Procedure for Time-of-Flight Diffraction Technique (TOFD) of Welds

Doc No- NDT_TOFD_SR Rev. 00

1. Scope: This procedure is to be used for non-destructive testing method of Semi-Automated Time-of-Flight Diffraction
Ultrasonic Testing by contact examination for both detection and sizing of discontinuities in low alloyed carbon steel
welds (Welded by GTAW, SMAW). This Procedure shall be used with specified scanning plan and using Omniscan MX2
with HSMT scanner only, Qualified thickness range: 15 to 50 mm of plate butt weld (longitudinal) and the temperature
differential between the calibration block and examination surfaces shall be within 25-degree F (14 degree C). This
document specific for Examination “levels (according to ISO 10863:2020) A & B” and acceptance criteria are as per EN
ISO 15626:2018.
2. Revision & Approval Details:
Revision Status: 00 Revision Date: 17.09.2021 Description of Revision: New / Re-
write
Prepared By- Reviewed By- Approved By-
Signature: Signature: Signature:

Name : Name : Name :

Date : Date : Date :
Level : Level : Level :
3. Reference:
3.1 BS EN ISO 10863:2020
3.2 BS EN ISO 16828:2014
3.3 BS EN ISO 15626:2018
3.4 BS EN ISO 16810-2014
3.5 BS EN ISO 16811-2014
3.6 BS EN ISO 17640:2018
3.7 BS EN 12668-1,2 & 3:2013
3.8 BS EN ISO 9712:2012
4. Abbreviations & Terminology:
4.1 TOFD- Time-of-Flight Diffraction
4.2 PCS- probe Centre Separation
4.3 GTAW- Gas Tungsten Arc Welding
4.4 SMAW- Shielded Metal Arc Welding
5. Attachments:
5.1 Attachment-1: Non-parallel scan, with the typical direction of probe displacement shown on the left and the
corresponding B-scan shown on the right.
5.2 Attachment-2: Parallel scan, with the typical direction of probe displacement shown on the left and the
corresponding B-scan shown on the right.
5.3 Attachment-3: Reference Block for set the system sensitivity correctly & to establish sufficient volumetric
coverage.
5.4 Attachment-4: Recommended TOFD setups for simple butt welds dependent on wall thickness.
5.5 Attachment-5: Reference block containing notches- Figure A.4
5.6 Attachment-6: Reference block containing Reference block containing side-drilled holes and a notch Figure A.5
5.7 Attachment-7: Table-A.1, A.2 & A.3.
5.8 Attachment-8: A Sample Scan Copy for 20 mm Plate Butt Weld.
6. Non-compliance:
6.1 If there is any in accessible area, prior permission needs to be taken from end customer & shall be mentioned
in TOFD report.
6.2 Whenever Offset scanning required, if needed butt joints should be ground flash.
6.3 If any repair or malfunctioning happen then Equipment calibration is must and retest.
6.4 If the offered job is not matching with the on job permanent identification, get clarification from production.
And only after necessary correction TOFD to be performed.
6.5 If any visible surface opening defect noticed stop the inspection and informed respective person to do first
surface NDE and rectify the observed defect and then only do TOFD examination.
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Procedure for Time-of-Flight Diffraction Technique (TOFD) of Welds
Doc No- NDT_TOFD_SR Rev. 00

6.6 Any Non-Compliance as mentioned below during TOFD examination need to check the calibration of the
equipment and retest, re-evaluate all affected joints.
• Non-qualified operator or qualification expired operator engaged
• Couplant loss or damaged wedges / accessories use while scanning
• Damaged Equipment or probe use
In addition to above points if any changes that may affect the desired output of TOFD data and result, shall be
recorded and considered as non-compliance and action to be taken accordingly.
7. Safety: During performing TOFD all EHS norms of GE, Statutory and Regulatory requirements need to be complied. In
addition, below mentioned requirement shall be met.
7.1 If required work permit to be taken before execution for Work at Height, High Noise area or Confined place.
7.2 Electrical safety tested equipment’s only will be utilized.
7.3 For Site specific conditions, appropriate Induction training shall be provided to elaborate the site safety hazards
and its allied associated risks.
7.4 Appropriate PPE shall be utilized by the testing personnel while carrying out the testing
8. NDT Personnel: In addition to a general knowledge of ultrasonic weld testing, all personnel shall be competent in
the TOFD technique. Documented evidence of their competence (level of training and experience) is required.
8.1 When data collection is performed by personnel qualified to Level 1 according to ISO 9712, a written test
instruction shall be prepared.
8.2 Preparation of written test instructions, final off-line analysis of data, and acceptance of the report shall be
performed by personnel qualified as a minimum to Level 2 in accordance with ISO 9712 or equivalent in
ultrasonic testing in the relevant industrial sector.
8.3 In accordance with a written instruction and under the supervision of Level 2 or Level 3 personnel, equipment
setup, data acquisition, data storage, and report preparation can be performed by personnel qualified to a
minimum of Level 1 in accordance with ISO 9712 or equivalent in ultrasonic testing in the relevant industrial
sector.
Note: For data acquisition, the Level 1 personnel may be supported by an assistant technician. In cases where the above minimum
qualifications are not considered adequate, job-specific training shall be carried out.

