ISonic PA AUT
Automatic Ultrasonic Inspection of Girth Welds Combining Phased Array, TOFD, and Conventional Pulse Echo Techniques

Up to 512 channels for connection of phased array probes
Up to 64 channels for connection of conventional probes for pulse echo and TOFD inspection
Parallel A/D conversion and on-the-fly digital phasing and superimposing of PA elements signals, no multiplexing involved
Free setting of emitting and receiving aperture accumulating up to 512 elements each
Controlled by remote PC through Ethernet, multiple units operation possible
Easy-to-follow ray tracing, calibration, and strip chart forming wizard
Real time strip chart recording and presentation with complete capturing of raw data A-Scans
Ultimate ultrasonic performance for PA, conventional and TOFD probes
Rugged IP 67 case mountable on scanner
No need for long bulky umbilical for probes connection
Coordinate encoder input
Motor powering and control port
No water or other type of cooling required

Unique cutting edge technology solution for high-speed automatic ultrasonic inspection of girth welds

In the newly constructed gas and oil off-shore and on-shore pipelines pipes are girth-welded automatically then rapidly inspected, coated, and buried. Detection, evaluation, and repair of defects in the welds must be very quick in order not to affect the construction cycle, High-speed automatic ultrasonic testing (AUT) of girth welds is demanded as the sole codes accepted alternative to radiography
AUT is implemented through scanning of the weld along the fusion line using several probes situated on the OD surface from both sides of girth weld. Traditionally a frame with ultrasonic probes and a position encoder is carried by traction unit (scanner) along orbital travel band and the umbilical connects probes, position encoder, and scanner's motor to ultrasonic pulsing-receiving, control, data processing and recording electronics, which is placed either in the truck cabin (on-shore inspection) or in a separate room on the lay barge (off-shore inspection) at the distance of up to few tens of meters from the scanning deck. A team of operators handles the AUT system: usually there are two operators involved into placement of scanning stuff onto the pipe and one operator responsible for control of scanning, observation of the indications and recording process, and taking GO/NO GO decision

AUT of girth welds is regulated by couple of codes such as ASTM E-1961, API 1104, and DNV 2000 OS-F101, according to which the weld volume is divided into multiple horizontal thin slices (zones) in the cap, fill, hot pass, and root areas. Designated zones are insonified one by one through a sequence of independent pulsing-receiving shots. Use of phased array (PA) technology significantly minimizes the quantity of probes involved into multiple zone insonification thanks to electronic beam steering. This simplifies scanning stuff and accelerates the inspection. Use of several TOFD and conventional probes simultaneously with PA probes provides complete coverage of the weld volume at every cross-sectional position along fusion line: PA probes implement pulse echo and tandem technique for the detection of various compact and longitudinal defects; conventional probes perform inspection for the detection of transverse defects (K- and X- schemes), detection of laminations in the heat affected zone in parent material, etc.; TOFD probes implement complimentary technology allowing detection of compact and longitudinal defects through receiving of diffracted signals. Ability of defect detection in each zone is provided through calibration of the system on specially manufactured blocks containing certain number of artificial reflectors, who's location, orientation, shape, and dimensions represent variety of flaws to be sensed and recorded
Practical use of traditional PA AUT stuff over several years highlighted a number of inconveniencies experienced by the inspection providers:

Big expensive, heavy, bulky, and vulnerable umbilical causing relatively high operational cost as well as low signal to noise ratio and high power consumption due to transfer of analogue signals through tens meters length wires
Insufficient quantity of A/D converters leads to use of multiplexing and elevating pulse repetition rate further increasing power consumption
Insufficient quantity of pulsing-receiving channels requires more than one scanning revolution and / or making compromise by using the wedges of PA probes also for TOFD to inspect single girth weld completely, this slows the overall speed of AUT
Overheating of electronics caused by high power consumption requires water-cooling or frequent shutdown breaks during work shift

ISONIC PA AUT system from Sonotron NDT represents cutting edge technology solution for high-speed AUT of girth welds bringing practical implementation to the highest convenience level
ISONIC PA AUT instrument is packed into rugged portable light weight (6.8 kg only) IP 67sealed case, which is fitted onto the scanner's chassis; regular remote PC connected to instrument through Ethernet provides full control, data acquisition and imaging in real time, thus no big expensive, heavy vulnerable umbilical - just a thin light armoured tube carries DC wires and LAN cable, which are connected to the machine through specially designed rotating terminal
Probes signals are sampled and pre-processed in real time on-board; the digitised raw inspection data is transferred to remote PC for further processing, storage, and imaging. Fully digital through-Ethernet control and data transfer provide practically unlimited  distance to a remote PC enabling flexibility of creating control rooms or multiple monitor stations throughout the barge / factory / weld station, etc
Probes are connected to ISONIC PA AUT using short cables, compared to transfer through long umbilical this provides much better signal quality significantly improving signal to noise ratio and dynamic range
Further improvement of signal to noise ratio and dynamic range is achieved through firing probes with unique bi-polar square wave initial pulse reaching up to 300 Volt peak to peak for PA probes and up to 400 Volt peak to peak for the conventional and TOFD probes. Duration and amplitude for both positive and negative half-waves of the initial pulse may be tuned in wide range.

