Manual UT of Pipeline Digs

Manual ultrasonic detection, characterizing and sizing of thin-walled steel pipeline seam anomalies and flaws

https://UTofPipelineDigs.com

By Jimmy Ellis

FAST-UT basics:
• Setback dist = T X 2.75
• 70 deg L has a long walk and is the last one up when you pull
way back
• Flaws are seen from both sides
• Surface distances plot good
• Planar flaws have a lot of mode converted signals

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 Table of Contents

Section Pages
Cover Page 1
Table of contents 2
Welcome 4
Getting started 6
Equipment 6
Straight Beam UT 8
Dual element straight beam cals 8
Use of consistent gate and signal height 8
Roof angle 8
Orientation of crosstalk barrier 9
Rectification 9
Gain settings for straight beam UT 9
Recognizing the walk of laminations vs. internal corrosion 9
Temperature changes 9
First back reflection vs. multi-echo 10
Sonopen 10
Extremely thin pipe 11
Very high frequency probes and welds 11
Angle beam UT 11
Soundpath screen 11
ID@4, OD@8 screen 11
1-inch deep screen 12
Shear wave cals 12
45° shear, 1-inch deep screen 12
45° surface distance measurement 13
RATT 13
AATT 14
OD notches 15
60° shear, 1-inch deep screen 15
AATT 16
70° shear, 1-inch deep screen (PPATT) 16
Gain settings 18
Compare echo dynamics of 45°, 60° and 70° 18
Angled L-wave search units 19
FAST-UT 19
FAST-UT cal set-up 19

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 OD sizing with FAST 20
OD weld crown obstruction 21
SCC depth sizing prep grinding 21
FAST ID flaw sizing 21
Embedded, midwall, rounded flaw sizing with FAST 22
Determining ID connection 23
Midwall, planar flaw sizing 23
Identifying the L-wave 23
Recognizing low angle shear 23
Flaw length sizing 24
Establishing scan lines 24
Seam weld inspection process 25
Types of longitudinal seam welds 26
DSAW -double sub arc welds 26
Flash weld 26
ERW electric resistance welds 26
Geometry 26
Flaw sketches 27
Seamless pipe 27
Seam weld inspection strategy with encoded prove-ups of detection, 28
characterizing and sizing
6dB flaw height sizing does not work 28
After this training you should be able to … 29
Terms, definitions, acronyms 30-35
Figures 1-53 36-93
Figures 54-61, generic flaw sketch forms 94-101
Figures 62-68, Flaw sketch with encoded prove-ups 102-108
YouTubes list 109-110
Inside back cover; typical instrument settings 111
Back cover; FAST sizing tables, basics, seam weld steps 112

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Welcome
This material is similar to the material taught in manual UT (ultrasonic testing) training
classes given by Jimmy Ellis at PfiNDE and then at SGS from 2010 to 2016. The original printed
booklet was a reference supplement to the methods shown during ‘hands-on’ training. That
booklet could not be read by itself as a “stand-alone” to learn how to do UT of pipeline digs.
The material presented here is intended to stand alone. There is more detailed
explanation here for things that were shown in training classes but not written in the original
training booklet. Some of the material here is supplemented by YouTube videos linked here
and at https://UTofPipelineDigs.com
FAST-UT (Flaw Analysis and Sizing Technique) remains an important part of this
training. FAST-UT is effectively used for the initial detection of flaws. FAST-UT is a high angle
L-wave technique (see terms and definitions). Most conventional shear wave angle beam UT is
done with shear wave mode only. FAST-UT can hit flaws with several modes of sound and
greatly increases the probability of detection. FAST-UT also has many very useful flaw sizing
properties.
When Steve Sikorski and Rick Pfannenstiel began training people to perform FAST-UT in
the 1990s, it was not as common to perform manual UT by scanning. Scanning is the side to
side movement of the search unit, parallel to the seam weld centerline. Prior to that time, most
of us old UT hands were trained to perform manual UT by rastoring and skewing, mostly a
‘back and forth’ motion. Nowadays, it is common practice to perform all initial manual angle
beam detection by scanning. This training booklet will emphasize scanning for detection with
all angle beam search units, not just for FAST-UT. After doing scanning for detection,
rastoring-skewing is used for characterizing and sizing.
When FAST-UT was first introduced to pipeline integrity digs in the 1990s it was
emphasized how quickly an effective manual UT detection could be done; the quickest way to
the needed information. Some pipeline operators now consider accuracy and precision, to be
as important as quickness. They want accuracy and precision of manual UT measures for
detailed correlation to ILI predictions. (ILI: In Line Inspection tools)
This training stresses precision and accuracy using all the tools normally available to a
UT hand:
• Straight beam
• 45°
• 60°
• 70°
• FAST

Quickness is now considered good when the results are also accurate and precise. By
having set-ups/calibrations you are confident in, and after enough repetitions, a UT hand will
get quick. By using all your search units together, you get the most accurate and precise
results. This training will set you up, so you can be quick, accurate and precise in your UT.

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 This training is presented as prep for work on in-service pipeline integrity digs. Usually
the objective is to find anomalies predicted by ILI smart tools. If a predicted anomaly location
actually has a real flaw present, then the pipeline operators want to know exactly where the
actual flaw is, what type of flaw it is, and the measures of the height and length. This is what
we call detection, characterizing and sizing. This is not ‘code work’ in the sense that a
longitudinal seam weld, for example, is not being examined in terms of a code standard such as
evaluation with a DAC as described in ASME V, Art 4.
We are not generally accepting and rejecting. We are detecting, characterizing and
sizing.

The skills described here can be used in other applications but are described here
specifically for thin-walled steel pipe as found in most pipeline integrity work. The wall
thickness of most pipelines is 0.188” to 0.375” thick. There are some pipelines as thin as
0.125” and some newer pipelines are much thicker; up to about 0.750” thick. Many river
crossings were made with 0.500” pipe.

Today, the ‘state of the art’ preferred inspection strategy for seam welds is:
• Use manual UT including FAST-UT, straight beam, 45°, 60°, and 70° conventional shear
to detect, characterize, and size all the flaws.
• Perform encoded PAUT sector scans if the pipeline operator wants documentation of
detections. See an example in figures 62-64.
• Perform ToFD, or focused PAUT, or FMC-TFM, or IWEX if the pipeline operator wants full
proof of flaw height sizing. See an example in figures 62, and 65-68.

PAUT (phased array UT), ToFD (time of flight tip diffraction testing), FMC-TFM (full matrix
capture, total focus method) and IWEX are not within the scope of this training.

If you have questions or suggestions, you are welcome to contact me anytime.

Jimmy Ellis
718-757-9464
[email protected]
[email protected]

Feel free to print this book. A high quality, spiral bound, color printed copy can be obtained
from the author for the cost of printing and shipping.

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Getting started, shortcuts:
• For a thumbnail summary of how to set up all three conventional shear wave cals see
Figures 23A and 23B. The figures begin after the main body of text.
• For a thumbnail summary of how to create a FAST cal go to section “FAST-UT cal set-
up”
• For a thumbnail summary of FAST UT basics go to the back cover.
• For a thumbnail summary of how to use FAST-UT to inspect a seam weld go to the back
cover and to the section “Seam Weld Inspection Process”.

Equipment
4 cal blocks are needed:
1
Half inch thick steel step wedge. An example of this can be seen here: http://curtis-
test.com/product/5-step-block/ .
Or see figure 1.

2
Mini angle beam block. This is also known as the Rompas block. An example of this
block can be found on the internet here: http://curtis-test.com/product/angle-beam-
blocks/ . Either the thick version or the thin version can be used, but the 1” thick
version is also useful for doing instrument linearities. See figure 1.

3
FAST model 1 block. See figure 2 sketch. This block is available from CBIS (Circle B
Integrity Services) at 918-809-1583.

4
The 0.300” thick notched block, also available from CBIS. See figure 3.

For a listing of recommended search units and wedges see figure 4.

Manual UT is done with a UT flaw detector, not a thickness gauge.

Thickness gauges are not suitable because the gates operate differently, and the
displays usually can’t keep up with you while you are scanning a length or an area. Examples
of thickness gauges are GEIT DMS 2 and Olympus 45MG or 38DL-Plus.
For angle beam UT you need a flaw detector. Flaw detectors that would be good
include Olympus Epoch 600, 650, 6LT or GEIT USM36 or USM-GO, and many others. You will
learn here that we often make use of how indications walk on the A-scan display as you move
your search unit. It is extremely useful for the A-scan display to have an option that allows you
to see 10 major divisions of the screen range or baseline. This is usually seen as 11 vertical
lines on the screen (the zero line plus 10 equals 11). This used to be standard on all flaw
detectors, but now some manufacturers don’t have any option for it. Their displays have
arbitrarily defined sweep-range divisions.
You should try everything described here with your flaw detector. If you are new to
manual UT it can be a little overwhelming when you are trying to figure out how to navigate
amongst all the screens, menus, and options on your flaw detector. Start by watching the
YouTube UT-PLdigs-1.0 at https://youtu.be/LHI8o9HZ6sc . If you can’t get to this “YouTube”

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by using cntrl+click on the previous link, clickable links to the YouTubes can be found by
downloading the PDF of this book from https://UTofPipelineDigs.com . This first YouTube is
done with an Olympus Epoch 650, and attempts to show you how to set up your instrument to
prepare for straight beam UT and your “SB” cal. There are important differences among flaw
detector manufacturers. If you are using a different brand or model of instrument, try to get
help in figuring out the differences. Most things shown in that YouTube have similar options in
other manufacturers flaw detectors.
Recommended settings and helpful hints for getting set up are shown inside the back
cover of this book in figure #62.

A preliminary subject we should talk about is math. We have some things we talk about in
terms of fractions, such as 1/16th of an inch. We have other things that we talk about in terms
of decimal inches or mils. If you are a little rusty in measurement conversions and some basic
angle beam UT terminology you could get a refresher at YouTube UT-PLdigs-2.0. at
https://youtu.be/HgMEDzGzef0 . There are earlier versions of this training guide available in
metric units instead of inches.
Now we can get down to work and start to build up our UT skills, step-by-step, starting with
straight beam UT, then going on to 45°, 60°, 70° shear and then FAST-UT. Then apply our
skills using several sizing techniques.
The six manual UT cals we need are generically named the following:
• SB (straight beam)
• Sonopen
• 45
• 60
• 70
• FAST

We usually have generic versions of these cals that can be downloaded and installed on the
flaw detector. See https://UTofPiplineDigs.com . (Don’t download anything yet.) You would
only need to open them and tune them up a little. Every probe and wedge combination is very
slightly different. Sometimes the only difference is how much the contact surface has been
worn down on the wedge footprint. To distinguish between the generic cals that can be
downloaded, and your own cals, we usually recommend that after you have tuned them in for
yourself you rename the cal files with your initials appended to the end of the file name. So,
after I tune in precise cals with my search units, using my instrument, I name mine:
• SB-JE
• Sonopen-JE
• 45-JE
• 60-JE
• 70-JE
• FAST-JE

If you are new to manual UT, don’t begin your training by downloading the generic cals and
then just tuning them up. You won’t learn as much if you do that. Build up each of your cals
from scratch in the manner described in this training. This way you will understand how your
cals work, how you can improve them and have reasoning for making adjustments if you run
into problems.

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 After you have created final versions of all 6 of your cals, copy those files to your laptop and
you can reinstall them on a different instrument if you need to in the future.
The downloadable generic cals are good to have access to if you need to get set up on a
new instrument in a hurry.
On my machine I use for field work, I only keep these 6 cals. This helps me do things
quickly. I have 6 cals that I’m confident in. I can recall them, check them, set the gain, and
then go to work. I usually look at every flaw with several search units. Having too many cals
besides these will just get in the way and slow you down.

Straight Beam UT

Dual element straight beam cals; Alternating zero and velocity adjustments
Back in the day we were taught to calibrate for straight beam testing by doing the
following:
1. Couple to the 0.200” thick step of the half inch thick step wedge. Using gain, bring the
signal to 80% FSH (full screen height). Dial in the correct thickness using “zero”
(also known as “probe delay” in GEIT instruments).
2. Couple to the 0.500” thick step. Using gain, bring the signal to 80%FSH. Dial in the
correct thickness using velocity adjustment.

Complete the calibration process by repeating the above steps until the cal is accurate. The
cal is accurate when you get the exact thickness reading when the signal is brought to 80%FSH
without any zero or velocity adjustment. Try to remember this general rule; use ‘zero’ for the
short distance and velocity for the long distance. If you are using an Olympus flaw detector
and you have changed the velocity since you began, you may need to look at the Range and
bring it back to 1.000”. See YouTube UT-PLdigs-3.0. at https://youtu.be/zhWHJ9NY0VY .
Another method is to follow the instrument manufacturer’s instructions, which may use an
“auto-cal” function. If you do this, become aware if it is measuring peak or edge. We generally
don’t use peak. We use edge. If you use peak, especially with FAST, it is too much work to
keep moving the gate around to gate on the correct signal.

