PipeWIZARD ™

N° 2—09.2003 Newsletter
From the Editor
Michael Moles
michael.moles@rd-tech.com
WEPP PROJECT CONTINUES
Zheng Zhenshun
This second zhenshun@public3.bta.net.cn
edition of the
PipeWIZARD™
Newsletter gives
updates on
PipeWIZARD’s
progress through-
out the globe.
The main achievement this time has
been the WEPP (West East Pipeline
Project) in China, the world’s longest
pipeline. The Chinese have been do-
ing a very good job, largely on their
own, with multiple inspection service
companies, many different pipe pa-
rameters (wall thickness, diameter),
and different weld profiles.
The educational slant is targeted
at TOFD, Time-Of-Flight Diffraction.
TOFD was originally developed by
AEA Harwell in the UK in the 1980s
for accurate defect sizing in nuclear
reactors. However, TOFD turned out
to be very good and fast at detecting
defects as well. TOFD has since been Operating PipeWIZARD in western China.
applied very successfully in some
areas of the petrochemical indus-
The Chinese West-East Pipeline Project continues, with most of the pipe-
try (specifically pipelines), with one line now completed. Several different Chinese inspection companies are
major difference: the original nuclear using PipeWIZARD, all with success. These companies are Daqing NDT,
application used raster-type scanning North NDT, East NDT, Hualong NDT, Jiancheng NDT, and Dongfang NDT.
and signal processing, while modern
oil and gas applications use linear
scanning. Linear scanning saves a lot
of time and uses cheaper equipment, UNISPEC JOINS THE PIPEWIZARD CLUB
while the cost in defect detection and George MacLeod
info@unispec.co.uk
In This Issue Universal Inspection Systems Ltd (UNISPEC) During 2001 UNISPEC became involved
• Offshore China Investigating has its core business firmly in the inspection in Automated Ultrasonic Testing and
PipeWIZARD of pipeline welds and associated structures. late in 2002 took delivery of their first
• Brief Introduction of The company was formed in 1992 and oper- PipeWIZARD systems purchased from
Dongfang 1-1 Gas Field ates from its base in Evanton, Ross-Shire, R/D Tech. UNISPEC is currently going
• PipeWIZARD-Compatible Scotland. UNISPEC llc, a wholly owned sub- through an intensive training programme
NEW Small-Diameter Scanner sidiary is currently based in Alabama, USA. for its technicians, and the PipeWIZARD
• What You Should Know About UNISPEC’s core staff of multiskilled system is being used in conjunction with
TOFD Codes for Pipeline In- technicians work for the company both in radiography during fabrication of a 10 in.
spection the UK and internationally. The majority of pipeline. UNISPEC expect to purchase
• Enhanced Thick-Walled Weld UNISPEC technicians are competent in the further PipeWIZARD systems during the
Inspection Technique use of the company’s fleet of 20+ internal 3rd/4th quarters of 2003.
• Applying the TOFD Technique pipeline crawlers, which have a capability
working in pipelines 3 in. diameter and over.

In the Field New Products Special Collaboration TOFD Technique Track Record
PIPEWIZARD NEWSLETTER 1 R/D TECH
Page 2 Page 3 Page 4 Page 5 Page 6
 From the Editor
sizing inaccuracy is small. We look
forward to many more applications of
TOFD in the petrochemical industry.
One of the major disadvantages of
TOFD is the lack of codes; there are
two European codes (or guidelines),
but no North American codes. Our
external consultant (Ed Ginzel of the
Materials Research Institute) sum-
marizes the situation.
For new products, R/D Tech has
built a ring-type scanner for small-
and medium-sized girth welds. This
scanner has four different size ranges,
and ultimately can cover from 2.5 in.
to 16 in. (64 mm to 406 mm). The
ring-type scanner is operated with
PipeWIZARD instrumentation (that
is Tomoscan FOCUS™).
This edition also features a
description of R/D Tech’s new
OmniScan™ system, a portable, bat-
tery-operated, phased-array unit.
The OmniScan features a standard
16:128 configuration and offers rapid
scanning and imaging.
Dave Stewart, who has left R/D
Tech for Oceaneering OIS, has given
us a Tech Tip as he had before. This
tip is on carbide wear pins. We also
have an update on PipeWIZARD
owners’ activities, and an application
tailor-made for phased-arrays—pre-
mium thick-section pipe inspections.
