
21.54
20.56
19.65
18.82
18.06
17.35
16.70
16.09
15.52
15.00
14.50
14.04
13.60
13.19
12.80
12.44
12.09
30
45
60
17-43
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June 2004
Page 22 of 65

2.0 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
1.00
1.02
1.04
1.08
1.12
1.17
1.22
1.28
1.35
1.41
1.49
1.56
1.64
1.72
1.80
1.89
1.97
2.06
2.15
2.24
2.33
2.42
2.51
2.60
2.69
2.79
2.88
2.97
3.07
3.16
3.26
3.35
3.45
3.54
3.64
5.71
11.31
16.70
21.80
26.57
30.96
34.99
38.66
41.99
45.00
47.73
50.19
52.43
54.46
56.31
57.99
59.53
60.95
62.24
63.43
64.54
65.56
66.50
67.38
68.20
68.96
69.68
70.35
70.97
71.57
72.12
72.65
73.14
73.61
74.05
84.29
78.69
73.30
68.20
63.43
59.04
55.01
51.34
48.01
45.00
42.27
39.81
37.57
35.54
33.69
32.01
30.47
29.05
27.76
26.57
25.46
24.44
23.50
22.62
21.80
21.04
20.32
19.65
19.03
18.43
17.88
17.35
16.86
16.39
15.95
30
45
60
17-43
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June 2004
Page 23 of 65

2.5 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
1.25
1.27
1.29
1.31
1.35
1.39
1.43
1.48
1.54
1.60
1.67
1.73
1.80
1.88
1.95
2.03
2.11
2.19
2.27
2.36
2.44
2.53
2.62
2.71
2.80
2.88
2.98
3.07
3.16
3.25
3.34
3.44
3.53
3.62
3.72
3.81
3.91
4.00
4.10
4.19
4.29
4.38
4.48
4.57
4.67
4.77
4.86
4.96
5.06
5.15
4.57
9.09
13.50
17.74
21.80
25.64
29.25
32.62
35.75
38.66
41.35
43.83
46.12
48.24
50.19
52.00
53.67
55.22
56.66
57.99
59.24
60.40
61.48
62.49
63.43
64.32
65.16
65.94
66.68
67.38
68.04
68.66
69.25
69.81
70.35
70.85
71.33
71.79
72.23
72.65
73.04
73.43
73.79
74.14
74.48
74.80
75.11
75.40
75.69
75.96
85.43
80.91
76.50
72.26
68.20
64.36
60.75
57.38
54.25
51.34
48.65
46.17
43.88
41.76
39.81
38.00
36.33
34.78
33.34
32.01
30.76
29.60
28.52
27.51
26.57
25.68
24.84
24.06
23.32
22.62
21.96
21.34
20.75
20.19
19.65
19.15
18.67
18.21
17.77
17.35
16.96
16.57
16.21
15.86
15.52
15.20
14.89
14.60
14.31
14.04
30
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June 2004
Page 24 of 65

3.0 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
1.50
1.51
1.53
1.55
1.58
1.62
1.66
1.70
1.75
1.80
1.86
1.92
1.98
2.05
2.12
2.19
2.27
2.34
2.42
2.50
2.58
2.66
2.75
2.83
2.92
3.00
3.09
3.18
3.26
3.35
3.44
3.53
3.62
3.72
3.81
3.90
3.99
4.09
4.18
4.27
4.37
4.46
4.55
4.65
4.74
4.84
4.93
5.03
5.12
5.22
3.81
7.59
11.31
14.93
18.43
21.80
25.02
28.07
30.96
33.69
36.25
38.66
40.91
43.03
45.00
46.85
48.58
50.19
51.71
53.13
54.46
55.71
56.89
57.99
59.04
60.02
60.95
61.82
62.65
63.43
64.18
64.89
65.56
66.19
66.80
67.38
67.93
68.46
68.96
69.44
69.90
70.35
70.77
71.18
71.57
71.94
72.30
72.65
72.98
73.30
86.19
82.41
78.69
75.07
71.57
68.20
64.98
61.93
59.04
56.31
53.75
51.34
49.09
46.97
45.00
43.15
41.42
39.81
38.29
36.87
35.54
34.29
33.11
32.01
30.96
29.98
29.05
28.18
27.35
26.57
25.82
25.11
24.44
23.81
23.20
22.62
22.07
21.54
21.04
20.56
20.10
19.65
19.23
18.82
18.43
18.06
17.70
17.35
17.02
16.70
30
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47-73

