CHIME

Training Course
 Contents

1 Introduction

2 Principles of CHIME

3 Applications

4 Equipment Requirements

5 Personnel

6 Data Collection Techniques

7 Setting the System

8 Analysis
1.0 Introduction
The Creeping Headwave Inspection MEthodology, more commonly referred to
as CHIME, is an ultrasonic technique for the rapid screening of pipes, tanks
and vessels for corrosion, erosion and general pitting.

CHIME is often referred to as a long-range ultrasonic technique. This is not

entirely accurate. Techniques such as Gull can scan metres of pipe at a time
whereas CHIME is restricted to a few hundred millimetres. Therefore it should
be considered to be a medium range technique.

AEA Technology developed CHIME at the National NDT Centre in the mid
1990’s as part of the Harwell Offshore Inspection R&D Service (HOIS). ESR
Technology currently holds the patent and a licence must be obtained from
ESR Technology before the technique may be applied.
2.0 Principles of CHIME

CHIME can be used to detect and allow qualitive sizing of areas of corrosion ,
erosion and pitting in pipes, tanks and vessels. It can be used on material
from about 6mm up to 40mm in thickness, although in some circumstances it
is possible to collect data on material over 60mm thick. Under ideal conditions
the technique has the ability to scan bands of up to 1 metre in width.
However, on site it is unusual to be able to scan with the probes more than
500mm apart. This still allows rapid screening when compared to corrosion
mapping, although the precision of the results can be a little disappointing as
CHIME can realistically only categorise the wall reduction into three bands;
Less than 10%, between 10 and 40% and more than 40%.

The basic technique uses two probes mounted on wedges of a specific angle
to generate longitudinal sound waves into the object under inspection. See
Fig. 1. The sound covers the full volume of material between the probes.

Fig. 1
CHIME Inspection Arrangement

Tx Rx
Obstruction
Test Piece

The CHIME image is actually an amalgamation of three wave types; Creeping

waves, bulk waves and CHIME waves; (1) a creeping wave follows the
surface profile of the test piece. See Fig. 2.

Fig. 2
Scan Surface Creeping Wave

Tx Rx
Creeping Wave

( 2) Bulk waves are reflected from the opposite surface, skipping the distance
between the probes as understood in conventional pulse echo inspection.
Due to the various beam paths a number of bulk waves of varying signal
strength will be imaged. See Fig 3. The bulk waves are generally of low
amplitude and the sound decays quickly.

Fig. 3
Bulk Waves

Rx
Direct Reflection

( 3 ) The creeping waves produce Head waves (or CHIME waves) at a critical
angle of 33°. When the head waves interact with the far surface another
creeping wave is generated. Head waves return to creeping wave mode when
they reach the next surface, (be it scan surface or far surface), and those on
the scan surface return to the receiving probe in that form. See Fig. 4.
The wider the probes are apart for a given thickness of material the more
head waves are generated. There is a direct relationship between the arrival
time of the CHIME signals and the plate thickness.

Fig. 4
Head Waves & Creeping Waves

Tx
Creeping Wave ( scan surface)

Creeping Wave ( far surface)

The CHIME signals are relatively strong and appear within and after the bulk
waves. See Fig. 5. The first few CHIME waves may be masked by the bulk
waves. If the system is refined sufficiently it is possible to take thickness
measurements by measuring the distance between the CHIME signals.
Fig. 5
Typical CHIME A-Scan

Time (ps)
The CHIME A-scans are allotted various snaaes of grey depending upon the
signal amplitude and viewed as a D-scan in a similar way to Time of Flight
Diffraction (TOFD) scans.

The absence of CHIME responses on a scan is indicative of an area of

significant wall reduction, (<40% wall loss). However, the system will record a
similar response if one or both of the CHIME wedges are not in contact with
the work piece or the couplant is insufficient. To identify this the CHIME
wedges have 0° probes positioned over the CHIME index point to monitor the
coupling. See Fig. 6. The couplant monitoring channels are set up
independently of the CHIME channels and are usually represented as red and
green “go/no go” bands on the screen presentation.
Fig. 6
CHIME Wedge Design
Couplant
Monitoring
CHIME Probe
Probe

Work Piece

The technique can be used with or without manipulation guidance aids such
as tracks or bars to maintain a fixed probe separation and slight variations in
separation can be tolerated. This is particularly useful when scanning vessels
with nozzles, insulation bands, small-bore pipework , cable trays, etc. Optical
encoders can be fixed to the probes, track or scanning bar if required to
provide positional feedback although again this is not always necessary or in
some cases practical.

