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14-C-053-AUT

PIPL-06.01.0001
4
08-04-2014
Automated Ultrasonic Testing
General Procedure

GENERAL PROCEDURE FOR

AUTOMATED ULTRASONIC TESTING

This is a core procedure.

All Project requirements shall be defined within a Specific Procedure document(s).

Development Revisions
Revision No. Prepared By
0
M.Wilson
1
M.Wilson
2
M.Wilson

Date
5th July 2012
2nd Feb 2013
10th Apr 2013

Approved By
J.van der Ent
J.van der Ent
J.van der Ent

3
4

31st Jan 2014

09th Apr 2014

J.van der Ent

J.van der Ent

M.Wilson
M.Wilson

Prepared by: M.Wilson

Date

th

09 Apr 2014

Reviewed by: E. van Kessel

Date

th

09 Apr 2014

Date
5th July 2012
2nd Feb 2013
10th Apr 2013
31st Jan 2014
09th Apr 2014

Amendment Details

6.1,6.3,6.7,7.2.8,7.3.2,7.3.3,7.7,
9.2, Attachment 3
Contents list
Lay-out and 7.3.3

Approved by: J. van der Ent

Date

09th Apr 2014

This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the
business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without
the permission of Applus RTD.

Applus RTD Global Project Services

If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use.
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Automated Ultrasonic Testing
General Procedure

2014 Applus RTD

Company
Address
Place
Country
Phone
Fax
Internet

Inquiries in Canada can be directed to ;

Applus RTD
5504 36 Street
Edmonton, Alberta T6P 3B3
Canada
+1 780 440 6600
+1 780 440 2538
www.applusrtd.com

Company
Address
Place
Country
Phone
Fax
Internet

Inquiries in the USA can be directed to ;

Applus RTD
Suite 200,11801 S Sam Houston Parkway W
Houston, TX 77031
United States of America
+1 832 295 5000
+1 832 295 5001
www.applusrtd.com

Company
Address
Place
Country
Phone
Fax
Internet

Inquiries in Europe can be directed to ;

Applus RTD
Delftweg 144, 3046 NC Rotterdam
P.O Box 10065, 3004 AB Rotterdam
The Netherlands
+31 10 716 6000
+31 10 415 8943
www.applusrtd.com

Company
Address
Place
Country
Phone
Fax
Internet

Inquiries in Asia can be directed to ;

Applus RTD
No.70 Kian Teck Road
628798
Singapore
+65 6430 0665
+65 6898 9704
www.applusrtd.com

Company
Address
Place
Country
Phone
Fax
Internet

Inquiries in Australia can be directed to ;

Applus RTD
94 Discovery Drive
Bibra Lake
Western Australia 6163
+61 8 9410 9300
+61 8 9410 9380
www.applusrtd.com

Company
Address
Place
Country
Phone
Fax
Internet

Inquiries in South America can be directed to ;

Qualitec RTD
Rua Petrovale, 450
Distrito Industrial MARSIL, Ibrite - MG
Brasil
+ 31 10 7166 218
+ 55 31 32881000
www.applusrtd.com

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Automated Ultrasonic Testing
General Procedure

Contents
1

Introduction

Scope

References

3.1
3.2
3.3
3.4
3.5

Internal Documents
Codes and Standards
Pipeline Contractor / Company Specific Documents
Abbreviations
Definitions

4
4
4
4
5

Personnel Qualifications

4.1
4.2

AUT Rotoscan Operator

Scanner Technicians

6
6

Rotoscan Equipment Description

5.1
5.2
5.3
5.4
5.5

Multi-Channel Ultrasonic Equipment

Recording
Scanner and Umbilical
Power Supply
Calibration Dummy Set-up

6
7
7
7
7

Rotoscan Set-Up Configuration

6.1
6.2
6.3
6.4
6.5
6.6
6.7

Inspection Set-up Configuration

Probes Used for Inspection
Creep Wave / Transverse Flaw Probes
Probe Frame Layout
Parameters of Rotoscan Inspection Program
Essential Variables
Reference Block

8
8
8
8
8
9
9

Equipment Settings

7.1
7.2
7.3
7.4
7.5
7.6
7.7

General
Setting of Inspection Gates
Sensitivity Settings
Scanning Preparation & Surface Condition
Reference Line
Datum Point
Acoustic Coupling Fluid

9
10
11
12
12
12
12

8.1
8.2
8.3

Dynamic Calibration check

Circumferential Scanning Direction
Step by Step Description of a Rotoscan Examination

9.1
9.2
9.3

General
Coupling Criteria
Imperfection length, Depth and Height

Examination

Interpretation of results

10
11

11.1
11.2

12

12
13
13
14

14
14
14

Acceptance/Rejection Criteria

15

Repairs

15

Repair Marking and Reporting

Examination of Repairs

15
15

12

Reporting

16

13

Storage of data

16

Attachment 1

Rotoscan site report

17

Attachment 2

Decision Flow Chart WMS

18

Attachment 3

Decision Flow Chart ECA

19

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Automated Ultrasonic Testing
General Procedure

