Falcon S-Series Procedure Rev09

FALCON S-SERIES Document No: SECT- IP1
SATURATION EDDY CURRENT TECHNIQUE Date: 02-26-19

INSPECTION PROCEDURE
State of the Art Products and Revision: 09
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Document Review Record
Rev Date Reviewed By Amendment Details

RR, MP, RB, JA,
Rev 01 03-02-16 Section 1.1.0 and Section 1.2.0
LM
Rev 02 03-03-16 RR, RB, LM, LH Section 1.1.0, added Appendix D
Rev 03 03-05-16 RR, RB, LM, LH Section 1.1.0, added Appendix E
RR, RB, LM, LH,
Rev 04 03-07-16 Edited Section 1.1.0 and 1.2.0, edited Appendix D and E
BH
Rev 05 03-10-16 RR, RB, LM, LH, Edited Sections: 1.8, 1.9, 1.10, 1.11, 1.12
BH
Rev 06 03-10-16 RB Edited Sections: 1.8, 1.9, 1.10, 1.11, 1.12, 1.14 appendix D is
taken out. Appendix. E is renamed to D
Rev 07 03-11-16 Edited 1.8.5, 1.11
Rev 08 02/23/17 Comments added
Rev 09 02/26/19 AB New Calibration Procedure
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TABLE OF CONTENTS
1.0 SECT INSPECTION PROCEDURE 3
1.1 INTRODUCTION 4
1.2 SCOPE 4
1.3 INSPECTION PREPARATION 5
1.4 PERSONNEL 5
1.5 SITE ESTABLISHMENT 5
1.6 GENERAL SURVEY/MAPPING 6
1.7 VISUAL INSPECTION 7
1.8 EQUIPMENT SETUP AND CALIBRATION CHECK 7
1.9 CALIBATION OF DIFFERENTIAL CHANNELS 10
1.10 CALIBRATION OF ABSOLUTE CHANNELS 11
1.11 ENCODER SETUP 12
1.12 CALIBRATION CURVE SETUP 13
1.13 FALCON JNR SETUP 18
1.14 DATA ACQUISITION 22
1.15 DATA ANALYSIS 24
1.16 UT PROVE-UP AND CALIBRATION ADJUSTMENTS 25
1.17 REPORTING 27
1.18 REFERENCES 27
APPENDIX A – CALIBRATION PLATE DRAWING (CARBON STEEL)

APPENDIX B – TROUBLESHOOTING
APPENDIX C – SOLUTION SETUP
APPENDIX D – WAVEFORMS AND REPORT SAMPLES
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1.0 SECT INSPECTION PROCEDURE

1.1.0 Introduction
This document describes the equipment and methods to be utilized by TesTex, Inc. personnel in conducting
Saturation Eddy Current technique inspection (SECT) of storage tank floor bottoms, using the TesTex, Inc.
developed Falcon S-Series system that provides defect discrimination and sizing. The advanced features of
the system applicable for inspection of carbon steel and all ferromagnetic materials are listed below in
Table #1.
FEATURES
MAIN FEATURES:
- Inspection of plates up to 1.0” or 25.4mm (ferromagnetic materials)
- Inspection through various non-metallic coatings up to 0.500” or 12mm thick
- High sensitivity and discrimination of Top and Bottom side defects
- Localized Wall Loss can be detected and sized
- Pitting can be detected and sized
- Cracks can be detected
- The signal response is not affected by the residual plate magnetization due to controllable level of magnetization
- Consistency in repeatability (the signal response from symmetrical defects is not affected by the direction of scans)
HARDWARE:
- 14” wide scanner with high resolution 16-sensor array
- DC electromagnet with controlled level of magnetization to achieve adequate saturation of the plate to be tested
- Linear encoder to measure and log signal duration
- Variable scanning speed up to 58 square feet per minute (5.4 square meters per minute)
- Integrated Hand-held 5” wide 8-channel scanner (4-sensor array) to target specific hard-to-reach areas
ELECTRONICS:
32-channel system (16 DIFF + 16 ABS) that produces high resolution signal response; provides the ability to scan heavily
corroded plates with top side pitting that other techniques may have a difficulty in implementing.
MEASURING PRINCIPLE:
- Using a strong DC field to make the material testable at kHz frequency ranges and then measure the changes in AC fields to
detect and characterize flaws.
SOFTWARE:
- Real time data acquisition with full control for system setup and operation
- Data analysis with in-depth access to the signal characteristics, such as: Signal Curvature, Duration, Phase Value and Voltage
Span.
- C-scans Plots and 3D-Plot for defect visualization
- Automated data logging with an option for editing (UT prove-up and over-ride)
- Filters for data processing
- Preliminary report available immediately after scanning is completed (progress report can be issued at any time upon request).
Table #1 – SECT features
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The list of features that displays the advantage of the TesTex, Inc. developed Falcon S-Series System over
the Silverwing VS2 System is listed below:
Silverwing VS2 TesTex Falcon S-Series

