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In an MFL tool, magnetic sensors are placed between the poles of the
magnet to detect the leakage field. The signal of the leakage field is analyzed
to identify the damaged areas and estimate the amount of metal loss. Thus,
the transducer includes magnetizers and magnetic sensors.
1.1.1 This practice includes rope diameters up to 2.5 in. (63.5 mm). Larger
diameters may be included, subject to agreement by the users of this practice.
1.2 This standard does not purport to address all of the safety concerns, if
any, associated with its use. It is the responsibility of the user of this standard
to establish appropriate safety and health practices and determine the
applicability of regulatory limitations prior to use.
Keywords:
changes in metallic cross-sectional area
local flaws
Charlie Chong/ Fion Zhang MAGNETIC FLUX LEAKAGE TESTING WITH CIRCOFLUX®
Alternating Field MFL method
Charlie Chong/ Fion Zhang MAGNETIC FLUX LEAKAGE TESTING WITH CIRCOFLUX®
Alternating Field MFL method
Charlie Chong/ Fion Zhang MAGNETIC FLUX LEAKAGE TESTING WITH CIRCOFLUX®
FIG. 1 Schematic Representation of an Electromagnetic Instrument Sensor-
Head
Sensor Head
Hall Devices
Hall Devices
While the information is not quantitative as to the exact nature and magnitude
of the causal flaws, valuable conclusions can be drawn as to the presence of
broken wires, internal corrosion, and fretting of wires in the rope.”
5.2 The instrument’s response to the rope’s fabrication, installation, and in-
service-induced flaws can be significantly different from the instrument’s
response to artificial flaws such as wire gaps or added wires. For this reason,
it is preferable to detect and mark (using set-up standards that represent) real
in-service-induced flaws whose characteristics will adversely affect the
serviceability of the wire rope.
air gap
Keywords:
■ Electromagnetic Method (AC-LMA) (electromagnet)
■ Magnetic Flux Method (DC-LMA) (electromagnet or permanent magnet)
■ Magnetic Flux Leakage Method
(DC-LF) (electromagnet or permanent magnet)
9.2.7 When more than one setup is required to examine the full working
length of the rope, the sensor head should be positioned to maintain the
same magnetic polarity (?) with respect to the rope for all setups. For strip
chart alignment purposes, a temporary marker should be placed on the rope
at a point common to the two adjacent runs. (A ferromagnetic marker shows
an indication on a recording device.) The same instrument detection signals
should be achieved for the same standard when future examinations are
conducted on the same rope.
9.3 Local flaw baseline data for LF and LMA/LF instruments may be
established during the initial examination of a (new) rope. Whenever
applicable, gain settings for future examination of the same rope should be
adjusted to produce the same amplitude for a known flaw, such as a rod or
wire attached to the rope.
12. Keywords
12.1 electromagnetic examination; flux leakage; local flaws (LF); Magnetic
flux; magnetic flux leakage; percent loss of metallic cross-sectional area
(LMA); rod reference standards; sensor head; wire rope; wire rope reference
standard
■ https://www.youtube.com/watch?v=8JtVJJp3mc8
■ https://www.youtube.com/watch?v=c22z9Mo0PVs
Most of the MFL inspection tools make use of "passive" Hall effect sensors to
detect flux leakage as indication of metal loss. The systems using Hall
elements we call "traditional" MFL tools. Due to physical limits of the size of
magnets and total weight of the necessary scanner there is an optimum in
performance of traditional MFL tools. As a consequence thickness range is
limited to 10 or at best 15 mm under favourable circumstances. Sensitivity
drops dramatically with increasing thickness. Thus the challenge to design a
tool for a much greater wall thickness remained.
Magnetic saturation not only creates a low permeability and uniform flux, it
also suppresses the usual local permeability variations in the material. This
eliminates an enormous source of noise, which can hardly be filtered out, and
otherwise would prohibit proper functioning of flux sensing systems.
Keywords:
Magnetic saturation
Magnetic permeability μ=1
Uniform flux
Deeper penetration
Skin effect
Local permeability variations
Hall sensor (passive!)
