Ultrasonic non-destructive examination TOFD method of welded joints at pressure equipment

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1 International Conference Structural integrity of welded structures Ultrasonic non-destructive examination TOFD method of welded joints at pressure equipment E. Nastase 1, C. Grămescu 2 1 S.C. Artimmex Impex, artimmex_srl@yahoo.com 2 S.C.Griro SA, cgramescu@gmail.com Abstract: The ultrasonic examination method TOFD (time-of-flight diffraction) is a usual technique, recognized when examining welded joints, especially as it allows the recording and the automation of the system. The method is recognized by the ASME code, legislated in Europe and recently implemented in Romania. The implementation of the method firstly supposed the widespread of knowledge in the field, convincing the users of the advantages it presents and purchasing the best equipment. A contribution to the spread of the method in the country has ISIM Timisoara that included it in its curricula of training and certification in the field. Description and application of the method is presented to the enterprise SC Griviţa who used it for several years through collaboration with foreign firms. Key words: non-destructive examination, welding, ultrasonic, diffraction (TOFD), 1. Introduction Leadership in the examination of welds in the internal discontinuities was held by the penetrating radiation technique, because the scan is provided by a registered document. The emergence of ultrasonic technology has completed radiation screening method on determining the stratification of material, presence of cracks oriented in other directions than the beam of radiation, the use of thick materials, where the examination of radiation decreased sensitivity. A good part of time, in the law, it was used only one or the other method, or both methods to reveal internal discontinuities. Both methods have discontinuity in two dimensions, but with different projection planes. In the evolving technique based on ultrasound echo amplitude reflected pulse and transmitted pulse is completed by the tandem method. Diversification continued with the working methods: diffraction method, time of flight technique (TOFT Time of Flight Diffraction); the PA- Phase array, techniques; the SAFD - Synthetic Aperture Focusing Techniques; the Acoustic Holography method a.s.o. The time of flight technique (TOFD Time of Flight Diffraction) was requested by foreign partners to examine pressure vessels made in Romania seven years ago. Meanwhile, ultrasonic devices offered in Romania came from Olympus, General Electric and later Sonatest firms. ISIM, within the certification courses in ultrasonic non-destructive examination (SR EN 473), introduced information on the equipment Olympus and General Electric in the endowment. 2. Ultrasonic examination At the beginning of the ultrasonic examination one or two transducers were used with a technical presentation of the image A, B or C, today the diffraction method and multicristal

2 transducers, which have from 16 to 128 parts, have revolutionized the technique of examination. The displacement of transducers with a motion assisted by a scanning device, changing the focus and direction of ultrasonic beam, including data storage and processing, permitting an assessment of a discontinuity in the 3D image. The first information on the TOFD (Time of Flight, Diffraction) technique named Time of Flight Diffraction to replace the traditional ultrasonic methods was presented in 1977 [1]. The TOFD technique is a computerized system that scans, records and assesses the indications of a discontinuities as regards the height, length and position, with high accuracy, in a short time, by the ultrasonic technique. This technique is achieved by placing two transducers separated in opposite directions, the same angle, one operating as a transmitter and the second as a receiver, a tandem configuration. Thus most of the energy emitted by the ultrasound transducer is lost through absorption and diffusion in the material examined or discontinuity reflects that, actually takes. Meanwhile, at the end there is a discontinuity phenomenon of diffraction wave of small amplitude, which are received. These "wave diffraction" by a process of separation from background noise can create a picture identification orientation and location of discontinuity geometry. In a single transducer technique called "pulse reflected," reflected energy was dependent on many factors such as that the ultrasonic pulse beam, beam orientation to the discontinuity, the surface discontinuity, the coupling conditions. If TOFD, the obstacles do not interfere, and an overview of the indications in the A-scan shows that the size of discontinuity is inferred from the difference between two diffraction signals. Waves during the TOFD technique for the examination of butt welds is shown in Fig. 1 Figure 1 2