FEATURES
12” wide MFL Scanner 14” wide SECT Scanner
Rare Earth Permanent Magnets √ n/a
DC Electromagnet n/a √
Magnetization Control - √
Active Measuring of Permeability n/a √
Passive Measuring of Flux Density √ n/a
Scanner Speed Control - √
Top/Bottom Side Discrimination - √
Adjustable Data Processing - √
Sample Waveform in 3D - Plotting - √
Indication List Summary √ √
Table #2 – list of features of Silverwing VS2 and TesTex Falcon S-Series
.
Recently TesTex introduced the technique to the Middle East market. The technique was qualified and
recommended by one of the largest oil producing company in Saudi Arabia. All storage tanks that have a
protective coating are already undergoing inspections using TesTex, Inc. developed Falcon S-Series
system, utilizing the principles of Saturation Eddy Current Technique. The benefit of the approved
technique is the ability to discriminate Top and Bottom side defects and to keep the protective coating
intact which leads to reduced cost and down-time.
TesTex has successfully provided tank inspection services in North America and Europe using this
technique. For additional information regarding waveforms and report samples, refer to APPENDIX D.
1.2.0 Scope
This document details the procedures to be followed during the inspection of above ground storage tanks
using Saturation Eddy Current technique (SECT).
The specific equipment calibrations and system setups will be detailed in the job work instructions for the
specific plate and/or coating type.
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1.3.0 Inspection Preparation
WARNING:
Falcon S-Series system generates a strong magnetic field. When the system is energized, the
attractive force between the scanner bottom and any metallic object has the potential to cause
physical injury. The system is to be energized only when the front AND rear wheels of the
scanner are on the surface to be scanned.
WARNING:
The Falcon S-Series generates a strong magnetic field which may interfere with the operation of
certain medical devices.
1.3.1 A calibration plate must be manufactured from the same type and the same nominal thickness of the
material to be examined. The calibration standard(s) must include, but is not limited to:
- 20% Groove
- Top/Bottom Side hemi-spherical pits of with depths of 20%, 40%, 60 & 80%.
-
Refer to Appendix A – STANDARD DRAWING for more details.
1.3.2 A full system check must be conducted on all systems to be used on the inspection.
1.3.3 All equipment must be packed securely and safely for transportation to site.
1.3.4 Pack according to the Tank Equipment Checklist.
1.4.0 Personnel
Personnel interpreting data collected must be qualified to ET Level II or higher. Prior to receiving
certification, all personnel shall have completed the training program recommended by SNT-TC-1A and
the TesTex written practice.
1.5.0 Site Establishment
1.5.1 Contact the client representative.
1.5.2 Obtain information concerning the unit (age of the unit, contents, expected problem
areas, previous inspection records, etc.) Find out how the tank needs to be numbered and marked.
1.5.3 Ensure all permits are in order and the unit to be tested has been checked for entry.
1.5.4 Check that suitable power source, lighting and ventilation have been provided.
1.5.5 Ensure the gas levels are initially tested prior to entry and then continually monitored during the
inspection.
1.5.6 Entry to the vessel must be in accordance with the TesTex Inc. Confined Space Entry Policy.
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1.6.0 General Survey/Mapping

1.6.1 Start the Tank Floor Mapping Software. On desktop, double-click on TankFloorMap v2.04.XX
1.6.2 Follow the prompts of the mapping software and enter the tank information, it's properties to
generate the floor map. It must be done prior to the floor scanning.
There are 3 different ways to create a

map:
1) Keep the “Symmetrical Tank” and

“Manual” cells unchecked. This way
dimensions for each individual plate,
row by row, must be entered following
the software prompts before map is
generated.
2) In case of Symmetrical Tank, keep
the “Symmetrical Tank” cell checked.
This way dimensions for the plates
only from one quadrant of the floor will
be prompted. The rest of the plates will
be generated automatically.
Figure 1 – Tank properties
3) More accurate way to generate the floor map is using “Manual” mode. Only one center
plate will be generated at first. Operator will have to assign the dimensions and reposition
the plate to the left side of the center row, then copy, paste and re-size the second one and
so on.
To copy and paste use the following key-strokes: CTRL + R, CTRL + L, CTRL + B,
CTRL + T.
This way the selected plate will be copied and pasted to the Right, LEFT, Bottom and Top
respectfully.
1.6.3 Number the plates, Right-click on the mouse, select VIEW and check the “Show Reference Node
Locations”. This is very important, as it dictates the physical position of the scanner and sweep
directions on each individual plate in relation to the reference node. Sweep Setup Dialog, which is
prompted before each scan, functions according to the reference node.
Number the plates in S-pattern. Go left to right on the first row, right to left on the second row, left
to right on the third, etc... (In other words, plan the numbering scheme that will be most productive
so that you do not have to reposition the scanner to the other side of the tank for each row).
Paint the corresponding number on every plate (if you were given permission to do so; If you can
not use paint, use chalk or another acceptable means).
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1.6.4 Note the direction of the manway(s). Reference this to geographical compass
direction or some permanent landmark.
1.6.5 Enter the following items on the map: sumps, pipes, support beams, etc.
1.7.0 Visual Inspection
1.7.1 Stand at full height and let a bright light hang just above the floor and look for
shadows in the light beam. If a topside flaw is seen, pick at it with a sharp tool until base metal is
hit. Note these areas on the Floor Map. Size it with a pit gauge for depth and estimate the area.
1.7.2 Walk the full area of the tank. Note visible features of the tank (i.e. depression
areas, areas where water gathers, rough floor areas, topside corrosion, mechanical
damage, patches, stray welding beads, buckling, cracks, topside pits, dents, areas
of discoloration etc.)
1.8.0 Equipment Set Up and Calibration Check:

1.8.1 Unpack and setup the equipment (Scanner and DC power supply)
1.8.2 Set up the Falcon S-Series system.
1.8.3 On desktop, double-click on the Acquisition software (Falcon S Acquisition R03.XX).
1.8.4 Setup Folders (F2) and file name (F3). For calibration, set the file as 9999-HOUR-MIN then
bring up Falcon S Control Panel (CTRL + Y).
1.8.5 Enable ASSISTED MODE, motor and encoder. Select the scanner's width. In case of using hand-
held scanner, enable “Falcon S Junior Mode”.
1.8.6 Initially, use this table to select the setting for the Saturation Electromagnet:
DC CURRENT VALUES, A DC CURRENT VALUES, A

Power Plate Power Plate
14” scanner 5” hand-held scanner
Supply NWT Supply NWT
Coating Thickness, in Coating Thickness, in
model Inch model Inch
0.00 0.04 0.08 0.12 0.25 0.00 0.04 0.08 0.12 0.25
0.250 6 7 9 11 13 0.250 6 7 8 10 12
0.312 7 8 10 12 14 0.312 7 8 10 12 14
80V – 19A 0.375 9 10 12 14 15 80V – 19A 0.375 8 9 11 13 15
0.500 11 13 14 15 16 0.500 9 11 13 15 16
Table #3 DC Power Supply current values for 14” and 5” hand-held scanners
For inspection of coated floors simulate the coating on the calibration plate using non-magnetic sheets. The
thickness of the sheets must match the thickness of the coating on the tank plates. Use coating thickness
gauge, if necessary.
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Vary the current value by ± 1 A. Collect and compare the signal waveforms to see what Current value
produces the best signal response (40% defect should approximately double the voltage span of 20%
defect). Repeat, if necessary.
Caution: DO NOT over-saturate the plate (Current value to high), as this will cause a loss of sizing
capability.
1.8.7 Set up Frequency, POWER LEVEL and SAMPLE RATE for all channels, as in the table #4:
FREQUENCY POWER LEVEL SAMPLE RATE
F = 20.1 ±10 kHz Between 550 – 575 350
Table #4 settings
1.8.8 Set up DIFF and ABS Gains (CTRL + G).

Initially for DIFFs and ABSs, set all values to 100 (Figure 2).
Figure 2 – Gain Selection Box
1.8.9 Adjust the scanner's lift-off (see Section 5.0 of the Operator’s Manual).
1.8.10 Position the scanner in a defect free portion of the calibration plate (by the 20% Bottom Side
Notch), allowing equal distance from left and right edge of the calibration plate, as shown below:
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Figure 3 – Calibration Plate
1.8.11 Balance the system (CTRL + Z). When changing the Frequency, Gain, Driver Level or Current of
the DC power supply or accessing to Falcon S Control Panel (CTRL + Y), the system needs to be
re-balanced in the indicated part of the calibration plate.
1.8.12 Set the motor speed to 0.666 feet per second maximum.
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1.9.0 Calibration of Differential Channels (C1 DIFF – C16 DIFF):
There are two ways to do the calibration: assisted and manual.
In order to do assisted calibration, go to “INSTRUMENT SETUP”, from drop-down menu click

“Assisted Calibration” (Figure 4). Follow the screen prompts (Figures 5 – 7).
Set the Voltage at 3.0V, if plates have no coating (2.5V, if plates have coating).
Figure 5 – Initialization of ASSISTED CALIBRATION
Figure 4 – Selection of ASSISTED CALIBRATION
Figure 6 – Setting Voltage Span

to be produced from 20% Bottom Side Notch
Figure 7 – Guideline to perform the ASSISTED CALIBRATION
Verify the response following Sections 1.9.1 through 1.9.6 and 1.9.7.
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In order to verify the assisted-calibration or to calibrate the system manually follow the steps below.
1.9.1 Press F4 and set the Voltage Span at 2 volts (in ACQUISITION program).
1.9.2 Press CTRL + Z to balance the coil array.
1.9.3 Scan the calibration plate. Press and hold the START button. In order to stop the scanner, simply
release the button.
1.9.4 Press F10 to switch from DATA ACQUISITION to ANALYSIS program
1.9.5 Press F4 and set the Voltage Span at 2 volts (in ANALYSIS)
1.9.6 Ensure that the Voltage Span response from the 20% Bottom Side Notch is approximately
3.0 volts (2.5 volts with coating) for all 16 channels.
If the Voltage Span responses are different, follow the steps below:
1.9.6.1 Press F10 to switch from ANALYSIS to DATA ACQUISITION program

1.9.6.2 Adjust the GAIN settings (CTRL + G).
1.9.6.3 Repeat the steps 1.9.2, 1.9.3, 1.9.4 and 1.9.6
1.9.7 Ensure that the Phase Value response from the 20% Bottom Side Notch to be at 90 degrees in all
16 channels.
If the Phase Value responses are different, follow the steps below:
1.9.7.1 Press F10 to switch from ANALYSIS to DATA ACQUISITION programs