8.4 The candidate (All Level) shall provide documentary evidence of satisfactory vision in accordance with the following
requirements:
• Near vision acuity shall permit reading a minimum of Jaeger number 1 or Times Roman N 4.5 or equivalent
letters (having a height of 1.6 mm) at not less than 30 cm with one or both eyes, either corrected or
uncorrected.
• Colour vision shall be sufficient that the candidate can distinguish and differentiate contrast between the
colors or shades of grey used in the NDT method concerned, as specified by the employer.

Note: The certification body may consider replacing the requirements in a) by compliance with an appropriate alternative.
9. Test Equipment:
9.1 Ultrasonic Instrument: Ultrasonic equipment used for the TOFD technique shall, as a minimum, comply with
the requirements of EN 12668-1, EN 12668-2 and EN 12668-3.The ultrasonic instrument used for the TOFD
technique shall comply with the requirements of ISO 22232‑1, where applicable. The TOFD software shall not
mask any problems such as loss of coupling, missing scan lines, synchronization errors or electronic noise. In
addition, the requirements of ISO 16828 shall apply, taking into account the following:
9.1.1 receiver bandwidth shall, as a minimum, range between 0,5 and 2 times the nominal probe
frequency at - 6 dB, unless specific materials and product classes require a larger bandwidth.
Appropriate band filters can be used;
9.1.2 transmitting pulse can either be unipolar or bipolar. The rise time shall not exceed 0,25 times the
period corresponding to the nominal probe frequency;
9.1.3 unrectified signals shall be digitized with a sampling rate of at least six times the nominal probe
frequency;
9.1.4 for general applications, combinations of ultrasonic equipment and scanning mechanisms shall be
capable of acquiring and digitizing signals with a rate of at least one A-scan per 1 millimetre scan

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length. Data acquisition and scanning mechanism movement shall be synchronized for this
purpose;
9.1.5 to select an appropriate portion of the time base within which A-scans are digitized, a window with
programmable position and length shall be present. Window start shall be programmable between
0 μs and 200 μs from the transmitting pulse, window length shall be programmable between 5 μs
and 100 μs. In this way, the appropriate signals can be selected to be digitized and displayed;
9.1.6 digitized A-scans should be displayed in amplitude related grey or single-colour levels, plotted
adjacently to form a B-scan. See Attachment-1 and Attachment-2 for typical B-scans of non-
parallel and parallel scans respectively. The number of grey or single-colour scales should at least
be 64;
9.1.7 for archiving purposes, the equipment shall be capable of storing all A-scans or B-scans (as
appropriate) on a magnetic or optical storage medium such as hard disk, tape or optical disk. For
reporting purposes, it shall be capable of making hard copies of A-scans or B-scans (as appropriate);
9.1.8 equipment should be capable of performing signal averaging. In order to achieve the relatively high
gain settings required for typical TOFD-signals, a pre-amplifier may be used, which should have a
flat response over the frequency range of interest. This pre-amplifier shall be positioned as close
as possible to the receiving probe.
9.1.9 The instrument shall be able to select an appropriate portion of the time base within which A-scans
are digitized.
9.1.10 It is recommended that a sampling rate of the A-scan of at least 6 times the nominal probe
frequency be used.
9.2 Ultrasonic probes: Ultrasonic probes used for the TOFD technique shall comply with at least the following
requirements:
9.2.1 number of probes: 2 (transmitter and receiver);
9.2.2 type: any suitable probe
9.2.3 wave mode: usually compression wave; the use of shear wave probes is more complex but may be
agreed upon in special cases;
9.2.4 both probes shall have the same centre frequency within a tolerance of ± 20 %; for details on probe
frequency selection;
9.2.5 pulse length of both the lateral wave and the back wall echo shall not exceed two cycles, measured
at 10 % of the peak amplitude;
9.2.6 pulse repetition rate shall be set such that no interference occurs between signals caused by
successive transmission pulses.
9.2.7 Probes used for the TOFD technique on welds shall also comply with ISO 22232‑2. Adaptation of
probes to curved scanning surfaces shall comply with ISO 17640. A recommendation for the
selection of probes is given in Attachment-4 (Table 2).
9.3 Scanning mechanisms: Scanning mechanisms shall be used to maintain a constant distance and alignment
between the index points of the two probes. An additional function of scanning mechanisms is to provide the
ultrasonic equipment with probe position information in order to enable the generation of position-related B-
scans. Information on probe position can be provided by means of e.g. incremental magnetic or optical
encoders, or potentiometers.
9.3.1 Scanning mechanisms in TOFD can either be motor or manually driven. They shall be guided by
means of a suitable guiding mechanism (steel band, belt, automatic track following systems,
guiding wheels, etc.).
9.3.2 Guiding accuracy with respect to the centre of a reference line (e.g. the centre line of a weld) should
be kept within a tolerance of ± 10 % of the probe index point separation (probe centre separation
PCS).
10.Instrument Checks:
10.1 Linearity of The Timebase: This check is carried out using a standard calibration block defined in EN ISO 2400
or EN ISO 7963, and a normal-beam compression wave probe or shear wave angle-beam probe. The linearity
shall be checked over a range at least equal to that which is to be used in subsequent testing. Where
appropriate, due allowance can be made for the fact that a range of 91 mm for compressional waves in steel is
equivalent to a range of only 50 mm for shear waves.

