Student Training Notes Floormap 3DiM

FLO
MFL floor Scanner with STARS Top & Bottom Defect Discrimination
FLOORMAP3DiM
MFL Floor Scanner with STARS Top & Bottom Defect Discrimination
Operators Training Course

SECTION 1B - Floormap3DiM System Overview – Rev 1
Floormap3DiM
Product Training Course
Improving Inspection Through Technology
Floormap3DiM Training Course

Aim
To provide technicians a working knowledge in the operation,
maintenance and limitations of the Floormap3DiM system.
Objectives
Outline the technology used by the system.
Recognise system and inspection and limitations.
Identify the requirements for a successful inspection.
Discuss the components and maintenance of the system.
Establish how to prepare the system for an inspection.
Demonstrate efficient operation of the system.
Evaluate the captured data and generate a report.
Floormap3DiM Training Course

Agenda
System Overview.
MFL and STARS technology.
MFL Tank Floor Inspection.
Scanner components and maintenance.
Inspection setup and calibration.
Scanning of a tank floor.
Operation in manual MFLi3000 mode.
Data Analysis and Reporting.
1
Floormap3DiM System Overview

What is the Floormap3DiM?
Motor driven Magnetic Flux Leakage (MFL) Scanner.
Incorporates Surface Topology Air-gap Reluctance (STARS)
technology.
A scanner which incorporates 2 different systems.
Floormap3Di MFLi3000
Floormap3DiM

The Floormap3Di system is:
A mapping scanner for above ground storage tank (AST) floors.
Provides top and bottom defect discrimination.
Enhanced probability of corrosion detection.
Advanced defect sizing and classification tools.
The MFLi3000 system is:
A rapid MFL screening scanner with Autostop, stop on defect
capability.
Free scan mode with Real Time Scan (RTS) view.
MFLi plate view for scan analysis.
STARS top surface view.

Components of the Floormap3DiM system:
MFL300 mechanical chassis.
Floormap3Di Data Acquisition Software and Desktop Analyser
(licenced).
MFLi3000 Data Acquisition software (licenced).
Silverwing Inspection Mapping Software (SIMS) (licenced).
2

Video of the Floormap3Di and MFLi3000

Intended Use
Flat ferrous inspection surfaces between 5mm [1/2inch] to
12mm [1/2inch] in thickness for sizing.
A coating thickness of no greater than 6mm [1/4inch].
Be free of excess rust, scale, ferrous debris, oil, ice, frost.
Operating temperature from -30oC to 55oC [-22oF to 131oF].
Intended User
Persons not fitted with a ICD and without limitations in the
physical abilities of upper and lower limbs or sight.
Persons who has undergone manufacturer equipment training.
Understand MFL technique and its limitations.
Undergone other specific safety training related to storage tank
inspection.
8

Floormap3Di scanner performs two functions:
Detection of indications Sizing of indications

Sizing of indications is based on estimated percentage loss (EPL).
Percentage loss is corrosion depth relative to plate thickness.
Percentage values are based upon the calibration curve.
A calibration provides a relationship between the quantity of
leakage field for a given volume loss at a known depth.
3

MFLi3000 scanner performs one functions:
Detection of indications above

a user set threshold level
Detected indications require further prove up for correct sizing.
A detection threshold level is set based upon a calibration.
A calibration provides a relationship between the quantity of
leakage field for a given volume loss at a known depth.
10
4
SECTION 2 – MFL and STARS technology – Rev 1
MFL and STARS technology
MFL and STARS technology

Aim
To explain the theory of the technology utilised by the scanner,
how it generates percentage loss values and identify what
factors that affect the MFL signal.
Learning Outcomes
Describe the MFL principle and STARS principle.
Discuss the purpose of the calibration and reference plate.
Establish a percentage value and surface origin from the
calibration trace and detected MFL and STARS ‘u’ values.
Identify a suitable Suggested Minimum Operational Threshold
level based on the Signal to Noise Ratio of the calibration trace.
List the factors that affect MFL detection and discover how
each can alter the systems results.
2
Magnetic Flux Theory

