PR7373

July 2003

Development of Phased Array and Swept Frequency Guided Wave Long Range
Ultrasonic Techniques for Fitness-For-Service Assessment of Pipe Corrosion
For: A Group of Sponsors

Pipe
Axis

Axi-symmetric modes

Road Crossing

Pipe
Axis

Transducer
Ring

Flexural Modes
A-scan

-50m

Pipe
Axis

+50m

Torsional Mode

Figure 1 Guided Wave Ultrasonic Technique

Figure 3 Guided Wave Modes

Figure 4A

On Bends

Transducer

At Branches

Figure 4B

Pipe Vibration
Axi-symmetric

Axi-symmetric
Pipe wall

Transmission

Under Supports

Flexural

In Weld Grooves

Figure 4D

Figure 2 Corrosion at Geometric Features

Reception

Flexural

Figure 4C

Figure 4 Phased Arrays for Transmission and Reception

of Guided Waves.

The guided wave Long Range Ultrasonic Technique (LRUT) has been shown to be capable of inspecting pipe
for several tens of metres from the point of access, even when the pipe is buried or under insulation. More
sophisticated operation of the equipment will allow identified defects to be quantified, and the discrimination
defects from signals generated by welds, bends, branches and other geometric features in the pipe. This
project aims to develop guided wave LRUT as an assessment tool as well as a screening tool. It will validate
the performance of the more sophisticated use of guided wave LRUT including using phased arrays and swept
frequency, and provide guidelines for its successful operation in industry.

BACKGROUND
Many pipes are inaccessible for inspection, because they are buried or insulated. The guided wave Long
Range Ultrasonic Technique (LRUT) is a special ultrasonics NDT technique that is capable of inspecting
pipe for corrosion several tens of metres from the point of access [1] even when the pipe is inaccessible ie
buried or under insulation.
The guided waves are propagated from a ring of ultrasound transducers wrapped around the pipe (Figure
1). A typical application is detection of corrosion in pipe under a road crossing. The technique was
introduced commercially by Pi Ltd.in 1998, and has been under continuous improvement since then with
support from TWI and Penn State University. This programme of research will make a step change in its
capability. Currently guided wave LRUT can broadly discriminate between minor and major corrosion
and, very importantly, can measure the distance to the corrosion from the transducer ring [2]. The pipe can
therefore be exposed at the corroded position, where it can be assessed visually, if the corrosion is on the
outside surface or with another NDT technique such as radiography or B-scan ultrasonics, if it is in the
inside surface of the pipe.
Currently, guided wave ultrasonics has been limited to detection only. Other techniques have to be applied
to evaluate the corrosion.
This programme of work aims to develop guided wave LRUT as an assessment tool as well as a
screening tool by improving procedures with current techniques and introducing new techniques.
Guided waves are complex. There are a great many wave modes travelling at different velocities,
depending on the wall thickness - diameter combination of the test pipe. They are also dispersive, that is to
say their velocity varies with frequency. The A-scans must therefore be calibrated from dispersion curves;
such curves being available for each wave mode and pipe diameter and thickness. LRUT systems allow for
this in the analysis software.
However, the complex nature of guided waves could be turned to advantage. The bulk waves used in
conventional ultrasonics provide information about discontinuities from signal amplitude and time-offlight data only. Guided waves on the other hand, also provide wave mode data. There is an interaction
between guided wave mode, wave frequency, pulse flight-time, the pipe wall thickness pipe diameter
combination and discontinuity that could be used to characterise the discontinuity.
Laboratory trials have shown that a discontinuity could be investigated by using the transducer ring
as a phased array and sweeping through a range of ultrasound frequencies [3]. Trials conducted in
this project will quantify the results of this work and validate existing and new test procedures.
BENEFITS

Greater confidence in the use of existing

guided wave LRUT after collecting
performance data covering a wide range of
test conditions.
Enhanced guided wave long range ultrasonic
techniques that:
o Provide better discrimination
between different levels of
severity of corrosion.
o Detect corrosion in presence of
geometric features in the pipe
such as branches, bends,
supports and welds (Figure 2).
Cost savings through avoidance of exposing
pipe for inspection, eg. 100,000 for digging
up a road crossing.