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10.1.1 Procedure: Place the probe on the calibration block in a position where the range to the last
backwall or radius echo is equal to or exceeds the range over which the linearity shall be checked.
Adjust the timebase so that the first and the sixth backwall echoes coincide with the first and last
scale marks respectively. Check the linearity with the four other echoes.
Bring the backwall echoes, in turn, to approximately the same height e.g. 80 % full screen height.
The leading edge of each echo should line up with the appropriate graticule line. Check that any
deviations from the ideal positions are within the specified tolerance when measured at the same
screen height when the first and the sixth echo were positioned.
10.1.2 Tolerance: The deviation from linearity shall not exceed ± 2 % of full screen width.
10.1.3 The check shall be carried out at least once per week for ultrasonic instruments to be used during
that week.
10.2 Linearity of equipment gain: This check monitors the combined result of two characteristics that affect the
linearity of the equipment gain, i.e. the linearity of amplifier and the accuracy of the calibrated gain control. Any
standard calibration block can be used for this test, preferably in conjunction with the probe that will be used
in subsequent testing.
The linearity shall be checked with the ultrasonic instrument controls (frequency, range, pulse energy, etc.)
switched to positions to be employed in subsequent testing. Variable suppression and swept gain controls shall
be switched to “off”.
10.2.1 Procedure: Position the probe on a calibration block to obtain a reflected signal from a small
reflector e.g. the 5 mm hole in the EN ISO 7963 block.
Adjust the gain to set this signal to 80 % of full screen height and note the value of the calibrated
gain control (dB). Then increase the gain by 2 dB and confirm that the signal rises to more than full
screen height (101 %). Restore the gain to its original value and then reduce it by a further 6 dB.
Confirm that the signal amplitude falls to approximately 40 % screen height. Successively reduce
the signal by three further increments of 6 dB and confirm that the signal amplitude falls
respectively to 20 %, 10 % and 5 % screen height.
10.2.2 Tolerance: To be acceptable, signal amplitude shall be within the limits given in the below Table.

10.2.3 The check shall be carried at least once per week for ultrasonic instruments to be used during that
week.
11.Equipment Set-Up Procedures:
11.1 General: Probe selection and probe configuration are important equipment set-up parameters. They largely
determine the overall accuracy, the signal-to-noise ratio and the coverage of the region of interest of the TOFD
technique. The set-up procedure described in this subclause intends to ensure:
11.1.1 sufficient system gain and signal-to-noise ratio to detect the diffracted signals of interest;
11.1.2 acceptable resolution and adequate coverage of the region of interest;
11.1.3 efficient use of the dynamic range of the system.
11.2 Probe choice and probe separation:
11.2.1 Probe selection: In this clause typical probe arrangements are given for TOFD in order to achieve
good detection capabilities on both thin and thick specimens. Note that these arrangements are
not mandatory and that the exact requirements to achieve a specification should be checked.

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11.2.1.1 For steel thicknesses up to 70 mm, a single pair of probes can be used. The recommended
probe selection parameters to achieve sufficient resolution and adequate coverage are
shown in below Table 1 for three different ranges of wall thicknesses.

11.2.1.2 For thicknesses greater than 70 mm, the wall thickness shall be divided into more than
one inspection zone, each zone covering a different depth region. Below mentioned Table

2 shows the recommended centre frequencies, transducer sizes and nominal probe angles
to achieve sufficient resolution and adequate coverage for thick materials from 70 mm up
to 300 mm. These zones can be inspected simultaneously or separately.
11.2.1.3 For butt welds of simple geometry and with narrow weld crowns at the opposite surface,
the testing shall be performed in one or more setups (scans) dependent on the wall
thickness (see Attachment-4). For other configurations, e.g. X-shaped welds, different
base metal thickness at either side of the weld, or tapering, Attachment-4 may be used
as guidance. In this case, the effectiveness and coverage of the setup shall be verified by
using reference blocks. Selection of probes for full coverage of the complete weld
thickness should follow Attachment-4.
11.2.1.4 For testing levels A and B, it is recommended that the TOFD setup be verified by the use
of reference blocks. For testing levels C and D, all the setups chosen for the test object
shall be verified by use of reference blocks.
11.2.1.5 If setup parameters are not in accordance with Attachment-4, the capability shall be
verified by using reference blocks. For in-service inspection the intersection point of the
beam centerlines should be optimized for the specified volume to be tested.
11.2.2 Probe Separation: The maximum diffraction efficiency occurs when the included angle is about
120°. The probes should be arranged such that the (imagined) beam centre lines intersect at about
this angle in the depth region where discontinuities are anticipated/sought.
Deviations of more than – 35° or + 45° from this value may cause the diffracted echoes to be weak
and should not be used unless detection capabilities can be demonstrated.
11.3 Time window setting: Ideally, the time window recorded should start at least 1 μs prior to the time of arrival of
the lateral wave, and should at least extend up to the first back wall echo. Because mode converted echoes can
be of use in identifying defects, it is recommended that the time window recorded also includes the time of
arrival of the first mode-converted back wall echo signal.
11.3.1 For full-thickness testing using only one setup, the time window recorded should start at least 1 μs
prior to the time of arrival of the lateral wave, and should extend beyond the first mode-converted
back-wall signal, where possible.
11.3.2 If more than one setup is used, the time windows shall overlap by at least 10 % of the depth range.
11.3.3 The start and extent of the time windows shall be verified on the test object.