Magnetic Fields
To understand how magnets interact with each other the
concepts of a “Magnetic Field” is used.
The idea of a magnetic field is based on the patterns made by
ferrous particles when they are placed in a magnetic field.
These patterns are called “Magnetographs”.
Magnetic fields are thought
to consist of “Lines of Flux”.
A bar magnet can be
described as a “Dipole”. NN SS
1
Magnetic Flux Theory

Properties of Lines of Flux
They flow from a North Pole to a South Pole outside the
magnet.
They flow from a South Pole to a North Pole inside the
magnet.
Most densely packed at the poles.
They form closed loops.
Take path of least resistance.
They never cross.
Like poles repel.
Opposite poles attract.
Magnetic Domain Theory

A magnetic domain is region in which the magnetic fields
of atoms are grouped together and aligned.
In an un-magnetised object, the magnetic domains are
pointing in different directions.
Each domain comprises of 1015 to 1020 atoms – typically
there are several million domains in each individual grain
of the material.
S
N
N
S
Magnetised Bar
Un-Magnetised
Magnetic Domain Theory

When
If the Magnetising
the domainsForce
are partially
is increased
aligned
andbythe
andomains
outside
become fully aligned
“Magnetising Force” athe
ferromagnetic
bar is said tomaterial
be magnetically
will
saturated.
become magnetised.
If the Magnetising Force is increased and the domains
become fully aligned the bar is said to be magnetically
saturated. MAGNETISING FORCE
MAGNETISING FORCE
S
N
S N
N
S
N
N N N
N
N
N N
S
S N N N
S
Saturated Magnetised
Un-Magnetised
Saturated BarBar
Magnetised
2
Magnetic Flux Leakage Principle

Location of the magnetic bridge and MFL sensor array.
The system is detecting a change in the quantity of flux
leakage between floor plate and MFL sensors.
Air gap
(Measuring flux leakage)
Bridge Permanent Magnets
Pole piece Pole piece

MFL sensors
Floor plate

Scanner magnets creates a localised magnetic field that
fills or “Saturates” the full thickness of the plate.
Corrosion causes the magnetic field to “leak” out of the
plate.
Hall effect sensors located in the MFL sensor head detect
the leakage field and resulting signals are processed to
show an estimate percentage loss (EPL).

The leakage field is primarily affected by the volume loss
of the indication.
The larger the indication, the greater the leaking field the
so larger the outputted MFL signal.
The raw MFL view is represented as a dark then light
rendered image.
DIRECTION OF SCANNING
40% EPL 60% EPL 60% EPL

9
3

A major limitation of MFL is that it cannot discriminate
the surface origin of indications.
Consider the response from a know feature that has a
50% wall loss and is 5mm long.
0.15
Defect from top (By)
Defect from top (By)
Defect from bottom (By)
Defect from bottom (By)
0.1
Magnetic flux density (T)
0.05
Difficult to discriminate -0.05
as there is a 7% difference -0.1
in the peak to peak. 0 10 20 30 40 50 60 70 80 90 100

Scan distance (mm)
Another technique is required for surface discrimination.

10
STARS Principle
Consider the magnetic bridge and MFL sensor array.
STARS sensor array are located below the rear pole piece.
The sensors measure the rate of change of the magnetic
field under the pole.
This rate is dependant on the field disturbance caused by
changes to the surface.
Bridge Permanent Magnets
Pole piece Pole piece

MFL sensors
STARS sensors
11
STARS Principle
Bottom side indications have no effect on STARS sensors
because magnetic field under the pole does not change.
Top side indications cause a disturbance in the magnetic
field so the rate of change is measured by STARS sensors.
STARS technology has been developed by Silverwing.
Surface Topology Air-gap Reluctance Sensors
POLE PIECE POLE PIECE