Testimony from COOEC
Dear Sirs:
The DF1-1 pipeline is one of the
most important projects for the
CNOOC (China National Offshore
Oil Corp.) in 2003. The pressure test
on the 22 in. x 12.7 mm x 105 km
export pipeline has been completed
on July 27, 2003. It was the first time
we were carrying out pipeline weld-
ing using automatic MIG welding and
AUT, and the facts have proven that
we have achieved all of our goals.
From the feasibility study of AUT
used on our barge to the execution
stage of project, we could always
count on your help and assistance. I
would like to take this opportunity to
express my sincere thanks to you and
your team, especially, Messrs. Tom
Lee, Ed Ginzel, Pascal Piché, Zheng
and Jerry Lee; without your assis-
tance, it would have been impossible
to successfully complete the DF1-1
pipeline inspection.
I wish you good luck, and we can
foresee further cooperation in future
projects.
Ma Baojia
COOEC
PIPEWIZARD NEWSLETTER
N° 2—09.2003
In the Field
OFFSHORE CHINA INVESTIGATING PIPEWIZARD
Zheng Zhenshun
zhenshun@public3.bta.net.cn
COOEC (China Offshore Oil Engineering
Company) is involved in gas development in
the DF1-1 offshore field. PipeWIZARD™ was se-
lected for the entire project. The project is now
terminated and was very successful. A second
barge will be equipped with two units by the
end of the year.
BRIEF INTRODUCTION OF DONGFANG 1-1 GAS FIELD
The CNOOC (China National Offshore Oil Corp.) is developing the Dongfang 1-1 Gas Field,
located in the south-west part of the South China Sea, approximately 105 km off Hainan
Island, with a maximum water depth of approximately 70 meters.
The Dongfang 1-1 Gas Field development is scheduled to be implemented in three phases:
1. In the first phase, the involved facilities include a central platform (CEP), one
wellhead platform-E (WHPE), two submarine pipelines: the first is a 22 in. wide,
12.7 mm thick, and 105 km long export pipeline running from the CEP to the Dong-
fang Terminal Station (DFTS) onshore; the second is a 12 in. wide, 9.5 mm thick, and
3 km long interfield pipeline between the CEP and the WHPE.
2. In the second phase, an additional, unmanned, wellhead platform-A (WHPA) and the
relative interfield pipeline will be involved.
3. In the third phase, an additional, unmanned, wellhead platform-B (WHPB) and the
relative interfield pipeline will be involved.
The COOEC contracted to construct the first phase, which has been completed on
August 1, 2003.
Many new technologies and processes are firstly used in the pipeline project. For example,
our 3800T Lanjiang lay barge built in 2000 is firstly carried out to lay the pipeline; we then
used an automatic welding machine manufactured by Serimer Dasa and an automatic ultra-
sonic testing system manufactured by the Canadian company R/D Tech.
The pressure test of the 22 in. export pipeline and 12 in. interfield pipeline have been
completed in July 2003. The successful use of these new technologies and processes is a
milestone for the China offshore engineering enterprise.
OCEANEERING-OIS UPDATE FROM TRANSCO PROJECT
Oceaneering-OIS inspected the Bacton to
King’s Lynn pipeline, in Norfolk for Transco. It
consisted of 70 km of 48 in. x 14.27 mm and
48 in. x 20.6 mm. Murphy Pipelines was the
contractor using the CRC welding system.
With our PipeWIZARD system onboard the
Landrover AUT vehicle we found the whole
project a breeze—coping with a production of
up to 80 joints a day—this included changing
from light wall to heavy wall setups (which
takes no time at all with phased arrays). Mainline production was completed in just over 10
weeks. Both Transco and Murphy were left very pleased with the level of service provided by
Oceaneering-OIS.
2 R/D TECH
 New Products
PIPEWIZARD-COMPATIBLE
SMALL-DIAMETER SCANNER
Gaétan Fortier
gaetan.fortier@rd-tech.com
R/D Tech has developped a new pipeline
inspection system, the ring-type scanner,
and first production models have been
completed. This gives R/D Tech a full range
of pipe weld scanners from 3.5 in. and up.