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11.3.4 As a minimum requirement, the time window recorded shall at least cover the depth region of
interest, as shown e.g., in Tables 1 and 2.
11.3.5 Where a smaller time window is appropriate (e.g., to improve sizing accuracy), it will be necessary
to demonstrate that discontinuity detection capabilities are not impaired, for instance by using
representative flaws or diffracting artificial defects in a reference block as described in Annex A.
11.4 Time-to-depth conversion: This setting shall be verified (for all testing levels) by a suitable block of known
thickness (accuracy 0.05 mm). At least one depth measurement shall be performed in the depth range of
interest, typically by recording a minimum of 20 A-scans. The measured thickness or depth shall be within 0.2
mm of the actual or known thickness or depth. For curved components geometrical corrections can be
necessary.
11.5 Sensitivity setting: Setting of range and sensitivity shall be carried out prior to each testing. Any change of the
TOFD setup, e.g., probe centre separation (PCS), requires a new setting. Noise should be minimized, e.g., by
signal averaging.
11.5.1 The probe separation and the time window shall be set to those values that will be used in the
subsequent inspection. The aim is to make sure that the signals from discontinuities are within the
range of the digitizer and that the limiting noise is acoustic rather than electronic.
11.5.2 he equipment settings (electronic noise suppression and system gain) are to be adjusted such that
the electronic noise prior to the arrival of the lateral wave indication is at least 6 dB lower in
amplitude than within the region of the time-base after the arrival of the lateral wave. The latter
should be set to approximately 5 % of the amplitude scale.
11.5.3 The sensitivity setting can now be checked making use of representative flaws or diffracting
artificial defects in a reference block as described in Annex A. The results can be used to justify
reducing the gain setting or give warning that the signal-to-noise ratio is insufficient.
11.5.4 For all testing levels, the sensitivity shall be set on the test object.
11.5.4.1 The amplitude of the lateral wave shall be between 40 % and 80 % of full screen height
(FSH).
11.5.4.2 In cases where the use of the lateral wave is not appropriate (e.g., because of surface
conditions, use of steep beam angles), the sensitivity shall be set such that the amplitude
of the back-wall signal is between 18 dB and 30 dB above FSH.
11.5.4.3 When the use of neither a lateral wave nor a back-wall signal is appropriate, sensitivity
should be set such that the material grain noise is between 5 % and 10 % of FSH.
11.5.5 For testing levels B, C, and D, it shall be verified by the use of the test block(s) that the sensitivity
is sufficient to detect real discontinuities in the respective depth zone or, if not available, machined
discontinuities (e.g. notches, side‑drilled holes)
11.6 Scan resolution setting: It is recommended to record one A-scan per mm of probe displacement. The scan
increment setting shall be dependent on the wall thickness to be tested.
11.6.1 For thicknesses up to 10 mm, the scan increment shall be no more than 0.5 mm.
11.6.2 For thicknesses between 10 mm and 150 mm, the scan increment shall be no more than 1 mm.
11.6.3 Above 150 mm, the scan increment shall be no more than 2 mm.
11.7 Setting of scanning speed: Scanning speed shall be selected such that it is compatible with the requirements of
11.3 to 11.6.
12.Checking System Performance: It is recommended that system performance is checked before and after an
inspection by recording and comparing a limited number of representative A-scans.
12.1 Checks to confirm the range and sensitivity settings shall be performed at least every 4 h and on completion of
the testing.
12.2 Checks shall also be carried out whenever a system parameter is changed or changes in the equivalent settings
are suspected.
12.3 If a reference block was used for the initial setup, the same reference block should be used for subsequent
checks. Alternatively, a smaller block with known transfer properties may be used, provided that this is cross-
referenced to the initial reference block.

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12.4 Where a reference block was not used, but instead the test object was used for checking, then subsequent
checks shall be carried out at the same location as the initial check.
12.5 If deviations from the initial settings, in accordance with 9.4 and 9.5, are found during these checks, the

corrections given in Table 3 shall be carried out.

