Advancement in NDE

By: Dilip Kumar Singh, Sr. Engr./ATP-NDTL-Quality

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 1

 Outline
Basic of NDE & Background

Significance of NDE

Challenges in application of NDE

PAUT, TOFD & Microfocal

Future expectations in NDE

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 2

 Bharat Heavy Electricals Limited, Tiruchirapalli

Introduction to NDE

NDE
Indication
Interpretation

False Relevant Non-Relevant

Evaluation Acceptance
Criteria

Accept Reject

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 3

 Impact of NDT on Rail System

UK network used various NDT methods to curb the rail breaks. As

per Rail Accident Investigation Branch, in UK, the number of rail
breaks have reduced from 919 in 2000 to 178 in 2013.
Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 4
 Challenges in application of NDE
 Acceptance Criteria
 Engineering Critical Assessment
 POD
 Paradigm Shift
 Failure Modes Effect Analysis (FMEA)
 Accurate characterization of imperfections
 Online Assessment
 In-service Inspection without shutdown
 NDE challenge on 3-D printed components
 Assessment and management of ageing of major nuclear power plant components
 100% volumetric NDE for the Complex Geometry

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 5

 Paradigm Shift

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 7

 Future expectations

• Non Destructive testing, then

• Non Destructive testing, now
• What is next ??

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 8

 Non Destructive testing, then
• Basic methods (i.e. MT, PT, RT, UT… etc.)

• NDT after manufacturing of the product.

• More skill required for NDT personal.

• Manual result recording

• Possibility of the hazards (i.e. Radiation, Chemical…)

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 9

 Non Destructive testing, now
• Advancement in basic methods (i.e. RTR, CR, PAUT, TOFD…etc.)

• NDT after manufacturing or in-service of the product.

• Comparatively less skill required for NDT personal due to

advancement.

• Manual result recording become easy.

• Possibility of the hazards reduced. (i.e. Radiation, Chemical…)

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 10

 Non Destructive testing, Now
• New methods with the combination of basic NDT methods.
– Electrochemical NDT.
– Electromagnetic NDT.
– Visual and optical NDT.
– Non contact NDE metrology.
– Ultrasound burst phase thermography ( UT+ Thermography).
– Portable Computed RT
– MT + NIS ( near infrared spectroscopy )
– RTR+ TOFD
– PAUT + TOFD
Combinations are endless…

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 11

 Radiography
Differential absorption of radiation

 Good for the

defects which are
in line with
radiation
 Not Good for
planer
discontinuity.
Lamination can go
undetected

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India

12
 Bharat Heavy Electricals Limited, Tiruchirapalli

Conventional Ultrasonic Testing

BB
A B • Pulse Echo (Reflection)
• Transmission
• Pitch-Catch
Good For Planer Defect ( to wave propagation). Like LOF, Lamination

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 13

 Bharat Heavy Electricals Limited, Tiruchirapalli

Consideration in Ultrasonic Testing

• Dead Zone
– Time Between Two Electrical Pulse
– Can Be Eliminated if Two Probes are
used; One is transmitter and one is
receiver
• Near Zone
– Time taken to overcome internal
interference (Constructive and
Destructive)
– N=D2/4
• Near Zone can be controlled if interference
can be controlled

14
• Radiography – Problem related to Execution
• Radiation safety, Licensing
• Difficulty to defect planer discontinuity
• Disruption to work area
• Chemical wastes ,Large volumes of film
• Film storage and deterioration
• Subjective interpretation
• Relatively slow inspection
Handling the Job is the biggest NPA

Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India

15
 • Radiography – Technical Problems
• Thinner, stronger vessels under construction due to:
– Increased resource costs
– Higher strength materials
– Better quality materials

• Developments of Fracture Mechanics and crack growth

predictions require defect depth measurements

=> RT cannot size in vertical plane

=> RT poor at detecting planar defects.