1.9.7.2 Adjust the Rotation settings (CTRL + R).
1.9.7.3 Repeat the steps 1.9.3, 1.9.4 and 1.9.7
1.10.0 Calibration of Absolute Channels (C1 ABS – C16 ABS)
1.10.1 Press F10 to switch from ANALYSIS to DATA ACQUISITION programs
1.10.2 Set the GAIN setting (CTRL + G) to 100 for all 16 ABS Channels.
1.10.3 Set the Rotation values to 0 for all 16 ABS Channels (by default ABSolutes are at 0 degrees).
Note, ABSOLUTE channels will be used as an indication of lift-off/ coating thickness changes.
Severe Top Side defects and/or 100% though-holes will also be displayed on ABS C-scan plot.
As per current procedure all the sizing is done by Solution based on Differential signals.
Important: Conduct additional and thorough investigation of the area of the tank floor, if ABS C-scan
plot shows an indication that correlates with an indication from DIFF C-scan and/or
Solution. Due to permeability variations, there may be a time when Top Side defects and
100% though-holes are under-called. Conduct visual inspection (pit-gauging/ UT) to
confirm/backup the Solution calls. Adjust the calibration curve if needed (refer to § 1.15.0
for details).
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1.11.0 Encoder Setup
Note: Although the encoder is pre-calibrated the encoder should be checked prior to inspection using the
following setup instructions.
1.11.1 Select the longest plate in the tank. On the floor plate, mark the distance that the scanner will be
pushed by hand without obstruction. Make START-mark (0-feet-mark) and STOP-mark
1.11.2 Press F11
Figure 8 – Encoder calibration window
1.11.3 Position the scanner near 0-feet-mark. In the “Length Latched” field, enter the distance marked off
in the previous step. Click “Turn Saturation On” and then click LATCH START button. Push the
scanner by hand till it reaches the STOP-mark. Then click LATCH STOP button. Click OK.
1.11.4 Verify that encoder has been calibrated properly by re-positioning the scanner again by 0-feet-mark.
1.11.5 Set the motor speed to a minimum.
1.11.6 Press F12 and make sure that X-position is set to 0’ – 0”. Click OK
1.11.7 Press and hold the START button on the left handle of the scanner. Gradually increase the motor
speed, travel the marked distance and then gradually decrease the motor speed in order to stop
exactly at STOP-mark.
1.11.8 Look at the bottom right corner of the acquisition program, the traveled distance should match with
the distance displayed by encoder. If the encoder reading is ±0.02 feet off, the encoder needs to be
re-calibrated to achieve necessary accuracy.
1.11.9 Scan and save the calibration waveform as 9999-HOUR-MIN.
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1.12.0 Calibration Curve Setup
1.12.1 Go to Analysis program (press F10 to toggle from Acquisition to Analysis).
1.12.2 Press F4, set the Voltage Span to 2 Volts (<<2 Volts if coating is present) and Select “Apply the
span to all plots”. Then click OK.
Note, 16 channels are

displayed in 8 plots
(2 channels per plot). In
order to display all 16
channels select all odd
numbers in plots
1 through 8 (all even
channel numbers will be
automatically displayed).
Figure 9 – Analysis plot view setup
1.12.3 Press F7 to expand the Solution C-Scan Plot as shown in figure 9 and 10 below:
Figure 10 – Default layout of the Data Viewer Figure 11 – Layout with expanded Solution C-Scan
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1.12.4 Select calibration setup from the drop-down menu as shown in figure 12 below.
Figure 12 – Calibration Setup Menu
1.12.5 In the next window select Get Bottom Grove V-span (figure 13), an Auto Calibration window will
appear (figure 14) press OK and follow the instructions and highlight the Bottom Side Grove Defect
and press ENTER (figure 15).
Figure 13 – Calibration Window with Get Figure 14 – Auto Calibration Window.