STARS STARS
SENSORS SENSORS
12
4
STARS Principle
The raw STARS view of the data is represented as a dark
then light rendered image. Similar to that of the MFL.
If there is a depression on the surface (corrosion pit for
example), the image is black then white.
If there is a protrusion on the surface (weld spatter), the

image is then white to black.
13
MFL Reference plate

To accurately size any discontinuities the system must
first be calibrated on the reference plate.
The reference plate have machined pits to represent
different values of estimated percentage loss (EPL).
These pits represent volumetric loss and are created
using a 22mm diameter ball end cutter.
Available reference plate thicknesses:
6mm – CP30 [1/4inch – CP72]
8mm – CP28 [5/16inch – CP74]
10mm – CP29 [3/8inch – CP75]
12mm – CP31 [1/2inch – CP76] 22mm diameter ball
end cutter
14
MFL Reference plate

Defect dimensions vary depending upon plate thickness.
Depth is based on percentage loss of plate thickness.
Diameter is governed by the tool diameter at the depth.
Volume is based on depth, tool diameter and plate thickness.
20% 40% 60% 80%
Plate
Thickness
Plate 20% defect 40% defect 60% defect 80% defect

Thickness Depth Diameter Volume Depth Diameter Volume Depth Diameter Volume Depth Diameter Volume
6mm 1.2mm 10.0mm 20.81mm3 2.4mm 13.7mm 109.48mm3 3.6mm 16.3mm 282.97mm3 4.8mm 18.2mm 542.87mm3
8mm 1.6mm 11.5mm 41.95mm3 3.2mm 15.5mm 215mm3 4.8mm 18.0mm 535.63mm3 6.4mm 20.0mm 1012.28mm3
15
5
MFL Reference plate

Estimate Percentage Loss (EPL) values are generated
based on the defects within the calibration plate.
Reference plates must not contain pitting, weld repairs,
deep scratches, through holes or any other defects.
Incorrect shaped defects in the reference plate can
prevent accurate calibration and sizing.
Straight edges from Burs around cut Incorrect tooling used Drill bit used
drill bit
16
Purpose of the calibration

The MFL calibration trace links the amount of magnetic
leakage signal to a defect of a known EPL depth and
volume found in the reference plate.
Amount of leaking magnetic field
Defect Volume Estimated Percentage Loss depth
The magnetic leakage signal is identified for defects

located on the Bottom side and Top side of the plate.
The STARS calibration trace links the rate of change of the
magnetic field disturbance for top side defects of known
EPL depth and volume found in the reference plate.
17
Calibration trace and the unit ‘u’ value

Two calibration traces display the MFL and STARS data
found for the 20%, 40%, 60% and 80% defects.
The calibration trace displays the data as a unit ‘u’ value.
Y-Axis represents a unit ‘u’ value, ranging from 0 to 256.
18
6

MFLi ‘u’ value
This can be considered as the amount of magnetic leaking
field coming out from the top of the plate.
The larger the defect the greater the leaking magnetic
field and so the higher the displayed MFLi ‘u’ value.
A very low background MFLi ‘u’ value is displayed when
no indications are present within the plate.
higher MFLi ‘u’ value
lower MFLi ‘u’ value
19

Extracting the MFLi ‘u’ value
Consider top side and bottom side traces separately.
‘u’ value 20% 40% 60% 80% Background
Bottom MFLi 40 105 163 204 9
Top MFLi 56 109 149 173 10
u = 204 80%
u = 173 80%
u = 163 60%
u = 149 60%
u = 105 40% u = 109 40%
u = 56 20%
u = 40 20%
u = 9 Background u = 10 Background
BOTTOM TRACE TOP TRACE
20

STARS ‘u’ value
This can be considered as the rate of change in the
magnetic field as it enters the top of the plate.
The greater the change in the magnetic field as it enters
the top of the plate the higher the displayed STARS ‘u’
value.
A very low background STARS ‘u’ value is displayed when
no indications are present on the top of the plate.
Background low STARS higher STARS