June 2004
Page 25 of 65

3.5 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
1.75
1.76
1.78
1.80
1.82
1.85
1.88
1.92
1.97
2.02
2.07
2.12
2.18
2.24
2.30
2.37
2.44
2.51
2.58
2.66
2.73
2.81
2.89
2.97
3.05
3.13
3.22
3.30
3.39
3.47
3.56
3.65
3.74
3.82
3.91
4.00
4.09
4.18
4.27
4.37
4.46
4.55
4.64
4.74
4.83
4.92
5.02
5.11
5.20
5.30
3.27
6.52
9.73
12.88
15.95
18.92
21.80
24.57
27.22
29.74
32.15
34.44
36.61
38.66
40.60
42.44
44.17
45.81
47.35
48.81
50.19
51.50
52.73
53.90
55.01
56.06
57.05
57.99
58.89
59.74
60.55
61.33
62.06
62.76
63.43
64.08
64.69
65.27
65.83
66.37
66.89
67.38
67.85
68.31
68.75
69.17
69.58
69.97
70.35
70.71
86.73
83.48
80.27
77.12
74.05
71.08
68.20
65.43
62.78
60.26
57.85
55.56
53.39
51.34
49.40
47.56
45.83
44.19
42.65
41.19
39.81
38.50
37.27
36.10
34.99
33.94
32.95
32.01
31.11
30.26
29.45
28.67
27.94
27.24
26.57
25.92
25.31
24.73
24.17
23.63
23.11
22.62
22.15
21.69
21.25
20.83
20.42
20.03
19.65
19.29
30
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47-73

June 2004
Page 26 of 65

4.0 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
2.00
2.01
2.02
2.04
2.06
2.09
2.12
2.15
2.19
2.24
2.28
2.33
2.39
2.44
2.50
2.56
2.62
2.69
2.76
2.83
2.90
2.97
3.05
3.12
3.20
3.28
3.36
3.44
3.52
3.61
3.69
3.77
3.86
3.94
4.03
4.12
4.21
4.29
4.38
4.47
4.56
4.65
4.74
4.83
4.92
5.02
5.11
5.20
5.29
5.39
2.86
5.71
8.53
11.31
14.04
16.70
19.29
21.80
24.23
26.57
28.81
30.96
33.02
34.99
36.87
38.66
40.36
41.99
43.53
45.00
46.40
47.73
48.99
50.19
51.34
52.43
53.47
54.46
55.41
56.31
57.17
57.99
58.78
59.53
60.26
60.95
61.61
62.24
62.85
63.43
64.00
64.54
65.06
65.56
66.04
66.50
66.95
67.38
67.80
68.20
87.14
84.29
81.47
78.69
75.96
73.30
70.71
68.20
65.77
63.43
61.19
59.04
56.98
55.01
53.13
51.34
49.64
48.01
46.47
45.00
43.60
42.27
41.01
39.81
38.66
37.57
36.53
35.54
34.59
33.69
32.83
32.01
31.22
30.47
29.74
29.05
28.39
27.76
27.15
26.57
26.00
25.46
24.94
24.44
23.96
23.50
23.05
22.62
22.20
21.80
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47-73

