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Ultrasound v. Radiography on Thermowells

Radiographic Testing of flanged thermowells is not the ideal NDT application to achieve Volumetric
NDT and Evaluation. The reason it is not “ideal” is because the source should be perpendicular to the
weld, and because of the flange, this is unachievable with the resources available to anyone in the
industry. If the source was placed perpendicular to the weld, the X-Rays would have to penetrate the
entire diameter of the flange. The ratio of the flange diameter compared to the diameter of the
thermowell is on average, 6 to 1. If a strong enough source of radiation or X-Ray is used to penetrate the
entire diameter of the flange then the thermowell simply disappears in the negative image of the film or
digital image. What has typically been performed to satisfy customer requests is to take shots (multiple
shots) at an angle (30° - 50°). This technique technically does not meet ASME Code and can be
somewhat costly. By performing the X-Ray at an angle, detrimental defects such as cracks can be missed
because of the superimposing of the image at an angle rather than perpendicular.

Ultrasound however has a unique technique called Shear Wave. This is an Ultrasonic Testing Method
which can scan the entire volume of the weld at an angle. Shear Wave does qualify as Volumetric NDT
and is a proven method and an extremely accurate method to inspect welds for flaws. Flanges do impose
some challenges to ultrasound because of the distance between the bolt holes and the weld, however
PANAMETRICS NDT introduced a few years back a short approach wedge, which has ultimately
eliminated this limitation. Using the short approach wedges allows the transducer to be considerably
closer to the weld being scanned by ultrasound. The surface distance is reduced by 50% or more.
Another challenge is that ultrasound may not be accurate detecting defects open to the surface and this
would be true if both sides were not scanned. Daily Thermetrics scans both sides. Shear Wave is very
effective in finding defects open to the surface from the adjacent side. However, if so desired by the
customer, Penetrant or Magnetic Particle Testing can be performed on the surface of the welds to ensure
the surface integrity of the welds. It is Daily Thermetrics Corporation’s Standard Practice to perform
ultrasonic testing by the Shear Wave technique on every full penetration weld manufactured.

Christian R. Taylor
QHSE Manager
Level II NDT UT, PT, MT, VT, LT, RTFI
Daily Thermetrics Corporation