Perceptions and insight from industry on the reliability of phased array technology in weld inspection

Advanced ultrasonic techniques are now widely adopted in industry, though they present a risk of operators misunderstanding key features and misinterpreting results. The new phased array post-processing techniques, such as the total focusing method (TFM) and phase coherent imaging (PCI), have been implemented in the absence of agreed standards and consistent training. As human factors play a crucial role in the reliability of non-destructive testing (NDT), the effectiveness of these advanced techniques depends heavily on the proficiency of the inspector. The development of new equipment and techniques must be accompanied by appropriate training to mitigate the risk of human error. An assessment of inspectors’ perceptions regarding the reliability and implementation of phased array ultrasonic testing (PAUT) in weld inspection, with a specific focus on TFM and PCI, was conducted. The primary objective was to evaluate the industry’s proficiency, challenges and constraints in applying these advanced methods. Surveying Level 2 inspectors predominantly in the oil and gas sector, 76% of respondents have utilised TFM/PCI within the industry. However, 74% expressed little to no confidence in their ability to use these methods effectively. A significant concern highlighted was the inadequate training available, with over 75% of respondents indicating they had received little to no formal instruction on these techniques. This lack of comprehensive training underscores the importance of addressing human factors to enhance NDT reliability. Respondents also expressed a strong need for more detailed guidelines and standardisation across original equipment manufacturers (OEMs), specifically regarding pre-system set-up, including defining the region of interest (ROI) and selecting the correct wave set. Limited understanding of relevant codes and standards results in a shortage of qualified written instructions and structured procedures, while the high cost of training remains a major concern.