Bottom Grove V-Span Highlighted.
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Top Side Defects
Once highlighted press ENTER Bottom Side Defects
Figure 15 – Bottom Side Groove Signal Highlighted.
1.12.6 Once the Bottom Groove has been calibrated the software will return the Calibration window.
Select Auto Calibrate option for the TOP side defects as shown in figure 16 below. An Auto
Calibration window will appear (figure 17) press OK and follow the instructions and highlight the
topside 20% defect and press ENTER (figure 18). Repeat the process for the remaining 40, 60 &
80% defects. Once complete press APPLY as shown in figure 19.
Figure 16 – Auto calibration of the TOP side defects. Figure 17 – Auto Calibration Window.
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Once highlighted press ENTER
Figure 18 – Bottom Side Groove Signal Highlighted. Figure 19 – Calibration Window with Apply highlighted.
1.12.7 Once the topside defects have been calibrated the software will return the Calibration window.
select Auto Calibrate option for the bottom side defects and repeat the process the same as the for
topside defects. Once completed select OK, the software will return to the analysis window and all
defects should be color coded and sized correctly as shown in figure 20.
Figure 20 – Completed Calibration Curve.
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1.12.8 Save your calibration curve with the same name as the calibration waveform
(for instance, if the calibration waveform is saved as 9999-HOUR-MIN.SLX, then save the
calibration table as 9999-HOUR-MIN.SFC)
1.12.9 Verify that Solution works. It should differentiate between Top and Bottom Side flaws
by putting them automatically in the Top and Bottom C-scan Solution plots respectfully and
assigning color-coded tags.
Note: New Calibration Curve must be done if any of the following changes are made to the system:
• Span Thresholds
• % Peak Voltage
• Maximum Flaw Width
See APPENDIX C for Solution Setup.
Note, Flaw Start/Stop Angles serve as gates by function. Any indication within the
color-coded segments is evaluated. Any indication not fitting into the color-coded
segments is disregarded. Be careful when adjusting the Flaw Start/Stop Angles.
There may be a time when the permeability of the tank floor will vary significantly
from the one of the calibration plate. The sign of the permeability difference will be a
shift in phase values. For instance, a bottom side flaw may show a phase value of 60
degrees. In this case, lower the Flaw Start/Stop Angles by 30 degrees in order to
prevent the indications from their being missed by the Solution or misrepresented
(called Bottom Side rather then Top Side).
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1.13.0 Falcon Jnr Setup
1.13.1 In the acquisition software press CONTROL+Y and select Falcon S Junior Mode and set the Amps
and Frequency in accordance with Table 3 (Figure 21).
Scanner Size Selection
Scanner Width
Automatically Adjusts
Amps Setting
Frequency Setting
Figure 21 – Falcon S Control Panel
1.13.2 In the acquisition software selected Plot Setup & Plot View from the drop-down menus. In plot
View window set Plots 1 – 4 to C1 – C4 Diff as shown in the figure 22 below. Set the number of channels
per plot to 1 as shown below. Repeat the process with the Analysis software.
Plot Selection Settings
Channels Per Plot

Selection
Figure 22 – Plot View Window
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1.13.3 Perform the assisted calibration in accordance with section 1.9.0. As the scanner is manual operated
take care to keep a smooth and consistent speed as close to 0.666 feet per second as possible.
1.13.4 Perform the calibration curve setup in accordance with section 1.12.0. However. Two separate
waveforms shall be recorded for topside and bottom side defects as shown in figure 23 & 24. The
calibration setup should be conducted to the topside waveform first. Set the bottom grove signal followed
by the topside defects. Check that the voltage span from the 40% topside defect is approximately double
that of the 20% defect. Repeat the process to the bottom side waveform.
Figure 23 – Topside Waveform
Figure 23 – Bottom side Waveform
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1.13.5 Once completed select OK, the software will return to the analysis window and all defects should be
color coded and sized correctly as shown in figures 24 & 25.
Figure 24 – Completed Topside Cal Curve Waveform.
Figure 25 – Completed Bottomside Cal Curve Waveform.
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1.13.6 Save your calibration curve with the same name as the calibration waveform
(for instance, if the calibration waveform is saved as 9999-HOUR-MIN.SLX, then save the
calibration table as 9999-HOUR-MIN.SFC)
1.13.7 Verify that Solution works. It should differentiate between Top and Bottom Side flaws
by putting them automatically in the Top and Bottom C-scan Solution plots respectfully and
assigning color-coded tags.
Note: New Calibration Curve must be done if any of the following changes are made to the system:
• Span Thresholds
• % Peak Voltage
• Maximum Flaw Width
See APPENDIX C for Solution Setup.
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1.13.0 Data Acquisition
1.13.1 Position the scanner on the plate to be tested, preferably by the reference node.
1.13.2 Press F2 to select the location for data storage (Do not use spaces or special
characters) and then press F3 to enter plate, sweep and run number. Then press Enter (Sweep
Setup Dialog box is brought up automatically and each time for the next run).
1.13.3 Select the Sweep Type, Sweep Options, Plate Edge and type the Position.
In Sweep Options, if the “Auto Sweep

Increment” cell is checked, it will update the
Y-position by the scanner width minus 1 inch
(13 inches) to allow overlapping. When
checked, the S-Test Pattern” selection toggles
sweep type Left to Right and Right to Left
etc. and updates the Y-Position.
X-Position is measured orthogonally from

the edge of the plate (going away from) to the
center of the scanner.
Y-Position is measured orthogonally from

the reference node to the left side of the
scanner (channel 1).
Note, the direction and the measurement

