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Introduction to WeldSight

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Olympus WeldSight software
is designed to fast track

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the inspector to compliant,
repeatable, phased array

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and UT-TOFD inspections of welds.

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Made for weld inspection,
WeldSight contains

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the tools for setup,
calibration, acquisition

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and analysis of fabrication
and in-service inspections.

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Complete system inspection
solutions include

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Olympus Focus PX instrumentation,

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Olympus scanners,

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and Olympus New Weld Series
and custom

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phased array probes and wedges.

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BeamTool Integration and
Beamset Creation

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WeldSight integrates
Eclipse Scientifics'

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industry leading UT
and phased array

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technique development software,
BeamTool

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for all component piece, weld overlay,

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calibration block, probe, wedge

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and beamset management.

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Supported probe types are
1D linear array,

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dual linear and
1.5 dual matrix array,

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and conventional UT-TOFD probes.

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WeldSight is compatible with
a BeamTool software license

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or a USB hard key
using the standard installation.

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Beamsets are created in WeldSight

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in one click from any
pre-defined BeamTool file

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by selection of Update
All Beamsets and Piece,

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or by adding or replacing
any selected beamset.

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After beamset creation
beam delays, beam angles,

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beam exit offsets,
and trigonometry

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are validated using an S-scan\A-scan
\B-scan display layout.

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The BeamTool cal block .Btcb file

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is a modular component
for one-click toggle

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between the cal block
and weld overlays

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in the data displays.

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A-scan track mode
is selectable in preferences

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for gate A detections

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or the full UT range.

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The WeldSight header is
organized by work flow tasks

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for Setup, Calibration,
Inspection, and Analysis,

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and icons update appropriately

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for the selected beamset type.

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Focus PX Phased Array
Instrument

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The Focus PX phased array instrument

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is a lightweight, compact, rugged unit

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designed for use in harsh environments

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at operating temperatures
up to 40 degrees Celsius.

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Designed for IP65 rating,

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the FocusPX is protected by removable

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industrial strength
bumpers for rack mount,

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or installation directly
on the inspection system.

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The Focus PX provides
excellent phased array

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and UT signal quality resulting in

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improved signal-to-noise
ratio inspection data.

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Other features include
12-bit amplitude digitization,

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30 MB/sec digital throughput,

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65K samples per A-scan,

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and two encoder inputs.

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And supports up to 4 Focus PX units

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for simultaneous
inspection in WeldSight.

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PRF, data acquisition rates,
and scanner speed

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are measured real time
during inspection,

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and the throttling
bottlenecks are calculated

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for optimization of UT
quality and inspection speed.

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Calibration Tools

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After completion of basic setup,

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the work flow
continues in Calibration.

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The Acoustic Wedge Validation tool

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in one click creates
a single element aperture,

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single element step E-scan

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for validation of wedge parameters,

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and to visualize proper coupling
of the wedge to the probe.

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When the parameters are
within user-defined tolerances

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green indicators are displayed.

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The A-scan is available
for troubleshooting,

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and the active beamset can be updated

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with the new measured values

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by selecting Update Beam Delays.

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Like the Wedge check,

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the Probe check creates
a single element E-scan

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for validation of instrument pulsers,

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multiplexer, probe and
instrument connectors,

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coaxial cables, and individual
probe element activity.

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Inactive pulsers from the instrument

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or probe elements are visualized,

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and statistics are compared to
the user- defined tolerances.

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A dynamic single point
sensitivity calibration

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will store a gain offset
for each beam.

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The window displays 200% amplitude

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and 400% saturation limit,

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and a zone for the user-defined
tolerance in dB.

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While in the calibration functions,

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background activities
in WeldSight are suspended

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allowing a fast, smooth display
refresh rate for calibration.

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The manual sensitivity calibration

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is performed on a
user-defined number of beams

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while imaging targets
from a static probe position.

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The number of targets is entered,

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the gate is positioned
over the targets,

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and the peaks are selected
by the user in any order.

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When complete a curve is visualized,

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and a dB offset correction
applied to equalize

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all beams
to the reference sensitivity.

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The WeldSight TCG allows
simultaneous point creation,

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successive point creation,

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or combinations of the two.

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The number of required
TCG points is entered

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and a TCG gate and envelope
window is created for each point.

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The envelopes are cleared,

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and the calibration block is scanned.

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The TCG gates are positioned
on each target

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to include limits of
beam spread for all points.

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Individual TCG points can be
cropped on the first or last beams,

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and beams for which
the UT range is too short

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for the TCG point creation
are treated as cropped.