STARS ‘u’ value ‘u’ value ‘u’ value
21
7

Extracting the STARS ‘u’ value
These are for top side defects only.
‘u’ value 20% 40% 60% 80% Background
STARS 47 104 120 142 8
u = 142 80%
u = 120 60%
u = 104 40%
u = 47 20%
u = 8 Background
22
Surface Origin and Percentage Loss

MFL and STARS ‘u’ values are compared to the calibration
to determine percentage and surface origin.
Estimated Percentage Loss is from MFL ‘u’ value data.
Surface Origin is determined by comparing the STARS ‘u’ value
data to the MFL ‘u’ data.
MFL Severity
STARS Top
MFL
Severity
STARS
0.6
Bottom
23

What percentage would an MFLi ‘u’ value of 174 show?
Check to see what value the detected STARS ‘u’ is.
If STARS ‘u’ is around 146: 81% Top
If STARS ‘u’ is at the background level: 65% Bottom
65% BOTTOM
u = 174 81% TOP
u = 146
u=4
24
8

What percentage would an MFLi ‘u’ value of 174 show?
Check to see what value the detected STARS ‘u’ is.
If STARS ‘u’ is around 146: 81% Top
If STARS ‘u’ is at the background level: 65% Bottom
Top EPL View Bottom EPL View
25

Always confirm the origin by checking MFL, MFLi and
STARS views and when possible visually inspect the floor.
Example of incorrect surface origin.
Top percentage view displays six indications.
STARS view only displays four indications.
The two highlighted indications should be on the bottom side.
Top EPL View STARS View
26
Dynamic Cursor
Dynamic cursor is a software approximation tool for
estimating geometry based on the calibrated geometry.
The dynamic cursor consists of two circles linked by a
mesh.
Outer Circle
Inner Circle
The diameter of the cursor is determined by the MFL

calibration trace and changes to represent the expected
size of a percentage indication.
27
9
Dynamic Cursor
The diameter is determined for each percentages on the
MFL calibration trace by looking at the width of the MFL
signal a predetermined level below its peak.
Between each known percentages the diameter of the
80%
cursor changes linearly.
60%
The mesh has a tolerance of
+/-20% of the diameter.
40%
+/-20% of
diameter 20%
28
Dynamic Cursor
Typical examples of approximating defect geometry.
1. Indication lies between the inner and outer circle.
Likely to be accurately sized to the calibrated indications.
2. Indication lies outside of the outer circle.
Likely to be oversized and display a higher EPL than expected.
3. Indication lies within the inner circle.
Likely to be undersized and display a lower EPL than expected.
1. Accurately Sized 2. Oversized Indication 3. Undersized Indication

Pitting Type Lake Type Pipe Type
29
Indication colour gradient

Look at how the colour gradient changes to illustrate the
geometry of the indication.
Compare this to the know geometry of the calibrated

indications from the verification scan.
30
10
Signal to Noise Ratio

Signal-to-noise ratio is a measure that compares the level
of a signal to the level of background noise
For MFL based inspections the background noise can
affect the detection capability of the MFL equipment.
As the scanners sensitivity levels are increased so to is
the noise emanating from the inspection surface making
the identification of true defects more difficult.
Factors that can affect the signal to noise ratio include
Surface cleanliness.
Plate and coating thickness.
Sensor height.
31

The MFL calibration trace can be used to identify the
signal and background levels.
Typically an expectable signal to noise ratio is 3:1.
80%
60%
40%
20% Signal is above
the 3:1 ratio
20%
3:1 ratio is 45u

Noise level 15u
32

Suggested Minimum Operational Threshold (SMOT).
The signal to noise ratio affects the minimum discontinuity
percentage that can be reliably detected.
Viewing the calibration trace to can help to determine a
Suggested Minimum Operating Threshold percentage level to
view the inspection data.
The SMOT percentage level must
be set above the 3:1 ratio. SMOT of 40% since it is
above the 3:1 ratio
3:1 ratio is 45u

