PAUT-PoD Demonstration, Mock-Up Validation And Code Compliance Support

Demonstrate that your PAUT technique can detect, locate and size the required discontinuities before production inspection begins.

Integrity & Advanced Inspection Solutions India Private Limited provides comprehensive technical support for PAUT Probability of Detection demonstrations, customized flawed mock-ups, technique validation, procedure qualification and compliance documentation.

Our integrated approach combines PAUT Level III expertise, scan-plan development, reference-block manufacturing, realistic flaw implantation, customized wedges, scanners and encoded data analysis.

What Is a PAUT PoD Demonstration?

PoD means Probability of Detection. A PAUT PoD demonstration evaluates whether a proposed inspection technique can reliably detect specified discontinuities under defined conditions.

Depending on the project, the demonstration may evaluate:

➤ Detection capability

➤  Weld-volume coverage

➤ Indication positioning

➤ Length-sizing accuracy

➤ Through-wall sizing accuracy

➤ Near-surface detection

➤ Far-surface detection

➤ Repeatability

➤ Signal-to-noise performance

➤ False-call performance

➤ Operator and analyst capability

A project-specific technical demonstration should not automatically be described as a statistically established PoD study. A formal statistical PoD programme normally requires a sufficient number of controlled trials, flaws and test conditions supported by an approved analysis method.

Where a full statistical study is not required, we can conduct a documented PAUT performance demonstration or technique-validation trial.

Why Is PAUT Validation Required?

A PAUT instrument may generate clear images while still providing incomplete coverage or insufficient sensitivity in critical areas.

Inspection performance can be affected by:

➤ Material properties

➤ Weld geometry

➤ Component thickness

➤ Pipe curvature

➤ Probe frequency

➤ Wedge design

➤ Beam angle

➤ Focal depth

➤ Defect orientation

➤ Surface condition

➤ Scanner alignment

➤ Calibration-block suitability

➤ Inspector competency

Validation provides objective evidence that the proposed configuration is suitable for the actual inspection requirement.

Our Scope of Services

PAUT Feasibility Assessment

We review the component, weld and inspection objective before developing the final technique.

The assessment considers:

➤ Material specification

➤ Component diameter and thickness

➤ Weld-joint design

➤ Expected flaw types

➤ Expected flaw orientations

➤ Available scanning surfaces

➤ Access restrictions

➤ Inspection temperature

➤ Applicable code

➤ Acceptance criteria

➤ Required detection and sizing performance

The review identifies areas that are fully accessible, partially accessible or outside the proposed technique’s capability.

PAUT Procedure Development

We can prepare or review project-specific procedures covering:

➤ Scope and limitations

➤ Applicable standards

➤ Personnel requirements

➤ Equipment configuration

➤ Probe and wedge selection

➤ Focal-law parameters

➤ Calibration requirements

➤ Scanning pattern

➤ Data-quality controls

➤ Indication evaluation

➤ Sizing methodology

➤ Reporting requirements

➤ Essential variables

Weld-Specific Scan Plans

The scan plan demonstrates how the ultrasonic beams address:

➤ Weld root

➤ Lower and upper fusion faces

➤ Weld body

➤ Heat-affected zone

➤ Near-surface region

➤ Far-surface region

➤ Expected flaw orientations

Separate scan plans may be prepared for different diameters, thicknesses, weld designs or clock positions.

Customized Validation Mock-Ups

We can develop representative mock-ups for:

➤ Pipes

➤ Plates

➤ Pressure vessels

➤ Pipeline girth welds

➤ Nozzle connections

➤ Branch connections

➤ Small-bore piping

➤ Heavy-wall welds

➤ Austenitic welds

➤ Dissimilar-metal welds

➤ Cladded components

➤ Repair welds

➤ Complex geometries

The specimen can reproduce relevant component variables, subject to material and manufacturing availability.

Artificial and Realistic Flaw Implantation

Validation specimens may contain:

➤ Side-drilled holes

➤ Flat-bottom holes

➤ Surface notches

➤ Embedded notches

➤ Inside-diameter notches

➤ Outside-diameter notches

➤ Root-area reflectors

➤ Fusion-face reflectors

➤ Lack-of-fusion simulations

➤ Incomplete-penetration simulations

➤ Crack-like reflectors

➤ Volumetric flaw simulations

➤ Client-specified discontinuities

Reflector and flaw details are finalized through an approved manufacturing drawing.

Blind Performance Demonstrations

For blind trials, the flaw locations and dimensions can be withheld from the operator and analyst.

The participant may be required to report:

➤ Flaw detection

➤ Axial or circumferential position

➤ Clock position

➤ Flaw length

➤ Flaw depth

➤ Through-wall height

➤ Characterization

➤ Confidence or reporting status

The reported results are then compared with the controlled flaw information.