Introduction

Applus RTD provides a field-proven Automated Ultrasonic Testing (AUT) system, trademarked as Rotoscan . The
system was developed for the inspection of girth welds during construction of pipelines, both on and offshore. High
inspection speed, instantaneous recording of inspection results utilizing phased array and /or conventional probe
technology that characterize Rotoscan.
The purpose of this procedure is to describe generic system configurations and methodology of Applus RTD AUT
inspection process, to determine weld integrity.
The project parameters will be documented in a Specific Procedure(s) which shall accompany this document,
describing as a minimum the following items:
x Reference Specification(s).
x Probe frame layout.
x Rotoscan parameter set-up.
x Detailed project scope (Dia, WT, WPS).
x Reference block manufacturing drawings.
x Inspection set-up configuration.
x Probe selection.
x Acceptance criteria.
Note: Deviation or alternations of the processes defined within this core procedure require the approval of the
Applus RTD AUT Technical Authority.

Scope

The Rotoscan inspection system is based upon the Pulse Echo Method, enhanced with mapping images and
Time of Flight Diffraction. The weld is divided into a number of depth zones, which are each inspected by one or
more probes or array. The probes / array are arranged such that the entire weld is examined from both sides in a
circumferential scan. The ultrasonic information is transferred to a computer for data presentation, analysis and
storage.

References

3.1 Internal Documents

Relevant internal documents specific to region and application will be referenced within the Project Specific
Procedure(s).

3.2 Codes and Standards

Applicable Codes and Standards will be defined within the Project Specific Procedure(s).

3.3 Pipeline Contractor / Company Specific Documents

Documents as supplied and required by Pipeline Contractor / Company will be defined within the Project Specific
Procedure(s).

3.4 Abbreviations
AUT
Conv
DS
FBH
MUT
OD
PE
ToFD
UT
UPS
DIA
FSH
PCS

Automated Ultrasonic Testing

Conventional
Downstream
Flat Bottom Hole
Manual Ultrasonic Testing
Outside Diameter
Pulse Echo
Time of Flight Diffraction
Ultrasonic Testing
Uninterrupted Power Supply
Diameter
Full Screen Height
Probe Centre Separation

CCW
CW
ECA
ID
NDT
PA
PRF
US
WMS
WPS
WT
HAZ
SCR

Counter Clockwise
Clockwise
Engineering Critical Assessment
Internal Diameter
Nondestructive Testing
Phased Array
Pulse Repetition Frequency
Upstream
Workmanship
Welding Procedure Specification
Wall Thickness
Heat Affected Zone
Steel Catenary Riser

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3.5

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Automated Ultrasonic Testing
General Procedure

Definitions
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

AUT Contractor Applus RTD.

AUT Operator refers to the person responsible for all ultrasonic aspects of the inspection, recording
and interpretation of results.
Band Setter Technician refers to the person responsible for adjusting the band to meet the scribe
line or weld centre.
Company shall mean owner and shall include their engineering agencies, inspectors and other
authorized representatives. Company will be defined within the Specific Procedure.
Cycle is the complete set of measurements in which all sequences are consecutively run.
Defect is an imperfection of sufficient magnitude to warrant rejection based on the criteria referenced
by this procedure.
Depth of the imperfection is the through-wall distance to the bottom of the imperfection as measured
from the outside diameter of the pipe.
Downstream the side of the girth weld nearest to the AUT scanner band.
Evaluation level (Go/No-Go) is the level for pulse echo channels from which imperfections should
be evaluated and is used to determine imperfection length.
Gate The part of the time for the moment the ultrasonic pulse has been sent that is used for data
collection and data processing (time domain). Signals outside the gate are ignored. When translated
into the distance domain (multiplying the time with the sound velocity) along the sound beam into the
weld, this is the part of the weld or in the heat affected zone in which a defect is expected.
Imperfection is a discontinuity or irregularity that is caused by the welding process and is not related
to geometry indications.
Indication is evidence obtained by non-destructive testing.
Instruction is a description of the steps to be followed when preforming an NDT procedure.
Interzonal Imperfection is one that occurs at the overlap of two adjacent ultrasonic zones.
Length of an imperfection will be defined if it has at least one amplitude value equal to or greater than
the evaluation level.
May verbal form used to indicate a course of action permissible within the limits of the procedure.
Pipeline Contractor is company fabricating pipeline. Contactor shall be defined within the Specific
Procedure.
Procedure is a step-by-step description of the application of an NDT method.
Reference Sensitivity is the initial sensitivity applied to any reflector as applicable.
Rotoscan Applus RTD trade name for our AUT System.
Scanner Technician refers to the person responsible for maintaining and operating the AUT scanner.
Scanning Sensitivity is the additional sensitivity added to the reference sensitivity.
Scribe Technician (Pipeline Contractor) refers to the person responsible for scribing the reference line
on the pipe after weld bevel has been prepared.
Sequence is a separate ultrasonic function (measurement) as executed within a cycle. Channel
numbers are allocated to a sequence to associate them with a probe / focal law connection.
Shall is a mandatory term, from which no deviation is permitted
Should indicates that among several possibilities, one is recommended as particularly suitable, without
mentioning or excluding others, or that a certain course of action is preferred but not necessarily
required.
Stacked Imperfection consists of multiple discrete imperfections in different weld passes occurring
at the same circumferential location.
Threshold level is the level for pulse echo channels from which amplitude and transit distance are
recorded by the system.
Through Wall Height dimensions of the imperfection will be called the Vertical Height of the
imperfection.
Upstream the side of the girth weld furthermost to the AUT scanner band.
UT Channel Convention is the way UT channels are called from the inside out, i.e. from centre
screen and are called Root, Hot Pass, Fill-channels, and Cap.

