HydroFORM Phased Array Corrosion Mapping System

Part 2 – Mechanical Setup

HydroFORM Corrosion Mapping System – Mechanical Setup
 The HydroFORM Phased Array System is designed to perform corrosion mapping in two possible
configurations.

 Manual Encoded One Line Scans (1 axis)

 Semi-Automated Encoded Multiple Line

Scans (2 axis)

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HydroFORM Mechanical Setup – Probe Installation
 Ensure that the probe is installed into the
HydroFORM scanner where element
number 1 is positioned correctly for the
C-scan that will be created. The normal
position for this is 1-64 left to right when
scanning forward as pictured.
 When the Omniscan Start button is
selected, the 0,0 position will set 2mm to
the right of element number 1 as
pictured.
 The Index axis will increment in the
direction below indicated by the green
arrow. (1mm focal law resolution and
61mm total width)
 The Scan axis will increment below in the
direction indicated by the blue arrow at
the resolution entered into the Omniscan.

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HydroFORM Mechanical Setup – Probe Installation
 Loosen the knob (pictured at right),
apply light pressure on the probe to
ensure the foam seal is secure
against the inspection surface and
tighten the knob.
 The HydroFORM wedge used by
the focal law calculator has a
default height (Water column) of
12mm. This can be visualized on
the Omniscan display prior to
tightening the probe knob and
adjusted by applying light pressure
until the interface signal is at 0.
 It is also acceptable to modify the
Hydro wedge parameters to the
current position.

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HydroFORM Mechanical Setup – Probe Installation

 The phased array probe will align

parallel and level with the pipe
when secured with the one-knob
patent pending probe carriage.
 Minor differences in the water
column due to the scanner
“Crabbing” will not affect thickness
readings when the interface gate
(Yellow) is set to A-scan Syncro I/
 To achieve the intended focal
point, the real water column height
must match the Hydro wedge
height in the Omniscan database.
 Differences in the water column
and calculator will not affect beam
angle at 0 degrees for corrosion
mapping and thickness readings.

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HydroFORM Mechanical Setup – Probe Installation - Foam

 Pressure applied to the probe

during installation is directly
related to the foam insert
position and will affect the ability
to maintain the water column.
 Care should be taken to ensure
that the probe is not installed
with too much or too little
tension on the foam.
 To optimize both the position of
the probe and tension of the
foam the interface echo between
the water and component
surface should appear at 12mm.
This is the default height of the
Hydro wedge in the Omniscan
database and when positioned
correctly will result in the
interface signal appearing at
zero mm using the default set up
file. (With gate I Syncro on
Pulse, not \ I)

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HydroFORM System – Manual Encoded One Line Scans

 In the manual encoded one line scan configuration, the position of the data is maintained and
recorded using the encoder integrated in the HydroFORM carriage.
 The integrated encoder has a resolution of 8 steps\mm that is entered into the Omniscan MXU
software in the Scan-Encoder-Resolution for Encoder #1.
 In this configuration with the default aperture of 4 elements (4mm per A-scan), the HydroFORM will
provide a one line scan of 61 A-scans (61mm) up to the limit of either the 160 megabyte file size
(Standard) or 300 megabyte file size (Optional).

 For the 160 megabyte standard Omniscan, the

limit would be a C-scan of 61mm X 7680mm at a
resolution of 1mm in both axis.
 For the 300 megabyte optional Omniscan, the
limit would be a C-scan of 61mm X 14,400mm at
a resolution of 1mm in both axis.
 To piece multiple one line scans together in one
data file, the probe can be indexed manually in
the Omniscan software or indexed by use of a
clicker (Olympus P/N: OPTX674) and index of the
C-scan entered manual.

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HydroFORM System – Manual Encoded One Line Scans

 For manual encoded one line

scans, plug the Mini-Wheel
encoder cable to the Lemo-DE15
encoder cable extension. The
DE15 connector will connect to
the OmniScan.

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HydroFORM System – Semi-Auto Raster Scanning (2 Axis)
 Use of the HydroFORM system in the 2 axis semi-automated mode requires the
Olympus CHAIN Scanner (Chainscan-XY38) or similar.
 The HydroFORM adaptation kit includes all of the required hardware to adapt
the HydroFORM HD Mapper to a standard Olympus CHAIN Scanner XY38.
 Included in the adaptation kit is the crank handle, encoder junction with Lemo
connector, reversed spring loaded arm for HydroFORM scanner attachment,
four plastic wheels and parts to allow the CHAIN Scanner to inspect Flat
surfaces.

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HydroFORM System – Semi-Auto CHAIN Scanner

 In the CHAIN Scanner manual, locate the

required number of short links and long links for
the diameter of pipe to be inspected and connect
them in accordance with the manual.
 Insure the adjustment screw is set so that when
clamped on the pipe the scanner is snug to the
pipe and does not move freely.
 Make sure you use a small link with dovetail on it
for installation of the umbilical attachment device.

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HydroFORM System – Semi-Auto CHAIN Scanner
 Install the HydroFORM on the index arm as pictured below. The probe knob
should be on the far side of the HD Mapper from the CHAIN Scanner wheels.
 The probe should be installed with element 1 closest to the CHAIN Scanner
wheels.
 The umbilical should be configured with slack to allow a full range of movement
on the index arm.
Index Axis

Scan Axis
64 1

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HydroFORM System – Semi-Auto CHAIN Scanner

 The HydroFORM assembly is connected to the

CHAIN Scanner by a spring loaded arm that has
3 possible positions.
1. Locked up (for HydroFORM manipulation)
2. Locked down
3. Free moving

 When acquiring data and manipulating the

scanner the arm should be in the free
moving position.
 Acquiring data when the arm is in a locked
position results in poor data quality and
scanner operation.

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HydroFORM System – Semi-Auto CHAIN Scanner
 Position the scanner so that 0,0 (XY position) on the probe is in the intended
position on the pipe.
 Using the default aperture of 4 elements, this puts 0,0 (Focal law 1) 2mm from
the element 1 position line.

0,0

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Semi-Auto Chain Scanner – Position of 0,0 for C-scan

 To assist in positioning the HydroFORM at the correct 0,0 position a magnetic

template is provided.
 Place the magnetic template on the component with the 0,0 position of the C-
scan under the window below indicated by the red arrow.
 After the magnetic template is in place the HydroFORM can be put in place
prior to locking down the chain scanner.

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Semi-Auto Chain Scanner – Position of 0,0 for C-scan

 The chain scanner has a arm length (Index or Y axis) that will allow the probe
five revolutions or “Strokes” around the pipe. Using the default set up this
results in a C-scan acquisition of 305mm X pipe circumference. (61mm X 5
strokes)
 For multiple acquisitions, the chain scanner must be repositioned every
305mm. The magnetic template is used to set the original 0,0 position and to
maintain the correct position for successive scanner positions every 305mm.
 See Omniscan Setup Power Point for encoder preset position and C-scan area
creation for consecutive repositioning of the chain scanner for inspections
larger than five strokes (305mm)

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HydroFORM System – Semi-Auto CHAIN Scanner
 Move the scanner to the side slightly and open the water control valve until the
water chamber is flooded and all bubbles have disappeared from the S-scan
display.
 After initially flooding the water chamber and clearing the bubbles, the water
pressure can be reduced to a light flow during scanning.
 The surface condition of the pipe will determine how much water is required.
 Best results and fastest scan speed will be achieved with an electric pump due
to constant consistent pressure.
 Be sure to move the scanner back to 0,0 prior to starting the acquisition.

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