This scanner consists of the ring itself,
the probe rack, the motor grip, and the
instrumentation/cart as appropriate. The ring
comes in four sizes: 3.5 in. to 6.75 in.; 7.0 in.
to 10.125 in.; 10 in. to 13.125 in.; and 13 in.
to 16 in. As such, the ring-type scanner over-
laps on PipeWIZARD™’s range at larger diam-
eters. The ring-type scanner weigh from 7 kg
to 10 kg. It offers three probe pan options:
PIPEWIZARD NEWSLETTER
N° 2—09.2003
Tech Tips from Dave
WEAR PINS
Dave Stewart
dstewart@oceaneering.com
Wear pins are
small, carbide-
tipped pins
positioned at all
four corners of
the PipeWIZARD
ultrasonic wedge,
and they drasti-
cally reduce the wear on the wedge.
These pins run on the surface of the
pipe and allow a small gap between
the surface of the pipe and the ultra-
sonic wedge. The pins are adjusted
on the calibration block to establish
a good signal from the targets and
good water flow under the wedge.
The recommended gap is 0.2 mm
to 0.6 mm. During scanning, the
wedges experience small vibrations
from running on the surface of the
pipe. These vibrations will loosen the
wear pins and cause them to move;
this in turn causes a change in the
gap between the pipe and the wedge,
which causes differences in the signal
two small phased-array and two convention-
response from the targets in the cal
al probes (ex. for TOFD); four conventional
block.
probes; two larger phased-array probes.
The recommended solution to
When used, the scanner is clamped onto
correct this problem is to install
the pipe and positioned centrally over the
wear-pin locking screws. Drawings
weld using a simple ruler guide. This is
are available from R/D Tech on how
removed, and the motor drives the scanner
to install the carbide wear-pin lock-
round the pipe. The whole operation takes
ing screws. These screws are basically
less than one minute. Various data displays
mounted on the sides of the wedge
can be used, depending on the customer’s
through the aluminum wedge holder.
or regulatory requirements: B-scans,
A hole is drilled through the wedge
C-scans, S-scans, TOFD, or a combination.
holder and wedge to the carbide
The photographs above and below show the
wear-pin hole. The new hole is then
ring scanner.
tapped with the proper thread and
the locking screw installed. This new
locking screw secures the carbide
wear pin in place, resulting in no
movement of the wear pin and
stable calibrations.
If the wedge-pipe spacing is
greater than 0.6 mm, the operator
may experience coupling loss as well
as a “double image” sometimes for
the lateral wave when using TOFD.
The best way to check the spacing
is to use a feeler gauge between the
side of the wedge and the pipe. Do
not measure the spacing from the
front or the rear of the wedge as the
pipe radius will not allow an accurate
measurement. On some calibra-
tion blocks, the wedge may not sit
3 R/D TECH
 Special Collaboration
WHAT YOU SHOULD KNOW ABOUT TOFD CODES FOR
PIPELINE INSPECTION
Ed Ginzel, Materials Research Institute
eginzel@mri.on.ca
In 1979, Maurice Silk
and his associates in
Harwell introduced the
TOFD (Time-Of-Flight
Diffraction) technique
to the world. This came
about from the need
to more accurately
size defects than had been possible using
standard amplitude methods. The success
of the method as a detection and sizing
tool has been well documented through-
out the literature.
In spite of the acknowledged success of
the TOFD method, it has been a 30-year
struggle to get meaningful codes and
standards allowing its use. Still today, it is
difficult to apply TOFD and take advan-
tage of its benefits of speed in detection,
as well as its sizing accuracy, because it is
not described in most codes referenced
by designers.
The acceptance criteria in many codes
we have to deal with in NDT had their
foundation in workmanship standards and
these were often based on the results of
what radiography could find. Flaw detec-
tion and evaluation by manual ultrasonic
testing was more difficult to regulate
because its results are heavily dependant
on the skills of the ultrasonic operator.
Computerized imaging techniques
(CITs), of which TOFD would be just one,
were first introduced in the 1992 Adden-
da (Dec. 31 1992) of Article 4 in Section
V. This finally allowed TOFD to be used
and acknowledged TOFD’s ability to both
detect and size volumetric and planar
flaws. The addenda may be considered as
the “foot in the door” that TOFD needed
to be accepted as a viable ultrasonic tool
in a regulatory-conscious world.
