ALTERNATIVE CURRENT FIELD MEASUREMENT

(ACFM) INSPECTION REPORT

ALTERNATIVE CURRENT FIELD MEASUREMENT

(ACFM) INSPECTION REPORT
AT
China Energy Engineering Group - TEPC
Hassyan Power Plant

24” Dia Spool X 45mm Thickness of 1.5 Meter(Bevel Area)

Spool No - 4HR 54

Report No: BHS-TPEC-SIEVERT-ACFM-2022-001-Rev.01

Inspection Date: 26th MARCH 2022

NAME SIGNATURE REPORT DATE DESIGNATION

Inspected By Mr. PawanKumar 28.03.2022 Inspection Engineer

Reviewed By Mr. Rinto Rap hel 28.03.2022 Inspection Engineer

Authorized By Mr. Vikas Chandra 28.03.2022 NDT Level-III

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TABLE OF CONTENTS

1. EXECUTIVE SUMMARY

2. INTRODUCTION

3. SCOPE OF WORK

4. EQUIPMENT DETAILS & INSPECTION PROCEDURE

5. INSPECTION FINDINGS

6. CONCLUSION

 Defect Images

7. APPENDIX I

 Basic Principles and Operation Of ACFM

 Advantages And Limitations

 References

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1. Executive Summary

The ACFM Inspection was carried out on 1.5 meters full circumference inspection of 24”
dia SPOOL having a thickness of 45mm in Hassyan power Plant. The purpose of this
inspection was to detect and determine the depth and length of defects present at the surface
of the above-mentioned parts. Depth and length of the cracks were measured during the time
of inspection. Detailed results of the inspection are shown in the following pages.

2. Introduction

The ACFM Inspection was carried out at Hassyan Power Plant on 1.5 meters full
circumference inspection of 24” dia SPOOL having a thickness of 45mm . as per the
ACFM Inspection Procedure No.(L3-BHS-TP-ACFM-01-Rev.01). To investigate the
surface/near surface properties of Spool surface, probes from the EMA or FIELD GRADIENT
suites must be passed over the surface of the areas of interest. The electromagnetic filed
generated by the probe induces an electromagnetic event to occur in the alloy steel. This
interaction is simultaneously evaluated by the array of sensing elements built into the facets of
the probes surface. The length of each sweep was determined by the assistant, as the linear
distance that could be ‘comfortably’ covered in a single pass. Several contiguous passes are
then linked together until the required region is surveyed.

As different probes are attached to an ACFM system, a short series of automatic adjustments
are performed to align the processing algorithms and electronics with the new array. An ‘auto
adjustment’ of this nature is also performed when there is significant geometry or material
changes from one sweep to the next. The adjustment process (taking only a few seconds)
commences by holding the probe on to the metal surface and once the instructions issued by
the system have been obeyed, holding the probe away from any metallic surface for a few
more seconds completes the process. During both of these phases, the system automatically
executes the necessary adjustments and providing the resultant changes are within the systems
limits then an ‘OK’ message is presented. If for any reason the system is unable to make the

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required adjustment, then an error message is generated, and the inspector will repeat these
operations until a satisfactory result is obtained.
By reference to the procedure, it is necessary to perform quality assurance sweeps of known
defects within a standard reference block (CS/Alloy), during this inspection campaign, thus
proving that all of the systems in use did indeed perform according to specification. Refer
Figure i of CS/Alloy reference block.

Slots depth – 2.0 mm

Slot width – 0.175 mm
Max corner radius – 0.5 mm
Slot Length – 40 mm

All values are in mm

Figure i: CS/Alloy calibration block with EDM slots representing surface defects

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Figure ii: Typical ACFM scan on the LK100 calibration block

3. Scope of Work
The scope of work for the ACFM Inspection is as below:
 To carry out ACFM Inspection on the spool surface.
 To size any surface or near surface cracks detected during the ACFM inspection by measuring the length
and depth using the Lizard™ software
 To mark any anomalies observed for further investigation
 To take digital photographs of key features and any abnormalities found
 Submission of a detailed inspection report

4. Equipment Details & Inspection Procedure No

 Equipment : Lizard M8
 Software : LISS – M8 Lizard Software, Version 1.10
 Serial No : 24997
 Probes : LP851

 ACFM Inspection Procedure No.(L3-BHS-TP-ACFM-01-Rev.01).

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5. Inspection Findings:

24” Dia X 45mm thk. Spool

SIZE
Details Of Length Depth
TUBE NO (mm) Material Remarks
Discontinuity (mm) (mm)
Length Dia
RI -- 0.8
SA 723 Gr. --
6 16000 150 RI 1.1
3Mod. /K12X
RI -- 0.9

NRI: -Non-Relevant Indication

RI: - Relevant Indication

Calibration Details: -

Sizing Diagram Measured On 40mm Length 2mm Depth Notch

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6. Conclusion

The ACFM Inspection was carried out on 1.5 meters full circumference
inspection of 24” Dia X 45mm thickness Spool in Hassyan power Plant. No
Relevant indications (NRI) were found during the time of inspection.

Defect Images
24” Dia X 45mm Thk. Spool

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7. APPENDIX I

Basic Principles of ACFM Inspection

 An alternating voltage applied to a conductor (Probe/Coil) will cause an alternating electrical current to
flow in that conductor (Component), thus producing a magnetic field. In proximity to a conductive
material, eddy currents are produced.

