Application Note

Phased Array Pipeline Zone Discrimination Inspection

Summary

The Girth Welds used to connect pipe across country or offshore for the transportation of petroleum must be
inspected during construction to ensure safe operation. In order to prevent inspection from bottlenecking the
construction process, the inspection method must be rapid, repeatable and meet applicable code requirements.
By using fully automatic zone discrimination systems deployed on and offshore, Phased Array ultrasound is
increasingly used to meet this need.

Introduction

The most common volumetric inspection methods for newly constructed pipeline are radiography and ultrasonic
testing. In many cases the ultrasonic method is preferred due to its inherent lack of hazards for those working
around the inspection site, the immediate availability of test results, and the ability to precisely size defects
especially in the through wall plane. Pipeline weld joints often have very narrow bevel angles making traditional

is never received back to the probe for detection.

Typical Advantages of Ultrasound/Phased Array vs. Radiography:

High probability of detection (POD) especially for cracks and lack of fusion
Accurate sizing of defects height and less repair using Engineers Critical Assessment
No radiation, hazard, or additional licensing
No screened off areas, work can go on around AUT
No chemical or waste material
Real-time analysis for instant evaluation and feedback to welder
Setup and inspection reports in electronic format

Solution

The PipeWIZARD inspection system is a phased array based fully automatic inspection system for pipeline
girth welds. It usually consists of phased array and Time of Flight Diffraction (Tofd) probes to provide rapid full
volumetric inspection of these welds. The main components include an acquisition unit and motor controller, a
computer, and the scanner. The instrumentation is sealed and ruggedized to withstand the often harsh conditions
of the areas where pipelines are installed.

PipeWIZARD acquisition unit and motor controller box with computer and Scanner on band

The zone discrimination technique entails splitting the welded joint into small zones (typically 1-3mm) and using
a pitch and catch technique focusing a single ultrasonic beam into each one of these zones. By using separate
groups of phased array elements the historical need for cumbersome multi-probe systems consisting of many
conventional transducers is eliminated and the bevel can be inspected at the proper angle of incidence. Tofd
and phased array sector scans in addition to transverse probes can be added as needed for the inspection. After
the joint design is input into the software, the PipeWIZARD software calculates each beams position emission
and reception and other properties which then can be adjusted on a suitable calibration block accordingly. The
main data output is a strip chart, one strip for each beam or zone. Color coding and other tools allow for quick
assessment of detected anomalies to acceptance criteria levels. The scan speed can reach up to 100 mm /
second, depending on pipe details and inspection parameters. Along with length of defect the height is accurately
calculated for fracture mechanics or engineers’ critical assessment criteria which can often reduce defect rate
versus workmanship criteria found when used with other techniques.
 Illustration of Zone Discrimination Technique showing one beam

After inputting joint parameters the software predicts all beam paths

Strip charts, color coding and other analysis tools allow quick assesment and reporting
PipeWIZARD Key Points

Highly reliable, compact and modular

User-friendly advanced software with intuitive interface (fast setup creation, rapid and accurate analysis, and
easy training)
Sectorial and E-Scan views are available in addition to standard strip-charts and TOFD
High accuracy in defect height sizing: between 0.5mm (20 mil) and 1.0mm (40 mil)

variation)
Short AUT inspection cycle time for high production rates

PipeWIZARD is suitable for onshore and offshore inspections and code compliant
PipeWIZARD can be used in the vicinity of other processes and personnel and has no radiation safety or
chemical hazards

Conclusion

The PipeWIZARD zone discrimination systems allows for a rapid and accurate volumetric inspection of pipeline
girth welds both onshore and offshore. The phased array approach eliminates the need for cumbersom mechanics
found in old multi-probe conventional systems and also offers distinct advantages over radiography inspection
including safety, ability to work in vicinity of other personnel, and accurate through wall height sizing.

Products used for this Application