Parallel development was being carried
out to enlighten the potential hands-
on users about how to carry out TOFD
inspections. This led to the development
of the Standard Guides.
PIPEWIZARD NEWSLETTER
N° 2—09.2003
Standard TOFD Guides include:
• BS 7706 (1993) Guide to Calibration
and setting-up of the ultrasonic time-
of-flight diffraction (TOFD) technique
for detection, location and sizing of
flaws. British Standards Institute,
1993.
• CEN EN 583-6 Time of Flight Diffrac-
tion Technique as a method for defect
detection and sizing
Note: Although CEN EN 583-6 stipulates specific
requirements in some aspects of the test, many
aspects are addressed as recommendations as
opposed to requirements. For this reason, we
have included it with BS 7706 as a guide.
These two guides are very similar, even
following a nearly identical outline for-
mat. An ASTM TOFD standard is presently
being developed in an attempt to provide
the sort of parameter and scan limits that
a code like the ASME BPVC could use.
Recent revisions to the 1996 ASME
Code Case reduced the applicable thick-
ness to include 0.5 in. (12.7 mm) and it
specifically allows non-amplitude-based
ultrasonic techniques. This gave further
rationale to use TOFD. With the added
provisos that all flaws must be sized and
their aspect ratios compared to tables
provided in the Code Case, the need to
assess vertical extent becomes para-
mount. Again, TOFD is the solution by
providing one of the best options for as-
sessing the vertical extent of flaws.
Effective in 2003, the European
Standards Committee (CEN) has issued
a new draft Technical Specification, WI
00121377, Welding – Use of Time of Flight
Diffraction Technique (TOFD) for Test-
ing of Welds. This Technical Specification
details the application of the time-of-
flight diffraction (TOFD) technique for
the semiautomated or fully automated
ultrasonic testing of fusion welded joints
in metallic materials with a thickness of
6 mm or more. As such, it may be an ideal
document for some pipeline applications
where results of TOFD will be used in ad-
dition to the pulse-echo results.
In a more general respect, it is obvious
to more and more users that automated
ultrasonic inspections are superior to
manual UT in many regards, particularly
4 R/D TECH
where speed and repeatability are con-
cerned. Pipeline girth weld inspections are
one of the best examples of this way of
thinking. ASTM E-1961 was first published
in 1998. It had been developed to ensure
a minimum set of requirements for girth
weld AUT system. At that time in 1998,
TOFD was provided as an extra “service,”
so the ASTM E-1961 wording indicated
“TOFD may be added to improve charac-
terization and sizing.”
During a project in 1998, I was an
auditor and had observed as a company
first introduced TOFD to the collected
data. Most operators either ignored the
collected information or were not familiar
enough with the display to use it proper-
ly. More than once I pointed out that the
pulse-echo indication that was sized and
plotted on the 2D view of the weld was
in fact geometry, and it could be verified
using TOFD data. A year later, most of the
same operators would not be comfortable
without the TOFD and they were far more
competent at using it. The savings of 1 or
2 unnecessary girth weld repairs each day
because TOFD can discredit amplitude
signals as geometry instead of a repair-
able flaw has an immediate cost benefit.
After over 20 years, TOFD is being rec-
ognized as a powerful tool for NDT. But
no single NDT method finds ALL defects.
Each method has its advantages and limi-
tations. With the regulatory bodies now
gradually recognizing the strengths of
TOFD for detection and sizing, it is likely
that the financial benefits of TOFD will
now drive the industry to promote its use.
Tech Tips
square due to a slight warping of the pipe
material when it is removed for machining
(“Z” blocks). To reduce the wedge “rock”
when adjusting the pins, do the adjustments
so that the maximum signal response is
obtained while moving the scanner in the
forward direction. Never adjust carbide pins
to reduce wedge “rock” while moving the
scanner in reverse; we do not scan welds in
reverse.
 ENHANCED THICK-WALLED
WELD INSPECTION TECHNIQUE
Dave Stewart and Michael Moles
dstewart@oceaneering.com / michael.moles@rd-tech.com
R/D Tech and Oceaneering OIS
have developed and used a special,
high-quality inspection set up for
thick-walled pipe welds. The cus-
tomer wanted very high-quality
defect detection and sizing. The main
emphasis was on the root and cap
regions due to fatigue considerations.
