Inspectioneering

Ultrasonic Testing (UT) is a group of nondestructive examination (NDE) techniques that use short, high-frequency ultrasonic waves to identify flaws in a material. They generally work by emitting waves into a material. By measuring these waves, the properties of the material and internal flaws can be identified. Most UT devices consist of many separate units. These can include pulsers and receivers, transducers, and display monitors. The components included depend on the type of UT that the inspector is performing.


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Types of Ultrasonic Testing

There are several different types of ultrasonic testing, including:

Automated Ultrasonic Backscatter Technique

Advanced Ultrasonic Backscatter Technique (AUBT) is a UT technique developed for detecting damage from High-Temperature Hydrogen Attack (HTHA). The technique is for use in pressure vessels and piping. The technique makes use of high frequency, broadband UT probes and a digital oscilloscope. These allow it to provide both an A-Scan display and frequency analysis.

Phased Array Ultrasonic Testing

Phased Array Ultrasonic Testing (PAUT) is a UT technique that utilizes a set of UT probes made up of numerous (anywhere from 16 to over 250) small elements. Each of the elements in a PAUT system is able to pulse individually. This is done with computer calculated timing, through a process known as phasing. This allows the system to steer focused beam through various angles and focal distances.

Long Range Ultrasonic Testing

Long Range Ultrasonic Testing (LRUT) is a UT method developed to allow for testing large volumes of material from a single test point. This method works by fixing transducer rings uniformly around a pipe. These rings then generate a series of low frequency guided waves. The waves can then propagate symmetrically along the pipe axis. This provides complete coverage of the pipe wall.

Internal Rotating Inspection Systems

An Internal Rotating Inspection System (IRIS) is an ultrasonic technique used to detect corrosion in piping and tubing. using an internally inserted probe that generates sound waves. The system works by inserting a probe into a flooded pipe. The probe them move through the pipe, scanning as it goes.

Time of Flight Diffraction

Time of Flight Diffraction (TOFD) is a method used to look for flaws in welds. It uses the time of flight of an ultrasonic pulse to find the location of a reflector. To find the TOF, the method uses a pair of ultrasonic transducers. The transmitter emits low frequency waves that propagate at an angle. They only diffract back to the receiver if they hit a defect.

Dry-Coupled Ultrasonic Testing

Dry-Coupled Ultrasonic Testing (DCUT) is an alternative, low-cost method that does not require a liquid couplant to inspect metallic and nonmetallic material. Additionally, DCUT transducers are capable of withstanding high voltages. DCUT is a versatile method that can be performed using flexible, contact, wheel, or remote transducers.

  • Flexible transducers can be applied on an external or internal surface of a component to detect flaws.
  • Contact transducers are also used to detect flaws as well as thickness measurements.
  • Wheel transducers allow inspectors to inspect long piping systems in a short amount of time.
  • Remote transducers are advantageous because they can take thickness measurements at non-conventional angles (i.e., at angles that are not 90° to the surface). This eliminates the need to build supports or remove components in order to perform inspection.

Rapid Ultrasonic Gridding (RUG)

Rapid Ultrasonic Gridding (RUG) is an NDE method of performing ultrasonic thickness in which multiple ultrasonic thickness probes are utilized, simultaneously, to rapidly gather thickness measurements in a predefined or ad hoc space. Like other UT methods, RUG captures raw A-Scan data, which can be presented in B-Scan or C-Scan modes — or used to create visual representation as 3-D models. However, RUG is capable of capturing multiple A-Scan data points at a much faster rate than traditional thickness measuring techniques.

Advantages and Disadvantages

In general, UT has several advantages and disadvantages. It’s useful because it can scan for flaws both on and underneath the surface. It is also useful for it's incredible accuracy. On the other hand, not all materials are receptive to ultrasonic testing. It also has the disadvantage that it requires a good deal of skill and training to perform.