for diagonal sweep will require the value
(in degrees) in relation to the North
(measured clockwise). X-Position is
measured horizontally from the reference
Figure 26 – Sweet setup dialog box node to the left side of the scanner (channel
1) and Y-position is measured vertically
from the reference node to the left side of
the scanner (channel 1).
See the following page for examples.
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Figure 27 – Sweep types in relation to the reference point and plate marking
1.13.4 Mark the plate's edges with a chalk (left and right for long plates; left/right or bottom for the short
plates). Mark 1' – 2”, 2' – 3”, 3' – 4” and etc. This will help to position the scanner for the next run
without changing Y-position manually if “Auto Sweep Increment” feature is enabled.
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1.13.5 Measure X and Y position of the scanner with a measuring tape according to the reference node and
enter it to the Sweep Setup Dialog then press ENTER.
1.13.6 Press and hold the button on the left handle of the scanner. The electromagnet will be enabled to
ramp up the saturation, then after 2 seconds delay the motor will be engaged and the scanning
process will begin collecting the data. In order to stop the scanner, simply release the bottom.
Sweep Setup Dialog box will pop up to prompt the operator to enter the sweep information for the
next run.
Note, sweep dialog box will not be brought up if plate number is set to 0000.
(if system does not response on START button, press F12 and then ENTER).
1.13.7 Reposition the scanner. Align the left side of the wheel bracket with the chalk-mark.
Keep the scanner in parallel with the previous sweep. This will determine the
Y-position accuracy.
1.14.0 Data Analysis
Note: The percentage wall loss shall be taken from the solution software and not the displayed wall loss
percentage within the raw data (Figure 28).
Figure 28 – Solution Vs Raw Data Analysis
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1.14.1 Analyze the data by verifying the indications tagged by the Solution. The Solution Auto tagging
feature draws white boundary line around the color-coded indication in the C-scan Solution Plot.
1.14.2 Ensure that the indications are not false-positives caused by a noise spike. Left-click on the area of
the tagged indications. Lissajous-like pattern should appear in the impedance (XY) plots.
1.14.3 Press F7 to collapse the Solution C-scan in order to see the Strip-Chart.
1.14.4 Use LEFT arrow key to move blue or green tagging circles to the point of origin (zero balance).
1.14.5 Use RIGHT arrow key to scroll the blue or green circle through the defect area. Observe the
direction and the movement of the blue or green tagging circles on the Impedance Plane.
The legitimate signal response will cause the tagging circle to first go down to the left from the
point of origin (zero balance) followed by an upward motion and a downward motion
returning to the point of origin, just like figure “8”.
In order to manually over-ride the indication, simply Right-Click on the tagged indication and
adjust the percentage of wall loss in the pop-up INDICATION PROPERTIES window.
In order to delete the false-positives press CTRL + D and Left-Click on the tag(s) in the Solution
Plot, press Delete button and confirm by pressing Yes or No.
In order to delete the large area of the false-positives press SHIFT + D then hold Left-Click mouse
button and drag it over the area of the tag(s) in the Solution Plot, let go and press Delete button,
confirm by pressing Yes or No.
1.14.6 Data with questionable indications from a selection of plates will be sent back
to headquarters for review by the TesTex Level III or the Quality Assurance Manager or a designee
of the TesTex Level III or Quality Assurance Manager to insure integrity and quality of data and
calibration.
1.14.7 Analyze the data in the Data Viewer.
1.14.8 Conduct the UT prove-up if possible.
1.14.9 Import the indication list in the Tank Floor Mapping software.
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1.15.0 UT Prove-Up / Pit-gauging and Calibration Adjustments
1.15.1 As a rule, the inspection team, consisting from at least 2 people, must separate the responsibilities of
tasks for the tank floor inspection process. One person must concentrate only on the scanning of the
tank floor while another person must concentrate on the data analysis and UT prove up and pit-
gauging while using Tank Floor Mapping software in order to map out the tank floor in the real
time, plate by plate. This way the inspection report will be issued soon after the completion of the
floor scanning or the progress report may be generated promptly by the request of the contact
representative.
1.15.2 Conduct the UT verification and pit-gauging for the flaw greater than 30% wall loss or other
reporting threshold established by the customer.
In case of testing the floor bottoms that are coated, if possible, obtain a permission to remove the
coating in 4 – 5 spots to conduct UT verification/ pit-gauging and calibration curve adjustments.
1.15.3 Ultrasonic thickness gauging must be used for verification of flaws detected by the Falcon S-series.
The calibration curve may need to be adjusted if a discrepancy of 10% and greater between both
SECT and UT/pit-gauging inspection techniques is observed.
In case that the flaw size (linear width) of the indication matches or close to the size of indication
from the calibration waveform then adjust that specific calibration curve for that size pits, by
lowering or increasing the voltage spans.
For instance:
If UT/pit-gauging shows that the indication is actually greater then what Solution called by 10%,
then lower the Voltage Span values on the calibration curve by 10%. Check the results and if
needed, lower the Voltage Span values on the calibration curve by another 10%.
If UT/pit-gauging shows that the indication is actually smaller then what Solution called by 10%,
then increase the Voltage Span values on the calibration curve by 10%. Check the results and if
needed, increase the Voltage Span values on the calibration curve by another 10%.
1.15.4 Save the adjusted calibration curve, reload it, and re-analyze the data.
1.15.5 If the plate is buckled or humped, the solution will either under-call or over-call the
indications respectfully due to lift-off variation which affects the saturation and signal response.
Mark these areas for UT/pit-gauging survey, if UT/pit-gauging is possible. S-series indications will
need to be edited in the Data Viewer manually. If UT is not possible, make a note on the report.
Note, in case of calibration adjustments based on the UT prove-up/pit-gauging, the data may need to
be re-analyzed for a scanned plate using a different calibration curve or adjusted curve.
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In the Tank Floor Mapping software all sweeps will need to be deleted prior to re- importing the
indication list of the re-analyzed data. Ensure that manually inserted indications for areas such as
corners of the plates, inaccessible areas and etc. stay intact, do not delete those.
In the current Tank Floor Mapping software, the calibration curve cannot be applied globally for the
entire tank, but only through data viewer to a portion of a data that is being analyzed.
1.16.0 Reporting
1.16.1 A preliminary report must be submitted to the client before departure from the site. The preliminary
report will contain the most important information for any remedial work that may be necessary. In
most cases, the preliminary report given will be electronic, using the latest version of TesTex, Inc.
Tank Floor Mapping and Automated Reporting Software.
1.16.2 The final report will be created using the latest version of TesTex, Inc. Tank Floor Mapping and
Automated Reporting Software. The final report will be reviewed and will be forwarded to the
client within an agreed time period. The final report will include as a minimum a colored drawing
of the tank floor map with flaws clearly marked, an evaluation of the severity shown in color for
ease of interpretation, a tabulated report sheet detailing all flaws by plate number and location and
at least one printout of typical flaw detected.
1.16.3 In Tanks where no flaws are found, data from a good plate will be included in the report.
1.16.4 A copy of the final report and working copies must be maintained on file at the TesTex, Inc. offices
for a period of not less than five years form the date of completion. In addition an electronic copy of
the report will be stored.
1.16.5 The results must include the flaws locations and depth of the indication.
1.17.0 References
ASME: Section V Article 8: 2010 Edition