Because of these requirements, plus
variations in wall thickness and ve-
locity, a procedure with 84 channels
was developed for the 36 mm wall.
This setup used the following chan-
nels: eight strip chart root channels
at different locations and gains, plus
three volumetric root channels; two
hot pass channels; eight fill channels;
eight cap channels; one creeping
wave channel; three midwall chan-
nels; six volumetric channels; three
centerline cap channels, all per side,
plus two TOFD and two transverse
channels. The calibration block had
44 reflectors.
Since PipeWIZARD™ is limited to 32
channels per screen, three separate
screens were used (the maximum
is 128 channels on four screens).
Because there were no time con-
straints, the operator could flip back
and forth to view the various scan
areas on the different screens. Despite
all these additional channels, the
scanner could still travel at 40 mm/s.
The welds were also inspected using
wet fluorescent magnetic particle
testing (WFMT) for surface defects,
by manual UT and by a conventional
multiprobe system. To further compli-
cate the inspection, both forged and
rolled pipes were used, with velocity
differences of up to 3%. The figure
above shows the root beam coverage
from the automated setup proce-
dure—four times the usual coverage.
PIPEWIZARD NEWSLETTER
N° 2—09.2003
APPLYING THE TOFD TECHNIQUE
Michael Moles
michael.moles @ rd-tech.com
TOFD (Time-Of-Flight Diffraction)
The TOFD technique is very useful for weld
inspections. In the last few years, the use of
TOFD has grown rapidly for a lot of applica-
tions, such as pipeline and pressure vessel
inspections.
General Description of TOFD
These tip signals allow much greater sizing
accuracy than typical amplitude methods,
at least for larger defects. TOFD scans can
also be used for characterizing defects.
Linear Scanning
In the early days of automated UT, scanning
was performed using fixed angles and a raster-
The TOFD configuration needs a transmit- type pattern (see below). This approach satis-
ter and a receiver using a wide-angle beam. fied the ASME code, but was slow and inflexible.
Normally, longitudinal waves are used, and
With the development of multiprobe sys-
these cover the full volume from a single tems and, more recently, phased arrays, linear
probe pair. TOFD detects and records signals
scanning has been used. This approach is much
diffracted from defect tips for both detection faster and can be specifically tailored to the
and sizing. Four wave types are used in TOFD:
weld profile, defects, etc., as it is the case with
• Lateral wave: A sub-near-surface longi- zone discrimination. This concept is shown be-
tudinal wave generated from the wide low. Both phased arrays and multiprobe fulfill
beam of the probe. the ASME inspection requirements.
• Backwall reflection: A longitudinal wave
TOFD also works well with linear scanning,
reflected from the back wall. and is extremely fast. This means that both
• Reflected wave: A longitudinal wave TOFD and pulse-echo can be used for pipelines
reflected by a lamellar planar defect.
and general weld inspections, with the advan-
• Tip diffracted wave: A circular L-wave tages of both. A typical scan is shown below,
diffracted by the edge of a defect. where the TOFD and PE are complementary.
TOFD is a very powerful technique, and
allows the accurate sizing of defects. The
coverage of this technique can be around
90% of the through-wall thickness. About
10% is lost in the two dead zones (ID and
OD), but the actual figure depends on the
TOFD configuration, frequency, and damp-
ing. These two dead zones are located near
the lateral wave and the backwall reflection.
To get full 100% coverage, TOFD must be
combined with the pulse-echo technique.
Conveniently, TOFD and PE are complemen-
In summary, TOFD has significant advan-
tary; the strong features of pulse-echo (for
tages: good detection in the midwall region;
instance, surface defect detection) are the
good sizing; characterization of surface-
weak points of TOFD, and vice versa.
breaking defects. TOFD’s weaknesses are
Normally, TOFD scans are displayed as offset by pulse-echo: poor detection of near
gray-scale B-scans, as shown hereafter. The surface defects; overemphasis of benign
lateral wave (OD) and backwall (ID) signals defects (such as porosity, interlamellar lack
should be clearly visible, as shown in figure. of fusion). R/D Tech strongly recommends
The tips of any defects should also be using both together, as it is the case with
clearly visible, even though signal-to-noise PipeWIZARD.
for TOFD is much lower than for pulse-echo.