Use of consistent gate and signal height

Take thickness measurements with gate mode of flank or edge, and not at peak. Use a
consistent signal height on gates at a consistent %FSH. We typically set the gate at 30%FSH
and would measure an indication thickness when it is at 80%FSH. Many instruments have a
function called “Auto80” that quickly brings the highest indication in the gate to exactly
80%FSH.

Roof angle
Dual element thickness probes have two elements which are at a slight angle, called the
roof angle. They are not parallel to the inspection surface. This angle may be the cause of
some of the lack of linearity in thickness cals. See figure 5 and 6.
The thickness calibration described above is good from 0.200” to 0.500”. We would not
be calibrated for thickness readings below 0.200”. If you need to be accurate, precise, and
calibrated for readings from 0.100” to 0.200” you can consider setting up another cal that is
calibrated on the “100” step and the “300” step.

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 Below 0.100” thick we would need to say that any readings taken are out of the
calibrated range, unless we can obtain a calibrated thickness standard that is less than 0.100”
thick and recalibrate using it.
Orientation of crosstalk barrier
We’ve been taught to use a dual element thickness probe on a curved surface like the
OD of a small to medium diameter pipe with the cross-talk barrier perpendicular to the axis of
the pipe. There was good reason for this. If you put the cross-talk barrier parallel with the axis
of the pipe, one side or the other of the probe may lose contact with the pipe. A little bit of
rocking motion can introduce a lot of soundpath differences and throw your thickness readings
way off.
There are some occasions when it can be useful to turn the cross-talk barrier the
“wrong” way. See YouTube YouTube UT-PLdigs-4.0. at https://youtu.be/h8Dp9PRoCxQ . Try
practicing this on the ID notches of the 0.300” thick notch block.

Rectification
With your straight beam probe coupled to one of the steps of the step wedge, compare
the differences in the 4 types of rectification:
• Full
• RF
• Negative half wave
• Positive half wave

See YouTube YouTube UT-PLdigs-5.0 at https://youtu.be/sh91-gjvkfY and figures 7-10. We

usually use full wave for all our manual UT. We use RF for ToFD.

Gain settings for straight beam UT

A good amount for gain during most straight beam UT scanning to search for internal
metal loss, laminations, or other mill defects can be obtained by going to an unflawed part of
the pipe and then bringing the first back reflection to about 80%FSH, and then adding 6dB.

Recognizing the walk of laminations vs. internal corrosion.

Most of what we observe and learn from our UT has to do with the way indications walk
on the screen as the probe is moved. Only in the case a taking a static thickness reading is the
probe held still. The way laminations and internal corrosion walk on the screen is totally
different. See YouTube UT-PLdigs-6.0. at https://youtu.be/yF9_lMSfUgY .

Temperature changes
During the course of a work day the temperature can change. Temperature changes
will affect your UT cals.
Colder temperatures make UT louder. Warmer temperatures make UT signals less loud.
If the temperature is going up you might need to add gain to compensate.
Although it would seem that velocity would need to be adjusted to compensate for
warming temperature changes during the course of a work day, it is sometimes only ‘zero’ and
gain that need adjusting for straight beam thickness measurements.

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First back reflection vs multi-echo
We normally never need multi-echo functions. Multi-echo is normally used for
measuring material thickness through coatings. In-service pipeline digs almost always have the
coatings removed by abrasive blasting.
Multi-echo functions work great on cal blocks but not so well when either the top-side or
bottom-side surface or coating is rough, or irregular or corroded.
Keep in mind that if you find yourself needing to measure the steel wall thickness of an
item that has a paint coating, you may want to learn how to do multi-echo readings. For multi-
echo readings calibrate in the following manner.
• You set up two gates; gate A and gate B.
• Move Gate A to put the first steel back reflection of a step wedge step in gate A.
Choose a step similar in thickness to the item you will be measuring.
• Activate Gate B, then move Gate B to put the second back reflection of the same
step in gate B.
• Change both gate modes to read FirstReflector/Peak
• Using the “GateB minus GateA” measure function, adjust only the velocity until
the reading is correct.
• Proceed with measurements on coated parts.
A handy way to test the above cal is to put a credit card on the step wedge to act as
your coating of paint. Apply couplant on both sides of the plastic card.

Sonopen
Sonopen, is the Olympus version of a pencil probe. The pencil probe is only used for
taking thickness measurements in the bottom of a corrosion pit. Pencil probes are notoriously
difficult to use in the field. Due to the irregular surfaces found in the bottoms of corrosion pits,
it often does not get good ultrasonic coupling. Sound does not make a good entry into the part
and therefore does not get enough sound to reflect back and get a good reading. Don’t “force”
the readings. If the particular corrosion pit you are in does not give a good reading just move
on to another location, unless it is appropriate to grind the bottom of the pit into a better
surface. This is usually not appropriate and may not be safe.
Use as low a voltage or energy setting as possible, usually about 100 volts. High
frequency probes are said to become degraded if hit with high voltage too much.
Establish a Sonopen cal. See YouTube UT-PLdigs-7.0 at
https://youtu.be/4WMUxyXBamc . Consider using a half inch thick cal that starts at the fifth
major division. This is a reminder that you are using sound that has gone thru a delay tip
before entering the steel. As you couple the transducer to the delay tip, you can watch the
delay tip screw into place. Re-couple the delay tip with a fresh dab of couplant before each day
of Sonopen use. The first back reflection from the end of the delay tip is visible at the fifth
major division. The first back reflection from the 0.100” thick step is at the sixth major division.
Note the effect of search unit angulations on amplitude.
Have a cal ‘standard’ for very thin material. Use a dial caliper to establish a thin step on
something you normally have with you when you are at field sites.
Be able to recognize a second back reflection of very, very thin material and determine
the actual thickness by dividing the second back reflection reading by two.

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Extremely thin pipe.
When working with extremely thin pipe (Tnom; 0.201”, 0.188”, 0.156”, 0.125”) try to
obtain a 10 MHz dual element straight beam probe. See the recommended equipment list in
figure 4.

Very high frequency probes and welds

Be aware that if you are using very high frequency probes such as 10MHz, or 15MHz
(like the Sonopen) that welds will give many tiny grain noise reflectors scattered through the
weld metal. Overcome this effect by reducing gain so that the backwall reflector is not too
loud. For welds, only use these probes to help in sizing of weld defects you have already
detected with angle beam UT. Don’t use high frequency probes to go hunting for weld defects.
Only use the Sonopen for getting thicknesses in the bottom of pits.

Angle Beam UT
Before we begin creating cal files for angle beam we will digress for a moment to
develop the one inch deep angle beam screen range. There are many ways to set up your A-
scan display just by choice of screen range. Three common approaches are:
• Soundpath screen
• I.D. at 4, O.D. at 8
• One inch deep

Soundpath screen:
When I first began doing angle beam UT many years ago, I liked using the 10 inch
soundpath screen. My screen range was 10 inches and each of the ten major divisions on the
screen was one inch of soundpath. This helped with visualization for figuring out which
reflectors on the screen belonged to which parts of the cal blocks like the IIW, the DSC or the
Rompas. We commonly use angles of 45°, 60°, and 70°. For each angle, and for each T-nom I
had different places on the screen that represented the end of leg 1, 2 and 3 for each angle. It
was a lot of work to keep it all straight. And when the material thickness changed I had to
keep track of a whole new set of legs locations. For the thin materials we work on for pipelines
a common approach to the soundpath screen is a screen range of 2.5”. This makes each major
division ¼” of sound path travel.

ID at 4, OD at 8, screen
Another approach, used frequently in ASME work, is to put the ID at the fourth major
division and the OD at the eighth major division. [Note; ID literally, short for Inside Diameter,
meaning the inside surface and OD literally Outside Diameter, meaning outside surface] This
was good for figuring out where different reflectors were. But it requires new cals for each
thickness tested. This works really well when you have ASME cal blocks, and you can peak up
on ID and OD corners to set up. At pipeline digs, we usually don’t have any ASME cal blocks, or
access to any ID or OD corners. This can still be done using the “ID roll” signal or the “OD roll”
signal, but isn’t too precise. Again, this was a lot of work to keep it all organized, because you
would have to change each angle beam cal with every different thickness of pipe. For a
demonstration of what “ID roll” and “OD roll” signals look like see YouTube UT-PLdigs-8.0 at
https://youtu.be/LI7NdtvL6cU .

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One inch deep screen:
The approach we take here is to use one cal for each angle, no matter the thickness.
Makes everything simpler. Because almost all pipelines are less than ½” thick we can usually
see all of leg 1 and 2 for almost all the pipe T-noms we are likely to see. The one inch deep cal
also has the benefit of keeping the ID and OD at the same places on your angle beam screen
no matter if you are using 45°, 60°, 70° or FAST (which is also 70°) for each T-nom you work
on. These cals are always ready to go. No need to make new cals when you show up on a
new job with a different T-nom.
There are three magic numbers to use to get one inch deep screens for 45°, 60°, and
70°.
Figures 11-20 shows how these numbers are derived. This is reviewed in YouTube UT-
PLdigs-9.0 at https://youtu.be/e1emu_jb7SA which has a bit of trigonometry in it. Don’t worry,
you never need trig to do angle beam UT. Nowadays, flaw detectors do all the trig for you. (If
you are curious as to how the trig works you can watch YouTube UT-PLdigs-10.0 at
https://youtu.be/aNPTRbjHrYs . Feel free to skip this.) You just need to make use of the three
magic numbers for your screen ranges which are:

Angle Range
• 45° 1.414”
• 60° 2.000”
• 70° 2.924”

Figure 21 shows a summary comparing and contrasting the advantages and disadvantages
of the three strategies of establishing screen range:
• One inch deep screens (this is what we use)
• 2.5” soundpath screens
• ID@4, OD@8

Now that we have developed the “one inch deep screen” for all our angle beam work we
can create our 3 conventional shear wave cals.

Shear wave cals

45° shear, 1” deep screen

An abbreviated summary of how to set up the 3 shear wave cals; 45°, 60°, and 70° is
shown in Figures 23A and 23B.
Make a one inch deep screen by changing the range to 1.414” (see figures 11-14) and
to get started select the built in default shear wave velocity for plain carbon steel (Olympus;
0.1280”/µSec or GE/Krautkramer; 0.1320”/µSec).
For the 45° search unit, the probe ‘zero’ and velocity can be made precisely accurate by
looking at the middle and bottom figures of figure 22 and doing the following:

1. Go to the 0.3” thick notch block and peak up on the ID corner trap of the 0.150” deep
ID notch at the end of leg #1. It should peak up at 0.300” deep, in your “depth”
reading box. Adjust ‘zero’ until it does.

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 2. Peak up on the same corner trap reflector, but this time at the end of the third leg of
sound. It should peak up near 0.900” deep in your depth reading box. Adjust ‘velocity’
until it does.
3. Repeat steps #1 and #2 until the cal is consistently accurate at both 0.300” deep and
0.900” deep. If you needed to adjust your velocity and you are using an Olympus flaw
detector you may need to re-adjust your screen range to 1.414”.

See YouTube UT-PLdigs-11.0 at https://youtu.be/7p2aa75G0vA for the set-up of the 45°.

Check the cal by peaking up on the SDHs of the half inch FAST block. Note the results:

SDH 0.100” 0.200” 0.300” 0.400”

Peaks at: _____ _____ _____ _____ (USE PENCIL, NOT PEN)

Note how reflectors have a short ‘walk’ with a 45 (also known as a short echo-dynamic,
or envelope). See YouTube UT-PLdigs-12.0 at https://youtu.be/yrap5eZhWzo for the use and
appearance of the 45°.

45° surface distance measurements:

Put the index point 0.5” back from the end of the 0.5” FAST block and move the probe
into the position that shows the corner trap reflector is at 0.500” deep in the depth reading box.
This is the point at which 45 degrees is aimed at the corner. Measure the distance from the
front of the wedge to the end of the block with your scale. This is the actual “surface distance
minus X-value.” This is what you should see in your “surface distance minus X-value” reading
box. If not, adjust your X-value until the “surface distance minus X-value” reading box agrees
with what you see on your scale. With an Epoch 600 you can watch it as you “dial it in” with X-
value. With the USMGO you have to go back and forth between the menus. For the USMGO, if
the surface distance (-)x value is too great, increase the x value.
See YouTube UT-PLdigs-13.0 at https://youtu.be/0XVJ0XhnaCA for the use and
appearance of the 45° surface distance measure function.
A summary of the sequence for setting up each of the conventional angle beam cals is
shown in figure 23A and 23B.

RATT
Relative Arrival Time Technique
Observe relative distances between corners and tips. The deeper the crack gets, the
more separation along the baseline between the corner and the tip.