13.Preparation for Testing:
13.1 Volume to be tested: The purpose of the testing shall be defined by specification. Based on this, the volume to
be tested shall be determined. The volume to be tested is located between the probes. For testing levels A and
B, the probes shall be placed symmetrically about the weld centerlines. For testing levels C and D, additional
offset scans may be required.
13.1.1 For manufacturing inspection, the volume to be tested is defined as the zone which includes weld
and parent material for at least 10 mm on each side of the weld or the width of the heat-affected
zone, whichever is greater. In all cases, the whole volume to be tested shall be covered.
13.1.2 Normally these tests are performed in accordance with recognized standards applying acceptance
levels for quality assurance. If fitness-for-purpose methods are applied, then corresponding
acceptance criteria shall be specified.
13.1.3 For in-service inspections, the volume to be tested may be targeted to specific areas of interest,
e.g. the inner third of the weld body. The acceptance criteria and minimum discontinuity size to be
detected in the area of interest shall be specified.
13.2 Preparation of Scanning Surfaces: Scanning surfaces shall be wide enough to permit full coverage of the volume
to be tested.
13.2.1 Scanning surfaces shall be even and free from foreign matter likely to interfere with probe coupling
(e.g. rust, loose scale, weld spatter, notches, grooves).
13.2.2 Waviness of the test surface shall not result in a gap between one of the probes and test surface
greater than 0.5 mm. These requirements shall be ensured by dressing, if necessary.
13.2.3 Scanning surfaces may be assumed to be satisfactory if the surface roughness, Ra, is not greater
than 6.3 μm for machined surfaces, or not greater than 12.5 μm for shotblasted surfaces.
13.2.4 In addition, such features of the surface of the object that may give rise to errors of interpretation
shall be removed prior to examination.
13.3 Provision of datum points: In order to ensure repeatability of the testing, a permanent reference system shall
be applied.
14.Temperature: When using conventional probes and couplants, the surface temperature of the test object shall be
in the range 0 °C to 50 °C. For temperatures outside this range, the suitability of the equipment shall be verified.
15.Couplant: In order to generate proper images, a couplant shall be used which provides a constant transmission of
ultrasound between the probes and the test object. The couplant used for calibration shall be the same as that used in
subsequent testing and post-calibrations.
15.1 Different coupling media can be used, but their type shall be compatible with the materials to be examined.
Examples are: water (possibly containing an agent e.g. wetting, anti-freeze, corrosion inhibitor), contact paste,
oil, grease, cellulose paste containing water, etc.
15.2 The characteristics of the coupling medium shall remain constant throughout the examination. It shall be
suitable for the temperature range in which it will be used.
16.Data Recording: All raw data recorded during the examination, stored on a magnetic or optical storage medium
such as hard disk, tape or optical disk shall be kept for later reference. Data file name shall include: Project No, Component
No, Joint No, Segment No (If applicable) and Examination Stage.

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17.Reference blocks: Depending on the testing level, a reference block shall be used to determine the adequacy of
the testing (e.g. coverage, sensitivity setting). Recommendations for sample reference blocks are given in Attachment-3.
17.1 The reference block should be made of similar material to the test object (e.g. with regard to sound velocity,
grain structure and surface condition).
17.2 Reference Block Thickness: The thickness of the reference block should be representative of the thickness of
the test object. Therefore, the thickness should be limited to a minimum and a maximum value related to the
thickness of the test object.
17.2.1 Thickness of reference blocks is recommended to be between 0.8 times and 1.5 times the thickness
of the test object with a maximum difference in thickness of 20 mm compared to the test object.
Care should be taken
that on the centreline
between the probes
there is no angle smaller
than 40° at the bottom
of the reference block
(see Figure A.1). The
minimum thickness of
the reference block
should be chosen such
that the beam
intersection point of the chosen setup is always within the reference block (see Figure A.2).
17.3 The length and width of the reference block should be chosen so that all the artificial discontinuities within the
area of interest can be captured within the appropriate scan range.
17.4 Reference Block Curvature: For testing of longitudinal welds in cylindrical test objects, curved reference blocks
shall be used having diameters from 0.9 times to 1.5 times the diameter of the test object. For objects having a
diameter ≥300 mm, a flat reference block may be used.

17.5 Reference Block Reflectors:

17.5.1 For thicknesses between 6 mm and 25 mm, at least three reflectors are required. For thicknesses
>25 mm, at least five reflectors are required. Typical reference reflectors used are side-drilled holes
and notches. Different shapes of notches may be used provided
they generate diffracted signals. The reflectors may be machined
in one or more blocks as follows:
17.5.1.1 One notch at the bottom of the block with length, ln,
and height, hn, (see Table A.1 in Attachment-7).
17.5.1.2 One side-drilled hole located at 4 mm below the
surface, with a diameter of 2 mm and a length of 30 mm.
17.5.1.3 One side-drilled hole located at t/2 below the surface,
with a diameter Dd (see Table A.2 in Attachment-7) and a length of 45 mm. Alternatively,
a notch at the scanning-surface with a depth of t/2, a tip angle of 60° (see Figure A.3), a
width dsn (Table A.2 in Attachment-7) and a minimum length of 40 mm may be used.
17.5.2 For a thickness >25 mm, at least five reference reflectors are recommended (see Figures A.4 and
A.5). The reflectors may be machined in one or more blocks as follows:
17.5.2.1 One notch at the bottom of the block with length, ln, and height, hn (see Table A.1 in
Attachment-7).
17.5.2.2 One side-drilled hole located at 4 mm below the surface, with a diameter of 2 mm and a
minimum length of 30 mm.
17.5.2.3 Three side-drilled holes located at t/4, t/2 and 3t/4 below the surface, with a diameter Dd
(see Table A.2 in Attachment-7) and a length l (see Table A.3 in Attachment-7).
Alternatively, three notches at the scanning-surface with depths of t/4, t/2 and 3t/4, a tip
angle of 60° [see Figures A.3 and A.4 (in Attachment-5)], a width dsn (see Table A.2 in
Attachment-7) and a minimum length of 40 mm may be used.
17.5.3 The tolerances for all the dimensions are: Diameter: ±0.2 mm, Length: ±2 mm, Angle: ±2°.

