Shantou Institute of Ultrasonic Instruments Co., Ltd.

Automated Ultrasonic Testing

(AUT)

2022.01
 CONTENT

PART 01 PART 02 PART 03 PART 04 PART 05

Background Technical Overview of Process Field

Principle AUT System Assessment Application
 1.Background

Automatic welding has the advantages of good weld mechanical

properties, high welding efficiency, fewer welding defects, and data
collection of welding parameters. It is widely used in the welding of pipes
with large diameter and thickness.

The applied wall thickness range is 6~50mm, and the pipe diameter is
greater than 500mm.
Common Grooves

Compound grooves
The pipe automatic welding adopts narrow-gap groove for welding, which can greatly
reduce the filling amount of welding materials, reduce the swing width of the welding
torch, increase the swing frequency of the welding torch, and improve the welding
efficiency.

The main welding defect is non-fusion, and there are other defects such as incomplete
penetration, porosity and cracks.
 2. Technical Principle

AUT (Automated Ultrasonic Testing), the core principle is the "partition/zone

scanning method", which is to divide the weld into several partitions in the
vertical direction (each zone covers about 2-3mm), using complex beam
parameter settings to scan one circle along the circumference of the weld
from both sides of the weld, so to complete the testing of the entire weld and
heat-affected zone. TOFD and B-scan techniques are for auxiliary testing.
Multiple Probes and Phased Array Testing
Zones

Conventional Multiple
Probes method

The overall structure of the

probe is too large to set up
process parameters of the
instrument and difficult for
calibration.

PA Probe
Phased Array Method

No change in the principle

of partition.
No change in the physical
position of the probe.
Changes in the beam
focusing position and angle.
 Zone：Fusion + Volumetric

Coupling
Monitor
Zones
Up Side

Down Side
Fusion(US) Volumetric(US) Volumetric(DS) Fusion(DS)

A scan B scan TOFD B scan A scan

 Focusing Law

The AUT probe can emit thousands of focusing laws, adopts the partition
method, sets the testing plan of the fusion zone according to the non-
fused groove, and is supplemented by the volume channel and B-scan to
effectively judge the volume defects, and can be used for testing surface
defects and hidden defects in girth welds of long-distance pipeline. No
blind zone of ultrasonic testing.
 Focusing Law of Fusion Zone

Cap (60°) Fill Are（45°~50°）

Thermal welding (45°) Root face (60°) Root (52.5°)

Focusing Law of Volumetric Zone
(Non-focusing, 45°)
 Focusing Law of Coupling Channel
The coupling channel is tested on the comparison test block, with pitch-catch, pulse-
echo or the combined plan available. The coupling channel shall include all crystals, and
the number of excited crystals used in each coupling channel shall not be greater than
20. The coupling gate thresh shall be set 40% FSH (full screen height).

Pulse-echo (0°)
 Focusing Law of Fusion Zone

 When the strip chart is set, there is a gate, which is divided into
amplitude gate and time gate.
 The amplitude gate signal is displayed as an A-scan envelope.
 The time gate signal is displayed as color rank in the strip chart.
 Where the color of the color rank indicates the amplitude of the signal
in the time gate, Green for 20%-40%, Red for 40%-70%,
Yellow for 70%-90%, and Red for over 90%.
 The length of the color rank indicates the position where the
maximum amplitude signal in the time gate appears in the gate.
Focusing Law of Volumetric Zone(B scan)

The width range of the gate is the display width of B-scan.

 Feature of AUT System
 The AUT system can better detect incomplete-fusion equal-area defects that
are highly harmful in automatic welding.
 The AUT system can quantify defects such as incomplete fusion, incomplete
penetration and cracks, such as its own height.
 The AUT system can detect the weld a few minutes after the completion of the
welding, achieving process control and improving the first pass rate and reduce
costs.