 Solution of Technical Problem was to get some alternate technique

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 16

 • Early Alternative – Manual UT
• Advantage
– Better detection of planar flaws generally
– Better detection of mis-oriented flaws
– No environmental side-effects

• BUT, manual UT has major disadvantages

– No permanent record, i.e. not auditable
– Witness is only option available with inspectors
– Operator Dependent

Thrust for better solution was continue

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 18

Codes, Standards, Procedure
and Technique Sheet

Technique Sheet

Procedures

Standards

Codes

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 19

 Acceptance Criteria

Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 20

 Advantage of AUT

• Automated/Advanced ultrasonic potentially

offers solutions
• Capability of vertical sizing
• Better detection of critical planar defects
• Inspections tailored to weld profile and defects
• Permanent Record
• Less Operator Dependency

AUT is advancement in conventional UT

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 21

 Advantage of AUT

• Generally AUT has better detection than MUT or RT, especially for cracks

• Many trials performed globally (though not all compare AUT and RT)

• Overall results support AUT as better quality inspections

Survey Done for POD and Accuracy

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 22

 Bharat Heavy Electricals Limited, Tiruchirapalli

Scanning by Ultrasonic Testing

• 2 Angle Probes
• 1 Normal Probes
• Raster Scanning

Good for those orientation which are  to those angles

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 23

 Bharat Heavy Electricals Limited, Tiruchirapalli

 Ultrasonic Scanning– Raster Scan

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 24

 Bharat Heavy Electricals Limited, Tiruchirapalli

Optimum Solution

• Typically, the best solution is to use more than

one technique, especially if “independent”
• Recommend using pulse-echo and TOFD –
essentially independent, and rapid
– PE for detection, with TOFD confirmation
– TOFD for midwall detection & sizing
– TOFD for sizing with PE confirmation.
• Two techniques are complementary

Advanced Ultrasonic Testing : PAUT + TOFD – The Fatal Combo

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 25

 Bharat Heavy Electricals Limited, Tiruchirapalli

What is Phased Array

 Phased array technology is the ability to
modify electronically the acoustic probe
characteristics

 Probe modifications are performed by

introducing time shifts in the signals sent to
(pulse) and received from (echo) individual
elements of an array probe

 Any UT technique for flaw detection and

sizing can be applied using phased array
probes

Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 26

27
Basic principle of phased array ultrasonic testing

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 27

 Bharat Heavy Electricals Limited, Tiruchirapalli

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 28

 Bharat Heavy Electricals Limited, Tiruchirapalli

Wave Forming Fundamental : Beam Focusing

Delay from Side to Center

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 29

 Bharat Heavy Electricals Limited, Tiruchirapalli

Wave Forming Fundamental

• Beam Forming

• Focused Beam

• Inclined Beam

Above Fundamental is the Key of Success for PAUT

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 30

 Bharat Heavy Electricals Limited, Tiruchirapalli

Wave Forming Fundamental : Beam Steering

• The capability to modify the refracted angle of

the beam generated by the array probe

• Allows for multiple angle inspections, using a

single probe

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 31

 Bharat Heavy Electricals Limited, Tiruchirapalli

Wave Forming Fundamental : Beam Steering

Delay from one side to another side (350 to 800 )

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 32

 Bharat Heavy Electricals Limited, Tiruchirapalli

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 33

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Electronic Scanning

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 34

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Electronic Scanning

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 35

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Combined Beam Processing

Electronic Combined with Steering and Focusing.

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 36

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Sectorial (Azimuthal) Scanning

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 37

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Sectorial Scanning

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 38

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Sectorial Scanning

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 39

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Dynamic Depth Focusing (DDF)

• DDF is an excellent way of inspecting thick components in a
single pulse. The beam is refocused electronically on its
return.

Mechanical Displacement

FOCUSDEPTH(PULSER)
Beamdisplacement

DYNAMICFOCUSING (RECEIVER)