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18.Testing of base material: The base material does not generally require prior testing for laminations (typically
by using straight-beam probes), as they are detected during the TOFD weld testing. Nevertheless, the presence of
discontinuities in the base material adjacent to the weld can lead to obscured areas or to difficulties in interpretation of
the data.
19.Examination: The two probes are scanned parallel to the weld at a fixed distance and orientation in relation to the
weld centreline. Data collected during a scan can be used for detection and sizing purposes. Further evaluation of TOFD
indications as detected during the initial scanning may require additional scans such as offset scans, scans perpendicular
to the discontinuity or complementary TOFD setups.
19.1 Scanning speed shall be chosen such that satisfactory images are generated (For details see 12.2 of ISO
10863:2020). The scanning speed is dependent on scan increment, signal averaging, pulse repetition frequency,
data acquisition frequency, and the volume to be tested. Missing scan lines can indicate that too high a scanning
speed has been used. A maximum of 5 % of the total number of lines collected in one single scan may be missed,
but no adjacent lines shall be missed.
19.2 If a weld is scanned in more than one part, an overlap of at least 20 mm between the adjacent scans is required.
When scanning circumferential welds, the same overlap is required for the end of the last scan with the start of
the first scan.
19.3 Reduction of signal amplitude of lateral wave, back-wall signal, grain noise, or mode-converted signals during a
scan by more than 12 dB can indicate loss of coupling. If coupling loss is suspected, the area shall be re-scanned.
If the results are still not satisfactory, appropriate action shall be taken.
19.4 Saturation of the lateral wave or excessive grain noise (>20 % of FSH) during scanning requires corrective action
and re-scanning.
20.Interpretation and analysis of TOFD images: Interpretation and analysis of TOFD images are generally
performed by:
▪ Assessing the quality of the TOFD image,
▪ Identification of relevant TOFD indications and discrimination of non-relevant TOFD indications.
▪ Classification of relevant TOFD indications in terms of:
• embedded (linear, point-like),
• surface breaking.
▪ Determination of location (typically position in x-direction and z-direction) and size (length and
through-wall extent).
▪ Evaluation against acceptance criteria.
20.1 Assessing the Quality of the TOFD Image: A TOFD test shall be carried out such that satisfactory images are
generated which can be evaluated with confidence.
Satisfactory images are defined by appropriate:
▪ coupling
▪ data acquisition
▪ sensitivity setting
▪ time-base setting
Assessing the quality of TOFD images requires skilled and
experienced operators (see 7.1). The operator shall decide
whether unsatisfactory images require new data acquisition
(re-scanning). Examples of satisfactory TOFD images are given
in B.1, for unsatisfactory TOFD images please see Figures B.2
to B.8 of ISO 10863.