POD Comparison for 5 Qualification welds

100%
90%
80%
70%
60%
% POD 50%
40%
30%
20%
10% AUT
0%
AUT RT NDT Method
1 2 MUT
RT 3 4
MUT Weld # 5

AUT has the highest detection rate so far after comparing

the detection rates of the three testing methods.
 3. Introduction of AUT system
5
3
6
4 2

The AUT testing system is specially for single-plane double-sided

ultrasonic testing of automated weld joints of oil and gas pipelines. The
system consists of 6 components:
1. Ultrasonic module 2. Laptop (including testing software)
3. Automated crawler (including remote control) 4. Guide rail
5. Automatic irrigation device 6. Probes and wedges
 AUT system（Alpha-02/03）

Split Alpha-02 Integrated Alpha-03

The AUT testing system is designed with two models: split Alpha-02 and integrated Alpha-03.

The Syncscan32PT, which is the same configuration as the long-distance pipeline PAUT, is for ultrasonic
acquisition. It is connected to the crawler through a 6M cable and wirelessly connected to a laptop. It has rich
functions of a PA instrument, not only for AUT testing, but also for the PAUT solution of long-distance
pipelines, or can be expanded to other PA solution.

The integrated ultrasonic module is built in the automated crawler, designed in a small black box with a single
function for use. The ultrasonic module is built in the crawler that surrounds the pipeline, and the collected
data is wirelessly transmitted to the laptop. This configuration is dedicated for AUT testing, with small size
and light weight, and achieves wireless control and data transmission.
 3.1 AUT software:
Workpiece simulation and automatic partitioning
 The workpiece is designed for the narrow-gap
groove for pipe automated welding. The user can
quickly simulate the workpiece in real time. The
diagram is simple and easy to understand, and
the common groove types are preset for AUT.

 After the workpiece simulation, the software will

automatically partition the workpiece in the weld
height direction according to SYT 4112-2017 and
other relevant standards.
Workpiece Groove Simulation
 In addition to the workpiece modeling and
partition information, the software can also
accurately simulate the position information such
as the depth of many reflectors on the AUT
comparison test block to achieve a high degree
of consistency between the comparison test
block drawing and the software simulation, which
is prepared for AUT "high precision" detection.

Automatic Partition
 Process Parameter Setting

Editing Probe & Wedge

Information

Automatic process Setup and Beam Simulation

 The system will default to the best probe and wedge plan according to the simulated workpiece,
partition and reflector information, and automatically recommend and simulate the focal law
settings of dozens of channels in compliance with the requirements, saving user time to
manually set the process.
 Supporting offline creation of settings, that is, settings can be created without on site. Process
setting parameter files can be saved and sent to any job site via the network, where the operator
only needs to calibrate the system before starting the job.
 Calibration & Debugging

 A view is designed with dual gate of time and amplitude. After the gate covers the weld in the
simulation diagram, the echo in the gate of A view shall be the reflected echo of the reflector at
the weld position. During calibration, the user can quickly lock the reflector echo on the
comparative test block.
 The peak memory helps the user to better locate the maximum echo position of the reflector.
 R view provides a real-time simulation when calibrating and adjusting the process.
 One-button sensitivity and delay calibration.
 Provide A-scan amplitude envelope to help users determine whether the amplitude of adjacent
reflectors comply with -6 ~ -24dB coverage.
 Automatic Monitoring of Calibration Results and
One-Key Calibration

 As required by the standard GBT 50818-2013:

1. The peak signal of the reflector shall reach 80% FSH,
and the sensitivity shall be 70%~99% when re-tested.
2. The LW of TOFD is 40%~90%FSH.
3. When the wave amplitude of the main reflector
reaches
80% of the full screen, the coverage
wave height (up and down coverage) of the
One-Key Sensitivity &Delay Calibration
adjacent reflectors on both sides shall be 5~40%.

 The software can automatically measure the calibration

image of multiple channels at the same time with one key,
automatically obtain the main amplitude of each channel,
its adjacent reflector amplitude and wedge delay, and
determine whether they comply with the standard
requirements (green for Pass, and Red for failed).