Noise level 15u
33
11

Suggested Minimum Operational Threshold (SMOT).
When viewing inspection data below the SMOT of 40% the noise
generates lots of spurious indications.
Setting the SMOT to 40% helps clean up the inspection data by
removing the spurious indications.
SMOT of 40%
34
Factors that affect the MFL signal

Important to understand how each of the following
factor affect the detection of the MFL signal and the
resulting percentage value.
Magnetic Saturation.
Corrosion Shape.
Scanning Orientation.
Surface Origin.
Magnetic Lift-Off and Sensor Height.
Tank Floor thickness change.
Coating thickness change.
Surface Condition.
35
Magnetic Saturation
This is a key fundamental element of MFL technology.
Factors that can affect the saturation level of a plate:
Magnet Strength.
Plate thickness.
Coating thickness.
Three main states of saturation levels:
Perfectly Saturated.
Over Saturated.
Under Saturated.
36
12
Magnetic Saturation
Perfect Saturation
This is the ideal case.
When a plate is fully saturated no flux leakage is evident until a
defect is present.
The flux leakage is proportional to the volumetric loss of the
defect so allows defects to be sized correctly.
37
Magnetic Saturation
Over Saturation
This is when there is flux leakage outside of the plate even
when no defect is present.
The flux leakage from a defect will be greater than its
volumetric loss.
This can increase the likelihood of noise and spurious
indications as it causes defects to be oversized.
38
Magnetic Saturation
Under Saturation
This is the least desirable case since the plate cannot achieve
saturation.
The flux leakage from a defect will be much smaller than its
volumetric loss.
This can increase the likelihood of indications being missed as it
causes defects to be undersized.
39
13
Corrosion Shape
MFL is considered as detecting defect volumetric loss.
Volumetric loss does not always reflex as defect depth.
The calibration links volumetric loss to a specific depth.
Consider the following defects:
Volume = Length x Width x Depth
depth
Lake Type 6 = 2 x 3 x 1 depth
depth width
Conical pit Type 6 = 1 x 3 x 2 depth width
length width
Pipe Type 6 = 1 x 2 x 3 length
width
length
length
Identical Volumes but at different Depths
How are percentage values affected by defects with the
same volume but a different depth?
40
Corrosion Shape
Lake Type
Large diameter compared to their actual depth. LAKE TYPE
Creates a large flux leakage signal.
The percentage value is expected to be oversized.
Conical Pit Type
Conical in shape with rounding at deepest point.
CONICAL PIT TYPE
Similar to the defect in the reference plate.
The percentage value is expected to be +10% accurate.
Pipe Type
Small diameter compared to their actual depth. PIPE TYPE
Creates a small flux leakage field.
The percentage value is expected to be undersized.
41
Corrosion Shape
Through Hole
Holes typically form at the deepest point of conical pits.
Can also appear as very small pipe like in shape.
Leakage fields for holes can be very low since the field takes the
path of least resistance and so ‘jumps’ across the gap.
The percentage value for a hole is expected to be undersized.

A detailed visual inspection of the floor is always recommended.
42
14
Scanning Orientation
Corrosion shape and geometry can result in different flux
leakage signals when scanned in different directions.
This results in different percentage values for the same
indication.
An example can be seen when transverse scanning.
Different percentage
values detected for
the same indications
No transverse scan Transverse scan

43
Surface Origin
MFL alone cannot identify the surface origin of defects.
Bottom side defects generate a larger flux leakage field
compared to the same defect on the top side.
Percentage loss of defects on top and bottom together

cannot be added together due to their volume.
6mm reference plate, 40% volume is 110mm3, 80% is 543mm3

Does depend upon geometry and top / bottom loss quantity.
44
Magnetic Lift-Off and Sensor Height