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General Procedure

Personnel Qualifications

4.1 AUT Rotoscan Operator

x
x
x
x

Be qualified in accordance with the Applus RTD Written Practice, specific to the region.
Only accredited personnel qualified to level II or Level III UT (applicable certification body is referenced in
the Project Specific Procedure(s)) shall interpret the test results.
Be trained and passed the Applus RTD Rotoscan in-house course for Automated Ultrasonic Testing.
If required, be trained and passed Applus RTD in-house course(s) for specific advanced techniques, SCR as
example.

4.2 Scanner Technicians

Be trained in using an Automated UT-scanner to the satisfaction of the AUT Rotoscan Operator.

Rotoscan Equipment Description

5.1 Multi-Channel Ultrasonic Equipment

Multi-channel ultrasonic equipment shall be used, which provides for an adequate number of inspection channels
(referred to as sequences) to ensure a complete volumetric examination of the through weld thickness in one
circumferential scan. In cases where a single circumferential scan is not possible due to small diameter or heavy
wall thickness combinations, two scanners maybe required, one OD scanner covering the upper level of the weld
and one ID scanner which will cover the lower level of the weld. When ID/OD AUT setups are required, as a
minimum a single Pulse Echo zone at the transition point between ID & OD will be present on both scans to ensure
overlap between the inspection set ups.
Each inspection channel will provide a linear A scan presentation, which can be individually selected.
The system meets the following minimum requirements:

5.1.1 Software
Applus RTD Rotoscan software version 5 or higher.

5.1.2 Global Parameters

Number of Sequences
Digitizer Sampling Frequency
Overall System PRF

: Specific to the weld design

: 50/100 MHz (as a minimum 5 times centre frequency of probes in use)
: up to 10 KHz

5.1.3 Gate Parameters

In each
x
x
x
x
x
x
x
x
x
x
x

sequence, the following parameters shall be selectable:

Transmitter and receiver channel numbers.
Gain -100 dB to +100 dB (0.1 dB increments).
Gate start and length (min increment 0.1mm).
Delay in 1mm increments.
Threshold level 0% - 100% Full Screen Height (FSH) (1% increments).
Recordable output selection between; Amplitude and/or Transit Distance, Mapping, All Channels Mapping,
ToFD and Coupling.
Selection between First / Highest amplitude detection within the gated section.
Wave Velocity (Compression / Shear Wave / User Defined).
Selection between Phased Array and Conventional Probe.
Go/No-Go (Project Specific).
Mapping Colour Palette (Project Specific).

5.1.4 Phased Array Probe Parameters

In each
x
x
x
x
x

sequence, the following parameters can be programmed or selected:

Sequence Angle(s).
Number of Skips.
Number of elements used.
Single or Tandem configuration.
Focused / Unfocused.

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5.1.5 Signal to Noise

Electronic noise shall be lower than acoustical noise in all sequences.
For all probes, except Creep Wave and Transverse flaw probes, the acoustical noise shall be at least 20 dB
weaker than the signal from the reference reflector at the target distance. For Creep Wave and Transverse flaw
probes the acoustical noise should be at least 16 dB weaker than signal form the reference reflector at the target
distance.