Eddy current sensor (active)
Most probably the weight of the magnetic yoke and scanner dictate the real
physical upper limit. The limits have not fully been explored yet. The now
existing system, suitable for approximately 30 mm wall thickness, seems to
be an optimum. The "new" MFL technology is called "SLOFEC". The acronym
SLOFEC stands for Saturation LOw Frequency Eddy Current.
Keywords:
■ phase information is provided and from that it can be established whether
the defect is at the top or back wall of the component.
■ low enough eddy current frequency to penetrate the full wall without
sacrificing on inspection speed
CORROSION PITTING
There are many types and mechanisms of corrosion but in this instance we
deal exclusively with corrosion that is typical between the pad and the
underside of tank bottoms or from water contamination inside the tank. The
ultrasonic means of detecting erosion in pipework was so successful during
the 1960's that it has given a false impression of the accuracy that will be
obtained with pitting type corrosion. To help appreciate the difference we will
illustrate erosion and some typical pit shapes. Figure 1 shows erosion
whereas Figures 2 to 4 sketch corrosion shapes that have been given the
terms "Lake Type", "Cone Type" and "Pipe Type".
Hall effect devices are in principle less sensitive to speed variation, however
when filtration is used during signal processing to remove low and high
frequency spurious signals, the resulting band pass window imposes some
restriction on speed variation. When these devices are arranged to detect the
Horizontal component of the leakage field, they are relatively insensitive to
the eddy current signal mentioned above, but, like the coil, relatively sensitive
to lift off variations. When arranged to detect the Vertical component, they are
less sensitive to lift off variations but very sensitive to the eddy current signals.
One advantage of this arrangement, however, is that a larger gap between
the sensor housing and the test surface can be accommodated which
reduces housing wear and allows the housing to clear some of the surface
imperfections such as weld spatter.
Keywords:
acceleration and deceleration phases of the scanner
■ Vibration damping
One source of background noise and false indications is due to surface
roughness of the scanning surface. This is very common in the case of
storage tank floors and above ground pipelines that have not been coated.
The resulting corrosion on those surfaces causes the scanning carriage to
vibrate the magnet and sensor system. The resulting noise can be reduced in
three ways: by fitting broader wheels, by incorporating shock absorbers and
by signal processing since the vibration frequency is likely to be higher than
that from pit signals.
Keypoints:
by signal processing since the vibration frequency is likely to be higher
than that from pit signals. (unlike crack and weld defect!)
It must also be remembered that the MFL method does not discriminate
between pitting on the scanning surface and that on the remote surface,
however, for pits penetrating 50% or more through the material, the MFL
method is more sensitive to remote surface pitting. (comment: some vendor
provide eddy current probe with phase discrimination for depth analysis?)
■ Cleanliness
MFL is less sensitive to floor surface condition that ultrasonics but heavily
ribbed scale can cause false indications and corrosion products can build up
on the magnet poles and then give false indications as they break away and
pass under the sensor head. Generally removal of product and subsequent
water jetting of the surface is sufficient.
■ Pit depth
Pit depth is one of the main factors affecting flux leakage amplitude at a
particular distance above the test surface. Volume and contour also affect this
amplitude and these are discussed below. However within prescribed
limitations the amplitude of the flux leakage field can be used to assess the
percentage wall loss and thus reduce the amount of cross checking needed.
Scanning technique
It should be obvious that taking spot readings on a grid pattern is only suitable
for detecting areas of general corrosion and is useless in detecting isolated
pits. Therefore it is necessary to use an area scan technique with a suitable
overlap to ensure coverage by the effective area of the probe. With manual
scanning it is better to use a fairly rapid probe movement with suitable
calibration than to use a slow painstaking approach to the detection phase.
This is because the human eye naturally responds to a sudden change
(movement) in signal pattern. Once the pit has been detected, a more careful
investigation of pit depth can be carried out.
■ CLIMATIC CONDITIONS
Invariably, the range of temperature and humidity conditions will vary
enormously worldwide. The effect on both operator and equipment must be
taken into consideration. Human beings do not function well in extremes of
temperature. Use of the MFL equipment should not place too great a burden
on them from either a physical or mental point of view. In other words, the
simpler, more reliable and easy to use the MFL inspection equipment is made,
the more reliable the inspection results.