Magnetic lift-off is the distance between the floor plate
and the magnets.
Sensor height is the distance between the floor plate and
the MFL sensor head.
Alterations in these distances can be due to a buckled
floor, sensor head movement, cleanliness of the floor or
a change in coating thickness.
Magnetic bridge distance

MFL sensor head distance
45
15

Magnetic lift-off
Magnetic lift off changes the how much magnetic field enters
into the plate which affects the flux leakage field.
Increase in magnetic lift-off
Decrease in magnetic lift-off
46

Sensor height
A change in sensor height alters the amount of flux leakage
passing though the MFL sensors.
Increased sensor height
Decreased sensor height
47
Plate thickness change

It is acceptable to use a MFL reference plate up to 1mm
[0.04inch] thicker than tank floor plate.
Do not recommended to use a thinner reference plate.
Decrease in floor plate thickness
Increase in floor plate thickness
Reference Plate
Thickness
48
16
Coating thickness change

Nominal coating thickness greater than 0.5mm [0.02inch]
must be accounted for during calibration.
Decrease in coating thickness
The EPL value is expected to be oversized.
Increase in coating thickness
The EPL value is expected to be undersized.
Simulated Coating
thickness
49
Surface condition
Tank floor cleaning is required before MFL inspection.
Dirty or rough inspection surfaces will cause spurious
indications and generate incorrect percentage values.
Ensure there is no scale, product residue, loose metal
and debris or any blasting cleaning media.
Thick Scale Product Residue Rough inspection surface

50
Surface condition
Mechanical defects will cause spurious indications and
generate incorrect percentage values.
This include weldment, weld spatter, grinding marks,
dented plates, blistered or delaminated coatings.
Weld spatter Grinder marks Blistered coating

51
17
Practical Session
Exercise
Determine a Suggested Minimum Operational Threshold Level
for the following calibration traces:
52
Practical Session
Reviewing the Learning Outcomes
Establish a percentage value and surface origin from the
calibration trace and detected MFL and STARS ‘u’ values.
Identify a suitable Suggested Minimum Operational Threshold
level based on the Signal to Noise Ratio of the calibration trace.
List the factors that affect MFL detection and discover how
each can alter the systems results.
53
18
MFL and STARS Technology – Learning Outcomes Review Questions

1. Explain MFL principles?
2. What is a major limitation of MFL?
3. Explain STARS principles?
4. What does STARS stand for?
5. How can STARS be used to determine a protrusion in the plate?

6. What indications are found within the reference plates?
7. During a calibration what does the system identify for each indication in the reference plate?
8. What is the range of the ‘u’ value scale?
9. How is the ‘u’ value extracted from the calibration trace for an indication found in the
reference plate?
Establish a percentage value and surface origin from the calibration trace and
detected MFL and STARS ‘u’ values.
10. What data is used to determine the percentage loss value?
11. What must be known in order to assign a percentage loss value?
12. How is the surface origin of an indication determined?
13. What must be done to confirm the surface origin of an indication?
Identify a suitable Suggested Minimum Operational Threshold level based on the

Signal to Noise Ratio of the calibration trace.
14. Why does a SMOT level need to be set?
15. What is the typical Signal to Noise Ratio used to determine SMOT?
16. What calibration trace is used to determine the SMOT level?
17. What must identify in order to set a Signal to Noise ratio?
List the factors that affect MFL detection and discuss how each can alter the systems
results.
18. List factors can affect MFL detection.
19. What can affect the saturation level of a plate?
20. Which corrosion shape is the system designed to accurately detect?
21. Why are through holes expected to be undersized in the MFL results?
22. What is expected to happen to the MFL results when:
a. The MFL sensor head drops in height?
b. The coating thickness increases during the inspection?
c. Scanning across a rough inspection surface?
Doc Ref:
Rev: 1
Date of Release: June 2016
Page 1 of 1
SECTION 3 – MFL Tank Floor Inspection – Rev 1
MFL Tank Floor Inspection
MFL Tank Floor Inspection