June 2004
Page 27 of 65

4.5 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
2.25
2.26
2.27
2.29
2.30
2.33
2.36
2.39
2.42
2.46
2.50
2.55
2.60
2.65
2.70
2.76
2.82
2.88
2.94
3.01
3.08
3.15
3.22
3.29
3.36
3.44
3.51
3.59
3.67
3.75
3.83
3.91
3.99
4.08
4.16
4.25
4.33
4.42
4.50
4.59
4.68
4.76
4.85
4.94
5.03
5.12
5.21
5.30
5.39
5.48
2.54
5.08
7.59
10.08
12.53
14.93
17.28
19.57
21.80
23.96
26.05
28.07
30.02
31.89
33.69
35.42
37.07
38.66
40.18
41.63
43.03
44.36
45.63
46.85
48.01
49.13
50.19
51.22
52.19
53.13
54.03
54.89
55.71
56.50
57.26
57.99
58.70
59.37
60.02
60.64
61.24
61.82
62.38
62.92
63.43
63.94
64.42
64.89
65.34
65.77
87.46
84.92
82.41
79.92
77.47
75.07
72.72
70.43
68.20
66.04
63.95
61.93
59.98
58.11
56.31
54.58
52.93
51.34
49.82
48.37
46.97
45.64
44.37
43.15
41.99
40.87
39.81
38.78
37.81
36.87
35.97
35.11
34.29
33.50
32.74
32.01
31.30
30.63
29.98
29.36
28.76
28.18
27.62
27.08
26.57
26.06
25.58
25.11
24.66
24.23
30
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47-73

June 2004
Page 28 of 65

5.0 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
2.50
2.51
2.52
2.53
2.55
2.57
2.60
2.62
2.66
2.69
2.73
2.77
2.82
2.87
2.92
2.97
3.02
3.08
3.14
3.20
3.26
3.33
3.40
3.47
3.54
3.61
3.68
3.75
3.83
3.91
3.98
4.06
4.14
4.22
4.30
4.38
4.47
4.55
4.63
4.72
4.80
4.89
4.97
5.06
5.15
5.24
5.32
5.41
5.50
5.59
2.29
4.57
6.84
9.09
11.31
13.50
15.64
17.74
19.80
21.80
23.75
25.64
27.47
29.25
30.96
32.62
34.22
35.75
37.23
38.66
40.03
41.35
42.61
43.83
45.00
46.12
47.20
48.24
49.24
50.19
51.12
52.00
52.85
53.67
54.46
55.22
55.95
56.66
57.34
57.99
58.63
59.24
59.83
60.40
60.95
61.48
61.99
62.49
62.97
63.43
87.71
85.43
83.16
80.91
78.69
76.50
74.36
72.26
70.20
68.20
66.25
64.36
62.53
60.75
59.04
57.38
55.78
54.25
52.77
51.34
49.97
48.65
47.39
46.17
45.00
43.88
42.80
41.76
40.76
39.81
38.88
38.00
37.15
36.33
35.54
34.78
34.05
33.34
32.66
32.01
31.37
30.76
30.17
29.60
29.05
28.52
28.01
27.51
27.03
26.57
30
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60
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47-73

June 2004
Page 29 of 65

5.5 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
2.75
2.76
2.77
2.78
2.80
2.81
2.84
2.86
2.89
2.93
2.96
3.00
3.04
3.09
3.13
3.18
3.23
3.29
3.34
3.40
3.46
3.52
3.59
3.65
3.72
3.78
3.85
3.92
4.00
4.07
4.14
4.22
4.30
4.37
4.45
4.53
4.61
4.69
4.77
4.85
4.94
5.02
5.10
5.19
5.27
5.36
5.45
5.53
5.62
5.71
2.08
4.16
6.23
8.28
10.30
12.31
14.28
16.22
18.12
19.98
21.80
23.57
25.30
26.98
28.61
30.19
31.72
33.21
34.64
36.03
37.37
38.66
39.91
41.11
42.27
43.39
44.47
45.52
46.52
47.49
48.42
49.33
50.19
51.03
51.84
52.62
53.38
54.11
54.81
55.49
56.15
56.78
57.40
57.99
58.57
59.13
59.67
60.19
60.70
61.19
87.92
85.84
83.77
81.72
79.70
77.69
75.72
73.78
71.88
70.02
68.20
66.43
64.70
63.02
61.39
59.81
58.28
56.79
55.36
53.97
52.63
51.34
50.09
48.89
47.73
46.61
45.53
44.48
43.48
42.51
41.58
40.67
39.81
38.97
38.16
37.38
36.62
35.89
35.19
34.51
33.85
33.22
32.60
32.01
31.43
30.87
30.33
29.81
29.30
28.81
30
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47-73