■ ELECTROMAGNETS/PERMANENT MAGNETS
Powerful rare earth magnets are ideally suited for this application. They are
more than capable of introducing the required flux levels into the material
under test. Electromagnets by comparison are bulky and heavy. They do
have an advantage in that the magnetic flux levels can be easily adjusted and
“turned off” if necessary for cleaning purposes. Permanent magnet heights
can be adjusted to alter flux levels but the bridge requires regular cleaning to
remove ferritic debris. The buildup of debris can have a significant impact on
system sensitivity.
COILS
Coils are passive devices and follow Faraday’s Law in the presence of a
magnetic field. As a coil is passed through a magnetic field, a voltage is
generated in the coil and the level of this voltage is dependent on the number
of turns in the coil and the rate of change of the flux leakage. From this, it is
clear that speed will have some influence on the signals obtained from this
type of sensor.
Since the year 2000, tunnel barriers of crystalline magnesium oxide (MgO)
have been under development. In 2001 Butler and Mathon independently
made the theoretical prediction that using iron as the ferromagnet and MgO
as the insulator, the tunnel magnetoresistance can reach several thousand
percent.[4][5]
Applications
The read-heads of modern hard disk drives work on the basis of magnetic
tunnel junctions. TMR, or more specifically the magnetic tunnel junction, is
also the basis of MRAM, a new type of non-volatile memory. The 1st
generation technologies relied on creating cross-point magnetic fields on
each bit to write the data on it, although this approach has a scaling limit at
around 90–130 nm.[10] There are two 2nd generation techniques currently
being developed: Thermal Assisted Switching (TAS)[10] and Spin Torque
Transfer (STT). Magnetic tunnel junctions are also used for sensing
applications. For example, a TMR-Sensor can measure angles in modern
high precision wind vanes, used in the wind power industry.
One way to solve these problems is to use a high sensitivity magnetic sensor
that can detect a low magnetic intensity field at low frequency such as a
magnetoresistive (MR) sensor. If such a sensor were installed, we could
operate MFL at extra low frequency, which would give deep skin depth and
detect small magnetic flux leakage caused by a low power source.
δ= √(2/ωσμ) = (πfσμ)-½
R’ = R sin(θ+φ)
Here, φ is a common phase adjusting the phase shift of the entire
measurement system.
The samples used in this study were two steel plates (SPHC) with four back-
side pits as shown in Figure 3. Both samples were 8.6 mm thick. The pits of
Sample (a) are of the same diameter (6 mm) and different wall thinning rates
(23, 57, 70, 93 %). Sample (b) has the same wall thinning rate (70 %) and
different diameters (4, 6, 8. 10 mm). Multipoint measurement was carried out
in the range of 20 mm × 20 mm around a pit from front surface with an
interval of 1 mm for 21 × 21 steps as shown in Figure4.
The next section discussion deals with the first step, producing the magnetizing
force.
http://jyhengrun.en.made-in-china.com/productimage/LXxJqIKWhmhC-
Charlie Chong/ Fion Zhang 2f1j00bScaFVoCEUql/China-Rolling-Ring-Forging-Stainless-Steel-Flange.html
Seams & Laps
Excitation systems that use permanent magnets offer the least flexibility.
Such systems use high energy product permanent magnet materials such as
neodymium iron boron, samarium cobalt and aluminum nickel. The major
disadvantage with such systems lies in the fact that the excitation cannot be
switched off. Because the magnetization is always turned on, it is difficult to
insert and remove the test object from the test rig. Although the magnetization
level can be adjusted using appropriate magnetic shunts, it is awkward to do
so. Consequently, permanent magnets are very rarely used for magnetization.
(1) Ф = N I / S = ampere/(ampere/weber)
where I is the current (ampere) in the coil, N is the number of turns in the coil
and S is the reluctance (ampere per weber) of the magnetic circuit.