 Presence of surface breaking flaws causes a deviation of the eddy current which appears as a change in
impedance measured by a coil coupled to the surface. A sensor array is then positioned to monitor the
interaction of these circulating currents and the flaw(s) by monitoring changes in the impedance and
analysing the voltage induced.

Operation of Lizard M8 ACFM Equipment

The ACFM System perform highly complex surface and near surface (within 1mm from surface) evaluations of
carbon steel structures and welded tubular carbon steel joints. The data that is acquired is processes by the
on-board microprocessor, presented & subsequently recorded by PC or Laptop. The inspection task therefore
is divided into two logical tasks:

i. Data Acquisition
ii. Data Analysis

Data Acquisition

To investigate the surface/near surface properties of the welded elements of the Structure, probes from the
ACFM or FIELD GRADIENT suites must be passed over the surface of the areas of interest. The
electromagnetic filed generated by the probe induces an electromagnetic event to occur in the Carbon steel.
This interaction is simultaneously evaluated by the array of sensing elements built into the facets of the
probes surface. The length of each sweep was determined by the assistant, as the linear distance that could
be ‘comfortably’ covered in a single pass. Several contiguous passes are then linked together until the
required region is surveyed. Each sweep is required to ‘overlap’ the previous one by 10% to ensure that any
defect indications will not be missed in these regions.

As different probes are attached to an ACFM system, a short series of automatic adjustments are performed
to align the processing algorithms and electronics with the new array. An ‘auto adjustment’ of this nature is
also performed when there is significant geometry or material changes from one sweep to the next. The
adjustment process (taking only a few seconds) commences by holding the probe on to the metal surface and
once the instructions issued by the system have been obeyed, holding the probe away from any metallic

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surface for a few more seconds completes the process. During both phases, the system automatically
executes the necessary adjustments and providing the resultant changes are within the systems limits then an
‘OK’ message is presented. If for any reason the system is unable to make the required adjustment, then an
error message is generated, and the inspector will repeat these operations until a satisfactory result is
obtained.

By reference to the procedure, it is necessary to perform quality assurance sweeps of known defects within a
standard calibration block (SS & CS), during this inspection campaign, thus proving that all of the systems in
use did indeed perform according to specification. Refer Figure i for typical view of SS & Figure ii for typical
view of CS calibration blocks.

Data Analysis

Once ACFM system is adjusted and in acquisition mode, the information that is sent to the central system
controller is immediately displayed on the PC/Laptop Monitor. This information appears on the screen as series
of parallel lines. The main central window shows four pairs of these traces, form the appearance of which the
inspector is able to evaluate the area under investigation. A detailed description of the trace analysis is not
possible here, but briefly; the pairs of data consist of two independent measurements made simultaneously.
One of these is an absolute (current lateral) impedance measurement, the other relates to a current
perturbation (current normal) measurement. The evaluation involves signature recognition of correlated
events. Any changes
are the referred to the right-hand portion of the screen where if probe lift-off is apparent then sweep may be
re- acquired. The inspector will recommend a suitable course of action based on his findings.

As shown in Figure ii, the time base mode of presentation is used for determining the length and depth of the
flaw. The technique used in the interpretation of the absolute trace (AT) (red), current perturbation (CP)
(blue) and lift off signal (green + red) for monitoring of contact integrity during scanning of the time base
mode is as illustrated in Figure iii. A maximum of 4 sets of CP and AT signals are presented to accommodate
the different faces of the probe used during the scan (special design probes that accommodate profile of the
weld are used during the inspection).

8. Advantages of ACFM

1. Surface can be inspected for surface breaking and near-surface defect without removal of paint or
coating.
2. Defect dimensions can be measured (length and depth).
3. Three-dimensional plot can be generated for post inspection analysis.

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4. Gives permanent record which can be used for monitoring the propagation of defects if the structure is
not available for repair due to tight schedule.
5. Speed of inspection (using special designed probe(s) for welds, which electronically detect
presence/absence of good contact integrity between surface of structure inspected and probe) is much
faster than compared to conventional surface inspection technique such as Magnetic Particle Testing (MT)
or Dye Penetrant Testing (PT).

Limitations of ACFM

1. Since the scanning area was rough surface, probe wobbling signal could be appeared in the
scan result.
2. Scanning was carried out on geometrically accessible areas only.
3. Physical measurement should be done due to scan time variation.
4. End effect will reduce the sensitivity of inspection at the edges of weldment.
5. Limited sensitivity for subsurface defects. Depends up on frequency, lift off, permeability and
conductivity values.

5. References

Alternative Current Field Measurement (ACFM) inspection was carried out in accordance with the following
standards & procedures:

 ASME BPVC.V-2019, Article 15 & 31. Alternative Current Field Measurement technique (ACFMT)
 ASTM E2261 / E2261M – 19 Standard Practice for Examination of Welds Using the Alternating Current
Field Measurement Technique
 ASTM E1316-11b: Terminology for Non-destructive Examinations.
 L3-BHS-TP-ACFM-01-Rev.01 - Alternative Current Field Measurement (ACFM) Inspection Procedure

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