 According to the information obtained from automatic

monitoring, the software realizes one-key correction for
the deviation of all channels.
Automatic Monitoring of Calibration
Results
Measurement Result and Reports
 3.2 Ultrasound Acquisition Unit

 Portable imaging testing equipment

integrating PA, TOFD and UT;
 Supports up to 32/128-channel PA, 2-ch
TOFD and UT;
Split  8.4inch display, full touch screen design;
 Low power consumption, high IP rating, light
weight (3.75Kg with battery included), easy
to carry;
 Battery working time ≥ 4 hours.

 Maximum support 32/128 channel PA.

 System acquisition unit can connect to the
cloud server through the wireless network.
 Digital sampling: 12-bit 100MHz full digital
sampling.
Integrated  Testing: full wave, positive half wave,
negative half wave, RF wave.
 Bandwidth: 0.5~20MHz
 PRF: 1Hz~20KHz
 Number of sampling points: 256/512/1024
adjustable, 16bit/dot
 With temperature sensor
 Powered by DC or lithium battery.
 3.3 Automatic Crawler AUS-03
　It consists of an automated four-wheeled car, a
scanning truss assembly, and a wireless remote control.
No cable connection between the components.
　The truss can hold 2 PA probes and 1 pair of TOFD
probe for testing at the same time through the probe
arm.
　The whole piece of the crawler and the guide rail
can be quickly disassembled.
　High battery life: The whole machine is powered by
a built-in battery, which can be used interchangeably
with the instrument battery. A single battery can
continuously supply power for more than 12 hours.
　The detachable arm can realize quick disassembly
and assembly, and the probe arm supports pressure
adjustment to ensure a highly consistent coupling state
of the probe during the testing process.
　High protection: IP65, which can effectively cope
with the harsh environment and conditions on site and
prevent equipment damage.
The partition scanning requires strict control 　Safety design: The crawler is equipped with an
of the position of probe flank relative to the emergency stop switch, with built-in power-off locking
centerline of the weld, to ensure that the and stall lockout functions to ensure the user safety.
beam can cover the specified area, so as to 　Scanning speed: The crawler has 10 adjustable
scan the entire weld. speeds, which can achieve a scanning distance of 3m
Accuracy requirement: ± 1mm in 1 minute at the highest speed.
 3.4Probes & Wedges

Operating
Manufacturer Model Description
Frequency/Angle
SIUI 7.5SL60-1.0-10-R100E PA probe 7.5 MHz

SIUI 60N33.7I-IC2-AOD-1422 PA wedge 33°SW

SIUI Temperature sensor Temperature sensor

 PA curved focusing probe: frequency 7.5MHz, number of elements 60, size of a single element 0.6×10mm,
pitch 1mm.
 Wedge angle 33.7°, high wear-resistant material, designed with wear-resistant nail to improve the service
life of the wedge.

Manufacturer Model Description Operating Frequency/Angle

SIUI T5‐6L‐UN/T7.5‐3L‐UN TOFD probe 5MHz/7.5MHZ

SIUI TFB‐60/70‐UN‐I TOFD wedge 60/70L

3.6 Irrigation Device

IA-01: The advantage is that the coupling water

can be recycled. There is no need to add and
replace the water source frequently, suitable for
coupling water injection during long-time
calibration and retest of the equipment.

IA-02: using high-power and high-speed

diaphragm pump, with fast water output and high
pressure. The thickened pot body is made of high-
quality PP new material, resistant to falling and
aging. It has a large capacity of 18L and is
engraved with a scale for viewing the water level.
Long battery life. Comfortable handle and back
pad design, easy to carry and work, suitable for
field testing.