Keywords:
Reluctance (ampere per weber)
In a DC field, the reluctance is the ratio of the "magnetomotive force” (MMF) in a magnetic circuit
to the magnetic flux in this circuit. In a pulsating DC or AC field, the reluctance is the ratio of the
amplitude of the "magnetomotive force” (MMF) in a magnetic circuit to the amplitude of the
magnetic flux in this circuit. (see phasors)
S = N I / Ф, F =NI
where
S is the reluctance in ampere-turns per weber (a unit that is equivalent to turns per henry).
F is the magnetomotive force (MMF) in ampere-turns
Ф is the magnetic flux in webers.
"Turns" refers to the winding number of an electrical conductor comprising an inductor
Tesla, a flux density of one Wb/m2 (one weber per square metre) is one
tesla.
■ The SI unit of magnetic flux is the weber (Wb) (in derived units: volt-
seconds), and the CGS unit is the maxwell.
Where:
H: (magnetic field intensity) is measured in units of amperes per meter
(symbol: A·m-1 or A/m) in the SI.
Tesla, (B: magnetic flux density) a flux density of one Wb/m2 (one weber
per square metre) is one tesla.
Officially,
Weber (unit of magnetic flux) - The weber is the magnetic flux which, linking a
circuit of one turn, would produce in it an electromotive force of 1 volt if it were
reduced to zero at a uniform rate in 1 second
Comment:
H-field – magnetic field intensity? Relates to A∙m-1
Keywords:
Fmagnetic = q∙v∙B sinϴ
The magnitude of the force is F = q∙v∙B sinϴ where ϴ is the angle < 180
degrees between the velocity and the magnetic field. This implies that the
magnetic force on a stationary charge or a charge moving parallel to the
magnetic field is zero.
Comments:
H: (magnetic field intensity) is measured in units of amperes per meter (symbol: A·m-1 or A/m) in
the SI.
B: (magnetic flux density) is measured in teslas (symbol: T) and newtons per meter per ampere
(symbol: N·m-1·A-1 or Newtons per Ampere meter N/(m·A)) or weber/m2 in the SI.
(2) (3)
(4)
(4)
Where:
• ax is the cross sectional area (square meter) of the air gaps, test object or
yoke;
• Lx is the length (meter) of the air gaps, test object or yoke; μ0 is the
permeability of free space (μ0 = 4π.10–7 H·m–1); μr is relative permeability;
and subscripts g, s and y denote the air gaps, test object and yoke,
respectively.
Note that the magnetic circuit consists of two air gaps, one at each end of the
test object. Both air gaps need to be taken into account in calculating the total
reluctance of the magnetic circuit.
Legend
I = electric current
P, Q = points of discontinuities in
example
R = point at which magnetic field
intensity H is measured
S = point at which magnetic flux
density B is measured
(5)
Question: a or r?
Legend
H = magnetic field intensity
I = electric current
Legend
H = magnetic field intensity
I = electric current
r = tube radius
Legend
C = capacitor
Ic = capacitor discharge current
Ie = eddy current
SCR = silicon controlled rectifier
Legend
C = capacitor
Ic = capacitor discharge current
Ie = eddy current
SCR = silicon controlled rectifier
(6)
Here Ie is the amount of eddy current (ampere) contained within the cylinder
of radius r (meter). Investigation of the effect of the eddy current is
theoretically quite complicated because of its effect on the inductance, which
in turn affects Ic. In practice, however, measurement of the magnetic flux
density B in the material will yield the final degree of magnetization of that
material.
Several other practical conclusions can be drawn from the above discussion.
• Pulse duration plays a greater role than pulse amplitude Ic(max) in
determining the amount of flux induced in a test object. This is intuitively
seen in direct current tests.
• It is not possible to give simple rules that relate Ic(max) to magnetization
requirements. This relationship can be shown with a magnetic flux meter.
• The eddy currents induced during pulse magnetization play an important
role in the result. They can shield midwall regions from magnetization.
• Larger capacitances at lower voltages provide better magnetization than
smaller capacitances at higher voltages because larger capacitances at
lower voltages lead to longer duration pulses and therefore to lower eddy
currents. The lower voltage is an essential safety feature for outdoor use.
A maximum of 50 V is recommended.
(7)
Where:
N is the number of turns in the coil,
V is the voltage induced in the coil and
Ф is the magnetic flux (weber) linking the coil.