June 2004
Page 30 of 65

6.0 inches
depth
L-Dist.
angle
X-ducer angle
(or thickness)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
3.00
3.01
3.01
3.03
3.04
3.06
3.08
3.10
3.13
3.16
3.20
3.23
3.27
3.31
3.35
3.40
3.45
3.50
3.55
3.61
3.66
3.72
3.78
3.84
3.91
3.97
4.04
4.10
4.17
4.24
4.31
4.39
4.46
4.53
4.61
4.69
4.76
4.84
4.92
5.00
5.08
5.16
5.24
5.33
5.41
5.49
5.58
5.66
5.75
5.83
1.91
3.81
5.71
7.59
9.46
11.31
13.13
14.93
16.70
18.43
20.14
21.80
23.43
25.02
26.57
28.07
29.54
30.96
32.35
33.69
34.99
36.25
37.48
38.66
39.81
40.91
41.99
43.03
44.03
45.00
45.94
46.85
47.73
48.58
49.40
50.19
50.96
51.71
52.43
53.13
53.81
54.46
55.10
55.71
56.31
56.89
57.45
57.99
58.52
59.04
88.09
86.19
84.29
82.41
80.54
78.69
76.87
75.07
73.30
71.57
69.86
68.20
66.57
64.98
63.43
61.93
60.46
59.04
57.65
56.31
55.01
53.75
52.52
51.34
50.19
49.09
48.01
46.97
45.97
45.00
44.06
43.15
42.27
41.42
40.60
39.81
39.04
38.29
37.57
36.87
36.19
35.54
34.90
34.29
33.69
33.11
32.55
32.01
31.48
30.96
30
45
60
17-43
32-58
47-73

June 2004
Page 31 of 65
Axial Ligament Crack Detection & Sizing

Two techniques for detection and sizing of axial header ligament cracking:
1_____Through-Transmission
2_____Manual TOFD
The orientations of axial ligament cracks as shown in the previous section
B-B are used as the basis of the Through-Transmission ultrasonic set up. The
following sketches show a series of transducer positions for ThroughTransmission set ups for a series of progressively smaller transducer sound
angles for a header. Only the OD of the header is shown. As an example, a
header with an outside diameter of 20 is shown.

June 2004
Page 32 of 65
depth = 0.6"
70 degree sending
transducer
70 degree receiving
transducer
soundpath
Example header is 20" diameter
D = 20"
10" radius
transducer angle shown
depth as a fraction of the radius
depth, d, in inches
R = 10"
70 degree, shear
= 0.060
d = 0.6"

June 2004
Page 33 of 65
depth = 0.94"
65 degree sending
transducer
65 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
65 degree, shear
= 0.094
d = 0.94"

June 2004
Page 34 of 65
depth = 1.34"
60 degree sending
transducer
60 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
60 degree, shear
= 0.134
d = 1.34"

June 2004
Page 35 of 65
depth = 1.81"
55 degree sending
transducer
55 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
55 degree, shear
= 0.181
d = 1.81"

June 2004
Page 36 of 65
depth = 2.34"
50 degree sending
transducer
50 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
50 degree, shear
= 0.234
d = 2.34"

June 2004
Page 37 of 65
depth = 2.93"
45 degree sending
transducer
45 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
45 degree, shear
= 0.293
d = 2.93"

June 2004
Page 38 of 65
depth = 3.57"
40 degree sending
transducer
40 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
40 degree, L-wave
= 0.357
d = 3.57"

June 2004
Page 39 of 65
depth = 4.26"
35 degree sending
transducer
35 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
35 degree, L-wave
= 0.426
d = 4.26"

June 2004
Page 40 of 65
depth = 5.00"
30 degree sending
transducer
30 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
30 degree, L-wave
= 0.500
d = 5.00"

June 2004
Page 41 of 65
depth = 5.77"
25 degree sending
transducer
25 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
25 degree, L-wave
= 0.577
d = 5.77"