c =velocity inmaterial

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 40

 Bharat Heavy Electricals Limited, Tiruchirapalli

PAUT Scan : Continual or Wrapped Scanning

NORMAL BEAM ANGLE BEAM

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 41

 Bharat Heavy Electricals Limited, Tiruchirapalli

Summary of Scan Types

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 42

43

Probes & Wedges

• Set1-64 elements
– Wedge: SA2-N55S-IHC-DUAL
– Probe: 2.25L64-A2

• Set2-32 elements
– Wedge: SA5-N60L-IHC-PLANE
– Probe: 2L32A5

• Set3-16 elements
– Wedge: SA1-N60S-IHC
– Probe: 2L16-A1

• Encoder: ENC1-2.5DE-224825-10

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 43

 Bharat Heavy Electricals Limited, Tiruchirapalli

ES-Beam/Set Up Builder Tool(for Old Version or latest

Equipment) – Simulation of Joints

One Sided or Two Sided

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 44

 Bharat Heavy Electricals Limited, Tiruchirapalli

ES-Beam/Set Up Builder Tool(for Old Version or latest

Equipment) – Simulation of Joints

One Sided or Two Sided

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 45

 Bharat Heavy Electricals Limited, Tiruchirapalli

ES-Beam/Set Up Builder Tool(for Old Version or latest

Equipment) – Simulation of Joints

One Sided or Two Sided

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 46

 Bharat Heavy Electricals Limited, Tiruchirapalli

Arrangement of PAUT Probes

One Sided or Two Sided

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 47

 Bharat Heavy Electricals Limited, Tiruchirapalli

Delay

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 48

 Bharat Heavy Electricals Limited, Tiruchirapalli

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 49

 Bharat Heavy Electricals Limited, Tiruchirapalli

Focusing

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 50

 Bharat Heavy Electricals Limited, Tiruchirapalli

Basic Calibration

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 51

 Bharat Heavy Electricals Limited, Tiruchirapalli

Velocity

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 52

 Bharat Heavy Electricals Limited, Tiruchirapalli

Wedge Delay

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 53

 Bharat Heavy Electricals Limited, Tiruchirapalli

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 54

 Bharat Heavy Electricals Limited, Tiruchirapalli

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 55

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 56
22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 57
22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 58
 TCG

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 59

 Ultrasonic Views

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 60

 Ultrasonic Views

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 61

 A-Scan

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 62

 B-Scan

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 63

 C-Scan

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 64

 D-Scan

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 65

 S-Scan

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 66

67
Representation of scanned data

Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 67

 Polar View

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 68

 Strip Charts

Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India

22-Nov-18 69
70
Phased Array Ultrasonic Testing
• New Technology using multiple element probes
• Used for Welds Advanced Technology Products
Results in
• Improved defect detection &sizing capability since beam angle
can be swept to cover all defect orientations.
• Improved inspection speed compared to manual inspections and
reduced complexity compared to automated inspections by
avoiding the need to scan several probes.
• Improved reliability since it can be much easier to interpret the
features within the image (defect, weld cap, un-fused land) when
they move in synchronization with probe movement

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 70

71
Conventional UT vs. Phased Array UT

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 71

72

Conventional UT vs. PA-UT

Raster Linear scanning

scanning

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 72

73

Understanding PA-UT language

Indications

GATE 1

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 73

74
Calibration

• Velocity Calibration

• Wedge Delay Calibration

• Sensitivity Calibration

• TCG-Time Corrected Gain flaw

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 74

75
Defect locating
SIDE
DRILLED
HOLE

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 75

76

Pipe Butt weld Auto scanner

22-Nov-18 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 76

 Bharat Heavy Electricals Limited, Tiruchirapalli

Why Phased Array

• High speed electronic scanning

• Improved inspection capabilities through
software control of beam characteristics
• Inspection with multiple angles with a single
electronically controlled probe
• Many configurations: P/E, T/R, TOFD, Tandem
• Greater flexibility for inspection of complex
geometries
• Optimized focusing
• Optimized beam angle

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 77

 Bharat Heavy Electricals Limited, Tiruchirapalli

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 78

 Bharat Heavy Electricals Limited, Tiruchirapalli

TOFD
The Diffraction Phenomenon
Incident
wave
Diffracted
waves

All directions

Low energy

Independent of incidence angle

Reflected Flaw
wave

Diffracted
waves

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 79

 Bharat Heavy Electricals Limited, Tiruchirapalli

Diffraction Phenomenon

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 80

 Bharat Heavy Electricals Limited, Tiruchirapalli
Advanced Ultrasonic Testing : PAUT and TOFD

Transmitter Receiver
Lateral wave

Back-wall reflection

LW BW

Upper tip Lower tip

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 81

Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli
 Bharat Heavy Electricals Limited, Tiruchirapalli

Inspection zone & probe selection

 Bharat Heavy Electricals Limited, Tiruchirapalli

Beam Focus
Bharat Heavy Electricals Limited, Tiruchirapalli

PCS
Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli
Bharat Heavy Electricals Limited, Tiruchirapalli

Data
 Bharat Heavy Electricals Limited, Tiruchirapalli

Data Visualization (TOFD)

A-scan

Indication

Lateral Back wall

wave

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 94

 Bharat Heavy Electricals Limited, Tiruchirapalli

Advanced Ultrasonic Testing : PAUT

Typical TOFD Image
and TOFD
Lateral wave

Back-wall echo

TOFD Indications

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 95

 Bharat Heavy Electricals Limited, Tiruchirapalli

Advantage of TOFD
• The Best Technique for Vertical Sizing
• Accurate sizing of defects using the time of arrivals
of diffracted signals.
• Defects mis-oriented defects ,or defects located
away from the weld centreline.
• Very rapid linear scanning (raster scanning not
required)
• Non-amplitude scanning and detection.
• Set-up independent of weld configuration.
Very Sensitive Technique

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 96

 Bharat Heavy Electricals Limited, Tiruchirapalli

Advanced Ultrasonic Testing : PAUT

Limitation of TOFD
and TOFD
• Dead zone at surface
• Sensitive to very small defects with a risk of
overcalls (add pulse echo) to our application
• Low signal-to-noise ratio.

