PHASED ARRAY ULTRASONIC

INSPECTIONS FOR REFINERY

APPLICATIONS

INTEGRITY NDT Ltd. SOLUTIONS

Prepared by: Gorkem Bayten

 APPLICATIONS

Detection of Stress-Oriented Hydrogen Induced Cracking or
SOHIC

Detection of HTHA (High temperature hydrogen attack)

Corrosion mapping in nozzles

PA&TOFD imaging and sizing of welds

Inspection of Bolting for Cracks and Corrosion

Inspection of Complex Geometry

Heavy Wall Vessel Crack Detection and Sizing

Heavy Wall Power Piping Inspection to ASME B31.1 and
B31.3

ASME CC 2235 PA Inspection for the Replacement of
Radiography
 HYDROGEN INDUCED CRACKING (HIC)

Set up consists of a -30 +30o S-scan at 0.5o resolution.

The A-scan display was switched between Auto Track Mode
and Normal to best characterize the indication.
HYDROGEN INDUCED CRACKING (HIC)

As the probe is moved left and
right and back and forth the
side step cracking can be
tracked in real depth display
allowing the operator to easily
determine severity, depth, and
characterization of the HIC

The two images show actual
HIC side step cracking and
inclusions and spot laminations
that are not considered
detrimental to the vessel
HYDROGEN INDUCED CRACKING (HIC)

The corrosion mapping vender has to make a decision. Is it
corrosion? Is it a lamination from the pre-service?, is it
spot inclusions from the pre-service? or is it Hydrogen
Induced Cracking that could rupture at any time?
HIGH TEMPERATURE HYDROGEN ATTACK

HTHA in the petrochemical plants is caused when the
hydrogen from the stream seeps into carbon and low alloy
steels at high temperatures.

Hydrogen reacts with the carbides in the steel,
decarburizing the steel and forming methane gas bubbles
at the grain boundaries with no loss of thickness.

The methane gas bubbles grow with time and result in
micro cracking.

The combination of micro cracking and decarburization
reduces the fracture toughness of steels and leads to
major failures
HIGH TEMPERATURE HYDROGEN ATTACK

Damage originally measured by changes in velocity.

New NDE approach uses PA’s to detect increased
backscatter (right) over clean material (left).
NOZZLE EROSION-CORROSION
PA Probe
32 Element, 10MHz

Smooth
End Surface
Beam swept 0-70 L-
Waves 70 Degree
Law

Corner

0 Degree Bottom Surface

Law
 NOZZLE EROSION-CORROSION
10MHz PA Probe

178 mm test block

Bevel End Step end

NOZZLE EROSION-CORROSION

Bevel End Zoomed

 WELD INSPECTION

Select arrays to give adequate coverage; need to ensure
HAZ and weld zone covered

Scan weld in parallel linear motion, or move weld past
stationary arrays -> much faster.

Left: Conventional UT Right: Phased Array

WELD INSPECTION

Typical weld inspection using combined electronic and
linear scanning.

ASME-type 45o and 60o shear wave & TOFD inspections;
~10x faster than raster scanning.

Need to cover weld, HAZ, any position errors => significant
amount of coverage.

Works well for wide gap welds.

WELD INSPECTION

This image shows weld profile superimposed on “top,
side,end” and waveform view.
INSPECTION OF BOLTING

One zone was created for the body (non-threaded) area and
one zone for the threaded area on the near side. The only
difference between the set up for the two zones were
adjustments to the range and gain to account for the longer
sound path.

Moving the probe back and forth and side to side, a full
volumetric inspection can be achieved from either side.
Care must be taken to maneuver the probe around the
retaining pin hole to ensure complete coverage. The 15
degree sector scan allows you to steer the beam under this
obstruction.
INSPECTION OF BOLTING
INSPECTION OF BOLTING

Corroded bolt inspected in place showing complete thread
loss from 24-33mm
INSPECTION OF COMPLEX GEOMETRY

In the example below there is an acceptable length of non
penetration that cannot exceed 10mm. This can be easily
measured by using the delta between the two signals from
the sector scan.
HEAVY WALL VESSEL INSPECTION

Sector scan image at over 100mm in depth detecting ID
connected thermal fatigue crack
HEAVY WALL POWER PIPING INSPECTION

Replaces radiography and radiation hazard for increased
productivity.

Provides detailed defect depth, height and length sizing

Computer based software utilizing weld overlays, advanced
focal low programming, and custom displays

15 minute per weld on 100mm + 10-20 inch diameter
power piping

One side and two sided inspections for pipe-pipe, pipe-elbow,
pipe to flange, etc.

Utilizes standard ASME type calibration blocks

Typical instrumentation is TD HandyScan 32:128 and
Omniscan 32:128 with and Tomoview 2.7 for computer
based acquisition
HEAVY WALL POWER PIPING INSPECTION

Full calibration of all A-scans for sensitivity, TOF, TCG\DAC
to meet ASME standards

Typical ASME calibration standard using similar material
and specified SDH
HEAVY WALL POWER PIPING INSPECTION

100mm+ full volumetric inspection

Lack of fusion easily characterized, sized, and recorded for
code accept/reject
ASME CC 2235

Integrity I-Scan magnetic scanner does not require power or
complex motion controllers

Combines TOFD and Phased Array for detailed defect
detection and sizing

Less than 3 hours of up front engineering to include creation
of scan plan, inspection strategy, calibration, and equipment
mobilization

Using existing ID/OD notch and SDH type calibration
standards typical of ASME Sec VIII

No power required. 100% battery operated inspection using
TD Handy Scan 32:128 with PA and TOFD accessories

Can be used on material thickness from 12mm to 100MM+
ASME CC 2235

Scan plan required 1 probe on each side of the weld utilizing
linear scans for the upper 1/3, middle 1/3, and lower 1/3
+ 2 TOFD channels

All-scans acquired simultaneously and analyzed in real time
during the inspection

Weld overlay allows easy placement of defects in weld for
analysis and documentation

200+ A-scans acquired, all are programmed to be the direct
equivalent of a 5MHz 20mm diameter convention UT probe
calibrated for sensitivity, TOF, and TCG\DAC.
ASME CC 2235
ASME CC 2235

Primary inspection view displays 2 TOFD channels and a C-

scan merge of all focal laws on all channels. The merge view
is the sum of all A-scans allowing analysis of 200+ A-scans
simultaneously.

A weld with no defects can be analyzed in less than 1 minute
ASME CC 2235
ASME CC 2235

When a defect is detected the operator changes to the sizing
layout to measure the defects depth and height utilizing the
weld overlays, data projection tools, amplitude drop sizing
tools and measurement cursors
ASME CC 2235

Every A-scan on every channel is recorded and can be
analyzed independently. The electronic raster below on the
upstream Midwall channel can be electronically rastered in
and out from the weld in analysis mode and is the direct
equivalent of a single channel conventional raster scan.
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