Through Weld Inspection of Wrought Stainless Steel Piping Using Phased-Array Ultrasonic Probes

Through Weld Inspection of Wrought Stainless Steel Piping Using Phased-Array Ultrasonic Probes
Author: Steven R. Doctor
Publisher:
Total Pages: 5
Release: 2004
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ISBN:

A study was conducted to assess the ability of phased-array ultrasonic techniques to detect and accurately determine the size of flaws from the far-side of wrought austenitic piping welds. Far-side inspections of these welds are currently performed on a ''best effort'' basis and do not conform to ASME Code Section XI Appendix VIII performance demonstration requirements. For this study, four circumferential welds in 610mm diameter, 36mm thick ASTM A-358, Grade 304 vintage austenitic stainless steel pipe were examined. The welds were fabricated with varied welding parameters; both horizontal and vertical pipe orientations were used, with air and water backing, to simulate field welding conditions. A series of saw cuts, electro-discharge machined (EDM) notches, and implanted fatigue cracks were placed into the heat affected zones of the welds. The saw cuts and notches range in depth from 7.5% to 28.4% through-wall. The implanted cracks ranged in depth from 5% through wall to 64% through wall. The welds were examined with two phased-array probes, a 2.0 MHz transmit-receive longitudinal wave array and a 2.0 MHz transmit-receive shear wave array. These examinations showed that both phased-array transducers were able to detect and accurately length-size, but not depth size, all of the notches and flaws through the welds. The phased-array results were not strongly affected by the different welding techniques used in each weld.

Improvements in 500-kHz Ultrasonic Phased-Array Probe Designs for Evaluation of Thick Section Cast Austenitic Stainless Steel Piping Welds

Improvements in 500-kHz Ultrasonic Phased-Array Probe Designs for Evaluation of Thick Section Cast Austenitic Stainless Steel Piping Welds
Author:
Publisher:
Total Pages:
Release: 2011
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PNNL has been studying and performing confirmatory research on the inspection of piping welds in coarse-grained steels for over 30 years. More recent efforts have been the application of low frequency phased array technology to this difficult to inspect material. The evolution of 500 kHz PA probes and the associated electronics and scanning protocol are documented in this report. The basis for the probe comparisons are responses from one mechanical fatigue crack and two thermal fatigue cracks in large-bore cast mockup specimens on loan from the Electric Power Research Institution. One of the most significant improvements was seen in the use of piezo-composite elements in the later two probes instead of the piezo-ceramic material used in the prototype array. This allowed a reduction in system gain of 30 dB and greatly reduced electronic noise. The latest probe had as much as a 5 dB increase in signal to noise, adding to its flaw discrimination capability. The system electronics for the latest probe were fully optimized for a 500 kHz center frequency, however significant improvements were not observed in the center frequency of the flaw responses. With improved scanner capabilities, smaller step sizes were used, allowing both line and raster data improvements to be made with the latest probe. The small step sizes produce high resolution images that improve flaw discrimination and, along with the increased signal-to-noise ratio inherent in the latest probe design, enhanced detection of the upper regions of the flaw make depth sizing more plausible. Finally, the physical sizes of the probes were progressively decreased allowing better access to the area of interest on specimens with weld crowns, and the latest probe was designed with non-integral wedges providing flexibility in focusing on different specimen geometries.

Technical Letter Report Assessment of Ultrasonic Phased Array Inspection Method for Welds in Cast Austenitic Stainless Steel Pressurizer Surge Line Piping JCN N6398, Task 1B.

Technical Letter Report Assessment of Ultrasonic Phased Array Inspection Method for Welds in Cast Austenitic Stainless Steel Pressurizer Surge Line Piping JCN N6398, Task 1B.
Author:
Publisher:
Total Pages:
Release: 2009
Genre:
ISBN:

Research is being conducted for the U.S. Nuclear Regulatory Commission (NRC) at the Pacific Northwest National Laboratory (PNNL) to assess the effectiveness and reliability of advanced nondestructive examination (NDE) methods for the inspection of light water reactor components. The scope of this research encompasses primary system pressure boundary materials including cast austenitic stainless steels (CASS); dissimilar metal welds; piping with corrosion-resistant cladding; weld overlays, inlays and onlays; and far-side examinations of austenitic piping welds. A primary objective of this work is to evaluate various NDE methods to assess their ability to detect, localize, and size cracks in coarse-grained steel components. In this effort, PNNL supports cooperation with Commissariat à l'Energie Atomique (CEA) to assess reliable inspection of CASS materials. The NRC Project Manager has established a cooperative effort with the Institut de Radioprotection et de Surete Nucleaire (IRSN). CEA, under funding from IRSN, are supporting collaborative efforts with the NRC and PNNL. Regarding its work on the NDE of materials, CEA is providing its modeling software (CIVA) in exchange for PNNL offering expertise and data related to phased-array detection and sizing, acoustic attenuation, and back scattering on CASS materials. This collaboration benefits the NRC because CEA performs research and development on CASS for Électricité de France (EdF). This technical letter report provides a summary of a technical evaluation aimed at assessing the capabilities of phased-array (PA) ultrasonic testing (UT) methods as applied to the inspection of welds in CASS pressurizer (PZR) surge line nuclear reactor piping. A set of thermal fatigue cracks (TFCs) was implanted into three CASS PZR surge-line specimens (pipe-to-elbow welds) that were fabricated using vintage CASS materials formed in the 1970s, and flaw responses from these cracks were used to evaluate detection and sizing performance of the PA-UT methods applied. This effort was comprised of multiple elements that included use of microstructural knowledge (dimensional analysis, grain orientation, and grain type) as well as sound field modeling to more effectively modify inspection parameters and enhance the inspection outcomes. Advanced probe design and sound field simulations were employed to enhance detection and characterization of circumferentially oriented flaws, and an assessment of lateral (circumferential) flaw localization capability and performance was also conducted. An evaluation of flaw detection, length sizing, depth sizing, and signal-to-noise ratio was performed for all flaws in the subject specimens, as a function of various inspection parameters, and finally, measurements were made to quantify and assess the baseline CASS material noise and its potential impact on flaw detection.