5.2 Recording
Inspection results are presented on-line with a colour monitor. The screen layout and number of used sequences
are configured to present the thickness of the weld to be examined. Distance delays are applied to the output
channels to compensate for variable probe circumferential positioning therefore achieving a coherent display
presentation.
The following information is presented:
x Pulse echo channels section (US/DS), recording amplitude and relevant transit distance (superimposed).
x All channel mapping section (US/DS), digitized pulse echo image converted into colour/mapping pattern.
x Mapping image sections (US/DS), digitized pulse echo images for pattern recognition purposes of cap
reinforcement and root penetration.
x Go/No-Go image section.
x Coupling check section.
x ToFD image section / ToFD View.
x Circumferential position information.
x Header section with possibility to present job specific information.
x Time and date of inspection.
x Indication mark-up.
x Wall Thickness recording check (if applicable).
x Wedge Temperature (if applicable).

5.3 Scanner and Umbilical

The scanner/umbilical to be used should meet the following minimum requirements:
x Automated operation during examination.
x Easy and quick mounting to the guide-band.
x Capable of taking up a minimum of 10 individually spring loaded ultrasonic probes, of which the distances
to the weld centreline can be individually set.
x Coupling controllable per probe, or per set.
x 15-45 metres of umbilical cable length.
x The scanner is equipped with an encoder for accurate measurement of the scanner position around the
pipeline circumference.
x Resolution (counts/mm)
:1/mm.
x Scanning speed
:20-80 mm/sec (depending on inspection configuration).

5.4 Power Supply

The Rotoscan system shall have a dedicated power supply. In the event of mains power failure the UPS shall be
used as a means of alternative supply, enabling completion of already commenced scanning / data collecting.

5.5 Calibration Dummy Set-up

The calibration dummy set-up consists of a support of the same diameter as the project pipe. Within this support
there is a cut-out area, which is where the Reference block(s) are mounted. Unless otherwise specified in the
Project Specific Procedure(s), the Reference Standard(s) shall be manufactured from uncoated project specific pipe
with the same surface condition as that to be inspected in production. On the support, a guide band is mounted at
the same distance from the Reference block centreline as the guide band on the weld to be tested.

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Rotoscan Set-Up Configuration

6.1 Inspection Set-up Configuration

Zonal discrimination method will be used for inspection (refer to Figure 1, example only). The inspection set-up is
documented and described in the Project Specific Procedure(s).

Figure 1 Example zonal discrimination

6.2 Probes Used for Inspection

When using either conventional or PA probes for a particular inspection zone, coverage shall be taken into
consideration. The beam (spot size) at the designated distance (target reflector) should be such that signals from
the adjacent zone reflectors in the vertical axis (at the same angle of incident) are present at the defined levels
stipulated within the Project Specific Procedure.
The selected probes and their parameters for each set up configuration shall be included in the Project Specific
Procedure(s).
All probes have a unique number for QA/QC purposes, which relate to the manufacturing process and tests
conducted by either Applus RTD probe department or the supplying manufacturer.
These probe numbers become part of the inspection parameter file held within the Rotoscan inspection program.

6.3 Creep Wave / Transverse Flaw Probes

The following probes should be employed unless otherwise dictated by the Pipeline Contractor and/or Company;
a.

Transverse flaw probes should be integrated in the AUT inspection system in the following cases;
i.
In specific welding processes where the likelihood of transverse cracking occurs (i.e. SMAW).
ii.
Is specified in the applicable standard and/or client specification not being waived by Company.

b.

Creep Wave should be integrated in the AUT inspection system in the following cases;
Fatigue sensitive welds having weld cap reinforcement that may interfere with defect detection
capability using full skip inspection functions.
ii.
Is specified in the applicable standard and/or client specification not being waived by Company.
i.

6.4 Probe Frame Layout

The probes used for inspection are positioned within a probe frame. The position of each probe in the
circumferential direction and their inspection functions is detailed into the Project Specific Procedure(s).

6.5 Parameters of Rotoscan Inspection Program

During inspection all parameter settings of the Rotoscan program are stored on the computer hard drives
together with all inspection data. The settings for each inspection sequence are subject to adjustments within the
defined essential variables.

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6.6 Essential Variables

A. Probe Parameters
x Change in frequency, crystal size or number of elements.
x Change in beam angles greater than the applicable applied Code/Standard or Client specific deviation.
x Specified PA wedge angle.
B. Material (steel all grades)
x Changes in nominal wall thickness outside of the manufacturing tolerances and/or Client Specifications.
x Changes in nominal pipe diameter.
C. Gates
x Changes in transit distance greater than the defined tolerances stated in the Project Specific Procedure(s).
D. Threshold Levels
x Change in Project Specific Procedure(s) mandatory defined threshold levels.
E. Software
x A change of software version (unless written permission is provided by the Company).
F.

WPS
x Tolerances on bevel outside the relevant WPS in relation to Reference Standard.
x Changes in type of consumable or alternations within the WPS that may affect the validity of the Reference
block(s) if manufactured to include a project specific weld.