In 2004 experiments were conducted to assess the effectiveness of using the

CHIME probes to produce shear waves in an effort to detect cracking or sharp
edged corrosion/erosion. These were imaged separately to the CHIME
responses on the screen. It was considered that this was a positive step
forward for the CHIME technique. However due to the large probe size, low
probe frequency and the wedge design the shear wave responses were not of
the quality required for weld examination. There were numerous standing
echoes caused by the wedge design that could not be damped out. Any crack
or sharp feature would have to be very close to the probe, (typically within
125mm) , as the shear waves produced appeared to lose strength very
quickly.

Each scan channel is shown in separate (fixed) windows within the scan
image.
• The CHIME image is shown in various shades of gray, from black to
white. See Fig. 7.
 • The pulse echo images, if used, are shown in various shades of gray,
from black to white. See Fig. 8.
• The couplant monitoring channel can be shown in one of two ways. A
simple red and green “go/no go” band for each probe can be used. See
Fig. 9. When the CFIIME signal is above the selected threshold the
colour is green. When the signal falls below the threshold the colour is
red. Alternatively , an echo dynamic representation of the couplant
monitoring channels can be set. Both type of display save the signal
height, which can be displayed by moving the cursor over the
appropriate position within the window. Either or both type of couplant
monitoring display may be enabled.

Fig. 7 Fig. 8 Fig. 9

CHIME Scan PE Scan Couplant Monitoring

The CHIME technique relies on maintaining signals along the length of the
scan. If signals begin to disappear it is indicative of something wrong. It could
be a loss of coupling, which should also show in the couplant monitoring
section, or it could be a reduction in the wall thickness , which would leave the
couplant monitoring section unaffected.
The amount of signals that are lost has relevance to the degree of wall loss. If
all signals are relatively consistent throughout the scan there is reasonable
confidence that there is no wall loss greater than 10% throughwall extent.
If the CHIME signals are lost and the bulk signals are reduced it is a sign that
the wall loss is greater than 10% and can be as much as 40%.
If the bulk signals have disappeared it indicates a wall loss of more than 40%.

The CHIME scan shown in Fig. 7 is from a pipe that was resting on a pipe
support. The scan shows the full circumference with the twelve o’clock
position at the top and repeated again at the bottom of the image. The 6
o’clock position is half way down and a loss of all the CHIME signals and
much of the bulk signals is evident.
3.0 Applications
CHIME can only be used for the inspection of plate or pipe material. It cannot
be used for examining welds for welding flaws or complex geometry
configurations.
Its main strength is testing material than cannot be easily accessed for
examined by any other method. This includes areas such as pipe or vessel
supports and clamps where the gap between the supports or clamps and the
plant can become moisture traps and corrosion can occur. On some plant,
particularly pipework , vibration and movement caused by cycles of heating
and cooling can result in the pipe material being slowly worn away when it
rubs against the supports . CHIME can also be used on areas of vessels or
pipework to provide rapid screening to detect a reduction in the wall thickness.

There are two basic methods of applying the CHIME technique. The probes
can be deployed circumferentially or longitudinally . See Fig. 10 and 11.

Fig. 10
Circumferential scan (Transverse Beam)

j S
Probe
Tx Sound Path
^
Movement

Pipe Support ^
As Viewed from the Side
Fig. 11
Longitudinal Scan (Circumferential Beam)

Probe Tx
Movement
ft
Sound
Path

B
|R X
7
Pipe Support

As Viewed from Below

When performing longitudinal scans, with the beam in the circumferential axis
the OD/ID ratio must be <1.19. This is because the CHIME technique is
dependent upon the reflected angle at the inner surface.

On pipework of 6” diameter or less, it is possible to put the probes “back to

back ” to examine the majority of the pipe in one scan. To enable 100%
coverage it would be necessary to conduct another scan with both probes
outside the previous scan positions. For an example see Fig 12a & Fig 12b.