This is where we begin talking about “sizing”, or flaw height measurement. First, we’ll
start with a technique that requires observation of how signals walk on the screen. Actually,
most sizing and characterizing is obtained from how signals walk on the screen. When we
rastor at the ID notches on the notch block with the 45 we can see a very loud corner trap
signal from the notch root and low amplitude tip signal radiating out from the notch tip. Some

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of this low amplitude tip signal may be from reflection but an important portion of it is from
diffraction.
When sound encounters a tip or facet, diffracted sound echoes radiate out from the tip
in all directions. This is often compared to dropping a pebble in a pond and seeing the wave
pattern that travels outward in all directions.
The loud corner trap, and the low amplitude signal walk with each other on the screen.
The deeper the notch, the further apart these signals are along the base line. See YouTube
UT-PLdigs-14.0. at https://youtu.be/tiXch-7TUhc .

We can use this qualitatively for sizing:

• When the space between the corner trap and the tip along the baseline is small, the
notch height is relatively small.
• When the distance along the baseline between the corner trap and the tip is large, the
notch height is relatively large.

This is called the “RATT” or Relative Arrival Time Technique because we are observing the
arrival times of the corner and tip, relative to each other.
If we had a notched cal block that was exactly equal in thickness to each pipe that we test
in the field, we could use this technique to take depth measurements. We usually only have
the one notch block that is 0.300” thick and we almost never have an actual T-nom of 0.300” so
this technique will almost always be qualitative.

AATT
Absolute Arrival Time Technique
With the same set-up we are able to do tip diffraction depth measurements by peaking
up the tip signal and then reading the depth from the depth reading box.
We can check how our cal looks by filling in the table below. It’s a good idea to use
pencil so it can be erased and re-used later. See YouTube UT-PLdigs-15.0 at
https://youtu.be/Gcc3CX2DsTc . These ID notch tips are in leg number one.

ID notches:
(USE PENCIL, NOT PEN, for all the “fill in the blanks”)
Notch 0.010” 0.030” 0.060” 0.090” 0.120” 0.150” 0.180” 0.210”
RL*
0.290” 0.270” 0.240” 0.210” 0.180” 0.150” 0.120” 0.090”
(depth to tip)
Your measure ** **

*RL is shorthand for remaining ligament. This is the amount of good material above the tip,
not affected by the notch or the crack or other flaw.
**We usually can’t detect a tip for the 0.010” and 0.030” notches if we are using a 5MHz search
unit because there isn’t enough resolution.

Once we have the above tables filled in we can decide if we like our cal. In my opinion
if your sizing numbers are plus or minus 0.005” then you are about as close as we should ever
expect to get with manual UT. If you are plus or minus 0.015” you are probably good enough
for most sizing purposes.

UT of Pipeline Digs 08/15/2018 Page 14 of 112

 If your “depth to tip” is close to the RLs listed above you are done. If you think you are
too far off you can make adjustments to your cal.
If everything is off by the same amount, for example, all depths are +0.020”, you can
usually make a good adjustment with Zero alone.
If everything is off by more and more towards the left or towards the right, for example,
(-)0.005”, (-) 0.010”, (-) 0.015”, (-) 0.020”, etc., you can adjust velocity alone.
If everything is off by random amounts plus and minus, assume that you need more
practice with your “hand-to-screen” coordination. When you ‘peak up’ on a reflector you are
rastoring back and forth, and skewing clockwise and counterclockwise, and observing the
resultant signal on the screen. The moves you make with your hand have to be coordinated
with what you see on the screen. This “hand-to-screen” coordination is an essential part of
doing manual UT. Most people need a lot of practice to peak up on signals consistently well.
Don’t be frustrated if you don’t master this at the first attempt. This takes practice; repetitions.
If you make an adjustment to your cal recheck the “fill-in-the-blanks” above.

OD notches:
We can use the same technique to do tip sizing for OD connected cracks. The technique
we are still talking about is AATT, taking a measure to the tip signal.
This time flip the notched block over so that the notches are on the top side as in figure
24.
We can use the table below to use “AATT” for sizing of OD connected flaws. See
YouTube UT-PLdigs-16.0 at https://youtu.be/yt_EMyf7CW0 .

Notch 0.010” 0.030” 0.060” 0.090” 0.120” 0.150” 0.180” 0.210”

RL*
(depth 0.590” 0.570” 0.540” 0.510” 0.480” 0.450” 0.420” 0.390”
to tip)
Your ** **
measure

*RL is shorthand for remaining ligament. This is the amount of good material above the tip,
not affected by the notch or the crack or other flaw.
**We usually can’t detect a tip for the 0.010” and 0.030” notches if we are using a 5MHz search
unit because there isn’t enough resolution.

60° shear, 1” deep screen

Make a 1” deep screen by using a 2.000” screen range. See figures 15-17. Use the
velocity found for the 45°. The velocity in the material doesn’t change with different angles.
Use the one inch radius of the mini-angle beam block as shown in figure 23B to find the new
probe zero.
Check surface distance measurements by walking the reflector from the bottom corner
of the half inch thick SDH block to the point where the depth reading box indicates that the
reflector is 0.500” deep. This is usually not where the signal peaks up. Then measure with
your scale the distance from the front of the search unit wedge to the end of the block. This is
the actual “surface distance minus X-value”. Adjust your X-value until the “surface distance
minus X-value” reading box has the same number as what you see on your scale. In figures
17B and 23B this is shown for a 60° wedge and the “surface distance minus X-value” reading
box should read 0.650” just as shown on the scale.

UT of Pipeline Digs 08/15/2018 Page 15 of 112

 See YouTube UT-PLdigs-17.0 at https://youtu.be/GAOwTKFAiMM .
For an explanation of why the 60° does not peak up at the correct depth for a corner
trap reflector see YouTube UT-PLdigs-18.0 at https://youtu.be/KU8ui6ygpdk .
Raster back-and-forth to peak up at each of the SDHs of the 0.5” FAST block and record
here the depth that the signal peaks.

SDH 0.100” 0.200” 0.300” 0.400”

Peaks at: _____ _____ _____ _____

Observe 60 degree ‘walk’. Repeat for the ID notches and their tips on the 0.3” thick
notch block.

Absolute Arrival Time Technique (60°)

Half Vee (ID notches):

Notch 0.010” 0.030” 0.060” 0.090” 0.120” 0.150” 0.180” 0.210”

RL
0.290” 0.270” 0.240” 0.210” 0.180” 0.150” 0.120” 0.090”
(depth to tip)
Your ** **
measure

**We usually can’t detect a tip for the 0.010” and 0.030” notches if we are using a 5MHz search
unit because there isn’t enough resolution.

Once we have the above tables filled in we can decide if we like our cal. If your “depth
to tip” is close to the RLs listed above you are done. If you think you are too far off you can
make adjustments to your cal. If everything is off by the same amount you can usually make a
good adjustment with Zero alone. If everything is off by more and more towards the left or
towards the right you can make adjustments to velocity. If you make an adjustment, recheck
the “fill-in-the-blanks” above.
See YouTube UT-PLdigs-19.0 at https://youtu.be/1YtQyHoOunk .
A summary of the sequence for setting up each of the conventional angle beam cals is
shown in figure 23A and 23B.

70° shear, 1” deep screen

Make a 1” deep screen by using a 2.924” screen range. See figures 18-20. Use the
same velocity as the 45° and 60°. The velocity in the material doesn’t change when you
change angles.
Find the new probe zero by putting the index point of the search unit lined up with the
mark on the half inch FAST block for the 0.300” deep SDH and adjust zero (probe delay) until
you get 0.300” in your depth box. Now each SDH should be close to 0.100”, 0.200”, 0.300”
and 0.400” when the index point is on each marked spot.
This setup is actually very different than the setup for the 45° or the 60°. Those two
setups were based on where the 45° peaked up on the ID corner trap signals. They were both
“peaking” cals. The setups were based on where things peaked up. This 70° setup is not
based on where things peak up. This 70° setup is based on the probe position. The 70° is

UT of Pipeline Digs 08/15/2018 Page 16 of 112

positioned with the index point on the exact spot that directs 70° to the SDH. Steve Sikorski
refers to this type of setup as a “PPATT”; Probe Positioning Arrival Time Technique.
We use the probe positioning set up for the 70° because the FAST Model 1 cal block is
built for a 70° probe. It is very quick to set up and most of the time we are more concerned
with getting precise surface distance measurements with the 70° and this type of cal is ideal for
that. When we are working on thin walled piping we usually do a lot of indication verification
by taking surface distance measurements from both sides of a seam flaw. We do this instead
of traditional indication plotting.

Now check how it works by peaking up on each SDH:

SDH 0.100” 0.200” 0.300” 0.400”

Peaks at: _____ _____ _____ _____

Observe the 70° ‘walk’. Repeat for ID and OD notches on the 0.3” thick notch block.
Check surface distance measurements by walking the bottom corner reflector from the
end of the 0.300” thick notch block to a point where the depth reading box reads 0.300” deep.
Now you are hitting the corner with 70°. Hold/freeze that search unit position. Use a scale to
measure the distance from the end of the search unit wedge to the end of the block. This is
the actual “surface distance minus X-value”. See the bottom of figure 23B. Adjust the X-value
in the instrument until the “surface distance minus X-value” reading box reads the same as
what you see on your scale. For the 70° search unit shown in figure 23B the “surface distance
minus X-value” reading box should say 0.510” for that probe.
We don’t need to take surface distance measurements as often with a 45° or a 60° but
we need to be able to take precise and accurate surface distance measurements with a 70°
shear and with FAST.
On the very thin pipeline material we work with, we do surface distance measurement
checks instead of traditional indication plotting. See YouTube UT-PLdigs-20.0 at
https://youtu.be/cLztGCpKSqI .
The previous two sections for 45° and 60° ended with exercises for taking ID crack
depth measurements by going to each ID notch corner trap signal and then pushing forward to
search for its tip signal. Those tip signals are not 100% due to reflection, but is to some
portion a tip diffraction signal. With the 70° we don’t get a separate tip diffracted signal. When
you find the corner trap reflector near 0.300” deep and then push forward you are seeing the
reflection from the face of the notch or the crack as the shear wave walks up the face of the
notch. Eventually the center of the sound beam walks over the top of the notch or the crack.
You can see the top of the flaw or notch by following the walk of the 70° and watching for
where it goes over the top. To get accurate depths to the tips you have to re-zero your cal for
this type of sizing. This should only be used for extremely deep flaws. A good way to set this
up is by dong the following whenever you need it:
• Walk over the top of the 0.210” deep ID notch. The depth to the top of the notch (or
RL) is 0.090”. When the echo dynamic is at its peak, like the walks shown in figure 25,
stop the search unit at the peak and hold it there.
• Use zero (probe delay for USMGO) and make the depth reading box read 0.090”.
• Verify the ID notch sizing by walking up the face of the following notches, and record it
in the table below.
• Decide if you want to save this as a separate cal file or not. I recommend not.

UT of Pipeline Digs 08/15/2018 Page 17 of 112

 Notch 0.010” 0.030” 0.060” 0.090” 0.120” 0.150” 0.180” 0.210”
RL
0.290” 0.270” 0.240” 0.210” 0.180” 0.150” 0.120” 0.090”
(depth to tip)
Your measure ** ** ** **

**Only use this sizing technique for extremely deep ID connected flaws.
See YouTube UT-PLdigs-21.0 at https://youtu.be/xS7hYl3sUvA .

An abbreviated summary of how to set up the 3 shear wave cals; 45°, 60° and 70° is
shown in Figures 23A and 23B.

Gain settings
Be careful not to use too much gain. It’s often tempting to use a little more gain to see
things ‘better’. Using too much gain can be just as bad as not enough gain. Too little gain and
you won’t find anything. Too much gain and everything will look cracked.
As a general rule, set your gain with whatever angle beam search unit you are using
(including FAST) so that the SDH at the thickness you are working with is at 50%FSH.
Example: for Tnom = 0.312”, bring the 0.300” deep SDH to 50% FSH.
Here is a general angle beam set-up routine. Try to form this habit every time you open
an angle beam or FAST cal:

• Recall the cal

• Check the cal; go briefly to each SDH in the 0.5” thick FAST block. They should appear
on your 1 inch depth screen in the neighborhood of 0.100”, 0.200”, 0.300”, and 0.400”
deep.
• Set your gain: go to the SDH closest in depth to the thickness of the material you will be
examining and bring it to 50%FSH in whole numbers of gain. Note this home base gain
setting. Always return to this gain setting.
• Change your gain increments to increments of 6dB. If for some reason you momentarily
need to increase or decrease your gain, do it in increments of 6dB, then immediately
return to your home base gain setting and try to always stay there. At this gain setting
everything you see will be from something real. Could be geometry.

Get into the habit of looking at your flaws with several different search units. These steps
above should become a mantra for you each time you open a different cal;
• Recall the cal
• Check the cal
• Set the gain
• Change dB to increments of 6 and enable reference dB function if you have it

Compare the echo dynamics of 45°, 60° and 70°.

Switch back and forth between the 45°, 60° and 70°. Scan the SDHs and the notches
and observe the characteristic ‘walks’ of the 3 different angles. See YouTube UT-PLdigs-22.0.
at https://youtu.be/NyWnq2ut-Jo .
45° has a short walk along the length of the baseline.
60° has a medium walk.
70° (and FAST, which is also a 70°) has a long walk.