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20.2 Identification of Relevant TOFD Indications: Satisfactory TOFD images shall be assessed for the presence of
TOFD indications. TOFD indications are identified by patterns or
disturbances within the image.
TOFD is able to image discontinuities in the weld as well as
geometric features of the test object. In order to identify TOFD
indications of geometric features, detailed knowledge of the test
object is necessary. Those TOFD indications arising from the
intended or actual shape of the test object are considered as
non-relevant. Examples of geometric TOFD indications are given
in B.3 (see Figures B.15 to B.18 of ISO 10863).
To decide whether a TOFD indication is relevant (caused by a
discontinuity), patterns or disturbances shall be evaluated
considering shape and signal amplitude relative to general noise
level. To determine the extent of a TOFD indication, it can be necessary to take into account the grey level values
or patterns of neighboring sections.
20.3 Classification of Relevant TOFD Indications: Amplitude, phase, location and pattern of relevant TOFD
indications can contain information on the type of a discontinuity. Relevant TOFD indications are classified as
indications from either surface-breaking or embedded discontinuities by analyzing the following features:
▪ disturbance of the lateral wave,
▪ disturbance of the back-wall reflection,
▪ TOFD indications between lateral wave and back-wall
reflection,
▪ phase of TOFD indications between lateral wave and
back-wall reflection,
▪ mode-converted signals after the first back-wall
reflection.
Some typical TOFD images of discontinuities in fusion-welded
joints are provided in Figures B.9 to B.14 of ISO 10863.
20.3.1 TOFD Indications from Surface-Breaking Discontinuities: Surface-breaking discontinuities can be
classified into three categories:
20.3.1.1 Scanning surface discontinuity: This type shows up as an elongated pattern generated by
the signal emitted from the lower edge of the discontinuity and a weakening or loss of the
lateral wave (not always observed). The TOFD indication from the lower edge can be
hidden by the lateral wave, but generally a pattern can be observed in the mode-
converted part of the image. For small discontinuities, only a small delay of the lateral
wave can be observed.
20.3.1.2 Opposite surface discontinuity: This type shows up as an elongated pattern generated by
the signal emitted from the upper edge of the discontinuity and a weakening, loss, or
delay of the back-wall reflection (not always observed).
20.3.1.3 Through-wall discontinuity: This type shows up as a loss or weakening of both the lateral
wave and the back-wall reflection accompanied by diffracted signals from both ends of
the discontinuity.
20.3.2 TOFD Indications from Embedded Discontinuities: TOFD indications of embedded discontinuities
usually do not disturb the lateral wave or the back-wall reflection. Embedded discontinuities can
be classified into three categories:
20.3.2.1 Point-like discontinuity: This type shows up as a single hyperbola-shaped curve which can
lie at any depth.
20.3.2.2 Elongated discontinuity with no measurable height: This type appears as an elongated
pattern corresponding to an apparent upper edge signal.
20.3.2.3 Elongated discontinuity with a measurable height: This type appears as two elongated
patterns located at different positions in depth, corresponding to the lower and upper
edges of the discontinuity. The TOFD indication of the lower edge is usually in phase with
the lateral wave. The TOFD indication of the upper edge is usually in phase with the back-
wall reflection.

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20.3.3 Unclassified TOFD Indications: TOFD indications that cannot be classified in accordance with
Clause-20.3.1 and 20.3.2 can require further testing and analysis.
20.4 Determination of Location: The location of a discontinuity in the x-direction and z-direction is determined from
the data collected in accordance with Clause 19.
The location of a point-like discontinuity is sufficiently described by its x-coordinate and z-
coordinate. The location of elongated discontinuities shall be described by the x-coordinates and
z-coordinates of their extremities.
If the location in the y-direction, additional scans are necessary in accordance with ISO 16828.
If a more accurate determination of the location is required, reconstruction algorithms, e.g.
synthetic aperture focusing calculations (SAFT), may be used.
20.5 Definition and Determination of Length and Height: The size of a discontinuity is described by the length
and height of its indication. Length is defined by the difference of the x‑coordinates of the indication.
The height is defined as the maximum difference of the z‑coordinates at any given x‑position. For
details see below Figures 1, 2 and 3.

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20.5.1 Determination of length: Depending on the type of indication, one of the techniques for length
sizing according to 20.5.1.1 or 20.5.1.2 shall be applied.
20.5.1.1 Length sizing of embedded indications: A
hyperbolic cursor is fitted to the indication.
Assuming the discontinuity is elongated and
has a finite length, this is only possible at each
end. The distance moved between acceptable
fits at each end of the indication is taken to
represent the length of the discontinuity (see
Figure 4).
20.5.1.2 Length sizing of elongated curved surface-
breaking indications:This type of indication
does change significantly in the through‑wall
direction. A hyperbolic cursor is positioned at
either end of the indication at a time delay of
one third of the indication penetration. The
distance moved between the cursor positions
at each end of the indication is taken to
represent the length of the discontinuity (see
Figure 5).
20.5.2 Determination of height: The height determination
shall be done from the A‑scan and by choosing a consistent position on the signals, if applicable,
taking phase reversal into account. It is recommended to use one of the following methods (as
shown in Figure 6):
▪ method 1: by measuring the transit time between the leading edges of the signals,
▪ method 2: by measuring the transit time between the first peaks,
▪ method 3: by measuring the transit time between the maximum amplitudes,
▪ method 4: by measuring the transit time between the first zero crossings of the signals.

20.5.2.1 Surface‑breaking discontinuities: The height of an indication of a surface‑breaking

discontinuity at the scanning surface is determined by the maximum difference between
the lateral wave and the lower‑tip diffraction signal (see Figure 1). For a surface‑breaking
discontinuity at the opposite surface, the height is determined by the maximum
difference between the upper‑tip diffraction signal and the back-wall reflection (see
Figure 2).
20.5.2.2 Embedded discontinuities: The height of an indication of an embedded discontinuity is
determined by the maximum difference between the upper‑tip diffraction signal and the
lower‑tip diffraction signal at the same x‑position (see Figure 3).
20.6 Evaluation Against Acceptance Criteria: After classification of all relevant TOFD indications and after
determination of their location and size, they shall be evaluated against specified acceptance criteria, for details
see Clause-21. Based on this evaluation, the TOFD indications can be categorized as “acceptable” or “not
acceptable”.