Detection and Sizing Evaluation

Performance can be assessed against predetermined criteria such as:

➤ Required flaw-detection rate

➤ Permitted location error

➤ Length-sizing tolerance

➤ Through-wall sizing tolerance

➤ False-call limit

➤ Repeatability

➤ Required signal-to-noise ratio

➤ Data-quality requirements

➤ Required weld coverage

Acceptance criteria must be agreed before the demonstration begins.

Code-Compliance Review

Our technical review can identify how the proposed procedure aligns with the contractually applicable code and project specification.

Support may include:

➤ Applicable-requirement identification

➤ Procedure gap analysis

➤ Essential-variable review

➤ Personnel-qualification review

➤ Scan-plan review

➤ Calibration-block review

➤ Demonstration requirements

➤ Acceptance-criteria review

➤ Reporting checklist

➤ Compliance matrix

➤ Technical clarification support

Final code acceptance remains subject to the client, authorized inspector, third-party inspection agency or responsible engineering authority.

Typical Validation Workflow

flowchart TD

Phase 1: Technical Input Review

We review:

➤ Component drawings

➤ Weld-joint details

➤ Material certificates

➤ Diameter and thickness

➤ PAUT procedure

➤ Probe and wedge details

➤ Scanner arrangement

➤ Applicable code

➤ Acceptance criteria

➤ Project-specific requirements

Phase 2: Validation Plan

The validation plan defines:

➤ Purpose of the demonstration

➤ Scope of qualification

➤ Essential variables

➤ Mock-up design

➤ Flaw types and sizes

➤ Flaw distribution

➤ Blind or open demonstration

➤ Number of trials

➤ Acceptance criteria

➤ Witnessing requirements

➤ Reporting format

Phase 3: Mock-Up Design and Approval

A manufacturing drawing is prepared showing:

➤ Overall specimen dimensions

➤ Material requirements

➤ Weld configuration

➤ Flaw or reflector type

➤ Flaw dimensions

➤ Flaw orientation

➤ Flaw location

➤ Machining tolerances

➤ Datum and coordinate system

➤ Identification markings

Manufacturing starts after drawing approval.

Phase 4: Specimen Manufacturing and Verification

Quality controls may include:

➤ Material-certificate review

➤ Dimensional inspection

➤ Base-material examination

➤ Weld inspection

➤ Flaw-position verification

➤ Surface examination

➤ Final drawing verification

➤ Unique specimen identification

➤ Photographic documentation

The applicable checks depend on the specimen design and project requirements.

Phase 5: PAUT Demonstration

The inspection team performs the examination using the proposed production setup.

The demonstration may verify:

➤ System calibration

➤ Focal-law performance

➤ Scanner installation

➤ Encoder accuracy

➤ Coupling stability

➤ Weld-volume coverage

➤ Reference-flaw detection

➤ Data quality

➤ Indication positioning

➤ Length and height sizing

Phase 6: Results Evaluation

Reported results are compared with the known specimen information.

The evaluation may include:

Evaluation parameter	Typical assessment
Detection	Detected or not detected
Position	Difference from known location
Length sizing	Reported versus actual length
Height sizing	Reported versus actual through-wall height
Characterization	Comparison with known flaw type
Repeatability	Results from repeated scans
False calls	Reported locations without implanted flaws
Data quality	Coupling, coverage and recording quality

Phase 7: Validation Report

The final report may include:

➤ Validation objective

➤ Applicable code and specification

➤ Component and mock-up details

➤ Flaw schedule

➤ Personnel information

➤ Equipment configuration

➤ Probe and wedge details

➤ Scanner and encoder details

➤ Calibration records

➤ Focal-law information

➤ Scan plans

➤ Demonstration conditions

➤ Reported results

➤ Actual flaw data

➤ Detection and sizing comparison

➤ Deviations

➤ Technical limitations

➤ Qualification range

➤ Conclusions and recommendations

Formal Statistical PoD Studies

Where the client requires a statistical Probability of Detection study, the programme must be planned differently from a single performance demonstration.

A formal PoD programme may require:

➤ Defined target flaw population

➤ Sufficient number of flawed and unflawed trials

➤ Multiple flaw sizes

➤ Controlled flaw distribution

➤ Blind testing

➤ Defined response variable

➤ Repeated trials or multiple operators

➤ Statistical model

➤ Confidence bounds

➤ Treatment of false calls

➤ Controlled essential variables

➤ Independent review

The final output may include a PoD curve and a defined metric such as the flaw size associated with a stated detection probability and confidence level, where supported by the approved statistical method and available dataset.

The exact study design should be agreed with the client’s engineering or regulatory authority before specimen manufacturing.