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Angled L-wave search units
FAST and similar search units are high angle L-wave search units. FAST probes will
ideally produce a 70° L-wave.
Let’s take a moment to review some UT basics. If you have taken formal Level 2
ultrasonic classroom training you might recall that zero degree straight beam probes produce
compression waves which are also known as L-waves or longitudinal waves. If these L-wave
producing transducers are put on plastic wedges the sound can be refracted into steel at a
chosen mode (shear or L) or angle. The origin of conventional shear wave probes and FAST
high angle L-wave probes is shown in figures 26A, 26B, 27A, 27B, and 27C.
FAST-UT
A FAST search unit has a nominal angle of 70 degrees. If the footprint of the FAST
transducer is worn unevenly it won’t have good high angle. Although there is a wide range of
refracted L-wave angles that are useful, it is best if the angle is not too high or too low. If it is
worn down unevenly, you must shave the footprint down until it is the right angle again. If the
footprint is not perpendicular to the rectangular casing, it might not even be close to 70°. You
can shave it down quite a way, even into the black plastic casing. It is also very important that
the footprint be a flat plane.
Note: New FAST model 1 search units made by GE/Krautkramer were designed to
produce 70° L-waves in stainless steel which will normally result in a 74° L-wave in carbon
steel. This 74° angle is too high for many purposes.

FAST cal, set-up

1. FAST model one probes often have mis-marked index points from the factory. Remark
them to show the index point as being 0.250” from the front of the search unit on both
sides of the search unit.
2. Set velocity to 0.2330”/microSec. Frequency 5.0MHz Dual element. Tell the trig
function this is 70°. Enter 0.250” for an initial “X-value”.
3. Start with an initial gain setting of about 60 dB. For your reading boxes to work you
need to have the signal in the gate.
4. Set range to 2.924”. This converts you to a 1” deep screen as shown in figures 18-20
for a 70° probe.
5. Put the index point on the mark for the 0.300” deep side drilled hole on the 0.5” thick
FAST block and point the search unit towards the 0.300” side drilled hole.
6. Adjust ‘zero’ to make the depth reading box read 0.300” deep.
7. Done.

See figure 28.

Check your cal by putting your index point on each marked spot on the 0.5” thick FAST
block. Each side drilled hole should come up near the major division line on the screen; 0.100”,
0.200”, 0.300”, and 0.400”. See figure 29.

See YouTube UT-PLdigs-23.0 at https://youtu.be/2Vgic9HbHjQ .

Further check your cal by peaking up on each side drilled hole. Raster (back and forth
motion) to peak up the SDHs of the 0.5” FAST block:

SDH 0.100” 0.200” 0.300” 0.400”

Peaks at: _____ _____ _____ _____

UT of Pipeline Digs 08/15/2018 Page 19 of 112

See YouTube UT-PLdigs-24.0 at https://youtu.be/ZMbrubjRA6A .

Adjust the X-value for surface distance measurements bringing any ID corner trap
reflector on the 0.300” thick notch block to 0.300” deep in the depth reading box. Don’t peak
up. You could walk this signal back and forth to any depth you want because a 70° has a very
long walk. When you walk it to 0.300” deep in the depth reading box, you are hitting the notch
root with 70 degrees. Surface distance measurements with 70° shear and FAST are very
important so be sure this works consistently precisely well. See YouTube UT-PLdigs-25.0. at
https://youtu.be/DKh4jeb9TrI .

OD sizing with FAST

Use the 0.3” notch block and raster over the top of each of the OD notches and find the
point where the %FSH is maximum for the L-wave and record the depth reading and %FSH at
that point.

For now, don’t go deeper than a 0.120” deep OD notch.

Use your table to estimate OD crack depths by comparison. Always try to look at each
flaw from both sides.
Make a new table like this one for each day of OD sizing, or whenever the temperature
changes much.
The general pattern usually seen is:
• For OD cracks/notches less than or equal to about 0.075” deep, they will peak up near
_____ deep on the screen. However, the deeper these are, the louder they will be. So
generally, if an OD crack peaks up near ______ deep, its depth should be judged from
its amplitude.
• For OD cracks/notches deeper than 0.075” the reflector will peak up deeper than
______ so the depth should be judged more by where the signal peaks up along the
base. It’s not how loud it is, it’s where it peaks up along the base line.
So, to state this another way:

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For the shallow ones, you can tell how deep they are by how loud they are. For the deep ones,
you can tell how deep they are by where they peak up along the base line.
The best OD depth sizing is done from whichever side of the weld is louder.
See YouTube UT-PLdigs-26.0 at https://youtu.be/uhlH7tLeIuU .

OD Weld crown obstruction

When you can’t rastor over the top of the flaw (because of the weld crown) use a piece
of mag tape to simulate the obstruction on the block. Find the combination of echo-dynamic
and %FSH that is the closest match to make depth sizing determination.
Always try to do this from both sides of the flaw. If the obstruction distance is different
from each side take this into consideration.
Determine the obstruction distance ultrasonically.
See YouTube UT-PLdigs-27.0 at https://youtu.be/wdsU7QoNQAg .

SCC depth sizing prep grinding

The FAST OD depth sizing described above is usually done on SCC in conjunction with
surface prep done with sanding discs. The more the surface is prepped to remove the adjacent
shallow SCC cracks, the better the sizing gets.
Two other things to think about while doing SCC prep or removing SCC a little at a time
is “dishing” and “flattening”.
When you grind out SCC a little at a time pausing for re-MT-ing and re-FAST-UT-ing you
will get a much better result on your FAST depth sizing if you don’t create a ‘dished out’
concave excavation. UT coupling becomes poorer when you do this. Make the grind spot into
a ‘flat’. The ‘flat’ is similar to the surface of your OD notches on your notched block you are
using for sizing. Measuring on a ‘flat’ improves the sizing accuracy.
Axially oriented SCC is said to have an improved stress situation when the SCC is
removed with sanding discs.
Circumferentially oriented SCC should never be ground out because this is said to
weaken the pipe.

FAST ID flaw sizing

ID sizing with FAST, using notches:
Raster scan from way back to well beyond for each ID notch. Watch the echo dynamic
or envelope of the signal. As you raster towards the notch it’s signal gradually rises to a
maximum and then drops off when the sound beam centerline goes over the top of the notch.
The envelope of the walk for the 0.210” deep ID notch is shown in figure 30. A pattern for the
walk of all the ID notches is shown in figure 31.

Choose your depth sizing key point of the envelope. It could be:

• Signal peak
• Where the signal begins a straight slope change (shown with “X”s in Figure 31)

Fill in the table below for ID connected flaw sizing. Start at the bottom and work your way up
the table.

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ID sizing -- 0.3" thk notched block:

dB ______
FAST-
notch remaining UT
depth ligament depth %FSH
0.010" 0.290"
0.030" 0.270"
0.060" 0.240"
0.090" 0.210"
0.120" 0.180"
0.150" 0.150"
0.180" 0.120"
0.210" 0.090"

See YouTube UT-PLdigs-28.0 at https://youtu.be/6yO6QsOlaB0 .

Embedded, midwall, rounded flaw sizing with FAST

Raster over each SDH in the 0.5” FAST block. Note that the side drilled holes have a lot
less mode converted signals than the equivalent depth ID or OD notches do. If the flaw you
are looking at in the field does not have much mode converted signals, it might be an
embedded, rounded, midwall flaw (not ID or OD connected). If you see flaws and you think
they are embedded, rounded, midwall flaws, use the table below to help with your depth sizing
to the top of the flaw.
Peak up on each of the SDHs and record below:

It is difficult to detect and depth size the bottom of a midwall flaw. This is best done with a
special technique, ToFD; Time of Flight tip Diffraction.

See YouTube UT-PLdigs-29.0 at https://youtu.be/iJCyM4JYBQs . This YouTube helps contrast

different “walks” for ID and OD connected flaws and midwall flaws.

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Determining ID connection
It can be difficult to determine if a flaw is ID connected or only near the ID. To verify if
a flaw is ID connected the best method we have now is to look for a corner trap signal near the
ID on your depth screen with both 45° and 60°. If there is an ID connected flaw present you
should find a good corner trap signal near the ID with both. If only the 45° has a corner trap
signal near the ID then it is likely not ID connected. Use both 45° and 60° together to
determine if something is ID connected.
See YouTube UT-PLdigs-30.0 at https://youtu.be/vArida02D5E .

Planar, Midwall flaw sizing

For planar midwall reflectors like lack of fusion in an ERW weld that is not ID or OD
connected it is difficult to measure the flaw height with manual UT. We can measure the depth
to the top of the flaw with several of the techniques previously described; one way is by
walking FAST or 45° or 60° over the top of the flaw and noting the depth where you go over
the top.
The bottom of the flaw is difficult to measure with manual UT. One method is
measuring how loud the “gaps”, or virtual corners, are between the bottom of the OD notches
and the ID of the block for the 0.210”, 0.180” and 0.150” notches using 45. See YouTube UT-
PLdigs-31.0 at https://youtu.be/6rkB_XSpjcg .
Theoretically PAUT seems like it should always be able to see the bottom of a midwall
flaw. Sometimes it works. Don’t be surprised if it doesn’t.
The best method for getting the thru-wall extent or flaw height of a midwall planar flaw
is with Time of Flight tip Diffraction; ToFD. ToFD is a very powerful sizing tool, especially for
midwall and ID connected flaws.

Identifying the L-wave

Because FAST probes have high angle L-waves near 70°, low angle shear waves near
33° and so called “ID creeper” and “OD creeper” effects, and many other possible mode
conversion combinations, it’s important to correctly identify which signal is the high angle L-
wave signal. The high angle L-wave signal has a ‘walk’ or echo dynamic that is similar to a 70°
shear, since they are both 70°. It is a long walk.
If you are having difficulty identifying the L-wave, try pulling back from the flaw. If the
flaw is in fact an ID connected planar reflector, the last signal up, as you pull back, is the L-
wave. Be sure to pull way back.
If you are still not sure, take a ‘surface distance minus X-value’ measure at the point
where the flaw has been walked to the ID. Mark this distance on the weld. Repeat from the
other side of the weld. For a crack, if you have correctly identified the L-wave from both sides,
the two plots will plot to the same point from both sides. See YouTube UT-PLdigs-32.0 at
https://youtu.be/vsaM8EcBvt8 .

Recognizing low angle shear in FAST due to ID gouges

If you have access to a real or simulated ID gouge, look at an ID gouge. This can show
you what a shear wave walk from an ID gouge looks like. It is low amplitude, has a short walk,
and often appears as a series of 3 indications as you rastor back and forth. See YouTube UT-
PLdigs-33.0 at https://youtu.be/zMAOAgtxbAM .

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Flaw Length Sizing
The traditional, conventional UT shear wave angle beam method for measuring flaw
lengths was the 6dB drop method:
• Start at a loud part of the flaw, somewhere in the middle of the flaw length, if the flaw
was longer than the width of the search unit and note the %FSH.
• Move side-to-side and note the points at which the amplitude drops by 6dB. These
points are used as the start and stop of the length.

Natural flaws have varying textures, orientations, and amounts of reflectivity. Using the
amplitude of the flaw to define its length is inconsistent and unreliable.
Use the nature of the side-by-side arrangement of the sending and receiving elements of
the FAST search unit to define the starts and stops of flaws. A flaw can be seen with a side-
by-side, dual element, angle beam search unit when there is a flaw centered between the two
elements. This is the center of the FAST search unit. As you scan side-to-side on the part, the
flaw begins where the signal emerges from the baseline and ends where it disappears back
into the baseline. Use these points as starts and stops for length sizing.

Establishing scan lines

Before beginning a scan of a seam or girth weld you should be aware of the material
thickness and adjust the scan line location in relation to the base metal thickness.
A shortcut formula for determining a good setback distance for a FAST scan is the
following: Setback dist. = T * 2.75
This distance is the distance from the weld centerline to where you put your FAST index
point (Not the FAST1 front edge). See YouTube UT-PLdigs-34.0. at
https://youtu.be/k_BUA_Maook .

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Seam weld inspection process:
To inspect a pipeline longitudinal seam weld the following is a good way to get started:

1.
Do the mag of the weld first to find all the OD connected flaws. It is helpful to know where
those are because it will be less distracting when you see mode converted signals at those
spots.

2.
File down or power wire wheel or very lightly buff to remove the WCAMT paint from the areas
where you will be UT scanning. Anywhere you do FAST scanning should be nice and smooth so
you can get a nice smooth scan.

3.
Know the material thickness to figure out the set-back distance for your FAST scans.
[setback dist. = T * 2.75]

4.
Figure out where to put the guide to get a good set-back distance.

5.
Detect:
Do the scans from both sides. Scan the entire length without stopping to get the big picture.
Do both “butt up” and “set back” scans.
Re-scan and mark indication hot spots.
Characterize:
Determine if the reflectors are:
• OD connected, or
• ID connected, or
• Embedded, or
• ID gouge
Size:
Find the starts and stops of flaw lengths. Determine depth of flaw using OD sizing or ID sizing
techniques.