June 2004
Page 42 of 65
depth = 6.58"
20 degree sending
transducer
20 degree receiving
transducer
D = 20"
10" radius
depth, d, in inches
R = 10"
20 degree, L-wave
= 0.658
d = 6.58"

June 2004
Page 43 of 65
Through-Transmission Ultrasonic Calculations

Following sketches and equations show the calculations used to make a
Through-Transmission set up.
For each header the initial data known would be the header outside
diameter (OD) and inside diameter (ID). This is the only data needed to
calculate the set up. A drawing of the header would be needed to confirm that
the preparations for the penetrations do not have unusual geometries, and to
confirm the distance between the penetrations in the header.
What needs to be calculated is the circumferential distance between the
transducers on the outside diameter of the header.
For detection of the ligament crack, the transducer angle is chosen that is
deepest in the header without being blocked by the ID of the header.

June 2004
Page 44 of 65
R=1
R = hypotenuse
Construct 2 right triangles with a common equal side

and both hypotenuse equal to the radius of the
circle, which is equal to one. The resulting
horizontal line is the soundpath for the ThroughTransmission set-up, or can be the used as the
'Base Distance' for manual TOFD.

June 2004
Page 45 of 65
= 90 -
= transducer angle

June 2004
Page 46 of 65
Circumferential Distance between transducers (arc distance)
included angle =
The circumference of a circle, C = D
D = Diameter = (R O.D.) X 2
Circumferential Distance (arc distance) between transducers =
C X
2
360

June 2004
Page 47 of 65
Maximum depth to Through-Transmission Soundpath

or
Depth of material not examined by TOFD
adj
hyp.
RO.D. = 1 = hyp
cos = adj
hyp
(hyp = RO.D = 1)
cos = adj
1
cos = adj
adj
= RO.D. - depth
depth = 1 - cos
(This is the depth of the material not examined by TOFD,

or the maximum depth to the Through-Transmission Soundpath.)

June 2004
Page 48 of 65
adj.
opp.
hyp.
( =1 )
cos =
adj.
hyp.
hyp.
cos =
adj.

June 2004
Page 49 of 65
Soundpath
or
Manual TOFD 'Base Distance'
(chord length)
adj.
opp.
hyp.
( =1 )
cos =
adj.
hyp.
hyp.
cos =
adj.
manual TOFD 'Base Distance' (chord length)

or
Through-Transmission Soundpath
= 2 cos (times the radius to the outer diameter)

June 2004
Page 50 of 65
Through-Transmission Set-Up Spreadsheet
Outside Diameter
(OD)=
20
Circumference
(inches)=
62.83
sound
transducer angle mode
70
65
60
55
50
45
40
35
30
25
20
(insert the outside diameter in inches)
included
angle
2
shear
shear
shear
shear
shear
shear
L-wave
L-wave
L-wave
L-wave
L-wave
40
50
60
70
80
90
100
110
120
130
140
20
25
30
35
40
45
50
55
60
65
70
Arc distance
Depth
Circumferential
Circumferential
Distance (as a
Distance
Depth, as a fraction of the
fraction of C)
(inches)
radius
= C X 2
/ 360
= 1 - COS
0.111
0.139
0.167
0.194
0.222
0.250
0.278
0.306
0.333
0.361
0.389
6.98
8.73
10.47
12.22
13.96
15.71
17.45
19.20
20.94
22.69
24.43
(This is the distance measured

between the transducers on the
outside surface of the cyinder)
0.060
0.094
0.134
0.181
0.234
0.293
0.357
0.426
0.500
0.577
0.658
Chord
Depth
(inches)
= 2 COS X (RO.D.)
0.60
0.94
1.34
1.81
2.34
2.93
3.57
4.26
5.00
5.77
6.58
(This is the deepest point of the sound

beam centerline in the part)
6.84
8.45
10.00
11.47
12.86
14.14
15.32
16.38
17.32
18.13
18.79
= 1 X RO.D.
= 1.414 X RO.D.
= 1.732 X RO.D.
(This is the soundpath length in inches

through the material)