Applications

Our PAUT validation support is suitable for:

➤ Replacement of radiographic testing

➤ New PAUT procedures

➤ New equipment or probe configurations

➤ Pipeline girth-weld inspection

➤ Pressure-vessel weld inspection

➤ Critical process piping

➤ Power-plant welds

➤ Small-diameter piping

➤ Heavy-wall components

➤ Complex nozzle and branch welds

➤ Austenitic and dissimilar-metal welds

➤ In-service crack detection

➤ Repair-weld inspection

➤ PAUT and TOFD combined techniques

➤ FMC and TFM applications

➤ Client and third-party approval trials

➤ Technician qualification and training

Essential Variables and Qualification Range

The validation report should define the range covered by the demonstration.

Variables may include:

➤ Material group

➤ Product form

➤ Diameter range

➤ Thickness range

➤ Weld geometry

➤ Probe model

➤ Probe frequency

➤ Element pitch

➤ Active aperture

➤ Wedge model

➤ Wedge curvature

➤ Wave mode

➤ Refracted-angle range

➤ Focal depth

➤ Scanning surface

➤ Scan direction

➤ Scanner and encoder

➤ Calibration reflector

➤ Inspection sensitivity

➤ Sizing method

➤ Surface temperature

Changes outside the qualified range may require technical review or revalidation.

Code and Standards Support

Depending on the contract, our technical review may consider:

➤ ASME Boiler and Pressure Vessel Code, Section V

➤ Applicable ASME construction-code requirements

➤ ISO 13588

➤ ISO 17640

➤ ISO 20601

➤ ISO 4761

➤ ISO 22825

➤ ISO 23864

➤ ISO 23865

➤ API 1104

➤ AWS requirements

➤ Client specifications

➤ Project-specific written procedures

ISO 13588:2019 addresses semi- or fully automated PAUT of fusion-welded joints and defines four testing levels associated with different probabilities of detecting imperfections. It does not itself supply acceptance levels, so the applicable construction standard or project specification must provide the acceptance basis.

For thin-walled steel welds in the stated range, ISO 4761:2022 provides PAUT acceptance levels linked to indications detected according to ISO 20601.
For automated TFM weld testing, ISO publishes ISO 23864:2021, while the current ASME BPVC Section V edition listed by ASME is 2025.

The contractually specified edition must always be confirmed before preparing the compliance matrix or qualification programme.

Our Integrated Group Capability

Through the Benny Surya Venture group, we support the complete validation cycle:

➤ Integrity & Advanced Inspection Solutions India Pvt Ltd: PAUT/TOFD procedures, scan plans, Level III review, demonstrations and field inspection.

➤ NDE Tech India Pvt Ltd: PAUT/TOFD calibration blocks and reference standards.

➤ NDE Flaw Technologies Pvt Ltd: Flawed weld specimens, validation mock-ups and performance-demonstration samples.

➤The Sonic: Customized PAUT/TOFD wedges, scanners, encoders and inspection accessories.

This integrated capability reduces coordination between separate procedure developers, block manufacturers, flaw producers and inspection teams.

Deliverables

Depending on the agreed scope, our deliverables can include:

➤ Technical feasibility report

➤ Code-compliance matrix

➤ PAUT or TOFD procedure

➤ Technique sheets

➤ Weld-specific scan plans

➤ Mock-up manufacturing drawing

➤ Flaw schedule

➤ Material documentation

➤ Dimensional inspection report

➤ Mock-up verification documents

➤ Demonstration protocol

➤ Calibration records

➤ Encoded scan files

➤ Operator result sheets

➤ Detection and sizing comparison

➤ PoD analysis, where statistically supported

➤ Validation report

➤ Qualification-range statement

➤ Technical recommendations

Information Required From the Client

Please provide:

➤ Project and client details

➤ Applicable code and edition

➤ Project specification

➤ Component drawings

➤ Weld-joint drawing

➤ Material specification

➤ Diameter and thickness

➤ Inspection objective

➤ Expected flaw types

➤ Required flaw sizes

➤ Acceptance criteria

➤ Detection and sizing tolerances

➤ Proposed PAUT equipment

➤ Probe, wedge and scanner details

➤ Existing PAUT procedure

➤ Witnessing requirements

➤ Required documentation

➤ Delivery or demonstration location

➤ Required completion schedule

Contact Us

Your Global PAUT Inspection Services Partner
IAIS India PVT LTD
Specialists in Advanced PAUT Inspection, Weld Evaluation, Corrosion Mapping, Asset Integrity Support, and Engineering Inspection Solutions

📍 Headquartered in India | UAE Operational Support | Worldwide Deployment
📧 i@iaisindia.com
📞 Available for Global Mobilization and Technical Consultation

Speak with our PAUT engineering team to discuss inspection feasibility, project requirements, screening programs, procedure development, and deployment planning for your asset or facility.