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21.Acceptance Criteria:
21.1 Relation Between Quality Levels and Acceptance Levels: Three different acceptance levels are defined. The
relation between these acceptance levels and the quality levels as mentioned in ISO 5817 and Examination

level according to ISO 10863 are given in above Table 1. Classified indications are evaluated according to one
of the acceptance levels listed in 21.2 and 21.3
considering the additional explanations for groups of
indications and for point-like indications in 21.4 and
21.5, respectively. For welds joining two different
thicknesses, the acceptance levels are based on the
thinner of the two. For welds subject to dynamic
loading or being sensitive to cracking (e.g. longitudinal,
transverse), more stringent near‑surface acceptance
levels or the use of additional NDT techniques may be
specified.
21.2 Indications from Single Discontinuities: The symbols h1, h2 and h3 used in Tables-3 [Acceptance level 2 for
Examination Level-B] and Table-4 [Acceptance level 3 for Examination Level-A] are explained in Figure 7.

21.3 Total Length of Indications: The sum of the lengths of the individual indications with height larger than h1
measured along the weld over a length of 12 t shall be less than or equal to:
▪ 3.5 t with a maximum of 150 mm, for acceptance level 1,
▪ 4.0 t with a maximum of 200 mm, for acceptance level 2,
▪ 4.5 t with a maximum of 250 mm, for acceptance level 3.

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21.4 Grouping of Indications: Point‑like indications and indications with height smaller than h1 are not considered
for grouping. Grouping of indications is based on the size and the separation of individual indications. The length
and the size of a group shall not be used for further grouping. For evaluation, a group of indications shall be
considered as a single one if:
▪ the distance between two individual indications along the weld is less than the length of the longer
indication, and
▪ the distance between two individual indications in the thickness direction of the weld is less than
the height of the higher indication.
▪ In case of an indication with varying height, the maximum local height, h, as shown in Figure 6 shall
be used.
▪ hg for a grouped indication is defined as the sum of the heights of the individual indications plus
the distance between them (see Figure 8).
▪ lg for a grouped indication is defined as the sum of the lengths of the individual indications plus
the distance between them (see Figure 8).

Indications 2 and 3 shown in Figure 8 shall be treated as a single one, because their separation in
the x‑direction is smaller than l and their separation in the z‑direction is smaller than h.
Indication 1 is not included in the group, because the separation in the z‑direction is larger than h.
21.5 Point‑like indications: The following applies to all acceptance levels. The maximum acceptable number, N, of
single diffraction signals in any 150 mm of weld length can be calculated with Formula (1):

N = 1,2 t / mm (1)
▪ Where,
• N is rounded to the higher integer,
• t is the thickness, given in millimeters.

21.6 An Alternative method can be used to examine the dead zone area of TOFD.

22.Cleaning & Restoration:

▪ If any repair found, on job repair marking shall be done with permanent marker with the details of
length, depth & reference and same to be mentioned in report.
▪ Job surface shall be properly cleaned and all the applicable couplant shall be removed.
▪ A thin layer of non-corrosive oil/substance can be apply for protect the materials.
23.Test Report: The test report shall include at least the following information:
23.1 A reference to ISO 10863,
23.2 Information relating to the object under test:
▪ identification of the object under test,
▪ dimensions including wall thickness,
▪ material type and product form,
▪ geometrical configuration,
▪ location of tested welded joint(s),
▪ reference to welding process and heat treatment,
▪ surface condition and temperature, if outside the range 0 °C to 50 °C,
▪ stage of manufacture.
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23.3 Information relating to the test equipment:

▪ manufacturer and type of the TOFD equipment including scanning mechanisms with identification
numbers if required,
▪ manufacturer, type, frequency, transducer size and beam angle(s) of the probes with identification
numbers if required,
▪ details of the reference block(s) with identification numbers if required,
▪ type of couplant used.
23.4 Information relating to the test technique:
▪ testing level and reference to a written test instruction or procedure, if required,
▪ purpose and extent of test,
▪ details of datum and co-ordinate systems,
▪ details of TOFD setups,
▪ method and values used for range and sensitivity settings,
▪ details of signal averaging and scan increment setting,
▪ details of offset scans, if required,
▪ access limitations and deviations from this document, if any.
23.5 Information relating to the test results:
▪ acceptance criteria applied,
▪ TOFD images of at least those locations where relevant not-acceptable TOFD indications have been
detected,
▪ tabulated data recording the classification, location and size of relevant TOFD indications and
results of the evaluation,
▪ date of examination,
▪ name, qualification and signature of the examiner or any other responsible for the examination.
23.6 In addition, TOFD examination reports shall contain the following information:
▪ identification of the manufacturer, and/or the order,
▪ complete identification of the examined object,
▪ place of examination,
▪ state of examination object,
▪ reference to contractual documents (standards etc.),
▪ reference to the examination procedure,
▪ results of examination and evaluation,
▪ any deviation from the procedure.

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Attachment-1 Attachment-2

Attachment-3

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Attachment-4

Recommended TOFD setups for simple butt welds dependent on wall thickness
Attachment-5 Attachment-6

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Attachment-7

Attachment-8

24.Revision History:
Revision Status Description of Revision Prepared Approved / Reviewed
Status Date By Date By Date
00 17.09.2021 New / Re-write SR 17.09.2021 VG 17.09.2021

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