High stability of firing amplitude selected by an operator is provided while leading and falling edges of bi-polar initial pulse are electronically boosted
There is no limit for quantity of PA probe elements composing emitting aperture - all elements of each PA probe connected to ISONIC PA AUT may fire simultaneously if necessary. Advanced low noise design provides the ability of up to 100 dB analogue Gain for PA, TOFD, and conventional probes
ISONIC PA AUT performs 16-bit 100 MHz sampling rate digitising of signals obtained by all elements of receiving aperture at parallel independently on their quantity (aperture size) - there is no multiplexing involved; The digitised signals are phased (phase-shifted) and superimposed on-the-fly according to the desired focal law so each superimposed A-Scan is formed and memorized in the buffer in real time during the entire pulsing-receiving shot
ISONIC PA AUT performs complete raw data capturing allowing play-back of all A-Scans obtained during the scanning; this provides full compliance with ASME 2235 Code Case related to use of ultrasonic inspection in lieu of radiography
Rational power management eliminates heating problem; thanks to extremely low power consumption water or another type cooling is never required for ISONIC PA AUT
In the ISONIC PA AUT each pulser receiver for TOFD and conventional probes may be operated in both modes - dual and single, i.e. use of dual element probes, TOFD insonification, K- and X-scheme for pitch-catch detection of transversal defects with shear waves, etc employ only one channel per task
Typically ISONIC PA AUT comprises 128 PA channels allowing simultaneous use of two 64-elements probes and 16 conventional channels, which are totally separated from PA stuff; it is easy upgradeable to 512 PA channels for future state of the art use, for example matrix PA technology allowing 3D beam steering vs today's 2D. Quantity of conventional channels may be upgraded to 32 or 64 as well
One regular PC may control and acquire data from several ISONIC PA AUT systems simultaneously (up to 16) allowing rational organization of AUT job on-site and minimizing manpower involved

TECHNICAL DATA (Typical)

Single Pulser Receiver Channel for Phased Array and Conventional Pulse Echo and TOFD Probes

GIRTH WELDS

Example of Application SW Package - ASME 2235-9 Code Case Compatible Automatic Ultrasonic Inspection of Girth Welds

Pre-scanning Routine - Stage 1: Theoretical Setup Wizard

Theoretical rays tracing procedure is required for operating of PA probes - it is necessary to cover weld bevel surface and weld volume completely. Ray tracing for the ISONIC PA AUT is performed through very intuitive Theoretical Setup Wizard, which guides through:

Probe Definition dialogue for entering parameters of PA probes and wedges

Weld Definition dialogue for selection of appropriate weld bevel from data base and entering related geometry and dimensions

Zones Definition dialogue for "slicing" of weld volume, cap, hot pass, and root areas into zones to be insonified in each qualified position of PA probe:

Ray Tracing dialogue for determining of zone-by-zone insonification scheme (pulse echo or tandem; incidence angles; emitting and receiving aperture; focal distance) and appropriate positions for PA probes from both sides of the weld (Upstream - Downstream)

Pre-scanning Routine - Stage 2: Ultrasonic Setup Wizard

Ultrasonic setup is performed on specially manufactured calibration block including a number of artificial reflectors, which's location, orientation, shape, and dimensions represent variety of flaws to be sensed and recorded. Calibration blocks are manufactured for each pipe diameter, wall thickness, weld bevel, etc. by such a way that all defects may be detected and recorded through one revolution scan along the hypothetic fusion line. Typically calibration block is shaped as piece of pipe allowing setup of complete scanning stuff; each section containing artificial defect is appropriately marked on the OD surface of the pipe

Initial goal of the operator is one-by-one placement of appropriate probe either PA, TOFD, or conventional into every predefined position and providing necessary settings (Gain, Gate, Aperture, etc) ensuring detection and resolving of all artificial defects

Continuous coupling monitoring is a must for AUT and appropriate pulsing receiving shots to be calibrated for PA and conventional probes as well. In the ISONIC PA AUT it is possible to use as coupling reference either longitudinal wave back wall echo or through-transmitted signal between two probes or combination of above techniques

Final screen of Ultrasonic Setup Wizard relates to configuration of the strip chart. Strip chart is a method of AUT data presentation whereas each pulsing-receiving shot is continuously recorded into corresponding strip