6.
If needed, verify indications from both sides by comparing surface distances.

7.
Use additional search units and angles to refine your sizing and characterizing. See YouTube
UT-PLdigs-35.0. at https://youtu.be/yARZRUhtsRw .

UT of Pipeline Digs 08/15/2018 Page 25 of 112

Types of longitudinal seam welds
Once you have detected, characterized and sized a seam flaw indication you must create
a flaw sketch for it. The flaw sketch must show the sizing measures of the flaw with no doubt
as to what you have decided is the correct sizing. The weld types that you are likely to
encounter for the seam welds of longitudinally welded pipe are:
• Double sub-arc weld
• Flash weld
• ERW (high frequency or low frequency)

See figures 32-40 for generalized sketches of cross sections of these seam weld types.
There is a very large variety of appearances for ERW welds. Figures 37-40 just shows three
types of appearances. Figure 40 shows a plan view of one type of ERW weld sometimes seen
to look like the Figure 39 cross sectional view. These ERW welds often have three different
types of MT indications as shown in Figure 40, 40A, 40B, and 40C:
• Arc burns from the welding contacts. These linear indications are curved, run along
parallel weld edges and usually can be ground out within 0.025” of the surface. See
figures 40 and 40A.
• Distinct, straight, but not very dark, linears, that could be any distance from centerline,
and usually don’t depth size easily. They are usually caused by hook flaws that may or
may not be actual breaks in the material, or just a different composition, causing the MT
permeability change type of mag indication. Hook flaws can be found in any ERW or
flash weld and are caused by inclusions or laminars in the plate that the welds were
made from. See figures 40 and 40B.
• Extremely dark, straight, centerline indications that can be depth sized well with many
different techniques and are usually found to be due to lack of fusion at the bond line.
See figures 40 and 40C.

Geometry
Geometric indications are due to the shape of the part. For example, the internal weld
reinforcement of a flash weld is a geometric indication. It is a real indication, but it is not a
flaw. See figure 34.
Sometimes ILI tools will find ID or OD geometry. It is not enough to report the word
“geometry” and then move on, like a ‘get-out-of-jail-free’ card in a game of Monopoly. You
should be able to show a sketch of the cause of the geometric indication. Some geometry is
thought to be bad and some not to be harmful at all.
The table below defines some characteristics of “good” and “bad” geometry. See also
figures 41-44.
ID Geometry
Good Bad
Seen with angle beam UT from Seen from both sides and plots to same
only one side surface distance location
Does not encroach on the pipe Does encroach on the pipe ligament
ligament
Has a notch-like or crack-like stress riser
whether it encroaches on the pipe
ligament or not

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Flaw Sketches
Each flaw that is reported for a seam must be described with a flaw sketch that leaves
no doubt as to what you have decided is the correct sizing. It is difficult to make a flaw sketch
that cannot be misinterpreted. This might require some practice.
Figure 45 shows examples of items that can be included in flaw sketches of ID or OD
connected hook flaws in flash welds. There are so many measurable items, and dotted lines
and arrows and labels that could go to them, that a flaw sketch can become difficult to
understand because of too much detail. Figure 46 shows the same type of flaw sketch as in
figure 45, but it is simplified to make it easier to interpret. All the quantities described in figure
45 can be found in figure 46.
Note that the items in figures 45 and 46 have some things in common:
• The ExtWH + T + IntWH = TW
• T = CD + RL
• TRL + TCD = TW
• If the IntWH cannot be physically measured because it is inside the pipe, it can be found
from knowing the Ext WH, T and TW with the following:

Int WH = TW – (Ext WH +T)

Note that if you submit a flaw sketch that does not conform with the above
relationships, it will put doubt into the whole sketch.
Flaw sketches may be drawn on the pipe next to the actual flaw location, drawn on
paper and scanned or drawn with Excel drawing tools. See figures 47-50 for examples of flaw
sketches. An approach sometimes used is to draw to scale, using a scale of ten to one. (If your
pipe is 0.300” thick, then draw the pipe thickness as 3.0” on the sketch.) If you have never
drawn a flaw sketch this is a good way to get started.

Seamless pipe
Some pipeline pipe is seamless. It is fabricated without longitudinal seam welds. These
pipe often:
• Have numerous shallow, irregular linear MT indications from laps
• The MT indications often have a spiral orientation, with all the indications spiraling
similar directions. See figures 51-53.
• Have inconsistent wall thicknesses that often have a very thin clock position and a very
thick clock position sometimes found 180° away from the thin clock position.
• The wall thickness can vary as much as plus or minus 0.060” from nominal.

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Seam weld inspection strategy with encoded prove-ups of detection, characterizing
and sizing

The preferred strategy for seam flaws that require encoded prove up is the following:
• Use the manual UT described here to detect, characterize and size all the flaws present.
• Use encoded phased array angle sector scans to show the detections and characterizing.
See example at figures 62-64.
• Use ToFD to prove-up the flaw height sizing. The ToFD shown here, twenty years in the
making, has been proven accurate and precise for T-nom as low as 0.188”. See
example figures 62, and 65-68.

6 dB flaw height sizing does not work.

We often find folks using a 6dB drop technique to do flaw height sizing. This does not
work. See YouTube UT-PLdigs-36.0. at https://youtu.be/EKyNyMzU1RM . By the way, 6 dB
flaw height sizing does not work with phased array sector scans either. See YouTube UT-
PLdigs-37.0. at https://youtu.be/ti--pVD9iu0.

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After this training session you should…
1. Know that once you have a good cal set up for your dual element straight beam that
you might never have to mess with the velocity on that cal again and be able to adjust it
when you need to with 'zero'.
2. Recognize the difference between the ‘walk’ of ID corrosion and the ‘walk’ of laminar
reflectors with your dual element straight beam.
3. Be able to use the orientation of the crosstalk barrier of your dual element straight beam
probe to help define ID geometry of thin walled seam welds.
4. Know that if you are working with extremely thin nominal pipe wall thicknesses you
should find out about getting a 10MHz dual element straight beam probe.
5. Know that if you are using a very high frequency straight beam probes, such as 10 or 15
MHz, that weld metal can give many tiny grain noise reflectors.
6. Be able to determine where a good scan line is located for a FAST UT of any given
thickness of pipe using the shortcut formula: Setback Dist = T X 2.75
7. Be able to establish your own cals on a different model instrument than you have now
for the 6 cals we normally use.
8. Recognize what a good FAST UT scan of both flawed and unflawed material looks like.
9. Be able to do tip diffraction depth measurement with a 45° and a 60° shear at a half
Vee or a full Vee.
10. Know how to walk the 70° over the top of an extremely deep planar flaw for ID
connected depth sizing.
11. Be able to do FAST-UT, ID and OD crack depth estimates on welds ground flush or as
welded.
12. Know that OD cracks less than 0.075” deep all peak up at the same place on your 1”
deep screen with the FAST OD depth sizing technique.
13. Be able to download a fresh set of cals to your instrument’s SD card and install them.
14. Know how to back up your cals using the instrument’s SD card and your laptop.
15. Know how to construct a weld flaw sketch for describing ID, OD, or midwall defects for
any type of weld.
16. Know how to use both the 45° and 60° together to decide if a planar flaw is midwall or
ID connected.
17. Know that generally speaking we don’t do flaw depth sizing by amplitude because too
many factors affect flaw reflectivity like orientation, shape and texture. However, for
very small ID connected planar flaws we sometimes use the amplitude of the 0.010” and
0.030” deep ID notches to help with sizing of very small ID flaws.
18. 6dB drop flaw height sizing does not work

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Terms, Definitions, Acronyms
(not in alphabetical order)

Anomaly An ILI indication of a flaw.

Indication A response from an NDE exam.

Flaw A discontinuity or interruption in the homogeneity of a material.

Defect A flaw that is unacceptable, a reject

Geometry An indication that is caused by the shape of the part, such as an inside

surface corner of a flash weld

ILI In Line Inspection

Detection The action or process of identifying the presence of a flaw.

Characterization Defining the nature of a flaw

* ID, OD, midwall

* LOF, hook flaw, crack (Not always possible)

Sizing Determining the measures of a flaw; length, height, location, orientation.

T1 The thickness of the pipe body base metal on the counterclockwise side
of the seam weld, when the pipe is viewed in the direction of flow.
T2 The thickness of the pipe body base metal on the clockwise side of
the seam weld, when the pipe is viewed in the direction of flow.
TW Weld thickness

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WW Weld width (normally the weld width as it appears visually) is
recorded, knowing that ERW weld seams for example, have a bond
line that is actually only about 1/32” wide.

WH Weld crown (or cap) height. Also known as Ext. WH (external weld
reinforcement height). When the ID is visible or measurable there can
also be Internal Weld Height or Int.W.H. If T1, T2, ExtWH and TW are
known, Int.WH can be calculated.

RL Remaining ligament. This is the through-wall thickness of pipe wall that is

not involved with ID or OD connected flaws.

FH Flaw height. Through-wall extent of a flaw.

Leg 1 Angle beam sound travel from the search unit to the pipe ID.

Leg 2 Angle beam sound travel bounced from the ID traveling to the OD

Leg 3 Angle beam sound travel bounced from the OD and traveling to the ID

Half Vee One leg of sound travel

Full Vee Two legs of sound travel

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 Vee-and-a-Half Three legs of sound travel

Half Skip Surface distance traveled by sound in leg 1

Full Skip Surface distance traveled by sound in legs 1 and 2

Skip-and-a-half Surface distance traveled by sound in leg 1, 2, and 3

ID connected A flaw that extends in the through thickness direction and is

connected to the inside surface.

OD connected A flaw that extends in the through thickness direction and

is connected to the outside surface.

Hook flaw An ERW or Flash weld seam flaw originating in mill defects within
the base material that get turned into curved shapes along flow
lines within the parts of the weld and heat affected zones that
undergo plastic flow. See Figs 36A&B.

Hook crack A hook flaw that is cracking open. It is often difficult or impossible

to ultrasonically distinguish a hook flaw from a hook crack.

LOF Lack of fusion.

Mill Defect A flaw in the pipe material from the original pipe manufacturing
process. Seam pipe made from plate can have plate rolling type
mill defects from the plate the pipe was made from.

Scanning Side to side search unit movement.

Rastoring Back and forth search unit movement.

Oscillating A skewing or swiveling of the search unit which can have elements
of rotational and/or orbital motion.

Rocking When performing a UT of a seam weld, the probe can rock back
and forth without changing radial position on a smaller diameter
pipe which can have a big effect on the amount of sound to the
search unit. These are the four possible ranges of motion a probe
is subject to: scanning, rastoring, oscillating and rocking.

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Amplitude Based Method Some industries employ ultrasonic inspection
acceptance standards that are based on the
amplitude (loudness in dB) of sound received from
reflectors. If the amplitude is too loud, it is a reject.
The UT described here is not amplitude based. The
objective here is to find where reflectors are located,
what the dimensions of the reflectors are, and what is
the orientations, shapes, and nature of the reflectors.

%FSH Percent Full Screen Height; the loudness of an indication

SDH Side Drilled Hole, a common calibration reflector

ToFD Time of Flight Tip Diffraction technique, is a two transducer,

pitch catch method of UT.

PCS Probe Center Separation, a key parameter for a ToFD setup, is

the distance between the search units.

L-wave A mode of sound travel also known as a compression wave.

Sound travels through material by displacing tiny particles
(molecules) of material in a direction parallel to the direction of
sound travel in alternating series of compression and rarefaction.
Straight beam UT is done with L-waves. FAST-UT uses high angle
refracted L-waves.

Shear wave A mode of sound travel also known as a transverse wave where
the particle motion is transverse to the direction of wave motion
and consists of particle motion in alternating directions. Most
conventional angle beam UT is done with shear. Shear travels at
about half the speed of L-waves in a given material.

FAST-UT Flaw Analysis and Sizing Technique. A high angle L-wave type of
angle beam UT. The primary sound is 70° L-wave but also
produces many additional modes of sound that increase the ways
ultrasound can interact, detect, and size different types of flaws.

DAC Distance Amplitude Curve. Indications from the same size reflector
at different angles or depths are made to be equal amplitude

TCG Time Corrected Gain. In a defined range of angles and depths all
reflectors of the same physical size are made equal amplitude.

KAPA Kiefner Associates Pipe Assessment program is a freely

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 downloadable program that can be used to assess wall loss (and
sometimes crack-like defects) for pipelines and can be found here:
http://kiefner.com/news/publications/

R-Streng A program which can be purchased from Technical Toolboxes that

also assesses wall loss for pipelines.

FMC-TFM Full Matrix Capture – Total Focus Method, an emerging phased

array method that ideally shows all depths in focus

IWEX Inverse Wave Extrapolation, a proprietary phased array method

from ApplusRTD, generates 3D views of weld volumes.