Fig. 12a Fig 12b

Scan A at 0° Scan at 90° to Scan A
Tx 1/ Rx

Rx

Tx

Sound Sound
Path Path
Water fed through pressurised tubing has been found to be the best method
of couplant. The scanner operator is advised to wear a one-piece waterproof
suit and Wellingtons, as invariably he or she will get very wet.
4.0 Equipment Requirements
The number of manufacturers that produce CHIME equipment is relatively
few, although this is likely to increase in the future.

The companies with the most experience of supplying imaging systems for
CHIME are Veritec Sonomatic and Technology Design. Veritec Sonomatic
has used the Microplus, which dates from the mid 1990’s, for many years and
much of the initial AEA Technology development and site work was done with
this equipment. The Microplus digitisation rate was relatively low, but this was
increased with the introduction of the TD-PocketScan (Fig. 13) and TD-Scan
(Fig. 14), from Technology Design. Using the Stripscan software the TD
equipment provided clearer imaging capability and provided the CHIME
technique with the computing power it needed to be considered a practical
tool.

Fig. 13 Fig. 14
TD-PocketScan TD-Scan

The design of the CHIME wedge is critical. They are usually made from
Rexolite or Perspex. Wedges must be radiused for the profile of pipework or
vessel they are being used on. A wedge radiused too large may produce
acceptable scans but one radiused too small will produce poor quality data
due to the gap between the wedge and scan surface. Consequently a CHIME
kit will usually consist of a number of wedges of various radiuses some in the
longitudinal axis and some circumferential.

There are two width sizes of wedge available. These are approximately 40mm
wide and 25mm wide. The 40mm type has been found to provide better
stability when scanning with a track. When held by hand either width can be
used.

Phoenix Inspection Systems have been producing wedges and supplying the
probes for many years. Always take time to discuss your requirements and
the intended application before placing an order as there are so many
variables that it is easy to end up with something that isn’t exactly what you
want.
Fig 15
Each wedge must be fitted Pressurised Water Container
with water feed holes and
fittings to allow the connection
of the plastic tubing. The
tubing is then connected to a
pressurised water container
such as can be obtained from
Hozelock. See Fig. 15. It’s
best to get a water container
of at least 5 litres but no more
than 8. Before you buy one,
check it will fit in the shipping
box.

The CHIME probes are essentially large TOFD probes, with a frequency of
2Mhz and a diameter of 15mm. These screw into the fittings on the wedge.
Do not over tighten this probe as the wedge will crack where the fitting is
screwed into the wedge.
The couplant monitoring probes are usually 2.25Mhz frequency and 6mm
diameter. They usually slide into a fitting and secured by a small plate. The
plate is held in place by a screw at either end. In the middle of the plate is
another screw that holds the probe against the wedge. Be very careful when
tightening this. The couplant monitoring probes usually have the damping
material exposed and trying to tighten the screw onto the probe directly will
only damage the damping, which could result in probe failure. It is advisable
to put a small disk of metal or tough plastic on top of the probe before
tightening the screw.

Both the CHIME probe and the couplant monitoring probe must be coupled
with UCA-2 or equivalent. The probes should be re-coupled prior to every shift
and whenever the technicians suspect they may have started to dry out due to
a reduction in signal strength.
5.0 Personnel

The CHIME equipment requires the services of two technicians; one to

operate the imaging system and one to propel the probes.

The technician who operates the imaging system, usually the team leader,
should be qualified to PCN Level II in pulse echo ultrasonic techniques, or
equivalent. He or she should fully understand the techniques being deployed
and what constitutes an acceptable scan.

The scanner technician should have some experience of ultrasonic inspection

although anyone who can demonstrate his or her ability to position and propel
the scanner to the satisfaction of the team leader may be considered
acceptable for this duty.

The data is usually analysed by the lead technician, however this duty may be
performed by any other suitably qualified and experienced technician.
6.0 Data Collection Techniques
There are essentially three methods of deploying the CHIME technique.
These are:
• Circumferentially - Probes positioned along the axis of the pipe/vessel
moving around the circumference. See Fig. 10.
• Longitudinally with probes facing each other - Probes positioned
around the circumference of the pipe/vessel, moving along the length
of the pipe/vessel. See Fig. 11.
• Longitudinally with probes “back to back” - Probes positioned around
the circumference of the pipe/vessel, moving along the length of the
pipe/vessel. See Fig. 16 and Fig. 12a & 12b.