IA-03: It integrates the functions and features of

IA-02 and IA-03, which can be used for circulating
water supply in the lab or portable water supply in
the field.
 3.7 Durable Laptop

 8GB or higher RAM capacity;

 Intel Core i5 or higher processor;
 1TB hard disk space;
 1920*1080 (full HD) or higher pixel display adapter;
 Operating System: Microsoft Windows 7 or above, 64-bit;
 High-capacity battery, replaceable, can be swapped with the battery for
ultrasound module or crawler.
 4. Process assessment
(Testing performance assessment)
 Before the test, it shall be set and calibrated according to the AUT
pre-process.
 The repeatability test shall be carried out according to the following
procedures:
1．The reference block shall be placed at the 12 o'clock
position of 5G (horizontal) for a calibration scan as a basic
scan;
2．Place the reference block at the 12 o'clock, 6 o'clock, 3
o'clock and 9 o'clock positions of the 5G, and perform 10
consecutive scans respectively, and orbit correction can be
performed during the scan process.

 A unique data number shall be established for each scan,

and the repeatability test data file shall include the following:

1．Basic calibration scan data;

2. Scanning data under different location conditions;
3．The repeatability test data record table, the format of
which shall conform to the provisions of Appendix C.

 Compare the scan data of the four positions with the basic
scan data. The amplitude of the main reflector shall not change
by more than ±2dB, and the amplitude of the main reflector
shall not exceed 100%.
 Scanning results of AUT comparison test block
5% amplitude= 24dB resolution

20% amplitude= 12dB resolution

Volume reflector

Below 40% wave height =

greater than 6dB resolution
TOFD

Probe and wedge

temperature
monitoring

Fusion Fill
Volumetric Zone
Zone

 Compare the scanning image of each channel of the test block, where the test block is made according to SYT 4112-2017;
 Among them, the main reflector shall have a longitudinal resolution of 6-24dB relative to the adjacent reflector between each partition of the bevel
surface filling area;
 The size of the hole in the filling area of the groove face is Φ2mm, the distance between the centers of the holes is less than 2.5mm, the hole gap
is less than 0.5mm, and the longitudinal density distribution requires a longitudinal resolution of 6 ~24dB, so there is a higher requirement for the
focused beam. Generally, the size of the focused beam is required to be controlled at ≤2.5mm.
 The size of the drill hole in the internal volume area is Φ1.5mm, which requires a non-focused beam, and the size of the beam is controlled at
about 6.4mm.
 To test the TOFD testing capability of 5 reflectors, two grooves on the upper and lower surfaces, and a through groove in the middle, were all
detected.
 Instructions for Repeatability Tests

0 o’clock

9 o’clock 3 o’clock

6 o’clock

Before the testing, the AUT system was set up and calibrated with a reference block,
and the amplitude value of the reference reflector was recorded. In the repeatability
test of the test block, the center of the comparison test block shall be placed at 4
positions (0, 3, 6 and 9 o’clock) on the circumference, and no less than 10 consecutive
scans shall be carried out respectively.
 0 o’clock

 10 scans of the spectrum

monitoring are all green,
and the main amplitude
was within the specified
70%~99%;
 The upper and lower
coverage is 6~24dB lower
than the main amplitude.
 Gain deviation < ± 2dB.
 Delay deviation < ± 1mm.
Amplitude
response,
%FSH

Reference amplitude
Max. and Min. amplitude
80%FSH±2dB
80%FSH±1dB
 3 o’clock

 10 scans of the spectrum

monitoring are all green,
and the main amplitude is
within the specified
70%~99%;
 The upper and lower
coverage is 6~24dB lower
than the main volatility.
 Gain deviation < ± 2dB.
 Delay deviation < ± 1mm.
Amplitude
response,
%FSH

Reference amplitude
Max. and Min. amplitude
80%FSH±2dB
80%FSH±1dB
 6 o’clock

 10 scans of the spectrum

monitoring are all green,
and the main amplitude is
within the specified
70%~99%;
 The upper and lower
coverage is 6~24dB lower
than the main volatility.
 Gain deviation < ± 2dB.
 Delay deviation < ± 1mm.
Amplitude
response,
%FSH

