Dual Matrix Array for Ultrasonic Inspection

of Dissimilar Girth Welds of Large

Diameter CRA-Clad Pipeline
Background

CRA-clad pipes are increasingly used for the transport of hot and corrosive materials
because of the higher resistance to corrosion provided by the corrosion resistant
alloys (CRA) used for the pipe cladding. However, the layer of protection that these
alloys provide also impedes effective ultrasonic inspection of dissimilar girth welds in
the piping. The industry has been searching for a simple and reliable solution to this
particular challenge.

Problematic

Ultrasonic inspection of dissimilar girth welds in CRA-clad piping poses a particular

challenge. As the material of the clad layer (Inconel, stainless steel, etc.) differs from
that of the parent material (carbon steel), the quality of the interface between these
materials makes the rebound on the internal wall (ID) of the pipe unpredictable or
even impossible. In addition, the anisotropic structure of the cladding and the weld
creates ultrasonic mode conversion and different beam orientations. Consequently,
high-precision techniques like zone discrimination cannot be used. Pulse-echo using
the second leg of the ultrasonic beam is impossible, which makes inspection of the
cap and its subsurface extremely challenging.

Profile of a dissimilar girth weld of a CRA-clad pipe

Solution

Olympus has developed a dual matrix array (DMA) probe with the goal of increasing
the capacity for detection and sizing of flaws that are located at the root, in the
volume, and on the surface of dissimilar welds of large-diameter clad pipe. (For more
details about dual matrix array, please consult the application note: Dual matrix array
for the inspection of acoustically noisy welds.)

The tests discussed in this application note were performed on a 36-inch pipe
sample, using a 2.25 MHz DMA probe composed of 2 matrices of 28 elements (7 x 4)
mounted on a 55-degree LW wedge.

On the left: picture of the DMA probe; on the right: schematic of element distribution

A portable phased array instrument, the OmniScan MX2 32:128 PR, was
programmed to assure full coverage of the weld without skipping off the internal wall
of the pipe. Two different groups were used:

 Group 1 with a sector scan from 30 to 76 LW focused at 2 mm deep to provide

coverage of the upper volume of the weld and the surface
 Group 2 with a sector scan from 30 to 76 LW focused at 20 mm deep to provide
coverage of the root and the volume of the weld

The picture below shows the modeling of the beams generated at the interface
between the 2 matrices.

Beam modeling representation: (on the left) 75 LW beam focusing at 2 mm [part of group 1 ];
(on the right) 45 LW beam focusing at 20 mm [part of group 2]

The inspection was done manually without the use of a scanner or an encoding
device.
Equipment

The following equipment was used for the inspection:

Phased-array instrument: OmniScan MX2 32/128 PR (U8100149)

1 dual matrix array probe: 2.25DM7X4PM-19X12-A17-P-2.5-OM: (U8331715)
1 flat wedge: SA17-DN55L0-IHC (U8831948)
Software: SetupBuilder Software 1.0R5
TomoView (optional)

The mock-up used for the tests was a 36 in. diameter pipe composed of carbon steel
with a 3 mm thick mechanically bonded cladding of Inconel 625. The material of the
weld was composed of Inconel 625 as well.

Schematic of the clad-pipe configuration

The set of reference defects for the mock-up is shown below. They include: 2.5 mm
side-drilled holes located in the center of the weld at T/4, T/2, and 3T/4, as well as 10
mm long and 2 mm deep surface notches located at the toe position, at the top of the
weld, and at the root.

Schematic of the reference defects of the clad-pipe mock-up

Results

All SDHs were detected with a SNR superior to 45 dB. The SDHs located at 3T/4 and
T/2 were detected with group 2 focusing at 20 mm, and the SDH located at T/4 was
detected with group 1 focusing at 2 mm.

Detection of the SDH: 3T/4 on the left; T/2 in the center; T/4 on the right

The toe notch located on the same side of the probe and the notch located at the top
of the weld were detected with a SNR superior to 40 dB and by focusing group 1 at 2
mm (as shown below). The notch located at the root was easily detected with group 2
focusing at 20 mm; however, the picture was not recorded.

Detection of notch located at: (on the left) toe position; (on the right) at the top in the center
of the weld

Important to Note

The results presented in this application note concern the use of a 2.25 MHz DMA
probe on large-diameter clad pipe. The results that are discussed in this application
note cannot be transferred to smaller diameter pipe. Olympus is currently working on
developing specific solutions and inspection strategies for these diameters.

Also, this inspection was done manually without a scanner or an encoder. While this
technique is flexible, it is also operator dependent. Therefore, these results cannot be
transferred as is to a high-production-rate environment. Olympus is also in the
process of developing solutions for this type of environment with the use of similar
tools.
Conclusions

A 2.25 MHz DMA probe paired with the OmniScan MX2 32:128 PR can be
advantageous for the inspection of clad pipe with large diameters. Full coverage of
the dissimilar weld was ensured. SDHs located in the volume and notches located on
the ID and OD can be detected using an inspection scenario of two groups steering
the beams from 30 to 76 LW, focusing at 2 and 25 mm.

These results are very promising, and Olympus is intent on further developing this
strategy to extend the use of these tools to smaller clad-pipe diameters and high-
production-rate environments.