6.7 Reference Block

The Reference block(s) shall be used to verify the system for field inspection and to monitor on-going system
performance.
Reference block(s) shall be manufactured from a section of project specific line-pipe of matching wall thickness
supplied by the Company. For all Reference block(s) it shall be defined within the Project Specific Procedure(s) any
intended treatment of the OD and ID surfaces (sand blasted, partial machining (skimming) etc.). Reference
block(s) shall be designed such that the reflectors simulate the bevel geometry to be inspected and incorporate
Pipeline Contractor / Company specification requirements.
The Reference block(s) shall be designed with sufficient surface area to enable the probe array to scan the target
areas in one single pass.
The principal calibration reflectors shall be as per the requirements stated in the Specific Procedure. The central
axis of each FBH calibration reflector shall coincide with the central axis of the sound beam interrogating it. The
lateral position of each calibration reflector(s) shall be such that there will be no interference from adjacent
reflectors, or from the edges of the block.
The Reference block shall be manufactured and tested according to Applus RTD verification procedure referenced
in the Project Specific Procedure(s). The Reference block shall be identified with a hard stamped unique serial
number.
The Project Specific Procedure(s) shows the Reference block(s) manufacturing drawings.

Notes: Through-holes 2 mm or 5 x 1 mm slots in both ends of calibration block at centreline are to locate weld
centre position only.

Equipment Settings

7.1 General
The ultrasonic equipment shall be electronically calibrated in accordance with the relevant valid version of Applus
RTD control procedure for verification. This shall be referenced in the Project Specific Procedure(s).

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7.2 Setting of Inspection Gates

7.2.1 General
All gates shall be programmed to record amplitude and/or transit distance information.

7.2.2 Threshold level

The threshold level is based on data from the AUT system validation/qualification and is set low enough (% FSH) to
detect the minimum critical defect height identified in the acceptance criteria and shall be at all times lower than
the programmed evaluation or Go-NoGo level. The setting of the threshold level shall be defined in the Project
Specific Procedure(s).

7.2.3 Pulse-Echo (single transmit/receive) Channels

With each probe or element group positioned for the peak signal response from the relevant calibration reflector,
the detection gates are to be set.
The gate shall start at least 3-8mm (allowance for the width of heat affected zone) before the theoretical weld
bevel preparation. The gate ends will normally end 1mm after the theoretical weld centreline. The through drilled
holes or slots are used to identify the correct end position of set gates. The gate length of the transit distance in
the root channel will be extended to enable root penetration recognition.

7.2.4 Pulse-Echo (separate transmit/receive - Tandem) Channels

With each tandem configuration positioned for the peak signal response from the relevant calibration reflector, the
detection gates are to be set.
The gate position shall be set to accommodate the sound path applicable for the wall thickness in use, taking into
account possible wall thickness variations. The overall gate length (gate start and gate end) shall be set in such
way that the HAZ and weld centreline are covered.

7.2.5 Mapping Channels

The mapping gate shall start at least 3-5mm (allowance for width of heat affected zone) before the theoretical
weld bevel preparation. The gate length will be extended to enable cap reinforcement registration where applicable
or to establish over trace from adjacent mapping zones.
The mapping gates in the root will be set identical to the pulse echo transit distance channels to enable the
recognition of the root penetration.

7.2.6 ToFD Channel

The ToFD technique relies on the interaction of ultrasonic waves with the tips of discontinuities. This interaction
results in the emission of diffracted waves over a large angular range. Detection of the diffracted waves makes it
possible to establish the presence of the imperfection. The time-of-flight of the recorded signals is a measure for
the height of the imperfection, thus enabling sizing of the defect. The dimension of the imperfection is always
determined from the time-of-flight of the diffracted signals. The signal amplitude is not used in size estimation.
The ToFD gate will be set nominally 1sec or at 1mm before the arrival of the lateral wave and should extend past
the first back-wall echo and or mode converted echo (longitudinal / shear), to achieve full volumetric examination
of the through thickness of the weld. If warranted (either by wall thickness or Company request) two ToFD
channels can be employed. For double ToFD channels the theoretical crossing of beam centres at the weld
centreline should be at 66 to 95% of the wall thickness for one channel and approximately 33% of the wall
thickness for the other channel.

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7.2.7 Coupling Channels

For conventional probes with the exception of ToFD and Transverse flaw probes, coupling is set up using the pitch
/ catch technique (through weld). Using both Upstream and Downstream probes with identical zonal functions, the
sensitivity is established and gated.
With PA probes through weld and/or longitudinal zero degree (back wall) can be utilized. The number of coupling
channels, (through weld / back wall, method) for PA probes shall be defined within the applicable Project Specific
Procedure(s).
The coupling sensitivity values and threshold levels shall be defined within the Project Specific Procedure(s).
Coupling Verification
A re-examination of the Reference block with its surface wiped dry shall produce a record showing a lack of
couplant, i.e. absence of recording signal.