Reference amplitude
Max. and Min. amplitude
80%FSH±2dB
80%FSH±1dB
 9 o’clock

 10 scans of the spectrum

monitoring are all green,
and the main amplitude is
within the specified
70%~99%;
 The upper and lower
coverage is 6~24dB lower
than the main volatility.
 Gain deviation < ± 2dB.
 Delay deviation < ± 1mm.
Amplitude
response,
%FSH

Reference amplitude
Max. and Min. amplitude
80%FSH±2dB
80%FSH±1dB
 5. Field Engineering Applications
AUT Testing Process

Track
AUT block Water cooling
installation at
calibration for welding
the weld

1 minute 2 minutes 2 minutes

Interpretation Scanning
of weld joint Weld scan device
scanning data installation

2 minutes 3 minutes 1 minute

AUT block Complete the The entire testing

report
calibration can be completed
within 12 minutes
 Shengli Sea Inspection Heze Project of
Natural Gas Pipeline Engineering
Shandong Network Management South Main Line

SIUI Instrument: AUT test block calibration and detection

 Shengli Sea Inspection Heze Project of
Natural Gas Pipeline Engineering
Shandong Network Management South Main Line

Olympus Instrument: AUT test block calibration and detection

Comparing the calibration time spent for SIUI and Olympus instruments when using
the same AUT test block.

Initial Check In Check Out

calibration
SIUI 3.5h <0.5h <0.5h
Olympus >8h >8h /
 Instrument Comparison

SIUI
Olympus
 Natural Gas Pipeline Engineering
Shandong Network Management South Main Line
 The two sets of instruments were sent to the
field together. Upon arrival at the site there was
an inertia problem. Both generators failed. The
Olympus instrument could not start normally.
Due to the bulky device size and the car not
moving on the muddy road after the rain, the
Olympus instrument was delayed for hours.
 The SIUI instrument was not affected by the
adverse factors above. The original plan of
Installing the guide rail simultaneous testing and comparison of the two
instruments was changed to scanning and
mapping with SIUI instrument first and
subsequent comparison after returning to the
Project Department.

Installing the crawler

 Natural Gas Pipeline Engineering
Shandong Network Management South Main Line
SIUI OLYMPUS

Start testing

It took 2 minutes and 30 seconds for the scan

of one cycle (for the pipe diameter 1219mm), The construction team subsequently
dispatched two construction vehicles to
with neither frame break nor poor coupling
address the power supply problem.
during the period.
Project Department of Natural Gas Pipeline Engineering
Shandong Network Management South Main Line

 After finishing the testing job on site, perform the check-in calibration on
the AUT comparative test block to re-check the sensitivity and upper &
lower coverage of each channel.
 The amplitude of the main reflector of each channel shall be kept
between 70%~99% of FSH, and the displayed amplitude of the adjacent
reflector shall be 6~24dB lower than the main amplitude.
Project Department of Natural Gas Pipeline Engineering
Shandong Network Management South Main Line

Chroma display
at the root

Most of the welds and parts are free of

defects, but we compared the same
positions that show pseudo-defects.

Comparison site of SIUI and Olympus instruments images

by scanning the same welds
 Project Department of Natural Gas Pipeline Engineering
Shandong Network Management South Main Line

Images from SIUI and Olympus instruments for weld No. NGX05-01-HJY102-
033-Q, incomplete-fusion defects from the weld to the root are displayed on
both instruments at 1100mm.
 未检出

Comparing the similarities:

1.Defects found at 1100mm.
2.Defects found from both TOFD channel and volume channel.
Comparing the differences:
1.Not detected by the Olympus fusion channel; Clearly detected by the SIUI fusion channel.
2.Better and clearer defect S/N ratio displayed on SIUI images; Curved images tested by Olympus TOFD
channel.
3.Smaller defects at 1200mm were detected by SIUI instrument, but not by Olympus device.