ISONIC PA AUT may form strips of the following types:

PE
Amplitude / TOF Pulse Echo Strip represents peak amplitude and time of flight for signals matching with Gate and exceeding it's threshold level
Position of Amplitude Line on the strip is proportional to the signal height. Echo amplitude equal or exceeding 100% of A-Scan height brings Amplitude Line trace to full strip width level
Width of gray Time of Flight (TOF) Rectangle is proportional to the signal position in the Gate. For signals, which's time of flight measurement point matches with the Gate end width of gray Time of Flight (TOF) Rectangle is equal to the full strip width
For geometry echoes matching within specially designated Gate Tail the Amplitude Line is not produced, just TOF Rectangle

MAP
Up to 256 Colors Palette Map Strip represents sequence of A-Scans whereas color of points for each horizontal line is coded according to corresponding signal level and default palette

TOFD
256 gray levels TOFD strip represents sequence of RF A-Scans whereas brightness of points for each horizontal line is modulated according to corresponding signal level

COUPLING
Coupling Strip is formed through comparing amplitude of reference signal with the gate threshold. Green Sufficient Coupling record is provided for signals exceeding gate threshold; red Insufficient Coupling record is provided in opposite case

Reshaping of Strip Chart is possible through manipulating position / lateral displacement of each strip according to the probes fitting into the scanning frame:

Calibration scanning is performed then in automatic mode to ensure that all artificial defects are sensed, resolved, and recorded at proper locations
Ultrasonic Setup Wizard is finished with creation of complete Inspection Setup File; inspection becomes possible at any moment after said file is uploaded into scanning routine

Scanning & Postprocessing

Whilst scanning the raw A-Scan data obtained by PA, conventional, and TOFD probes is transferred to remote PC along with corresponding position encoder data. Remote PC provides raw data recording and forms strip chart in real time. Whilst scanning operator may monitor live A-Scans for every strip. Inspection results file compressing complete raw data bulk is created automatically on completion of scanning

At postprocessing stage it is possible to play back captured A-scans, to mark, size, and evaluate defects, to create defects list, etc

Built-in Utilities

Entering scanner parameters (gearbox rate, driving wheel diameter), encoder calibration and entering scanning speed are performed in dialogue mode through simple user interface

Every probe either PA, conventional, or TOFD may be driven independently through appropriate pulser receiver screen. This feature is very useful for various purposes such as verification of wedges, studying of phased array focusing effects, etc

SCOPE OF SUPPLY

1.  ISONIC PA AUT 2X64 / 16 - Portable Platform for Automatic Combined Phased Array, Conventional Pulse Echo and TOFD Inspection / 128 Phased Array (PA) Channels and 16 Conventional Pulsing Receiving Channels

ISONIC PA AUT 2X64 / 16 Electronic unit

IP 67 waterproof housing
Internal PC (AMD LX 800 500 MHz, RAM-512M, Quazi-HDD Flash Memory Card 4G, Windows XP Embedded, Ethernet Interface
SW 80500201 ISONIC PA AUT Services SW Pack for on-board hardware control and communicating with remote control computer
Spare Flash Memory Card 4G - plug and play (Operating System and SW 80500201 ISONIC PA AUT Services Package installed)
100 ... 250 VAC AC/DC converter
Incremental Encoder Terminal - 1 socket
Scanner Motor Control and Powering Terminal - 1 socket
"Emergency Stop Scanner" Button
64 Elements Phased Array Probe Terminals - 2 sockets
Conventional / TOFD probes connection terminals - 32 sockets LEMO 00
SE 254064 PA - 64-Channel Phased Array Pulsing Receiving and Processing Card - 2 pieces
SE 254016 - 16-Channel UDS 3-6 Pulser Receiver Card - 1 piece
Bipolar Square Wave - Tunable Width / Tunable Firing Level Pulser; Single / Dual Modes of Operation; Special Probe Protection Circuit to Prevent Probe Damage for Not Properly Adjusted Pulse Width
Gain: 0...100 dB controllable in 0.5 dB resolution; Advanced Low Noise Design: 81mV peak to peak input referred to 80 dB gain / 25 MHz bandwidth; Frequency Band: 0.2 ... 25 MHz Wide Band / 32-Taps FIR bandpass digital filter with controllable lower and upper frequency limits

Toshiba Satellite Laptop Control Computer
100 ... 250 VAC AC/DC converter (SK 80500201) - 2 pieces (1 for operation + 1 spare)
25 meter length armored power / data umbilical (SK 80500207) - 2 pieces (1 for operation + 1 spare, other length umbilical on request)
24 months warranty period for the electronics / Lifetime free software update

2.  ISONIC PA AUT Weld Inspection Software Package> API for communicating with ISONIC PA AUT 2 X 64 / 16 platform

Theoretical Setup Pack:

Selection and complete dimensioning of Weld Bevel for seam under test
Keying in dimensions and ultrasound velocity for phased array probe wedge or selection of phased array probe wedge from database
Division of weld root, cap, and volume into narrow zones for narrow gate / wide gate insonification
PA Probe positioning and beam tracing for Phased Array probes from both sides of the weld (Down Stream and Upstream) and defining of complete sequence of inspection shots
Creating of theoretical setup file

ISONIC PA AUT 2 X 64 / 16 Instrument and Scanner control pack:

Independent hardware control module of Phased Array pulser receiver for downstream 64 elements PA probe

Phased Array pulser receiver for downstream 64 elements PA probe
16-channel pulser receiver for conventional and TOFD probes
Scanner motor control and setup and encoder calibration

Virtual joystick for scanner control at setup time - start / stop / direction / speed
Pre-scanning routine:

Upload theoretical setup file
Pulsing/Receiving calibration of downstream PA Probe inspection shots
Pulsing/Receiving calibration of upstream PA Probe inspection shots
Pulsing/Receiving calibration of downstream and upstream coupling monitor shots (longitudinal wave back echo and / or throiuygh transmission)
Pulsing/Receiving calibration of conventional channels inspection shots (pulse echo and TOFD)
Pulsing/Receiving calibration of coupling monitor for conventional probes
Forming strip chart and test scanning
Automatic wedge temperature monitoring and compensation
Storing complete pre-scanning calibration file

Inspection routine - start / stop automatic scanning with strip chart recording and complete inspection file storing; automatic start of postprocessing routine upon completing each scanning

Postprocessing pack:

Viewing recorded strip chart with play back recorded A-Scans, defects marking and sizing
All-functional TOFD postprocessing for TOFD strips
Printing comprehensive inspection report

3. Orbital Scanner for Girth Weld Inspection

On-belt clamping and traction mechanism
Digitally controlled stepped motor with power / control cable and terminal at instrument side
Platform for fitting of ISONIC PA AUT 2 X 64 /16
Frame for fitting PA Probes, conventional pulse echo and TOFD probes
Incremental Encoder with cable and terminal at instrument side - 2 pieces (1 for operation + 1 spare)
Irrigation channel entry and distribution to probes with set of rubber pipes (plus one set spare)

4.
5 MHz 64 element Phased Array Probe, pitch size 0.8 mm with cable (64-pin terminal at instrument side)

5.
Wedge for Phased Array Probe with Pipe OD Matching Contoured Contact Face and Irrigation Channel

6.
TOFD Probe - active elements 1/4" dia, 5 MHz with cable (LEMO 00 Terminal at instrument side)

7.
TOFD Probe - active elements 1/4" dia, 10 MHz with cable (LEMO 00 Terminal at instrument side)

8.
Wedge for 1/4" dia TOFD probe, 60 deg - with Irrigation Channel and Fit-Into-Scanner Fixture

9.
Wedges for 1/4" dia TOFD probes, 65 deg - with Irrigation Channel and Fit-Into-Scanner Fixture

10.
Wedges for 1/4" dia TOFD probes, 70 deg - with Irrigation Channel and Fit-Into-Scanner Fixture

11.
45 Deg 4 MHz Miniature Probe for the detection of compact, longitudinal, and transversal cracks with cable (LEMO 00 Terminal at instrument side), irrigation channel and Fit-Into-Scanner Fixture

12.
60 Deg 4 MHz Miniature Probe for the detection of compact, longitudinal, and transversal cracks with cable (LEMO 00 Terminal at instrument side), irrigation channel and Fit-Into-Scanner Fixture

13.
70 Deg 4 MHz Miniature Probe for the detection of compact, longitudinal, and transversal cracks with cable (LEMO 00 Terminal at instrument side), irrigation channel and Fit-Into-Scanner Fixture

14.
Travel Bands for various pipe OD specified by customer

Click to download the brochure for the ISonic PA AUT

The ISonic PA AUT being utilized in the field to inspect 70mm thick steel pipe welds. ISONIC PA AUT - Platform for Automatic Ultrasonic Phased Array, TOFD, and Conventional Pulse Echo Inspection

The ISonic PA AUT Phased Array Ultrasonic inspection system performing a scan on a calibration test pipe. The system uses both phased array and conventional transducers to inspect the whole weld in one pass. ISONIC PA AUT - Platform for Automatic Ultrasonic Phased Array, TOFD, and Conventional Pulse Echo Inspection

The ISonic PA AUT recording the defects in a calibration pipe. Both phased array and conventional transducers are used to record all the weld defects in one pass. ISONIC PA AUT - Platform for Automatic Ultrasonic Phased Array, TOFD, and Conventional Pulse Echo Inspection