7.2.8 Pulse Echo Sizing Curves

All Sizing curves shall be programmed into all PE channels prior to any inspection within the Rotoscan software.
The curve shall be relative to the reflector and applicable zone height.

7.3 Sensitivity Settings

7.3.1 Pulse Echo Sensitivity Settings
With each chosen probe (conventional) or element group (PA) positioned for peak signal response from its
applicable calibration reflector (FBH or Notch) the reference sensitivity shall be set. The reference sensitivity (echo
amplitude) for all pulse echo channels shall be set nominally at 80% FSH.
Any project variance in relation to PE channel sensitivity requirements shall be defined within the Project Specific
Procedure(s).

7.3.2 Mapping Sensitivity Settings

Mapping channels in the body of the weld will be used to detect the presence of porosity and in addition to identify
the position of weld cap reinforcement for pattern recognition purposes. The sensitivity is normally set from a 1.5
mm FBH with additional dB added as defined in the Project Specific Procedure(s), but shall not be so great as to
cause interfering electrical or geometric noise that could be misinterpreted.
The sensitivity setting for mapping in the root, as a minimum, is equal to the related pulse echo channels,
increased with additional dB as defined in the Project Specific Procedure(s) to ensure proper detection but shall not
be so great as to cause interfering electrical or geometric noise that could be misinterpreted.

7.3.3 ToFD Sensitivity Settings

The lateral wave (RF signal) of the ToFD channel should be such that the unrectified signal response is between
40% and 80% FSH (refer to Figure 2 below).

+20-40% FSH

20-40% FSH

Figure 2 Example of Lateral Wave Screen Height Percentages (rectified)

In cases when use of the lateral wave is not applicable, e.g. surface conditions and steep beam angles, the
amplitude of the back wall signal shall be set at between 12 to 24 dB above FSH.

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General Procedure

The PCS for ToFD should be calculated at 2/3 of the wall thickness (nominal beam angle). The ToFD display on the
calibration scan shall demonstrate the ability to detect the smallest applicable root notch with a response at least 6
dB greater than adjacent grain noise.

7.4 Scanning Preparation & Surface Condition

Spiral welds or long seams shall to be ground flush over the scanning area at a minimum distance as to have no
effect of probe placement. The scanning area shall be free of weld spatter and other irregularities, which may
interfere with the inspection. The surface condition shall be equivalent to the applicable Reference block. The
surface condition and cap width shall be monitored by the scanner technician throughout production to ensure
there is no impact on the integrity of the AUT inspection.
When the surface condition prevents or interferes with scanning, the Pipeline Contractor / Company Representative
shall be informed.
Any weight coating application needs to be at a minimum defined cutback as to not to interfere with band
placement and scanner travel. Distance of required cutback as applicable shall be defined within the Project
Specific Procedure(s).

7.5 Reference Line

Prior to welding, a reference line shall be scribed on the pipe surface at set distance from the centreline of the weld
preparation, on the inspection band side. This is to be placed on the pipe by Contractor personnel. Training and the
scribe tool will be supplied by Applus RTD. The line shall be checked periodically (at least once every 2 hours) by
the Pipeline Contractor and maintain a tolerance of +/-0.5mm
The reference line (scribe line) shall be used to ensure that the band is adjusted to the same distance from the
weld centreline as to mimic the Reference block.

7.6 Datum Point

The zero reference point and scanning direction shall be clearly marked on the surface of the pipe before
commencement of scanning (data acquisition).

7.7 Acoustic Coupling Fluid

Salt free water shall be used as acoustic coupling fluid and be able to test welds up to 70C (unless otherwise
specified in the Project Specific Procedure(s)). The coupling is supplied between the probe contact surface and the
pipe via supply channels incorporated in the probe housing.
For winter construction (ea. North America) methanol or similar medium shall be used. This medium shall be
recovered, and filtered prior to reuse. No residue shall remain on the pipe surface after the liquid has evaporated.
Glycol mixes shall NOT be used.

Examination

8.1 Dynamic Calibration check

The calibration sensitivity shall be verified on the Reference block piece. Re-calibration shall be carried out if any of
the following exist:
x The reference sensitivity values fall outside the tolerances detailed in the Project Specific Procedure(s).
x The gate settings need to be adjusted by more than the previous calibration tolerances detailed in the
Project Specific Procedure(s);
x After an equipment break down and hardware changes;
In case the calibration differs from the initial setting, outside the given tolerances, the applicable probe(s) and
coupling shall be checked.
If the settings have to be changed to achieve an acceptable calibration, the welds before this calibration up to the
previous calibration will be re-evaluated taking the differences in the gain and/or gate adjustment into account.
Re-scanning shall be carried out from last valid calibration:
x After an equipment breakdown.
x If hardware changes have to be made to scanner to achieve a valid calibration.