Operator’s Manual (document SECT-IP_Rev02)
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APPENDIX A – STANDARD DRAWING (36” x 18” CARBON STEEL PLATES ONLY)
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INSPECTION PROCEDURE Revision: 08
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Problem Reason Solution
Acquisition screen was
toggled or minimized
System does not respond Press F12 and click OK to put the system in
(Safety feature to prevent
on START button READY mode.
accidental engagement of
the Electromagnet)
1) Communication is lost,
power is lost, turned off/on,
USB disrupted
2) Motor exceeded torque
threshold due to obstruction 1) Press CTRL + Y to reset the communication
System responses on followed by CTRL + Z
or poles' contact with floor
START button 2) Reset the breaker by pressing it inward.
plate which led to tripped
(Saturation is ON), but
breaker on the motor control 3) Switch the motor in forward direction.
Motor does not run
box. 4) Electronics Box needs to be repaired
3) Motor direction switch is
in neutral position.
4) Electronics box is
malfunctioning
System responses on
START button
(Motor runs), but
Saturation level was not Press CTRL + Y to setup the Saturation Current
electromagnet is
setup. value.
not energized.
Power supply
displays 0.00 – 0.00
System responses on 1) Press F11 (“Calibrate Encoder” window).
START button 2) Click on “Turn Saturation ON”.
(Motor runs), but 3) Walk to the power supply unit, press REM/LOC
Power Supply lost its
electromagnet is button, and then press OUT button.
settings.
not energized. 4) In the “Calibrate Encoder” window, click on
Power supply front panel “Turn Saturation OFF” then ESC.
displays “OFF”
Bottom of the scanner Increase the lift-off. Raise the scanner using
grabs the tank floor often The lift-off is too small supplied Allen Wrench, shims and tightening
that prevents it from wrench. (See Section 5.0 of the Operator’s Manual)
scanning
Not enough power from the
Electromagnet rapidly Reduce the load on the circuit. Separate the S-series
power source
pulsating (engaging and system from lights. Find two independent power
(from plant power or
disengaging) sources; one for S-series and one for the lights.
generator)
1) Encoder was not
1) Re-calibrate the encoder;
calibrated properly;
2) Increase the lift-off. Release the start-button
Distance of the Encoded 2) Front wheel is slipping
immediately upon or prior to running into
sweep file exceeds the due to floor
obstruction, floor undulation or weld;
actual traveled distance undulations/obstructions; or
3) Decrease the motor speed by 25%;
3) product residue;
4) Contact TesTex, Inc for part replacement
4) Encoder is damaged.
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Problem Reason Solution

Distance of the
1) Encoder was not
Encoded sweep file is 1) Calibrate the encoder;
calibrated properly;
less than the actual 2) Contact TesTex, Inc for part replacement
2) Encoder is damaged
traveled distance
1) Power cycle the Electronic Box (Turn OFF
the Electronics Box for 15 sec, then turn it back
ON).
2) Adjust the frequency. Acceptable noise level
1) Voltage spike
is 0.250V or less (at Power Level 600, Gain
2) Frequency is too high
Signal is noisy in one Level 100 and Frequency 13.1 kHz).
or too low (over
or more channels Press CTRL + Y. Disable ASSISTED MODE.
15kHz or under 10
Click OK. Press SPACE BAR to start
kHz)
collecting data. After 5 seconds press SPACE
BAR again. Press F10. Expand the cursor to 2.0
sec. Estimate the noise level in the impedance
plane (X-Y Plots).
Go to Power Supply front panel. Press
REM/LOC once then press the REM/LOC
System responses on button again and hold it for approximately 3
START button seconds. The voltage display (on the left) will
(Saturation is ON), indicate the address (it should be “00”), the
Motor is ON, but the Power Supply settings current display (on the right) will indicate the
current value stays the were changed. Baud Rate (it should be 19.2). If any of these
same regardless of values are different that stated above, the Power
Amperage changes in Supply current values cannot be changed
the control menu. remotely from a laptop. Use Voltage and
Current dials to obtain “00” for address and
“19.2” for Baud Rate respectfully.
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APPENDIX C – SOLUTION SETUP
Span Threshold – the value below which the signals will be ignored. Let’s suppose, a signal is 0.4Volts and the
threshold is 0.5Volts. Then the signal is not going to be detected/displayed in the Solution Plot, it will be
considered noise.
% Peak Voltage – the percentage of the maximum pick of the Voltage Span value of any detected indication
signal that exceeds the Span Threshold; the point at which the software will start to approximate the signal
duration (the flaw size or the flaw diameter) in the Solution Plot. The signal duration (the flaw size) and the
voltage spans are used for calculation of the percentage of wall loss. The typical value is 20 (for clean plates),
for noisy or heavily corroded plates, bump up the value to 40.
Minimum Solution Wall Loss Threshold – the reporting criteria in percentage of wall loss; the cut-off value
below which a signal is not going to be evaluated, displayed or entered into the database.
Maximum Flaw Width – This is a filter, typically run 13 or 14. Do not put it below 13 otherwise the General
Wall Loss is not going to be picked up by the Solution. Do not put the value above 14 otherwise the localized
defects are not going to be picked up.
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3D-Image of the Indication with 70% Wall Loss. Double