The maximum distance that the probes can collect data under ideal conditions
is 1 metre. In practice it is unlikely that the probes can be position beyond
500mm without there being a degradation of the signals.

Fig. 16
Probes on Large Diameter Pipe or Vessel

Tx Sound
Path

Support
Fig. 17
Probes on Pipes <150mm 0

TxIf Rx

Sound
Path
7.0 Setting the System

There are many ways to visually set up the system. This is usually the most
confusing aspect for many technicians. The order in which the various scans
appear on the screen is arbitrary so long as the correct data is collected.

Fig. 18
CHIME Scan Layout
-o
- 20
- 40
- 60
- 80
- 100
- 120
- 140 mm
- 160
- 180
- 200
Surface - 220
- 240
- 260
- 280
- 300
- 320
- 340
- 360
i i l i l
380
O LO O LO O LO o
oo (N CNI CO

ps
The CHIME scan, (Fig 18), is displayed with the scan surface on the left side
of the image. The time base, or gate is shown in the horizontal axis in ps and
the distance travelled from top to bottom in mm.

Ideally there should be approximately 1ps between the gate start and the
surface wave. There should be sufficient gate length to image all the CHIME
waves. The gate start position should be clearly seen on the A-Scan but the
position can be calculated using this formula:

Probe Separation (in mm) + Probe Delay = Time (in ps)

6

It is best to set the gate length at a little beyond the last visible CHIME signal.
If scanning freehand, (without a scanning ring or bars to hold the probes at a
fixed separation) always add another ps or two to the gate.

A typical CHIME A-scan presentation is shown in Fig. 19. Setting up the A-

scan should be performed on a clean section of carbon steel bar of a similar
thickness to the object to be inspected or on a known “clean” area of the
object that is considered to be free of inclusions, corrosion, erosion and
welds.

Fig.19
CHIME A-scan

The unusual aspect of the CHIME set-up is that the velocities used are non-
standard. The Longitudinal velocity is set at 2340m/s and the shear velocity is
set at 3200m/s. Couplant velocity is set at 1500m/s.
HT voltage, pulse width, bandpass filters, etc. are set as for any normal pulse
echo set-up.

It is important that the CHIME signals are not saturated. This is easier said
than done on surfaces that suffer from corrosion of the scan surface or rough
paintwork such that an irregular scan surface is encountered. See Fig. 17.

All scans are collected in pulse echo mode and may be allocated scan
identifications such as “CHIME Data”, “PE Data” and if the couplant
monitoring echo dynamic is to be collected, “Couplant Check ”. These in turn
can be allocated as “upstream” or “downstream”.
If the red/green couplant monitoring option is require ensure that the option
“Display - Go / No Go” is enabled.

The pulse echo probes , if used, should be set up as standard pulse echo
probes and the gates set such that there is no cross talk. This is however very
unlikely unless the probe separation is relatively small. The only way to
determine where the gates should be set is by using a V1 calibration block or
similar. There will be standing signals due to the design of the CHIME wedge.
It is possible to slightly reduce the standing signals by placing Bluetac on the
front of the wedge.
The couplant monitoring gates should be set over a good signal within the
CHIME A-scan. This should be a strong consistent signal. The threshold is
usually set to 40% FSH and the gain set to threshold +20db.

Prior to collecting any data the encoder, if one is being used, must be
calibrated.
If an encoder is not being used trials to select the correct “freerun” or
“unencoded” speed should carried out. If this is the case it is sometimes
helpful to mark every 50mm or 100mm along the scan path to maintain some
continuity. The keyboard operator can call out the distances as the scan is
collected to assist the probe manipulator maintain a consistent probe speed.

When the system is set to collect data a menu will appear giving the option to
“Map All”. For the CHIME and pulse echo this must be set to “Map All” to
produce the data in gray scale images. The couplant monitoring, if chosen to
be in echo dynamic mode should be left as “T & A”

Always turn off the “Display Defect Markup Boxes” option as this just takes up
space on the screen and reduces the visible CHIME and pulse echo areas.