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The result of each calibration scan may be printed or converted to pdf format and be stored on hard drive(s). Each
calibration will have the same number as the next corresponding weld with the applicable defined designation,
(example, Cal) as a postfix. Calibration performed at the end of a shift or after weld repairs shall use the same
number as the last weld inspected with the defined designation, (example, CalOut) as a postfix.
Calibrations are performed in the same direction and at the same nominal speed as the weld.
Calibration Frequency At the start of every shift and at intervals not exceeding one hour or ten consecutive
welds, or whichever comes first and at the conclusion of every shift, unless otherwise defined in the Project Specific
Procedure(s).

8.2 Circumferential Scanning Direction

The circumferential scanning direction shall be clockwise when viewed from the upstream side of the pipe in the
direction of construction. Reverse scanning may only be used where access, geometry or coating prohibits
clockwise scanning. All reverse scans shall be clearly marked in the comments section of the AUT software
program.
The encoder accuracy is to be verified following the steps outlined below:
x Physically measure the pipe circumference.
x Enter the measured circumference into the AUT software program.
x Perform a scan and compare the stop position of the scanner in relation to the 0 mm mark on the weld.
The difference, if any, shall be within the specified tolerance of +/- 10 mm. Once verified, add an
appropriate overlap relevant to pipe diameter, but no less than 50mm.
x During scanning, the functioning of the encoder shall be checked continuously at the end of each scan,
checking the end position of the last probe related to the 0 mm position.

8.3 Step by Step Description of a Rotoscan Examination

Before beginning an examination an acceptable calibration shall have been recorded.
The following description outlines the step by step process for 5G/6G orientation. For 2G positioned welds the start
point (datum) will need to be defined.
1. Adjust guiding band on the pipe to set distance from the scribe line (weld centreline) and parallel to the
weld. The accuracy of the band setting should be 1mm.
2. Mark a 0 datum point, illustrating scan direction on the top of the pipe at the 12 oclock position.
3. Attach the scanner to the band.
4. Switch on the water coupling supply.
5. Locate the scanner over the top of the pipe and make sure that all probes are past the zero point and are
in proper contact with the pipe surface.
6. Switch on the system and automatically the weld will be scanned in a clockwise direction.
7. The system will switch off automatically after a full scan with the appropriate overlap.
8. Check the encoder position of an indication at the start of the scan and confirm the position of that same
indication in the overlap, maximum difference in position allowed is 10mm.
9. Check the inspection results on defect indications and proper coupling. Use the transit distance recording,
mapping and images for validation of defect indications within the root area and proper alignment of the
guiding band.
10. If lack of coupling exists that exceeds the applicable limits, a second scan will be necessary.
11. Remove the scanner from the band and attach it to the calibration block.

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Interpretation of results

9.1 General
With the transit distance measurements and information from the Mapping and ToFD channels visible on the result
presentation, indications shall be judged whether they are from the weld geometry or weld imperfections.
Indications produced by ultrasonic testing may or may not be imperfections. Changes in the weld geometry due to
misalignment, cap profile, root penetration, internal chamfering and ultrasonic wave mode conversion may cause
geometric indications similar to those caused by weld imperfections but that are not relevant to acceptability.

9.2 Coupling Criteria

The coupling channels will be checked for coupling loss.
A rescan shall be carried out when coupling loss in a single channel equal to or exceeding the smallest allowable
defect, and or concurrent coupling loss in two adjacent channels occurs
Where coupling loss is due to the surface condition (e.g. grinding, oxidation) the affected area may be improved by
Pipeline Contractor and the weld re-scanned. If the loss of coupling cannot be resolved, with Company / Pipeline
Contractor acceptance, a combination of MUT, in accordance with Project MUT Procedure(s) and ToFD shall be
used to inspect the relevant area.
The location and inspection zone impacted by the loss of coupling will be recorded in the comments section of
the Rotoscan weld scan.
Note: Coupling criteria may be altered if dictated by the Client or applicable specification. Any deviation from
above criteria will be included in the Project Specific Procedure(s).

9.3 Imperfection length, Depth and Height

The inspection result should be evaluated and/or reported as follows;

9.3.1 Length
All indications in the pulse echo channels shall be evaluated which exceed the threshold level as defined in the
Project Specific Procedure(s).
Defect length in the pulse echo channels shall be measured at the Evaluation (Go/No-Go level as defined in the
Project Specific Procedure(s). The AUT Operator shall take lateral beam spread into account in defect evaluation as
shown in Figure 3 below. All beam spread calculations shall be performed at the Evaluation (Go/No-Go) level as
defined within the Project Specific Procedure(s) from echo dynamics derived from the calibration scan.