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Articles about Ultrasonic Testing (UT)
March/April 2023 Inspectioneering Journal

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September/October 2022 Inspectioneering Journal

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May/June 2022 Inspectioneering Journal

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This article presents two case studies that show how having a holistic approach, along with the right technology and experience, is essential to identifying smaller damage mechanisms like fretting in fired heater coils.

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July/August 2021 Inspectioneering Journal

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July/August 2020 Inspectioneering Journal

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May/June 2020 Inspectioneering Journal

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March/April 2020 Inspectioneering Journal

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Authors: Tim Haugen
March/April 2020 Inspectioneering Journal

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Authors: Ed Bryner
January/February 2020 Inspectioneering Journal

This case study discusses costly repairs that were needed on newly fabricated pressure vessels as a result of poor UT practices. The author shines a light on some industry problems that can be fixed with an understanding of what is actually required.

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November/December 2019 Inspectioneering Journal

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September/October 2019 Inspectioneering Journal

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Authors: Ed Bryner
September/October 2019 Inspectioneering Journal

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July/August 2019 Inspectioneering Journal

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May/June 2019 Inspectioneering Journal

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March/April 2018 Inspectioneering Journal

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January/February 2018 Inspectioneering Journal

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November/December 2017 Inspectioneering Journal

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March/April 2017 Inspectioneering Journal

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March/April 2017 Inspectioneering Journal

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July/August 2016 Inspectioneering Journal

This article details the basis for the lack of understanding about the potential for ultrasonic couplant auto-ignition and outlines an ALARP operating practice for mitigation.

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May/June 2016 Inspectioneering Journal

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March/April 2016 Inspectioneering Journal

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March/April 2016 Inspectioneering Journal

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January/February 2016 Inspectioneering Journal

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November/December 2015 Inspectioneering Journal

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March/April 2015 Inspectioneering Journal

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November/December 2014 Inspectioneering Journal

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November/December 2014 Inspectioneering Journal

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November/December 2014 Inspectioneering Journal

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November/December 2013 Inspectioneering Journal

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January/February 2013 Inspectioneering Journal

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November/December 2011 Inspectioneering Journal

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November/December 2010 Inspectioneering Journal

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November/December 2010 Inspectioneering Journal

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January/February 2010 Inspectioneering Journal

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January/February 2009 Inspectioneering Journal

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July/August 2007 Inspectioneering Journal

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July/August 2005 Inspectioneering Journal

The ultrasonic Time of Flight Diffraction (TOFD) technique was developed for the UK nuclear industry during the 1970s to provide a method for measuring the height of planar flaws. TOFD is now generally recognized as the most accurate ultrasonic...

September/October 2004 Inspectioneering Journal

The impetus for the development of LRUT is that ultrasonic thickness checks for corrosion, erosion, etc. are localised, in that they only measure the thickness of the area under the UT transducer.

September/October 2004 Inspectioneering Journal

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September/October 2002 Inspectioneering Journal

John has primary responsibility for NDE consulting and troubleshooting for BP around the world in the refining, chemical and gas processing industries. We at the IJ thought it might be valuable to spend some time chatting about his background,...

Authors: Greg Alvarado
May/June 2002 Inspectioneering Journal

We have discussed various factors that can affect the reliability of NDE techniques (i.e., probability of detection - POD and sizing accuracy) in Part 1. In general, it is difficult to quantify these uncertainties. In fact, it is impossible to fully...

November/December 2000 Inspectioneering Journal

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Authors: C.P. Hsiao
September/October 2000 Inspectioneering Journal

In part 1 of this article we covered the importance of quality assurance of UT data, that is, understanding for each particular application, the accuracy required of the UT data, and new ways/graphical program to analyze and show the...

July/August 2000 Inspectioneering Journal

The American Paper Institute Recovery Boiler Reference Manual Volume 1, October 1979, indicates that the two main goals of conducting ultrasonic thickness (UT) inspections are to determine (1) the current tube wall thickness and (2) the rate of...