Once the collection programme has been initiated the probes should be
moved at a steady pace. The system operator should view the data as it is
being collected to ensure that the quality is acceptable and that the couplant
monitoring channels do not indicate areas of missed data. Any area
considered to be unacceptable shall be rescanned.
8.0 Analysis
The analysis is at first very daunting! Different signal patterns are common
with CHIME for a given wall loss; strong, weak, mottled , etc. This is often due
to differences in the equipment used, probe separation, scan surface and
material type, (rolled plate, spun dome, extruded pipe, etc).
It does get easier as the operator gains more experience but the first few scan
on a new job with different probe separations and material thickness calls for
another “re-acquaintance” with the CHIME display.

It is possible to provide remaining thickness results to within a millimetre of

the actual remaining thickness. However this requires days of preparation on
numerous samples of the exact thickness, the same hardware and the same
probe separation. In practical terms this is not feasible, as it would likely take
longer to set up than to carry out the work. (This should not be spoken of to
the customer, as it would raise their expectations).

CHIME analysis is performed by viewing the collected data and directly

comparing it against scan files with know defects and using the criteria shown
below.

CHIME is to be reported by categorising each area with relation to the

estimated wall loss:
Category A = Up to 10% wall loss
Category B = 10 to 40% wall loss
Category C = More than 40% wall loss

It is sometimes difficult to establish what an area of corrosion will look like. A

good tip is to scan part of the pipe or vessel that it known to be in good
condition, i.e. If the vessel is anticipated to be corroded at the bottom take a
scan, on a similar plate thickness, as high up the vessel as possible. Again
with a pipe, if the corrosion is suspected at the bottom take a short scan at the
top. See Fig. 20.
Fig. 20
Good CHIME Scan

Bulk Responses CHIME Responses

1

This file has fairly good continuity along the scan, with few areas saturated.
The scan is sharp in the area of the bulk waves but slightly mottled at the
CHIME waves. This would be a Category A as there is no loss of the CHIME
or bulk waves.

Circumstances that will indicate the presence of corrosion will be:

• A disruption of the signals
• Changes to the patterns within the signals such as the distance
between the peaks reducing
• A curved response close to the scan surface
Typical Category A responses:
• No change in the CHIME signals other than fluctuations due to probe
manipulation and signal noise
• Thickness changes are probably unnoticeable with possible reduction
of the separation of the CHIME peaks
Typical Category B responses:
• Significant reduction of signal strength or loss of CHIME responses
• Change in the arrival times and an increase in the number and strength
of the bulk waves
• Areas of “clear” data to within three or four bulk wave signals of the
scan surface

Typical Category C responses:

• Total loss of CHIME signals
• Total loss of bulk waves or at the most one or two signals remaining
The size of an area of corrosion can be deduced by scanning the affected
area in two directions at 90° to each other.

When the signals are weakened or disappear altogether always check the
couplant monitoring channels. If in doubt rescan the area.
Cracks and laminations can provide indications similar to Category B or C
defects. If in doubt, carry out complimentary ultrasonic checks in the affected
area.
Areas of corrosion or pitting of less than 12mm width will probably not be
recorded due to the beam width.
The following pages show various CHIME files with their relevant categories.

TYPE A
No change in early signal timings. All signals present
T + T

100 - 100 -
No Corrosion
TWE 0%
WT: 7mm
150 150 - Longitudinal and
-
e circumferential scans
*»

-*
200 - 200 -

dt

i -
Shallow corrosion
(real) 130mm long
t i
x1.5mm deep
TWE 8%
WT: 19mm
Longitudinal scan
«

i ' I 1
I ' r
I ff 1 2 1 I I
TYPE B
Changes in signal magnitude/changes of arrival times of some signals at
defect, loss of latter CHIME peaks

150 -
I I J
- I

200 - ~
Gradual sided 50mm
250
— diameter and 3mm
deep pit ( artificial)
300 - TWE 12%
WT: 25mm
350 - Longitudinal scan
T
290 300 310 320 330 340 350

50 -

Corrosion (real)
150mm long x 2.5mm
100 - deep
I TWE 13%
WT: 19mm
Longitudinal scan
150 -

T T i T
10 20 30 <0 50 60 20
mm

50

Multiple pitting (real).

