RT vs Conventional UT vs PAUT

Te c h n i c a l & F i n a n c i a l C o m p a r i s o n s
 Contribution of Radiography….

Flaws in materials can lead to costly remediation and lost productivity.

These flaws can also lead to costly component replacement and process
bypasses that create more problems for production and maintenance teams.
During World War II, radiography for industrial purposes began to
develop, and isotopes such as caesium-137, iridium-192 and cobalt-60
became available for industrial radiography.
 Fruits of RT but with catch….
Radiographic testing is widely used in a variety of industry sectors including
aerospace, power generation, construction, petroleum, chemical and
automotive, and for all types of components and parts. The technique is
commonly used on welded parts, castings, forgings, composites and is also
used for corrosion mapping and the measurement of wall thickness.
The benefit of using radiography is that it requires minimum surface
preparation and provides a permanent record of testing.
Radiographic testing using X-rays and gamma rays are hazardous and as
such are controlled by stringent legislation.
When radiography carries out in site that
you should have complete assurance that all
legal requirements and legislative notifications
are adhered to, including the transportation of
isotopes, protective enclosure barriers and
warning systems.
 Health Hazards of RT….
Since this method uses ionizing radiation, it is
important to ensure not only the quality of
product, but also the safety of the technician and
the general public, as well as the protection of the
environment.
Improper practice could result in the technician
and the public being exposed to a large dose of
radiation in just a few seconds.
Moreover, contamination from a corroded or
damaged source can cause additional radiation
hazards to radiography personnel.
Therefore, a high degree of care and
professionalism is required for radiography work.
 Financial Hazards of RT….
In 2017, the global radiography test equipment market was valued at USD
858.6 million and is expected to reach a value of USD 1451.12 million by
2023, registering a CAGR of about 9.14% during 2018-2023 (the forecast
period).
It’s a profitable Industry in the point of Contract companies.
But as a Manufacturer & client its a loss per time.
Depending on location, preparation for radiographic inspection may require
permits and clearing the area of other personnel to ensure they are not
accidentally exposed to radiation.
Assessing the welding area to be inspected, the technician evaluates the best
locations for the x-ray generator and image plate so that the generator and
image plate are aligned properly.
 Financial Hazards of RT….
Frankly Speaking you need to halt your total Production in that specific
region in order to perform RT. Which can cause thousands of USD loss per
shift.
Its also time consuming since total coverage of the component in a single go
is not possible, Optimum inspection quality requires the radiation to be
directed to the middle of the section being inspected and be normal to the
material surface.
Exposure time varies depends upon component thickness & Curie strength.
Once the image has been captured, the negative needs to be developed and
interpreted.
The trained technician then examines the negative for subtle variations that
indicate any defect, its location, and size.
De-laminations and planar cracks can be very difficult to detect using
radiography, particularly to untrained technicians.
 Replacement for RT….
As the restrictions in the use of Industrial Radiography (RT) has increased
over the years, the need for alternative weld inspections methods and
techniques such as Conventional UT, Time of Flight Diffraction (TOFD) and
Phased Array (PA) has become more evident.
Where most codes & Standards directly mentioned about RT Replacements
while some codes are still in process of establishments.
Up until now The direct replacement of RT is Conventional UT.
Reason is that Ultrasonic Testing is the only other volumetric Testing
method apart from RT.
 Need Skilled Replacement….
First generation of Conventional UT is based on A-Scan presentation only
which indeed very difficult to interpret a discontinuities.
Conventional UT has its own merits & Demerits.
For an example Where Conv.UT has a low risk of health hazard, High
Probability of detection for Highly Severe defects like Through thick
Cracks, Lack of Fusion & Many Planar defects, but all those defects can
only be detected if operator properly select his UT Equipment & its
calibration.
Wrong calibration or poor Probe selection
may lead to missed call.
Which is the reason why you need a
highly skilled & experienced UT Inspectors.
More importantly that lack of technology
for storing a permanent record in Conv.UT
Is always a risky choice.
 Conv.UT Alternative….
Although it is on the decline, many NDT analysts still use radiography for
inspections. However, phased array ultrasound testing (PAUT) is rapidly
replacing radiography, Conv.UT and other less effective NDT methods as
the new standard emerges and for good reason also.
When Phased Array and Time of Flight Diffraction techniques are
performed correctly, the quality of performance is superior when compared
with radiography.
This means that the confidence level of the structural integrity of products
inspected with TOFD or PA is higher than those inspected using
radiography.
Because phased array & TOFD inspections are entirely digital, inspection
results are instantaneous, providing immediate feedback to enable faster
inspections, Permanent storage, confirmation of weld quality or detailed
identification of defects & Without affecting its surroundings.
 Costly Alternative….
The inspection costs of PA and/or TOFD are typically higher than the costs
of conventional RT, however, because dangerous radiation is not a factor
when using the advanced techniques, there can be huge savings associated
preventing the disruption of works within the area.
In addition, the speed of PA and TOFD shortens overall inspection time and
also eliminates the lost time associated with RT.
An inherent factor of using a more
accurate inspection technique is the higher
repair rate due to the more stringent
acceptance criteria of PA and TOFD.
Increased confidence in the integrity of
the product offsets the relatively small rise
of repairs thereby decreasing any significant
influence total costs.
 Reliable Alternative….
Unlike radiography, phased array inspection techniques don’t involve
hazardous materials or supplies, require additional licensing or
certification, or generate waste.
Phased array inspections can be conducted safely while other work is being
done in close proximity.
PAUT instruments can easily generate detailed standardized inspection
reports that can be printed or saved as digital records to meet compliance
requirements. Additional advantages of phased array inspections techniques
include:
High probability of detection (POD) for planar flaws such as
fatigue and stress corrosion cracks.
Ability to assess through-wall depth attributes to accurately
determine the location defects.
Calculation of defect height measurements as an indicator of
flaw severity.
Ability to discriminate among defects stacked throughout the
material thickness in a proximate circumferential location.
 Conclusion….
120%
100%
80%
60% Probability of Detection
40% False Call Rate
Reliability
20%
0%
PAUT TOFD Conv.UT X-ray &
Gamma ray

Various codes have accepted PAUT and TOFD as volumetric examination

technique.
Higher POD, lower FCR, higher accuracy in sizing and discontinuity
characterization, digital records, less dependency on operator, less regulatory
requirements attract the industry to think PAUT and TOFD to replace
conventional volumetric NDE methods.
 Continuous advancements in technology is driving Oil & Gas /
power industry to use higher efficient operating systems which led
to selection and manufacturing new and advanced materials.

These advanced materials are very critical in nature. Such

advancements in designs and materials deserves advancements in
discontinuity detection.
Thank You