March/April 2000 Inspectioneering Journal

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Authors: Paul Marks
January/February 2000 Inspectioneering Journal

This article covers the use of permanently attached ultrasonic transducers for inspection and process plant equipment condition monitoring while in service.

September/October 1999 Inspectioneering Journal

This paper describes the use of a UT fixture for detection of stress corrosion cracking in ferrous heat exchanger tube-to-tubesheet welds and external tube corrosion or pitting near the tubesheets including crevice OD corrosion.

Authors: Reggie Cross
May/June 1999 Inspectioneering Journal

Southwest Research Institute (SwRI) has developed an innovative method for rapid screening of heat exchanger tubing using Guided Wave technology. This screening method can lead to an improvement in heat exchanger reliability and a reduction in the...

May/June 1999 Inspectioneering Journal

EMATs (Electromagnetic Acoustic Transducers) have been used for over six years for field service inspection of in-service piping. Recent advances in technology have allowed us to inspect new types of on-stream piping.

Authors: Paul K. Davidson
March/April 1999 Inspectioneering Journal

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Authors: Mike Sparago
March/April 1999 Inspectioneering Journal

The API Subcommittee on Inspection (SCI) has determined to initiate a program covering the qualification of ultrasonic (UT) technicians conducting inspections.

January/February 1999 Inspectioneering Journal

Ultrasonic thickness monitoring programs represent one of the most intensive inspection activities in refining and petrochemical facilities. Despite numerous improvements in ultrasonic testing equipment and inspection techniques, however, there has...

Authors: Mike Sparago
July/August 1998 Inspectioneering Journal

The debate about advantages and drawbacks of the application of the TOFD (time of flight diffraction) approach for ultrasonic weld inspection should not forget the original reasons for its introduction in the 1960s. The major advantage at that time...

Authors: H. Wuestenberg
May/June 1998 Inspectioneering Journal

New inspection technology, when added to the proven practice of using tell tale holes (TTHs), proves effective in reducing significant releases and or catastrophic events that are related to internal corrosion / erosion of process piping. In fact,...

Authors: Mike Badeen
March/April 1998 Inspectioneering Journal

Furnace tubes in the petrochemical and refining industries lengths' can exceed 2,000 ft., often with multiple serpentine bends. This can make them extremely difficult to inspect using conventional NDE methods. The following inspection tool (FTIS)...

March/April 1997 Inspectioneering Journal

This is the second in a series of articles on piping inspection. In the last article, I enumerated four inspection issues that I believe contribute to inadequate piping mechanical integrity in the hydrocarbon process industry.

Authors: John Reynolds
November/December 1995 Inspectioneering Journal

Nelson Curve changes in the late 1980's provided cause for Shell Oil Company to look at more reliable NDE non-destructive evaluation methods for assessment of materials/equipment in high temperature hydrogen service. The primary change motivating...

September/October 1995 Inspectioneering Journal

Low-energy piping system failures in power-generating facilities are often the result of fouling and corrosion. These degradation mechanisms can affect the capacity of piping for fluid-carrying, the heat transfer rates of heat exchangers, and the...

July/August 1995 Inspectioneering Journal

With miles of piping and tons of equipment to consider for on-stream inspection or monitoring you probably have:

Authors: Greg Alvarado
July/August 1995 Inspectioneering Journal

Petrochemical and energy utility industries require a methodology which will allow them and the governing regulatory authorities to make technical and financially sound decisions for the repair or replacement of pressure vessels which suffer damage...

May/June 1995 Inspectioneering Journal

For reason of economy, the hot reheat pipework in many US power plants is fabricated from seam-welded low chrome-moly carbon steel spools. Unlike girth butt welds, where the critical weldment microstructures can off-load stress to the stronger...

Authors: Bob Browne
March/April 1995 Inspectioneering Journal

High energy piping (HEP) systems, main steam lines and hot reheat lines (typically low chrome molydbdenum steels), are susceptible to creep damage. Such damage can lead to leaks, and in extreme cases, catastrophic failure.

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