SSPC-SP10 A specification of surface preparation by the Society of Protective

Coatings. Essentially the same as NACE #2, “Near White Blast”.
Allows no more than stains on 5% of each 3” by 3” area.

90° The scanning directions are, by convention, for seam welds, called
“090° scans” when the sound is traveling clockwise when one is
looking in the direction of flow, and for a girth weld the sound is
traveling upstream. Conventions can vary between companies.

270° The scanning directions are, by convention, for seam welds, called
“270° scans” when the sound is traveling counter-clockwise when
one is looking in the direction of flow, and for a girth weld the
sound is traveling downstream.

A-scan An ultrasonic presentation with amplitude vs. time. The A-scan can
be fully rectified, which is normally used for manual angle beam
UT, or in RF format which is used in ToFD.

B-scan An ultrasonic presentation of depth vs index axis. B-scan and D-

scan are often reversed depending on the author and context.

D-scan An ultrasonic presentation of depth vs. scanning axis. B-scan and

D-scan are often reversed depending on the author and context.

C-scan Usually thought of as a plan view of the part with the vertical and
horizontal axes correlating with width and length of the part. In
Olympus Omniscan phased array sector scans, the “C-scan” is
angle (vertical axis) vs length (scan axis).

Sector scan A phased array ultrasonic presentation showing a range of angles,

UT of Pipeline Digs 08/15/2018 Page 34 of 112

 such as 40° to 75° shown at the same time. The vertical axis
usually representing depth and horizontal representing index axis
or the direction the sound is traveling towards. It is usually like a
cross section transverse through a weld. A sector scan can also
show a range of angles plus or minus from 0° which can be
thought of as being an enhanced form of straight beam UT.

Linear scan A phased array ultrasonic presentation showing the same angle
being used from a series of virtual probe positions. Also known as
an electronic scan or E-scan. This is sometimes used to attempt to
find reflectors using the only angle used by an ILI tool; 45° only.

DSAW Double SubArc Weld

ERW Electric Resistance Weld

WCAMT White contrast aid MT (magnetic particle test)

This training does not prepare you for everything you need to know to work a pipeline
integrity dig. This training material should help you prepare your UT skills. The actual step-by-
step instruction of how to conduct inspections at dig sites varies from client to client. Pipeline
operators all have their own unique requirements.
When you begin work in the field you should be getting detailed guidance from your
lead.

The material presented here is intended to supplement hands-on training conducted by an

experienced examiner. If you have any questions, contact the author anytime:

Jimmy Ellis
718-757-9464
[email protected]
[email protected]

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 [From PH Tool]

1 [From PH Tool] .

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 notch 4 side drilled holes notch

100 100 200 300 400 50

[0.500"]

0.5" thick FAST Model 1, side drilled hole cal block

12"L X 1"W X 0.5"thk

notches

[0.300"]
.210 .180 .150 .120 .090 .060 .030 .010

0.3" thick notch block .

12"L X 1"W X 0.3"thk

3
.

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 type manufacturer model # comments
GEIT FH2E
straight beam dual element 7.5MHz
Olympus Q3300873 7.5DS‐0.375‐0LW‐P‐1‐RP

straight beam for extemely thin  dual element, 10MHz, requires a unique 
walled pipe less than 0.210"  GEIT DA312 cable KBA 532, 083‐056‐906
Tnom Olympus PN DHC713‐RM dual element, 10MHz
pencil probe Olympus Sonopen V260‐SM 15MHz
GEIT MSWQC Benchmark 224‐591 5 MHz
shear wave transducer
Olympus C543SM 5 MHz, do not fit GEIT wedges well
Olympus Short approach ABSA‐4T‐45°
45° wedge
GEIT 118‐340‐295
Olympus Short approach ABSA‐4T‐60° these are all short approach wedges, helpful 
60° wedge
GEIT 118‐340‐296 for thin walled pipelines
Olympus Short approach ABSA‐4T‐70°
70° wedge
GEIT 118‐340‐297
made to produce 70° in SS, results in 74° in 
GEIT FAST‐Model1 CS, often helpful to sand down the angle a 
little
made to produce 70° in SS, results in 74° in 
CS, often helpful to sand down the angle a 
AT 25184
little, has more standing waves than the 
FAST‐UT Blatek
GEIT version
made to produce 70° in CS, has more 
AT 26393
standing waves than the GEIT version
longer ring time, less resolution, higher 
Sonatest Q‐Scan‐1 amplitude, less noise, very few standing 
waves.

When options are shown, they about equally good
4

UT of Pipeline Digs 08/15/2018 Page 38 of 112

receiver
sender
cross‐talk barrier

very thin material

footprint much thicker material

Above left: A dual element straight beam probe has a sending side and a
receiving side. Where the probe comes into contact with the material is called the
footprint.

Center: Taking a thickness reading on very thin material.

5 Right: Taking a thickness reading on much thicker material.

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For the thin material, for the first
back reflction, only a narrow strip
of sender (green) can talk to a
narrow strip of receiver (red).
The lateral edges of the sender
and receiver only contribute to
the second and other multiples of
the back reflection. Only a
narrow part of the center of the
probe right next to the cross-talk
barrier works for the first back
reflection.

For very thin material, you could

visualize that for the first back
reflection your "footprint" works
more like a skinny rectangle than
a circle.

For the thicker material, the entire sender (green) can talk to the entire receiver (red)
for the first back reflection.

Note also, that the angle the sound reflects at in the thin material is different than the
angle the sound reflects at in the thick material. This changing angle accounts for
some of the problems in getting a good thickness cal over an extremely large range of
thicknesses.
6

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7 .

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 RF rectification

8 .

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9 .

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10 .

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 Three formulas that can meet all your future trig needs are:
Three trig formulas can
1. 
do everything you would ever need in angle beam UT:
SP‐‐‐sound path
or
BP‐‐‐beam path
#1: or
angular dist
 =  T/cos

soundpath or
leg #1 length
or 2.  Surface dist  =  BP*sin
beampath 3.  Depth  =  BP*cos
or We almost never need to use these formulas.
angular distance
or
leg 1 length = T/cos

#2
Surface distance = soundpath * sin

#3
Depth = soundpath *cos

You won't need to memorize any trig formulas to do angle beam UT

11
.

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 45°

BP = T/cos45

BP = 1" / cos45

BP = 1" / 0.707

BP = 1.414"

OD

This is the length of the first leg of

1" deep 45°
sound with a 45° if your material was
1" thick.

ID
12

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 45°

80

60

Input 1.414 for the 40

screen range.

20

0 5 10

range = 1.414"

OD
45°
1" deep

ID
13

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 1" thk mini 
angle beam 
block

45° Now you have a one inch deep screen.

Shown here is one way to visualize it.
Zero on your screen is the sound entering
the material. The tenth major division on
your screen is at one inch of depth.

OD
45°

1" deep

ID
14

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 60°

BP = T/cos60

BP = 1" / cos60

BP = 1" / 0.5

BP = 2.000"

OD

60° This is the length of the first leg of

1" deep sound with a 60° if your material
was 1" thick.

ID
15

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 60°
80

60

Input 2.000 for the 40

screen range.

20

0 5 10

range = 2.000"

OD
60°
1" deep

ID
16

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 Now you have a one inch deep
60° screen. Shown here is one way
to visualize it. Zero on your
screen is the sound entering
the material. The tenth major
division on your screen is at
one inch of depth.

OD
60°

1" deep

ID
17

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 Surface distance
measurements with the 60

BP = T/cos60
The surface distance minus X-value above is 0.650" and this is
what you would want to read in your "surface distance minusX-
BP = 0.5" / cos60 value" reading box. You would do that by adjusting the X-value
in the instrument.

BP = 0.5" / 0.5 X‐value

BP = 1.000"

60°
60°
0.5"

1" deep
One inch of soundpath, half inch
thick block.
17B

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 70°

BP = T/cos70

BP = 1" / cos70

BP = 1" / 0.342

BP = 2.924"

OD

This is the length of the

70° first leg of sound with a
1" deep 70° if your material was
1" thick.

ID
18

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 70°

80

60

40
Input 2.924 for the
screen range.
20

0 5 10

range = 2.924"

1" deep

19

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 Now you have a one inch deep screen.
70° Shown here is one way to visualize it.
Zero on your screen is the sound entering
the material. The tenth major division on
your screen is at one inch of depth.

1" deep

20

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Tnom = 0.250" 1" deep screen 2.5" soundpathscreen ID@4 OD@8
(We use this.)

80 80 80
ID
60 60 60

45° 40

20
40

20
40

20 OD

0 5 10 0 5 10 0 5 10

Range = 1.414" Range = 2.500" Range = 0.884"

80 80 80

60°
60 60 60

40 40 40

20 20 20

0 5 10 0 5 10 0 5 10

Range = 2.000" Range = 2.500" Range = 1.250"

.
80 80 80

70°, 60 60 60

40

FAST
40 40

20 20 20

0 5 10 0 5 10 0 5 10

Range = 2.924" Range = 2.500" Range = 1.827"

ID & OD the same for all angles & don't
Advantages need new cals for new T-nom
You never change the range ID & OD the same for all angles

ID & OD at different place for every

Disadvantages Note the new ID and OD locations
angle and every different T-nom of Need new cals for every different T-
when you change thiickness nom of pipe
21 pipe

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 Soundpath 2.000"
(adjust velocity)

Soundpath 0.200" Soundpath 0.500"

(adjust zero) (adjust velocity)
Soundpath 1.000"
(adjust zero)

Depth 0.300"
(adjust zero)
0.300" deep

Depth 0.900"
(adjust velocity)

0.900" deep

For calibrating we usually use a process that involves adjusting "zero" at a short distance and velocity at a longer distance. "Zero" is called
"probe delay" in GEIT insturments. Examples of this for straight beam is shown above left, and for angle beam above, right.
To calibrate the 45°:
*First peak up on the corner trap reflector of the 0.150" deep ID notch at the end of leg 1, then adjust "zero" to make the depth reading box
read 0.300" depth. See middle figure above.
*Second, peak up on the same reflector at the end of leg 3, then adjust Velocity to make the depth reading box read 0.900", becuase to get to
it the sound will have traveled 0.900" in the up-and-down depth axis. See bottom figure.
22 *Repeat until no more adjusting needed.
.

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Summary of steps to set up the one inch deep shear wave cals.
45 deg 0.424
Use a screen range of 1.414"
80
‐x  varies
60 0.300
Peak up on the 0.150" deep ID notch at end of first leg
and use zero (probe delay) to bring depth reading to 0.300" deep 40

20

0 5 10
0.300"

Peak up on the same 0.150" deep ID notch at the end of leg three and use velocity to bring depth reading to 0.900" deep

1.272
80 ‐x  varies
0.300" 0.900
60

40

20

0 5 10

Repeat until end of leg one reads 0.300" deep and end of leg three reads 0.900" deep.

Re-position to check X-value.

Adjust X-value until the surface distance minus X-value reading box agrees with what you measure with your scale.

23A

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60 deg
Use a screen range of 2.000" and use the velocity found for the 45 deg.
Peak up on 1" radius of mini angle beam block and use zero (probe delay) 1.000
 to make it read 1.000" of soundpath in the soundpath reading box. 80
-X varies
0.500
60

40

20

0 5 10

Re‐position to check X‐value.
Adjust X‐value until the surface distance minus X‐value reading box agrees with what you measure with your scale.

1.000
In this case 0.650" -X 0.650
0.500

70 deg
Use a screen range of 2.924" and use the same velocity used for the 45 and 60. 80
0.877
Put the factory marked scribe line of the search unit on the mark for the 0.300" SDH of  ‐x  varies
the half inch thick FAST block.  Don't peak up. 60 0.300

40

20

0 5 10

Use zero (probe delay) to make it read 0.300" deep in the depth reading box.
Adjust X‐value until the surface distance minus X‐value reading box agrees with what you measure with your scale.

‐x  0.510
In this case 0.510"
23B

UT of Pipeline Digs 08/15/2018 Page 59 of 112

For OD crack depth sizing using tip diffraction (AATT) first peak up on the corner trap
signal as shown top, above. If you don't have a thickness input for your part, or have
a very thick number, the depth reading box will read 0.600" in depth because in
terms of depth (which is the up and down direction) the sound will have traveled
down 0.300" and then up o.300", for a total of "depth" travel of 0.600".

If you then push the probe forward you can peak up on the lower amplitude tip
signal. The tip signal will read 0.480" in the depth reading box because the sound
will have traveled down 0.300" and then up another 0.180".

0.300" + 0.180" = 0.480"

This would be 0.120" below the top surface at 0.600"

24 .

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 80

60

40

20

0 5 10

Walk of 0.090" deep tip for the 0.210" deep ID notch using 70° or FAST, which is also a 70°.

25
.

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 transducer producing straight beam
compression wave sound also known as L-
waves

Straight beam L-wave

STEEL Straight beam probes

produce compression
waves that go straight
down into the material.
Angled wedge is not used.