To provide guidelines for selecting wave

modes, test frequencies and other procedure
parameters.
To provide guidelines on interpretation of
test data e.g. discriminating corrosion
signals from signals due to welds, bends,
branches, supports and other geometric
features in the pipe.
To provide guidelines for setting thresholds
in terms of corrosion that can be left for
future inspections, corrosion that should be
evaluated further and corrosion that should
be remedied immediately.

PROJECT APPROACH
Test procedures will be validated by studying
influencing parameters on lengths of pipe in the
laboratory and in the field, with support from
numerical modelling.

OBJECTIVES

To gather sufficient data on known

discontinuities in sample pipes to validate
the performance of the existing guided wave
LRUT techniques.
To validate the performance of new
enhanced techniques, which use phased
arrays and swept frequencies.

Provision of test samples

Samples of test pipe will be collected to show a
wide range of test conditions including:
general,
localised,
Corrosion/erosion,
corrosion pitting, laminations, isolated
cracks, fretting.

Corrosion of differing depth, radial extent

and longitudinal extent relative to the pipe
axis.
Corrosion in the vicinity of pipe elbows,
pipe branches, pipe supports and other
attachments to the pipe.
Corrosion in the weld toe.
Corrosion on internal and external surface of
the pipe.
Pipe coatings, including soil, concrete,
bitumastic, insulation (wet and dry).
Carbon steel pipe and stainless steel pipe.

Where possible, use will made of existing pipe

samples with well documented corrosion e.g.
pipe samples used in the RACH/CRIS research
programmes and the pipe test loop at TWI. Pipes
may be welded up to give representative lengths.
If pipe with existing flaws is not available, then
artificial flaws will be manufactured on the pipe.
For example, machined flats on the pipe surface
could simulate erosion. Electrolysis through
pools of liquid kept on the pipe surface for
several hours could simulate localised corrosion.
Cracks could be simulated by spark-eroded slots.
Flaws will be simulated on internal as well as
external pipe surfaces.
Validation of Current Techniques
Current equipment propagates guided waves as
axi-symmetric (symmetric about the pipe axis)
longitudinal or torsional waves in pulses along
the pipe (Figure 3). Where they meet a
discontinuity that presents a change in the
thickness of the pipe wall, the pulses are
reflected or mode converted. The thickness
change may be an increase in thickness, such as
a weld with cap and root, or it may be a decrease
in thickness, such as corrosion. If the
discontinuity is symmetrical around the complete
pipe circumference, the pulse will be reflected as
an axi-symmetric wave mode. This would be the
case where the discontinuity is a pipe butt weld.
Normally in the case of corrosion however, the
discontinuity is localised to one section of the
pipe circumference and the pulse is mode
converted to a flexural wave.
Detecting flexural waves in the pulse reflected
back to the transducer ring is the principal
method of detecting corrosion. The plane of a
simple flexural wave that is causing the pipe to
vibrate in one plane can be polarised in an
infinite number of direction around the pipe
circumference.
Current
test
equipment
discriminates only the vertical and horizontal
vibrations.
The current techniques will be validated using
Teletest multimode (Plant Integritys new 24
channel LRUT system with phased array
capability) and studying the influence of the
following parameters:

Test frequency.
Wave mode i.e. longitudinal, torsional, and
flexural.
Signal/noise ratio at test range.
Distance amplitude correction.
Pipe dimensions.
Pipe coatings.
Corrosion/erosion characteristics.
Dimensions of corrosion/erosion.
Location of erosion/corrosion.