Phased Array Ultrasonic Testing of Corrosive Resistant Alloy Girth Weld of Cladded Pipes Using the Total Focusing Method

Phased Array Ultrasonic Testing of Corrosive Resistant Alloy Girth Weld of Cladded Pipes Using the Total Focusing Method
Author: Yixin Liu
Publisher:
Total Pages: 0
Release: 2020
Genre:
ISBN:

TFM implementation was adapted to support the usage of Transmit Receive Longitudinal (TRL) ultrasonic probes. A new algorithm was developed to correct for ultrasonic wave velocity variations caused by anisotropic material properties of Corrosive Resistant Alloy (CRA). Experimental testing was conducted on an XRD verified Austenitic Stainless-Steel girth weld sample. A cut-section macrographic image of the weld showing grain orientation and distribution was obtained. Ultrasonic wave velocity when pulse passes normal and parallel to weld grains are measured. The challenges in using TRL probes for TFM delay computation, including curved surface and 3D ray-tracing are addressed. A benchmarking sample was manufactured. The adapted TFM implementation was compared with an industrial phased array scanner. Comparison shows improved resolving capabilities and noise reduction with TFM compared with standard phased array. A velocity correction algorithm is proposed, where individual rays from TFM are analyzed and corrected based on the weld grain structure.

Proceedings

Proceedings
Author:
Publisher:
Total Pages: 192
Release: 2004
Genre: Nondestructive testing
ISBN:

Assessment of Crack Detection in Heavy-Walled Cast Stainless Steel Piping Welds Using Advanced Low-Frequency Ultrasonic Methods

Assessment of Crack Detection in Heavy-Walled Cast Stainless Steel Piping Welds Using Advanced Low-Frequency Ultrasonic Methods
Author:
Publisher:
Total Pages:
Release: 2007
Genre:
ISBN:

Studies conducted at the Pacific Northwest National Laboratory in Richland, Washington, have focused on assessing the effectiveness and reliability of novel approaches to nondestructive examination (NDE) for inspecting coarse-grained, cast stainless steel reactor components. The primary objective of this work is to provide information to the U.S. Nuclear Regulatory Commission on the effectiveness and reliability of advanced NDE methods as related to the inservice inspection of safety-related components in pressurized water reactors (PWRs). This report provides progress, recent developments, and results from an assessment of low frequency ultrasonic testing (UT) for detection of inside surface-breaking cracks in cast stainless steel reactor piping weldments as applied from the outside surface of the components. Vintage centrifugally cast stainless steel piping segments were examined to assess the capability of low-frequency UT to adequately penetrate challenging microstructures and determine acoustic propagation limitations or conditions that may interfere with reliable flaw detection. In addition, welded specimens containing mechanical and thermal fatigue cracks were examined. The specimens were fabricated using vintage centrifugally cast and statically cast stainless steel materials, which are typical of configurations installed in PWR primary coolant circuits. Ultrasonic studies on the vintage centrifugally cast stainless steel piping segments were conducted with a 400-kHz synthetic aperture focusing technique and phased array technology applied at 500 kHz, 750 kHz, and 1.0 MHz. Flaw detection and characterization on the welded specimens was performed with the phased array method operating at the frequencies stated above. This report documents the methodologies used and provides results from laboratory studies to assess baseline material noise, crack detection, and length-sizing capability for low-frequency UT in cast stainless steel piping.

Development of Ultrasonic Examination Methods for Austenitic Stainless Steel Weld Inspection

Development of Ultrasonic Examination Methods for Austenitic Stainless Steel Weld Inspection
Author:
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Total Pages:
Release: 1977
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ISBN:

Signal acquisition and analysis techniques were developed to permit locating notches placed in an austenitic stainless steel pipe weld. Ultrasonic techniques presented here utilized refracted longitudinal and shear inspection beams with a dual element, pitch-catch transducer. Sources of grain noise and the metallurgical iplications of inspecting austenitic stainless steel welds are reviewed. Data were analyzed in both time and frequency domains, and a simple frequency moment algorithm was developed which is sensitive to defect signal and somewhat insensitive to grain noise. Data were also used to train an adaptive learning network (ALN) and the results obtained demonstrate only slight sensitivity to grain noise.

Equipment for Inspection of Austenitic Stainless Steel Pipe Welds

Equipment for Inspection of Austenitic Stainless Steel Pipe Welds
Author:
Publisher:
Total Pages:
Release: 1979
Genre:
ISBN:

A computer controlled ultrasonic scanning system and a data acquisition and analysis system have been developed to perform the inservice inspection of welds in stainless steel sodium piping in the Fast Flux Test Facility. The scanning equipment consists of a six axis motion mechanism and control system which allows full articulation of an ultrasonic transducer as it follows the circumferential pipe welds. The data acquisition and analysis system consists of high speed ultrasonic waveform digitizing equipment, dedicated processors to perform on-line analysis, and data storage and display equipment.