Bottom Side corrosion with 70% Wall Loss that
hump is the representation of the rectified signal
was verified on cut-out coupon
amplitude for approximation of a defect deminsion
Impedance Plane with the following information:
• X-position
• Diameter of the defect,
• Percentage of wall loss,
• Phase Value
• Voltage Span
C-Scan Solution Plot

auto-analysis feature that automatically discriminates
and sizes the defect assigning color-coded signature
C-Scan Differential Amplitude Plot

for visual representation of Localized defects
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Figure above shows a plate with color-coded indications, indication summary

and the relative location of the plate in the floor layout
33

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FALCON S-SERIES Document No: SECT- IP1

SATURATION EDDY CURRENT TECHNIQUE Date: 02-26-19

Document Review Record

Rev Date Reviewed By Amendment Details

APPENDIX A – CALIBRATION PLATE DRAWING (CARBON STEEL)

1.0 SECT INSPECTION PROCEDURE

Silverwing VS2 TesTex Falcon S-Series

1.3.0 Inspection Preparation

1.3.4 Pack according to the Tank Equipment Checklist.

1.5.0 Site Establishment

1.5.1 Contact the client representative.

1.6.0 General Survey/Mapping

There are 3 different ways to create a

1) Keep the “Symmetrical Tank” and

Figure 1 – Tank properties

1.7.0 Visual Inspection

1.8.0 Equipment Set Up and Calibration Check:

1.8.2 Set up the Falcon S-Series system.

1.8.3 On desktop, double-click on the Acquisition software (Falcon S Acquisition R03.XX).

DC CURRENT VALUES, A DC CURRENT VALUES, A

FREQUENCY POWER LEVEL SAMPLE RATE

F = 20.1 ±10 kHz Between 550 – 575 350

1.8.8 Set up DIFF and ABS Gains (CTRL + G).

Figure 2 – Gain Selection Box

Figure 3 – Calibration Plate

1.9.0 Calibration of Differential Channels (C1 DIFF – C16 DIFF):

There are two ways to do the calibration: assisted and manual.

In order to do assisted calibration, go to “INSTRUMENT SETUP”, from drop-down menu click

Figure 5 – Initialization of ASSISTED CALIBRATION

Figure 4 – Selection of ASSISTED CALIBRATION

Figure 6 – Setting Voltage Span

Figure 7 – Guideline to perform the ASSISTED CALIBRATION

1.9.6.1 Press F10 to switch from ANALYSIS to DATA ACQUISITION program

1.9.7.1 Press F10 to switch from ANALYSIS to DATA ACQUISITION programs

1.10.0 Calibration of Absolute Channels (C1 ABS – C16 ABS)

1.10.1 Press F10 to switch from ANALYSIS to DATA ACQUISITION programs

1.11.0 Encoder Setup

1.11.2 Press F11

Figure 8 – Encoder calibration window

1.11.5 Set the motor speed to a minimum.

1.11.9 Scan and save the calibration waveform as 9999-HOUR-MIN.

1.12.0 Calibration Curve Setup

1.12.1 Go to Analysis program (press F10 to toggle from Acquisition to Analysis).

Note, 16 channels are

Figure 9 – Analysis plot view setup

Figure 12 – Calibration Setup Menu

Figure 13 – Calibration Window with Get Figure 14 – Auto Calibration Window.

Top Side Defects

Once highlighted press ENTER Bottom Side Defects

Figure 15 – Bottom Side Groove Signal Highlighted.

Once highlighted press ENTER

Figure 20 – Completed Calibration Curve.

See APPENDIX C for Solution Setup.

1.13.0 Falcon Jnr Setup

Scanner Size Selection

Figure 21 – Falcon S Control Panel

Plot Selection Settings

Channels Per Plot

Figure 22 – Plot View Window

Figure 23 – Topside Waveform

Figure 23 – Bottom side Waveform

Figure 24 – Completed Topside Cal Curve Waveform.

Figure 25 – Completed Bottomside Cal Curve Waveform.