Numerical modelling
TWI have extensive expertise in the use of
Finite Element models to provide support to
experimental studies of guided wave propagation
through pipes and, more recently rails. They will
provide additional evidence to validate the
procedures
and
extrapolate
between
measurements.
Validation of New Techniques
The new techniques will use equipment that
extends the mode of operation of Teletest to
include transducer ring operation as a phased
array and the sweeping of test frequencies during
a test. Investigating the same influential
parameters as were investigated with existing
procedures will validate the new procedures.
.
Phased Array
There are many complex flexural wave modes,
where there are multiple nodes, or pinch points
around the pipe circumference. Figure 3
illustrates two, three and four nodes. The new
test procedures will be sensitive to these more
complex wave modes. This will be accomplished
by using the transducer ring as a phased array.
To produce a wave that is axi-symmetric, the
transducers in the ring are fired in unison (Figure
4A). When stationary and in reception mode, the
transducers will recognise returning pulses
containing axi-symmetric waves because the
transducers all receive the same wave
simultaneously (Figure 4B). If they do not
receive the wave simultaneously, the waves will
be recognised as flexural (Figure 4C).
Using the transducers in reception as a multiple
array, for example top and bottom, left-hand side
and right-hand side, and diagonally across it will
be possible to determine the width of corrosion
and its position around the pipe.
A more difficult proposition is to use the
transducers in transmission as a multiple array
(Figure 4D), therefore propagating pulses with
flexural waves. In this way it may be possible to
differentiate internal from external corrosion and
corrosion in the presence of geometric
discontinuities. Figure 5 below shows that the
transducers can be fired using a phased array
technique to focus the guided waves. This will
increase the defect detection capability and also

differentiate small amounts of corrosion and

their location in the pipe.

capability and limitations of both the existing

and new guided wave LRUT techniques. This
will provide sponsors with a reference document
for writing test procedures and planning
inspections.
INTELLECTUAL PROPERTY RIGHTS
Any IPR arising from this project will be held by
TWI and will be confidential to the sponsors of
the project. Sponsors will be consulted on the
handling of the IPR generated in this project.
DELIVERABLES

Figure 5. This picture shows a simulation of

focusing beyond an elbow.

Swept Frequency
Marked changes in the amplitude of reflected
pulses from a discontinuity have been observed
when the frequency of the guided wave is
increased or decreased. This is partly a function
of the pipe diameter/wall thickness ratio and
partly a result of the equipments operating
characteristics. There is also evidence however,
that these changes may also be due to
interactions between the pipe wall thickness
diameter combinations and the discontinuity.
The technique will sweep through a range of test
frequencies and identify peaks in the signal
amplitude.
Field Trails
The techniques will undergo field trails. These
are necessary in order to measure performance
under realistic conditions, particularly as
parametric studies will be restricted to relatively
short lengths of pipe.
Guidelines
Based on the validation exercises, guidelines will
be written for writing procedures using existing
and new techniques. The guidelines will cover:
Wave mode selection.
Frequency selection.
Interpretation of results.
Test sensitivity levels.
Summary of evidence on capability and
limitations.
Based on a literature survey, experience with
other work and the results of this project, a
summary of evidence will be prepared of the

The deliverables for the project are.

Enhanced guided wave long range
ultrasonic techniques.
Data on the reliability and sensitivity of
existing and new techniques.
A guidance document for writing
procedures and interpreting results.
Information for setting thresholds in
inspection strategies.
SUGGESTED PRICE AND DURATION
The total estimated cost of the project is
210,000. It is planned to form a Sponsor Group
of seven companies, each contributing 15,000
per year for two years
Contact:
Dr Aamir Khalid or Dr. John Harrison
NDT Technology Group
TWI Limited
Granta Park
Gt Abington
Cambridge CB1 6AL
Tel: +44 (0) 1223 891162
Fax: +44 (0) 1223 890952
E-mail: aamir.khalid@twi.co.uk
E-mail: john.harrison@twi.co.uk
REFERENCES
1. Mudge P.J., Field application of Teletest
long range ultrasonic testing technique,
Insight Vol.43, No. 2, Feb. 2001, pp74-76
2. Cawley P., Lowe M.J.S., et al Practical
Long Range Guided Wave Testing,
Application to Pipe and Rail, Materials
Evaluation, Vol.61, No.1, pp.66-74.
3. Hay T.R., Rose J.L., Guided Wave Testing
Optimisation, Materials Evaluation, Vol.
60, No. 10, pages 1239-1252.