It must be mentioned that only the component of the flux parallel to the axis of
the coil (or alternately perpendicular to the plane of the coil) is instrumental in
inducing the voltage.
(8)
(a) (b)
(b)
flux
(a) flux
1. It is essential that the probe scan velocity (relative to the test object)
should be constant to avoid introducing artifacts into the signal through
probe velocity variations.
2. The output is proportional to the spatial gradient of the flux in the direction
of the coil. The output of the pickup coil can be integrated for
measurement of the leakage flux density rather than of its gradient.
figure 1
Charlie Chong/ Fion Zhang https://sensortech.wordpress.com/2010/06/25/better-alternatives-to-pneumatic-cylinder-end-of-stroke-detection/
However, there are some disadvantages of Hall Effects such as they typically
require fairly high magnetic gauss strength and they require a radially
magnetized magnet. Typically, a Hall Effect will not work as a replacement of
a reed switch or if it does operate, it may produce double switch points. A Hall
Effect sensor is looking for a single magnetic pole, so if it is used with an
axially magnetized magnet, it will switch when it sees the north pole and then
again with the south pole, thus causing the double switch points.
I know what you are thinking there must be some negatives. The initial cost of
the AMR or GMR sensor may be slightly more than the reed sensor however
this cost is becoming less and less and it is even less once you figure the cost
of down time after your reed switch fails or the proximity flag is moved. In
addition, the AMR and GMR sensors are 3-wire devices unlike the 2-wire
reed switch. However, in the end the AMR and GMR sensors are still the
better solution.
(9)
Where:
dl is an element of length (meter), H is the magnetic field intensity (ampere
per meter) and I is the current (ampere) in the test object.
In the electric case, the relation of field to source is quantified in Gauss's Law
which is a very powerful tool for calculating electric fields
(10)
(11)
Where:
R is the radius (meter) of the cylindrical test object. A surface field intensity
that creates an acceptable magnetic flux leakage field from the minimum
sized discontinuity must be used. Such fields are often created by specifying
the amperage per meter of the test object’s outside diameter.
Where the test object is a tube, the L·D–1 ratio is given by the length between
the poles divided by twice the wall thickness of the tube. (The distance L from
pole to pole can be longer or shorter than the actual length of the test object
and must be estimated by the operator.)
As a rough example, with L = 460 mm (18 in.) and D = 19 (0.75 in.), the L·D–1
ratio is 24.
(12)
9.5.0 Preface
Simulated defects of different shapes and sizes were created in a section of
API X70 steel line pipe and were investigated using a residual magnetic flux
leakage (MFL) technique. The MFL patterns reflected the actual shape and
size of the defects, although there was a slight shift in their position. The
defect features were apparent even at high stresses of 220 MPa when the
samples were magnetized at those particular stresses. However, unlike the
active flux technique, the residual MFL needs a sensitive flux detector to
detect the comparatively weaker flux signals.
Charlie Chong/ Fion Zhang Journal of Nondestructive Evaluation, Vol. 22, No. 4, December 2003 (© 2004)
9.5.1 Introduction
The magnetic flux leakage (MFL) technique is frequently used for in-service
monitoring of oil and gas steel pipelines, which may develop defects such as
corrosion pits as they age in service. Under the effect of typical operating
pressures, these defects act as “stress raisers” where the stress
concentrations may exceed the yield strength of the pipe wall. The main
objective of MFL inspection is thus to determine the exact location, size, and
shape of the defects and to use this information to determine the optimum
operating pressure and estimate the life of a pipeline. Most MFL tools rely on
active magnetization in which the pipe wall is magnetized to near saturation
by using a strong permanent magnet, and the flux leaking out around a defect
is measured at the surface of the pipeline.
Keywords:
■ Near saturation
■ Active magnetization
■ Flux leaking out
Keywords:
■ 30 G (Gauss)
Keywords:
■ Residual flux patterns are basically similar to the active flux patterns.
■ Very weak and may have opposite magnetic polarity
■ For high excitation current level, there is no reversal of polarity
MFLpp
Active
magnetization
Vertical lift-off
S N End lift-off