Straight beam, no wedge

If a plastic wedge with a

small angle is used, and
the velocity of sound in the
Plastic wedge plastic is much slower than
the velocity in the steel,
Refracted (angled) L-wave
some of the L-wave energy
will be refracted up. At the
STEEL
same time some of the
sound energy will be
refracted up as a shear
wave. Because the shear
wave travels at about half
the speed of the L-wave, it
will be refracted up about

Small plastic wedge Refracted shear wave

half as much as the L-
wave. This is the situation
that a FAST probe operates
in. See more detailed
views of this for a FAST
probe in Figures 27A, 27B,
and 27C, after reviewing
26A figures 26A and 26B. .

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 Angled L-wave
If the wedge angle is
increased enough, it will
reach an angle called The
STEEL First Critical Angle, where
the L-wave is refracted to
at least 90° and only the

First Critical Angle Refracted shear wave

shear wave is left to
refract in the steel.

Wedge angles between the

First and Second Critical
Angle will result in only
refracted shear waves in
STEEL
70° the steel. This is the
Only Refracted shear waves 60° 45° situation for conventional
shear wave UT, using
refracted angles typically
at 45°, 60°, and 70°.

Angles between First and Second Critical Angle

Wedge angles higher than

the second critical angle
STEEL
result in all the sound
being internally reflected
26B Surface wave inside the wedge.

Second Critical Angle

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 70 ° Angled L-wave

FAST

STEEL

In Figure 26B, bottom, the arrangement to produce angled L-wave is shown. Here, that is shown
with a search unit that looks like a FAST transducer.

This is a simplified view of a FAST search unit. We want to focus most of our attention on the main
sound coming out of the probe which is a 70° high angle L-wave.

This is not the only mode of sound that is produced. There are several others, shown in the next two
figures. Try to keep in mind that this is the mode of sound that you want to be working with most of
the time. This is the mode of sound that your UT setup will be calibrated for. This is the only mode of
sound that you can use for taking measurements and the only mode of sound that has meaningful
trig numbers in your instrument's reading boxes.

Be aware of the other modes of sound. They are very useful to observe in a qualitative sense, but this
is the sound mode you want to be looking for and working with most of the time.
27A
.

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 70 ° Angled L-wave

FAST

STEEL

70°

Any high angle L-wave probe has refracted L-wave and refracted shear wave coming out of it, as we
showed in figure 26A, bottom. There are actually many modes and combinations of modes of sound
coming out of a high angle L-wave probes.

L-waves travel faster than any other mode of sound.

See the next figure for identification of all these theoretical modes of sound.

27B
.

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 70 ° Angled L-wave OD creeper

FAST
shear, mode converted from
L-wave reflected shear
STEEL

70°

L-wave, mode converted from

shear
shear

reflected L-wave ID creeper

Sound modes and mode combinations theoretically produced by the high angle L-wave probe are
identified above.

Creeper wave modes are theoretically generated by the intereaction of the shear mode with a surface,
travel at about the speed of an L-wave, but only travel a very short distance before attenuating to
nothing.

Although we are aware of, and can see the affects of these other modes, and combinations of modes of
sound, we are normally only attempting to identify the main 70° L-wave sound.
27C
.

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 notch FAST notch

50 400 300 200 100 100

[0.500"]

SDH SDH SDH SDH

4th major  3rd major  2nd major  1st major 

div div div div

FAST
notch notch

100 100 200 300 400 50

[0.500"]

SDH SDH SDH FAST SDH

1st major  2nd major  3rd major  4th major 
div div div div

The setup for the FAST cal is done by putting the index point on the marker for the 0.300" deep SDH,
then adjusting "zero" until you see 0.300" deep in the depth reading box.

You can do this on either side of the block, as shown above. Be sure you are pointing the sound
towards the 0.300" deep SDH.
28
.

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 notch FAST FAST FAST FAST notch

50 400 300 200 100 100

[0.500"]

SDH SDH SDH SDH

4th major  3rd major  2nd major  1st major 

div div div div

FAST FAST FAST FAST

notch notch

100 100 200 300 400 50

[0.500"]

SDH SDH SDH FAST SDH

1st major  2nd major  3rd major  4th major 
div div div div

The first check of your FAST cal is to put the index point on each of the four marks for the four SDHs. These marks
are positioned on the block to send 70° sound directly to it's SDH.

You can do this on either side of the block as shown above and below.

29 Each side drilled hole should result in an indication very near the 1st, 2nd, 3rd and 4th major divisions on your A-scan
display and the depth reading box should read near 0.100", 0.200", 0.300" and 0.400". .

UT of Pipeline Digs 08/15/2018 Page 68 of 112

 80

60

40

20

0 5 10

Walk of 0.090" deep tip for the 0.210" deep ID notch using 70° or FAST, which is also a 70°.

30
.

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 80

RL:

60
90

120

150

180
40
210

240

270

290
20

0 5 10

Walks of all the ID notches using FAST.

31

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Double SubArc Weld The abbreviations at left are for typical
measures of welds:

T1 Pipe thickness on the counter

Ext WH clockwise side of the seam.

T1 TW
T2 Pipe thickness on the
T2 clockwise side of the seam.

Int WH TW Weld thickness

WW WW Weld width

ExtWH External reinforcement height

Above; cross-section of a typical Double SubArc weld. These welds are quite wide
and quite thick. IntWH Internal reinforcement height
Below; a view from the outside of a pipe with a double subarc weld that is quite
wide. The scale showing inches in tenths shows that this weld is 0.75" wide. Also
shown is a FAST1 probe being held-frozen as a surface distance measurement is For T-nom of 0.250" a typical double
being taken. See the next page for a view of the inside of this weld. subarc seam weld might measure (mils)
as:

T1 250
T2 245
TW 500
WW 625
ExtWH 125
DSAW
IntWH 125
weld
toes.
Note:
If you measure T1, T2 and TW with UT,
and you measure ExtWH with a scale,
then you can calculate the IntWH:

32 IntWH = TW - (ExtWH + T1)

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Double SubArc Weld

20" X 0.281"

Closer and closer views of the

inside of the DSAW weld
shown on the previous page.
The black scale is in tenths of
inches which shows that this
DSAW weld is even wider on
the inside than it was on the
outside: about 0.9" wide. The
closest view at left shows an
inside undercut. The yellow
engineers tape is in decimal
feet.
33
.

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Flash Weld For T-nom of 0.250" a typical flash weld
seam weld might measure (mils) as:

T1 250
Ext WH
T2 245
T1 TW T2
TW 390
WW 250
ExtWH 75
Int WH
IntWH 65

WW
Note:
If you measure T1, T2 and TW with UT,
Above; cross-section of a typical flash weld. These welds have lots of geometry and you measure ExtWH with a scale,
reflectors. There are four corner trap refelctors; one at the ID and one at the OD then you can calculate the IntWH:
from each side.

Below, left; a flash weld. Below, right; cross-sectional end view of the near end IntWH = TW - (ExtWH + T1)
shown at left. There is HiLo present in this joint.

34
.

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ERW Weld For T-nom of 0.250" one possible ERW
weld seam might measure (mils) as:

T1 250
Ext WH
T2 245
T1 TW T2
TW 260
WW 300
ExtWH 0
Int WH
IntWH 10

WW
Note:
The actual weld itself, in both a Flash
Above; cross-section of a typical ERW weld. Actually, ERW welds have many, many weld and an ERW weld, is a narrow bond
typical cross sections. Sometimes there is external reinforcement. The root can be line of melt, about 1/32" wide. In a
convex, as shown above, or can be concave, or a combination. There are tools that good weld, the melt gets completely
"scrape" the weld close to flush with the base metal and these tools can leave squeezed out of the joint. The area that
many types of profiles; flush, concave, convex or combinations on both the ID and visually appears to be weld is the area
the OD. that undergoes plastic flow during the
time the joint is squeezed together like
Below; an ERW seam weld similar to figure 39 and 40. Zoomed in at right. a forging.

ERW "weld toes"

35

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 At left a typical setup for ERW (electric resitance
weld) longitudinal seam welding. The pipe starts out
as a piece of plate which is curved into a pipe shape
and then welded along the joint. Alternating electric
current travels between the contacts along the
shortest path of the surface skin to heat the joint to
melting and near melting and then the joint is
squeezed together at the pressure rollers. The
squeezing action jams to the two sides together with
forging type action causing plastic flow and joining
of the two members.
Below:
plastic flow during squeezing/forging/welding

after welding/squeezing/forging
before welding before trimming after trimming

plastic
bond flow
line lines

laminar flaw before welding

The final profile shape
depends on the types of
squeeze action laminar flaw after welding trim tools used. See UT
becomes a hook flaw results in Fig 36B.
36A .

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Near ID hook flaw
With angle beam UT a
near ID hook flaw will
be near the end of leg
one from one side,
and the beginning of
leg two from the
other side.

important

Near OD hook flaw

With angle beam UT a

near OD hook flaw
will be near the
beginning of leg one
from one side, and
the end of leg two
from the other side.

36B .

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37

Here and
above;
different types
of ERW welds

38
.

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 At left, another type of
appearance of an ERW
weld. This is a cross
section. Below is a plan
view of this type of weld
with different types of MT
indications often seen.

39

.
Lack of fusion; very
Hook flaws; light, distinct, parrallel,
Irregular curvy linear dark, straight, and
often offset from centerline/bondline.
indications. Contact marks depth size well with
Come and go in different places if you
or arc burns from welding many types of UT
attempt to remove by grinding. Difficult
40 contacts. See figure 40A. sizing. See fig 40C.
to depth size. See figure 40B.
.

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 At left: Irregular curvy linear MT indications of
contact marks or arc burns from welding
contacts. In this case they are mainly found on
one side of the weld at what visually looks like
the weld toe. Closer view zoomed in below.

40A
.

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 Above left; ERW seam weld
with linear MT indications that
look like hook flaws. There are
many parrallel lines that don't ERW "weld toes"
line up with each other. Below
closer view of the linear MT
indications.

40B
.

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 ERW "weld toes"

When linear MT indicatons near the center of what visually looks

like the ERW seam result in very dark MT indications, which could
be Lack of Fusion, they can often be depth sized very well with
many different UT techniques;

*FAST OD depth sizing technique .

*Shear wave tip sizing at the end of leg 2
*phased array sector scans
*phased array linear scans

Above left, an ERW seam weld. Above right, zoomed in view.

40C
.

UT of Pipeline Digs 08/15/2018 Page 81 of 112

 An example of
a seam weld
profile that
could cause a
geometric
reflector.

41

An example of
a seam weld
.
profile that
could cause a
geometric
reflector.
42
.

UT of Pipeline Digs 08/15/2018 Page 82 of 112

 An example of
a seam weld
profile that
could cause a
geometric
reflector.

43

An example of
a seam weld
profile that
.
could cause a
geometric
reflector.

44
.

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 intentionally blank

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45
.

UT of Pipeline Digs 08/15/2018 Page 85 of 112

46
.

UT of Pipeline Digs 08/15/2018 Page 86 of 112

 Detailed job information
was shown here.

ERW seam weld

A flaw sketch drawn on the pipe surface right next to the flaw
location. The sketch on the right shows the axial location of flaw
Engineers #20; starting at 18.13' and ending at 18.30'.
tape in
decimal feet. The sketch at center is the flaw sketch cross section. It is a
midwall hook flaw.
TW = 0.230"
T = 0.210"
47 FH = 0.060"
RL = 0.120" .

UT of Pipeline Digs 08/15/2018 Page 87 of 112

 Detailed job information was shown
here.

Above is a flaw sketch for an ERW seam weld drawn on the pipe next to the flaw location that had
two flaws in the same spot; an OD connected hook flaw and an ID connected hook flaw. This work
was done in Canada so everything is measured in millimeters (mm).

OD connected: ID connected:

TW = 4.57mm TW = 4.57mm
T = 4.04mm T = 4.04mm
FH = 0.25mm FH = 0.91mm
TFH = 1.44mm
RL = 3.13mm
48
The lengths of these flaws were both also UT sized and reported. .

UT of Pipeline Digs 08/15/2018 Page 88 of 112

 49

Above is a flaw sketch for an ERW seam weld that had an ID

connected hook flaw. The flaw sketch was drawn on the pipe next
to the flaw location.

TW = 0.220"
T = 0.210"
FH = 0.087"
RL = 0.133"
49
.

UT of Pipeline Digs 08/15/2018 Page 89 of 112

 ERW seam weld

Detailed job
information
was shown
here.

Above is a flaw sketch for an ERW seam weld that had an ID connected
hook flaw. The flaw sketch was drawn on the pipe next to the flaw
location.

TW = 0.190"
T = 0.200"
FH = 0.020"
RL = 0.170"

flaw start = 21.72'

50 flaw end = 22.38' .

UT of Pipeline Digs 08/15/2018 Page 90 of 112

 job info

Seamless pipe. Linear MT

indication spiraling around the
pipe at a low angle. Closer view
at right.
51
.

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 Seamless pipe. Linear MT indication
spiraling around the pipe at a high angle
and in an axial orientation. See closer view
next page.

52
.