3 3. Experiments TOFD equipment is Olympus consisting of OmniScan MX and a scanner presented in figure 2 Figure 2 The welded joint is from SA516 as material, thickness 57 mm, for which the calibration block was achieved in the same time with the welding. The block is provided with side and surface holes, as in figure 3. Figure 3 Previously, any examination is based on a written procedure, in line with the requirements of official regulations, which in our case were provisions of the ASME code [1]. The procedure includes: the type of device and software used, scan lines, methods of measuring the length and height of the echoes. The procedure will provide a single value or a range of values for each requirement. The camera's sensitivity is set to the echo obtained 3

4 from the hole size of 3.2 mm, located mid-block thickness. Ultrasonic beam size must fall under the values given in table 1. Table 1 The height of the echo in % of the whole screen Changing steps of amplification in db Limit of indications in % from the height of the screen 80% - 6 db 32 la 48% 80% -12 db 16 la 24% 40% + 6 db 64 la 96% 20% + 12 db 64 la 96% The ultrasonic device shall be checked for linearity of the time base in A presentation and the shape of the signal shall be analyzed. The pulse shall be optimized as amplitude and duration. The nominal frequency band of transducers shall be analyzed including the preamplification of signals in the system. The equipment will allow the information storage in less than 64 degrees or shades of browning. The computer program includes TOFD estimation algorithm based on wave form for the storage of position information given by encoder location. Ultrasonic transducers must meet the following requirements: transducers, two in number, will work in broadcast-band reception (pitch-catch); will have the same nominal frequency and the same size, pulse duration should not exceed 2 cycles to measure the peak response level of 20 db. A single element transducer are unfocused, but can be used with several cell focus transducers (phased-array) if a better resolution for determining the size of discontinuities. Nominal frequency can range from 2-15 MHz, depending on the material structure, so as to ensure penetration and good resolution. In our case 10 MHz frequency was chosen. Encoder calibration was done on 500 mm length with an accuracy of 1%. The written procedure must be "qualified" in the sense that it demonstrates the application. Where there are essential non-compliance, the procedure does not require retraining. If the changes are critical or essential variables, the procedure will be revised or edited in the Addendum. Examination of the welded joint is made by moving a transducer fixed on the scanner side of seam, along the axis, lateral coverage of 25mm. It defines the points of departure and arrival at each area examined, and in areas where there have been interruptions to restore the checks. Interpretation of results is simultaneously pursuing several images in presentations. The method TOFD images can be influenced by several factors such as: "electric noise" given amplifier, the focusing transducers, diffraction signal distortion, etc. At a low level of amplification of diffraction signals can not be detected, while at high levels reduces the 4

5 probability of detection. High levels of noise can be produced and a large structure of the material, in which case it is advisable to reduce the ultrasonic frequency. Examination of welded joints with a high density of defects adversely affect the interpretation of results. Comparing current ultrasound equipment offered on the market, it appears that there is a constant in software development, of transducers, the accessories that are tailored to optimize for a certain kind of verification. This has led to acceptance of the method require additional specialized training of staff, followed by a period of practice. 4. Conclusions 1. TOFD method shows good sensitivity while discontinuities such as cracks and lack of fusion, which are not visible on radiographs, and those hardly detected on ultrasound, focusing the information obtained in a single fuller and more accurate method. 2. Images obtained by TOFD method ensures the quality of the welded joint in the examined the number of information obtained and records made simultaneously. 3. The method benefits from technological developments, both equipment and data processing and synthesis. 4. For several years, the ASME Code (CASE ) [2] introduced the possibility of substituting "radiography" by "ultrasonic weld inspection of the mechanical system" in thickness over 13 mm. 5. The ultrasound equipment must comply with accessories as standard on the subject examined, be maintained and updated regularly in terms of software performance. Bibliography 1. ASME Boiler & Pressure Vessel Code V Nondestructive Examination ASME Code CASE Secţiunea VIII Div II 3. Aastroem From Fifteen to Tow Hundert NDT Methode in fifty yars The 17 th WCND Octomber 2008 Shanghai China 4. Olympus Introduction to Phased Array Ultrasonic Technology Application R/D Tech Guideline Silk M.G. Sizing crack-like defects by ultrasonic means, in Research Techniques in Non-destructive Testing, Vol. III edited bz R.S. Sharpe, Academic Press,

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