June 2004
Page 51 of 65
Manual TOFD
Manual TOFD of axial cracks uses radial oriented transducers in pitchcatch pairs. The transducer pair can scan axially, or circumferentially.
The previous set-up shown for TOFD on flat surfaces is adapted for
cylindrical shaped scanning surfaces. The only difference being that the Base
Distance lies on a chord within the volume of the material. The same Excel
spreadsheets previously shown for flat plate are adapted for sizing of axial
cracks.
The following sketches show some of the relations of Base Distance, LDistance, chord length and arc or circumferential length.
Then the basis for calculations of Base-Distance and circumferential
distance are shown.
The final spreadsheet is the spreadsheet used for set-up of manual TOFD
on cylindrical scanning surfaces.

June 2004
Page 52 of 65
arc distance
chord distance
R-O.D.
R-I.D.

June 2004
Page 53 of 65
TOFD - Base Distance
R-I.D.
R-O.D.
R-O.D. = Radius to the Outer Diameter of the pipe, header or cylinder

R-I.D. = Radius to the Inner Diameter of the pipe, header or cylinder

June 2004
Page 54 of 65
2
R- I.D.
R- O.D.
= base-to-radial angle (this was the transducer angle for thru-transmission testing)
2
= included angle

June 2004
Page 55 of 65
TOFD - Base Distance
direct L-wave
Backwall
L-wave

June 2004
Page 56 of 65
flaw
Backwall
L-wave
L-Distance as
read from UT
machine as
Soundpath

June 2004
Page 57 of 65
Depth of
material not
examined by
TOFD.
flaw
Depth as read
from TOFD tables
for a given Base
Distance, for the
L-Distance
measured.
Backwall
L-wave

June 2004
Page 58 of 65
Circumferential Distance between transducers (arc distance)
included angle =
The circumference of a circle, C = D
D = Diameter = 2 X RO.D .
Circumferential Distance (arc distance) between transducers =
C X
2
360

June 2004
Page 59 of 65
Depth of material not

examined by TOFD
adj
hyp.
RO.D. = 1 = hyp
cos = adj
hyp
(hyp = RO.D = 1)
cos = adj
1
cos = adj
adj
= RO.D. - depth
depth = 1 - cos
(This is the depth of the material not examined by TOFD.)

June 2004
Page 60 of 65
Manual TOFD
'Base Distance'
(chord length)
adj.
opp.
hyp.
( =1 )
cos =
adj.
hyp.
hyp.
cos =
adj.
manual TOFD 'Base Distance' (chord length)= 2 cos (times the radius to the outer diameter)

June 2004
Page 61 of 65
Radial TOFD Set-Up Spreadsheet for Pipe, Headers or Cylinders
Base Distance =
Outside Diameter
(OD)=
20
Inside Diameter
(OD)=
16
circumference
(inches)=
62.83
(insert the Base Distance or chord, inches)
(insert the outside diameter in inches)
RO.D. = 10
(insert the inside diameter in inches)
RI.D. = 8
Arc distance
base to radial
angle (degrees)
78.46
included
angle
(degrees)
23.07
Circumferential
Distance (as a
fraction of C)
= 2
/ 360
11.54
0.064
Depth
Circumferential Depth, as a fraction of the

Distance (inches) radius
= C X 2
/ 360
= 1 - COS
4.03
0.020
Depth
(inches)
Depth to ID
of the TOFD
'Backwall Lwave'
0.20
1.80
(This is the distance measured between

the transducers on the outside surface (This is the depth of material not examined
of the cyinder)
by TOFD)

June 2004
Page 62 of 65
Circumferentially Oriented Manual TOFD Simulators

Three Excel spreadsheets have been made which can simulate TOFD setups with various base distances for an infinite variety of pipe OD and ID
combinations. The beam-spreads of 30 degree L-wave, 45 degree L-wave, and
60 degree L-wave are shown on separate spreadsheets.
Three print-screens of the spreadsheets follow as examples of what they
look like.

June 2004
Page 63 of 65

June 2004
Page 64 of 65

June 2004
Page 65 of 65

Header Ligament Crack Detection and Sizing

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Header Ligament Cracks -- UT Techniques