The Best Solution is to use with another independent Technique

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 97

 Bharat Heavy Electricals Limited, Tiruchirapalli

Limitations
 Bharat Heavy Electricals Limited, Tiruchirapalli

Arrangement of TOFD Probes

Always TOFD probes in Pair at Both the Side of The Weld

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 99

 Bharat Heavy Electricals Limited, Tiruchirapalli

Calibration
 Bharat Heavy Electricals Limited, Tiruchirapalli

Variables for Calibration

 Bharat Heavy Electricals Limited, Tiruchirapalli

Requirement of PAUT and TOFD

• Simulation Software (ES Beam Tool/NDT Setup Builder)

• PAUT + TOFD Machine, Probes and Mechanism

• Evaluation Software (Tomo View for Special Applications)

3 Basic Approach

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 102
 Bharat Heavy Electricals Limited, Tiruchirapalli

Machine and Mechanism

• Any Machine having
capability of PAUT and
TOFD

• Omniscan MX2, Topaz,

etc equipment available
• Accessories are job
dependent

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 103
 Bharat Heavy Electricals Limited, Tiruchirapalli

Evaluation Software : Tomoview

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 104
 Bharat Heavy Electricals Limited, Tiruchirapalli

Visualization of Indications : PAUT

Clear Location and Position of the Defect can be visualised

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 105
 Bharat Heavy Electricals Limited, Tiruchirapalli

Visualization of Indications : PAUT

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 106
 Bharat Heavy Electricals Limited, Tiruchirapalli

Main Factors Affecting Scan

• Clearance
• Roughness
• Surface Preparation
• Weld Geometry and Configuration
• What Kind of Indications We are Looking For
• Proper Scan Plan (Coverage and Single Side or Both Side)
• Proper Calibration
• Skilled Work Force

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 107
 Bharat Heavy Electricals Limited, Tiruchirapalli

Phased Array technique

Root Crack

TOFD technique

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 108
 Bharat Heavy Electricals Limited, Tiruchirapalli
Advanced Ultrasonic Testing : PAUT and TOFD
Phased Array technique

Porosity

TOFD technique

109
22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 109
 Bharat Heavy Electricals Limited, Tiruchirapalli

Phased Array technique

Concavity

TOFD technique

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 110
 Bharat Heavy Electricals Limited, Tiruchirapalli

Code’s Involvement

• Firstly Adopted by ASME B31.1

• ASME Code Case 168 ; 1997

• ASME Code Case 2235 : 1996

• ASME Section V Article 4 now well-codified

• Covers both phased arrays and replaces Code

Case 2235 (Included in Article 4)

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 111
 Bharat Heavy Electricals Limited, Tiruchirapalli

Code’s Involvement

• 265 of IBR asks to perform either RT or UT

• PAUT and TOFD – Advanced Technique of

UT

• Hence Comply IBR

• Acceptance Criteria is based on construction

Code : UT acceptance Criteria

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 112
 Bharat Heavy Electricals Limited, Tiruchirapalli

Code’s Involvement : Highlights from ASME Sec V

• ASME Sec-V- Article-4; MANDATORY APPENDIX III
• Time Of Flight Diffraction (ToFD) Technique.
• ASME Sec-V- Article-4; Mandatory Appendix IV,
• Phased Array Manual Raster Examination Techniques Using Linear Arrays.
• ASME Sec-V- Article-4; Mandatory Appendix V ,
• Phased Array E-scan And S-scan Linear Scanning Examination Techniques.

• ASME Sec-V- Article-23. SE-2491,

• Standard Guide For Evaluating Performance Characteristics Of Phased-array Ultrasonic
Testing Instruments And Systems.
• ASME Sec-V- Article-23. SE-2700,
• Standard Practice For Contact Ultrasonic Testing Of Welds Using Phased Arrays

22-11-2018 Dilip Kr Singh-Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 113
 Bharat Heavy Electricals Limited, Tiruchirapalli

Query/Discussion Time

Thank You all for Your

valuable Time
Non-Destructive Testing Lab /BHEL Tiruchirappalli, Tamilnadu-620014, India 114