Lateral Beam Spread

determined by
Calibration Scan

Defect Length

Evaluation (Go/No-Go) Level

Threshold Level

Figure 3

Note: If two indications are spaced closer than the width of the beam, the lateral beam spread correction must be
conservative. That is, the beam spread correction can be applied to one indication or partly to both indications, but
the total beam spread cannot be applied separately to both defects.

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Depth

Defect depth from OD surface will be established using ToFD. Where no clear ToFD signal is evident, depth shall be
established using pulse echo channels.
An Interzonal imperfection is defined as a single flaw, which is seen by adjacent channels. To be considered
Interzonal, the echo dynamics and the circumferential positioning should be similar. In the case of Interzonal
imperfections, only the imperfection and not the overtraces of the imperfection are to be sized. Where the echo
dynamics differ, the imperfection will be considered larger than the beam or stacked and reported as such. In all
channels mapping it can determined whether the indication is a single or multiple flaw by checking the following:
1.

Comparing transit distance in the adjacent zones.

2.

Compare the indication for pattern recognition in the adjacent zones.

3.

Comparing circumferential positions and length.

The interpretation sequence to be followed is visualized in Attachment 2 and 3, Decision Flow Chart for WMS and
ECA.

9.3.3 Height
Determine the height of the indication in the applicable pulse echo channel(s). Where the indication is present in
more than one PE channel (adjacent), it shall be established whether indications are derived from Single or
Multiple imperfections. In cases where it has been established that (1) defect is present in more than one
channels, the overall height needs to be measured taking into account relevant over trace values taken from the
previous calibration.
If there are resolvable ToFD (clear diffraction Upper and Lower tip) signals for the indication, then the ToFD
measurement for height shall be used.
The interpretation sequence to be followed is visualized in Attachment 2 and 3, Decision Flow Chart for WMS and
ECA.

9.3.4 Interaction
The interaction rules within the relevant Standard / Code applicable to the Project, or specifically defined by
Contractor / Company shall be taken into account when determining overall imperfection length or height. The
interaction shall be defined within the Project Specific Procedure(s).
Where possible the (Code dependant) interaction module of the software should be used to determine imperfection
interaction.

10 Acceptance/Rejection Criteria
The Acceptance/Rejection criteria shall be defined by the Pipeline Contractor or Company. This may be included as
an addendum to the Project Specific Procedure(s) or issued as a separate document by the Contractor.

11 Repairs

11.1 Repair Marking and Reporting

All repairs shall be marked (start, stop and depth of defect) on the pipe by Applus RTD personnel and a repair
indication sheet should be produced and handed over to Welding Foreman or their delegate.

11.2 Examination of Repairs

Repaired areas shall be inspected with the same AUT configuration that originally detected the imperfection. This
inspection will demonstrate that the original imperfection is removed and that no new imperfections are
introduced to the weld.
MUT should be used in addition to the Rotoscan inspection in accordance with appropriate approved procedure.
If the repair requires a cut-out, re-examination will be conducted using the Rotoscan equipment set-up for the
bevel defined in the relevant WPS.

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12 Reporting
The Applus RTD Rotoscan site report, as shown in Attachment 1, shall be used for reporting of inspection results.
The following information will be documented as minimum:
x Used procedure number;
x Project name/number;
x Weld No;
x Inspection date;
x Diameter;
x Wall thickness;
x Number of indications, location on circumference and location in depth;
x Acceptable or Rejectable.
An example of file naming, for Mainline Weld ML 1234;
x ML 1234 Cal
: Calibration scan performed prior to mainline weld
x ML 1234
: Scan of mainline weld
x ML 1234 CalOut : Calibration scan performed at shift end.
The naming and numbering system for weld files will be determined at project commencement in cooperation with
the Contractor / Company.

13 Storage of data
The raw data of each inspected weld including the parameter settings shall be stored on the main hard drive (CDrive). In addition, a full back-up shall be made on a second removable hard drive.
The Date and Time function shall be used to ensure that all welds scanned are accounted for. By selecting this
function the date and time of each scan made becomes part of the file name, removing the chance of overwriting
any file.
Welds shall be stored in directories which will be created every 24hrs. Operators are responsible for the daily
directory on the main hard drive and shall ensure that all welds are present and readable.
All calibration and weld inspection results should be printed in a compressed black-white image of the entire weld
circumference after an acceptable scan is completed or saved to PDF.
After completion of the pipeline project, all data (NDT, welds, repairs and calibrations) will be stored on a digital
medium, including a viewer program and presented to Client.
The official record of inspection shall be the Applus RTD Rotoscan Site Report (or other if specified by Client) and
shall bear the original signature of the AUT Applus RTD Rotoscan Operator.

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Attachment 1

Rotoscan site report

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Attachment 2

Decision Flow Chart WMS

Decision Flowchart Workmanship Acceptance Criteria

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Attachment 3

Decision Flow Chart ECA

Decision Flowchart ECA Acceptance Criteria

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