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All or selected TCG
points are calibrated,

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and the cal block is
rescanned for verification

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of user-defined tolerance in dB.

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TCG repeatability is
validated after creation

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or in a recalled file with
an A-scan envelope

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while imaging targets in the S-scan.

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Inspection Motion Settings
and Displays

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After completion of
Setup and Calibration,

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the work flow continues in
Inspection Motion Settings

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where the Scan Type is
configured for One-line Scan,

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Raster Scan, or Clock inspection.

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The gate A amplitude C-scan

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typical of OmniScan inspection

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will visualize all gate A detections.

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The amplitude weld gate C-scan

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will visualize only detections
in the weld

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and heat affected zones
of the piece overlay.

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The merged amplitude C-scan

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dynamically merges all beams
to visualize detections

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in a volume-corrected top-view
C-scan with weld overlay.

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ASME Vessel and ISO Wind Tower
(PA-TOFD)

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ASME pressure vessels,

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ISO wind towers,

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and similar inspections
add a TOFD beamset

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for improved POD on
vertical weld bevels,

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supplemental sizing,
and lamination checks.

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Scan offsets are configured
for multi-probe inspection

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and the BeamTool scan plan is
created in WeldSight

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in one click with Update All
Beamsets and Piece.

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For each PA beamset,
the TCG is created or imported,

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and the reference sensitivity is set

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using one or more calibration
targets for each PA probe.

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TOFD setup and calibration
is performed

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on an A-scan and
scrolling B-scan display.

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The UT range is set on cursors,

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and a wedge delay-PCS
calibration is performed

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using the UT cursors.

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TOFD calibration,
lateral wave synchronization,

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lateral wave removal, and SAFT

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are available after data acquisition.

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An inspection display
layout is loaded,

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and the type, length,
inspection resolution,

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and zoom window are configured,

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and the encoder resolution
calibrated if necessary.

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File name and data options
are configured,

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and the system is ready
for data acquisition.

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Acquisition rates of up to 100mm sec

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at 1mm resolution are typical

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depending on weld
thickness and UT quality.

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Upon completion of the scan the file
is saved and ready for analysis.

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API 620 LNG Tank Inspection

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LNG cryogenic storage tanks

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are made of 9% nickel shells

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and an Inconel 625
dissimilar metal weld

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that requires an austenitic
probe strategy.

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The Olympus LNG phased
array quad probe

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is optimized for the Inconel 625 weld

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and combines 4Mhz A32
shear wave pulse echo probes

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with 4Mhz A27 dual linear
array or DLA probes

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into a single phased array connector

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using all 128 elements
of the multiplexer.

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The four S-scans are
created in WeldSight

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in one click from the
BeamTool by selecting

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update all beamsets and piece.

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The API 620 acceptance criteria

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for LNG tank fabrication requires

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precision fracture mechanics
length and height sizing.

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Use of linear shear wave probes

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provides precision sizing
of bevel and HAZ flaws,

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but only the DLA probe
penetrates the weld volume.

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After UT configuration
and TCG import

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the refracted longitudinal
S-scan visualizes SDHs

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in the upper and lower weld volume

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to validate TOF and set
inspection scan sensitivity.

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Using the two SDHs

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a dB correction curve to 80% amplitude

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is applied to all beams.

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The dB correction can be copied

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or recalculated for
the opposing DLA probe.

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Successive shell inspections
are updated quickly

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by importing the weld overlays

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using Beamtool Ebp files
created in advance.

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Customizable data
acquisition layouts

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visualize the four C-scans
and linked S-scans.

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Typical configuration allows
data acquisition

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of 75mm per second at 1mm resolution
on up to 40mm thick weld bevels,

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and 1-3 GB data file size for welds
up to 12 meters in length.

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Typical system and
procedure qualifications

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require detection and
sizing of embedded,

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connected, bevel, and HAZ flaws.

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Production welds with
no recordable indications

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are analyzed real time
prior to the next inspection.

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Customizable data display
layouts for analysis

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are updated on the active beamset.

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In this example, an embedded
fusion flaw was detected

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and length sized using the RTT signal

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at reference sensitivity,

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and depth/height sized with the
direct L after software gain.

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Historically, much of the
skill and expertise

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required for advanced
phased array inspection

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was due to complicated software.

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WeldSight was designed
with this in mind.

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Leveraging the BeamTool software
for inspection engineering,

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WeldSight software was developed
for an efficient workflow

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and a fast training track
to productivity,

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with a focus on compliant,
repeatable inspections

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for the weld fabricator market.