5 R/D TECH
 PIPEWIZARD TRACK RECORD • AUGUST 2003
Company Location Length Diameter Wall thickness Bevel Constructor Comments
Onshore 1995
AIB Vincotte North Africa 800 km Maghreb line
conventional
Canspec Russia - Re-inspection of welds 1994 conventional
SCI South America - 1996
Institut de Soudure France ~100 km Mostly 36 in. CRC Gaz de France 1998 conventional
Canspec Ontario, Canada ~50 km Mostly 36 in. CRC TransCanada Pipelines 1997 conventional
New-Brunswick, Both PA and
Canspec/OIS ~300 km Mostly 30 in. CRC M&NP
Canada conventional
Onshore
Fernas Turkey 300 km Mostly 36 in. J-bevel Botas
conventional
Saipem Congo 63 km 8–12 in. 9.5–12.7 mm J-type AGIP Offshore S-lay
Saipem Angola 22 km 10 in. 14 mm J-type AGIP Offshore S-lay
Saipem Ivory Coast 19 km 10 in. 11–16 mm J-type Ranger Oil Offshore S-lay
OIS Scotland 4 km 12 in. 19.1 mm J-type CSOL/Bgas Onshore spool base
OIS China 60 km 26 in. 10.3 mm V-type CFPCC Onshore
Offshore J-lay.
Presto and Passo
Saipem Black Sea 640 km 24 in. 32 mm GazProm/Ini Deepest in world;
J-types
60,000 welds
Onshore double
Saipem Turkey 640 km 24 in. 32 mm Passo & subarc GazProm/Ini
jointing station
OIS UK 80 km 48 in. 15.1–21.8 mm CRC Transco Onshore
Onshore catenary
OIS USA 8 km 12–18 in. 14.3–25.6 mm CoFlexip Stena/Williams
risers
Onshore
Canspec Canada 10 km 30 in. 14 mm CRC TransCanada Pipelines
construction
OIS North Sea 35 km 10 in. 18 mm J-type Stolt Offshore/BP Offshore pipelay
Solus Gulf of Mexico 70 welds 4 in. 11 mm Manual V welds Unocal Offshore risers
Solus Nigeria - 6 in. - - - Offshore
COOEC China Sea 105 km 22 in. 12.7 mm 2003
COOEC China Sea 3 km 12 in. 9.5 mm 2003
Oceaneering OIS United Kingdom 70 km 48 in. 14.27-20.6 mm CRC Murphy 2003
WEPP ACHIEVEMENT STATISTICS

Section Company Position Quantities Completion to date

6 Daqing NDT Gansun 14 km

5 East NDT Gansu 60 km 24 km
11 North NDT Gansun 25 km 25 km
8 North NDT Gansun 40 km 30 km
7 North NDT Gansun 50 km 36 km
3 Hualong NDT Xinjiang 60 km 60 km
12 Hualong NDT Shanxi 40 km 21 km
4 Hualong NDT Xinjiang 28 km 25 km
4 Jiacheng NDT Xinjiang 130 km 2.4 km

RECENT AUT SERVICES PROVIDED TO DATE BY SAIPEM

Customer Project Lay barge Diam. [in.] WT [mm] Length [km]
AGIP Green Stream Castoro 6 32 26/30 In progress
EXXON MOBIL Kizomba FDS 20 31.8 In progress
DONG Nini Cecile Castoro 6 14 12.7 30
RAMCO Seven Heads Castoro 6 18 1588 35
OCPTEKINT Oleducto Crudos Pesados Ecuador Castoro 10 36 15.88/12.70 30
Devon Energy Panyu 4-2/5-1 field dev. Project Semac 1 12/16 11.1/12.2 18
Agip Congo Foukanda & Mwafi Castoro 8 8, 10, and 12 10 to 12.7 25
Texpan inc. Joint terminalling Prj Castoro 8 16 9.5 15
Elf EEA P.line PACF1/COBP1 Castoro 8 16 15.9 15
Ranger Oil Espoir Castoro 8 8, 10, and 12 10 to 12.7 10

PIPEWIZARD NEWSLETTER 6 R/D TECH

N° 2—09.2003
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