UT of Pipeline Digs 08/15/2018 Page 92 of 112

Seamless pipe.
Linear MT indications
spiraling around the
pipe at a high angle
and others parrallel
with the pipe axis.

53
.

UT of Pipeline Digs 08/15/2018 Page 93 of 112

Double SubArc Weld (generic flaw sketch)
TW
54
Ext WH

T1
T2

Int WH

name: _________ WW
specimen: ______
TW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________ T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
ExtWH External reinforcenent height
TW = _____________ IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.
ExtWH = __________
Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).
IntWH = __________
Provide the following measures:
RL = _____________ RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent
.

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Flash Weld (generic flaw sketch)

TW

Ext WH

T1 T2

Int WH
55

name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

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ERW weld, example 1 (generic flaw sketch)
TW

Ext WH

T1 T2

Int WH
56
TW
name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

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ERW weld, example 2 (generic flaw sketch)
TW

Ext WH

T1 T2

Int WH
57 (depth of concavity)
TW
name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

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ERW weld, example 3 (generic flaw sketch)
TW

Ext WH

T1 T2

Int WH
58 (weld flush with ID)
TW
name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

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ERW weld, example 4 (generic flaw sketch)
TW

Ext WH

T1 T2

Int WH
59
TW
name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

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ERW weld, example 5 (generic flaw sketch)
TW

Ext WH

T1 T2

Int WH
60 (depth of concavity)
TW
name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

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ERW weld, example 5 (generic flaw sketch)
TW

Ext WH

T1 T2

Int WH
61 (weld flush with ID)
TW
name: _________
specimen: ______ WW
flaw #: ______
Cross-sectional view of weld looking in the direction of flow.
T1 = ____________
T1 Pipe thickness on the counter-clockwise side of the seam.
T2 Pipe thickness on the clockwise side of the seam.
T2 = _____________ TW Weld thickness
WW Weld width
TW = _____________ ExtWH External reinforcenent height
IntWH Internal reinforcement height

WW = ____________ Draw the flaw into the Flaw Sketch.

ExtWH = __________ Clearly show where the flaw is located in regard to T1, Weld, or T2; the side to side circumferential position.

Clearly show if the flaw is ID connected, OD connected or midwall (not ID or OD connected).

IntWH = __________
Provide the following measures:
RL = _____________
RL Remaining Ligament above the flaw. The distance from the top of the flaw to the OD. For an OD
connected flaw RL = 0 (zero)
FH = _____________
FH Flaw Height; through-wall extent

UT of Pipeline Digs 08/15/2018 Page 101 of 112

 Flaw sketch for an ERW seam flaw that was detected,
characterized and sized using the manual techniques
described here.

The following figures show how this flaw was proved-up

with encoded scans. The PAUT sector scans showed the
detections and characterizing. The ToFD scans proved
up the flaw height sizing.

62
.

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 Angle beam sector scan for the flaw shown in fig 62 with the sound traveling
circumferentially in the pipe in the clockwise direction when looking in the direction of
flow.

63
.

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 Angle beam sector scan for the flaw shown in fig 62 with the sound traveling
circumferentially in the pipe in the counter-clockwise direction when looking in the
direction of flow.

64
.

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 Flaw length sizing from ToFD is bounded by the vertical red and green lines. Initial flaw height
sizing is shown in this non-parrallel scan by the horizontal red and green lines.

65
.

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 This is the same snip as shown in the previous page, but the cursors are removed so that more
detail in the ToFD scan can be observed.

66
.

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 This is a parrallel ToFD scan at the deepest part of the flaw. The two arcs are offset from each
other horizontally due to the fact that this flaw was an angled flaw. The through-wall flaw
height sizing is shown by the horizontal red and green cursors. The depth from the OD to the
top of the flaw is 0.151" and the flaw height is 0.091".

67
.

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 This is the same parrallel scan shown in the previous snip, but the cursors are removed
so that more detail in the scan can be observed.

68
.

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 YouTube subject link minutes:seconds
1 UT‐PLdigs‐1.0 Familiarization with menus in a flaw detector https://youtu.be/LHI8o9HZ6sc 24:29
2 UT‐PLdigs‐2.0 Math review https://youtu.be/HgMEDzGzef0 8:33
3 UT‐PLdigs‐3.0 Straight beam calibration https://youtu.be/zhWHJ9NY0VY 8:28
4 UT‐PLdigs‐4.0 Use of crosstalk barrier orientation during straight beam exams https://youtu.be/h8Dp9PRoCxQ 6:17
5 UT‐PLdigs‐5.0 Types of A‐scan rectification https://youtu.be/sh91‐gjvkfY 3:30

https://youtu.be/yF9_lMSfUgY
6 UT‐PLdigs‐6.0 Contrasting straight beam scans of laminars and internal corrosion 3:49
7 UT‐PLdigs‐7.0 Sonopen calibration https://youtu.be/4WMUxyXBamc 9:28
8 UT‐PLdigs‐8.0 ID roll and OD roll recognition https://youtu.be/LI7NdtvL6cU 1:57
9 UT‐PLdigs‐9.0 Screen ranges needed for one inch deep angle beam screens https://youtu.be/e1emu_jb7SA 9:56
10 UT‐PLdigs‐10.0 Trigonometry background info https://youtu.be/aNPTRbjHrYs 5:06
11 UT‐PLdigs‐11.0 45° shear cal https://youtu.be/7p2aa75G0vA 11:08
12 UT‐PLdigs‐12.0 45° shear measures https://youtu.be/yrap5eZhWzo 3:31
13 UT‐PLdigs‐13.0 45° shear surface distance minus X‐value https://youtu.be/0XVJ0XhnaCA 3:09
14 UT‐PLdigs‐14.0 45° shear RATT (Relative Arrival Time Technique) https://youtu.be/tiXch‐7TUhc 7:57
15 UT‐PLdigs‐15.0 45° shear AATT (Absolute Arrival Time Technique) https://youtu.be/Gcc3CX2DsTc 12:21
45° shear AATT (Absolute Arrival Time Technique) 
https://youtu.be/yt_EMyf7CW0
16 UT‐PLdigs‐16.0 for OD flaws 14:31
17 UT‐PLdigs‐17.0 60° shear cal https://youtu.be/GAOwTKFAiMM 10:56
18 UT‐PLdigs‐18.0 60° shear cal; why the corner trap does not peak up at the ID https://youtu.be/KU8ui6ygpdk 3:04
19 UT‐PLdigs‐19.0 60° shear AATT (Absolute Arrival Time Technique) https://youtu.be/1YtQyHoOunk 19:51
70° shear cal and surface distance measures instead of traditional 
https://youtu.be/cLztGCpKSqI
20 UT‐PLdigs‐20.0 indication plotting 13:33
21 UT‐PLdigs‐21.0 70° shear, walking over the top of extremely deep planar flaws https://youtu.be/xS7hYl3sUvA 5:57
22 UT‐PLdigs‐22.0 comparision of echo dynamics of 45°, 60°, and 70° https://youtu.be/NyWnq2ut‐Jo 15:24
23 UT‐PLdigs‐23.0 FAST cal setup https://youtu.be/2Vgic9HbHjQ 5:07
24 UT‐PLdigs‐24.0 FAST UT of side drilled holes https://youtu.be/ZMbrubjRA6A 5:10
25 UT‐PLdigs‐25.0 FAST cal surface distance minus X‐value https://youtu.be/DKh4jeb9TrI 3:59

UT of Pipeline Digs 08/15/2018 Page 109 of 112

 YouTube subject link minutes:seconds
26 UT‐PLdigs‐26.0 FAST OD depth sizing https://youtu.be/uhlH7tLeIuU 15:55
27 UT‐PLdigs‐27.0 FAST OD depth sizing when obstructed by weld caps https://youtu.be/wdsU7QoNQAg 6:47
28 UT‐PLdigs‐28.0 FAST ID depth sizing https://youtu.be/6yO6QsOlaB0 13:47
29 UT‐PLdigs‐29.0 FAST signal recognition of ID or OD connected, and midwall flaws https://youtu.be/iJCyM4JYBQs 7:37
30 UT‐PLdigs‐30.0 Determining ID connection with 45° and 60° https://youtu.be/vArida02D5E 8:37
31 UT‐PLdigs‐31.0 Theoretical measurement of gaps under midwall flaws https://youtu.be/6rkB_XSpjcg 2:59
Verification of ID connected flaws with FAST surface distance 
https://youtu.be/vsaM8EcBvt8
32 UT‐PLdigs‐32.0 measures 5:01
33 UT‐PLdigs‐33.0 Recognition of ID gouges with FAST https://youtu.be/zMAOAgtxbAM 3:44
34 UT‐PLdigs‐34.0 Establishing scan lines https://youtu.be/k_BUA_Maook 5:34
35 UT‐PLdigs‐35.0 FAST scans of seams and flaws https://youtu.be/yARZRUhtsRw 25:05
36 UT‐PLdigs‐36.0 6dB drop flaw height sizing still does not work https://youtu.be/EKyNyMzU1RM 15:14
37 UT‐PLdigs‐37.0 6dB drop flaw height sizing does not work with PAUT either https://youtu.be/ti‐‐pVD9iu0 11:48
total
5 hrs 37 min 19 sec

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 5MHz
FH2E sonopen shear FAST1 other settings & info
USM GO spike/SQ SQ SQ SQ SQ
freq. 5 15 5 5
volt. 300 120 300 300
energy/width 70ns 40ns 100ns 100ns
damp 50 50 50 50 echo max on
scheme 3 grid 2

dB step/auto80, freeze/env (during training)
dB step/auto80, freeze/recall dataset (after training)

reset: two outers, hold & turn on
op sys upgrade, new SDU: top inner + btm outer
plastic screen protector from B&N "Nook"….$25 apply windex, stick on, dry 
overnight.
If surface distance minus X value is too great, add to the X value.
EPOCH spike/SQ SQ SQ SQ SQ
600 freq. cal files
7.5 15 5 5
open‐select‐open…..open‐select‐contents‐recall
 2‐21  8‐26 1.5‐8.5 1.5‐8.5
filt.
P3: create & save
volt. 400 100 400 400
edge/pos/hi pk     or:
damp. 50 50 50 50 (for angle beam could be peak/dual)
baseline off
to re‐set: file/manage/reset/
mini SD card from Verizon store (not SDXC, not SDHC)

USN52L freq.  3‐10  3‐10  2‐8  2‐8

damp. 50 50 50 50

re‐set: copy+on
deep re‐set: freeze+home+on for 20 sec (all files will erase)

for longer battery life replace NiCads with
NiMH, 10,000Ah, keep battery pack switch set to NiCad, use only 
NiMH chargers, don't charge in instr
Omniscan 
PC PE PE PC
SX TxRx
freq. 7.5 15 5 5
energy (v) 95 95 340 340
PW (ns) Auto Auto Auto Auto
AcqRate Optimum Optimum Optimum Optimum
Filter BP 8 MHz BP 12 MHz BP 5 MHz LP 10 MHz
Video Filter off off off off
Averaging 1 1 1 1
Points Auto Auto Auto Auto
1st Peak, 1st Peak, 1st Peak, 1st Peak,
GateMode edge edge edge edge

timed timed timed timed

Scan
Phasor
10 brdbnd 5 brdbnd
XS freq.
volt. high low high high
energy high low high high
damp. 50 50 50 50

69 your settings may be different

UT of Pipeline Digs 08/15/2018 Page 111 of 112

 Summary of steps for 
FAST OD sizing
performing FAST‐UT of a seam 
weld:
dB _______
OD notch %  FSH depth reading 1.
0.010" Know your pipe thickness, T.  
0.030" The setback scan lines are at 
T*2.75
0.050"
0.060"     < 0.075"
2.
0.090"     > 0.075" Perform FAST scans from both 
0.100" sides, from both butt‐up and 
0.120" setback.  Mark the hot spots.  
do OD sizing from the louder side of the weld Real flaws are seen to some 
degree from both sides.

3.
FAST embedded flaw sizing with SDHs Characterize the flaw as ID, OD, 
midwall or ID gouge.
dB ______
4.
SDH 0.100 0.200 0.300 0.400 For ID connected flaws; from 
each side, verify the signal 
depth walks like a high angle L‐wave 
reading and then walk the L‐wave 
signal to the ID and check 
surface distance plot.  It should 
plot to the same point on the 
FAST ID sizing  ‐‐  0.3" thk notched block surface from both sides.
dB ______
remaining  FAST‐UT 5.
notch depth ligament depth %FSH Do FAST ID or OD depth sizing.
0.010" 0.290"
0.030" 0.270"
0.060" 0.240"
0.090" 0.210"
0.120" 0.180"
0.150" 0.150"
0.180" 0.120"
FAST‐UT basics:
0.210" 0.090"
70 deg L has a long walk and is the last one 
Do the ID depth sizing from the side where you up when you pull way back

walk over the top of the flaw at furthest point Flaws are seen from both sides
towards the left on the screen. Surface distances plot good
It might not be the loudest spot. Planar flaws have a lot of mode converted 
signals

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