100 - SfcR.
Pit diameter around
*
3mm and 0-2mm deep
TWE 18%
WT: 11mm
150 -
Longitudinal scan

50 100
 150 -

200
Gradual sided
(artificial) 50mm
250 diameter and 5mm
deep pit
300 TWE 20%
WT: 25mm
350 - Longitudinal scan
T T T
230 240 250 260 270 280 290

100 - 100 -

Two 15mm
diameter machined
cones
150 - 150 - TWE 24%
mm — mm WT: 11mm
Longitudinal and
- ssm circumferential
200 - 200 -
scan

0 100 200 300 400 0 50 100 150 200 250 300

mm mm

+ V

100 - 100 -
Two 13mm
diameter machined
cones
TWE 29%
150 150 -
WT: 7mm
mm
Longitudinal and
circumferential
scans
200 - 200 -

0 100 200 300 400 0 50 100 150 200 250 300 350
 » TJ r

-
r 9

TV

-
IXZ
V
Multiple pitting
r
' & ? (real) 10-20mm
t
vV - n
diameter and 0-
** -
3mm deep
%
v

I
TWE 30%
WT: 10mm
19 '
Longitudinal scan

19

Isolated pit (real)

11mm diameter
and 2.4mm deep
TWE 32%
WT: 7.5mm
Circumferential
scan
TYPE C
Significant loss of signal but transmission of sound in the early arrivals (bulk
waves). Also timing may change. Most severe defects will result in all CHIME
and bulk wave signal missing over discrete band.

150 -
Three gradual
200
'
"'
A 50mm
diameter pits
250 - ( artificial) in a
line along
300 - beam.
Maximum
350 -
depth 14mm
350 400
TWE 44%
WT: 32mm
Longitudinal
scan

too 100 -

Machined
I - groove 100mm
I - long
—
m

150 - -
150 .
TWE 46%
--
J-C r C WT: 7.5mm
Longitudinal
200 - 200 - and
circumferential
scans
0 100 200 300 400 0 50 100 150 200 250 300
mm mm

»
91 '
Line of
- 4
3
corrosion (real)
> along full
N+~ * » - extent
between
b
CHIME
II *
probes, depth
between 4-
111 '
6.8mm.
TWE 52%
11'
WT: 13mm
II *
Longitudinal
0 S IN 21 scan
 * Four pits (real)
in line ,
diameter
between 20-
40mm
TWE 55%
WT: 12.8mm
S'
Longitudinal
scan

9 «
Machined
100 100 A groove 100mm
long TWE 24%
and single
20mm
150 150 H

mm
diameter
machined
3:
SI • cone inside
200 H 200 H —- groove
TWE 56%
WT: 7.5mm
0 100 200 300 400 0 50 100 150 200 250 300 350
Longitudinal
mm
and
circumferential
scans

+
Machined
ioo 4 — 100 H groove 100mm
k a. -
long
TWE 58%

mm
150
Hi 1504
WT: 7mm
Longitudinal
and
r circumferential
200 H 2004 scans

0 100 200 300 400 0 50 100 150 200

mm
 +
Machined
groove 100mm
100 -
long
200 - TWE 63%
WT: 10mm
mm mm
Longitudinal
150 -
250 -
and
circumferential
scans
200 - .
S SS
300 - E- -
' fc SS

150 200 250 300 350

Isolated pit
(real), 30mm
diameter and
4.8mm deep.
TWE 64%
WT: 7.5mm
Circumferential
scan

Artificial
If gradual pit
50mm
-
Hiife diameter and
14mm deep
1' TWE 76%
WT: 18mm
Longitudinal
* *»
<
scan
5 *

i
 Corrosion
(real) 225mm
long on coated
jfc
mm pipe
TWE 94%
WT: 97mm
Longitudinal
..ifSi and
circumferential
scans

Corrosion
(real) 210mm
long on coated
-
"W
'

—
-
*
£535 ;«^
V
- pipe
TWE 99%
WT: 97mm
Longitudinal
and
circumferential
scans

Isolated pit
50 H (real), 60mm
diameter and
100%through
wall.
WT: 7.5mm
iooH Circumferential
scan

150 H

60 70 80 90 100 110