Aim
To be aware of the limitations and requirements in order to
conduct a successful tank floor inspection with the system.
Learning Outcomes
Establish the types of corrosion typically found on tank floors.
Recognise the limitations of scanning a tank floor.
Identify the roles within the inspection team and additional
equipment required for a successful tank floor inspection.
Assess the cleanliness of the tank floor for an MFL inspection.
Demonstrate the correct plate setup required for scanning,
identify the tank entry requirements and in-tank preparation.
Discover how to locate the MFL results for further prove up.
Utilize a correct sequence of work for inspecting a tank floor.
2
Tank Floor Corrosion

Corrosion attacks all areas of a storage tank however we
are interested in the tank floor corrosion.
Bottom Surface – soil side.
Top Surface – product side.
Coating on tank floor can break down and fail.
Floor coating Product Side
Tank Floor
Soil Side
1
Tank Floor Corrosion

Corrosion comes in many different shapes and sizes.
Typically grouped into three categories based on shape.
Their plan view tends to be circular / elliptical in outline
As corrosion sites grow these basic shapes tend to merge
into more complex profiles.
CONICAL PIT TYPE LAKE TYPE PIPE TYPE
Tank Floor Layout

Tank floors typical consists of:
Inner plates, usually rectangular in shape.
Sketch plate, non rectangular usually at the edge.
Annular plates, shell supporting.
Critical zone 75mm [3inch]
inwards from the shell.
Floor cones downward toward
the drain (sump).
The mapping system can
inspect this floor layout
since the plates are laid in
parallel rows and have at
least one 90O corner.
5
Tank Floor Layout

Petal design or Radial plates.
Smaller tanks, typically aviation fuel.
Floor cones downwards toward the drain (sump).
The manual MFL system is required to inspect this type
of floor layout.
2
Scanning coverage
Achieving 100% scanning coverage of the plate is not
possible due to its mechanical constraints of the scanner.
Rectangular Plates
Minimum non inspected “dead zone” areas include:
10mm [3/8inch] around the plate edge.
160mm x 160mm [6.3inch x 6.3inch] in each corner.
Annular Plates and Sketch Plates
Non inspected “dead zone” area depends
upon the size and shape of the plates.
Tank Floor Obstructions

Tank floor obstructions reduce the scan coverage area.
Obstructions always exist within a tank and can include:
Pipework and Heating coils.
Roof support legs and strengthening plates.
Undulating or buckled plates.
Brackets and Support.
Weldment and weld splatter.
Patch repair plates.
Sump.
Patch Repair Plates

Do not attempt to scan over any patch repair plates.
System cannot detect or size indication correctly.
Two plates with a slight gap between.
Magnetism flows though both plates reducing the sensitivity.
Damage the scanner when passing over the weld.
Treat patch repair plates as an obstruction.
3
Double floored tanks

A minimum distance of 50mm [2inch] between the floors
must exist and the gap contain non-ferrous material.
The inspection is for the replacement floor plates only.
If this distance is less than 50mm [2inch]:
Magnetic field flows through both plates.
Corrosion pitting may not
be detected because no
flux leakage is created.
Replacement floor plates

Original floor plates
Minimum distance of 50mm
10
Inspection Team
Team Leader (TL)
Take overall responsibility for the inspection, including ensuring
the scanner has been correctly calibrated.
Fully understands the operation and limitations of the scanner.
Ensures the final inspection report is produced and indications
have been followed up (visual/handscan/ultrasonic).
MFL Technician
Fully understands the operation and limitations of the scanner.
Ultrasonic Technician
Trained and certified to a minimum of PCN, ASNT level II in the
use of A-Scan equipment and corrosion assessment.
MFL inspection team require a minimum of two people.
11
Inspection Equipment
Personal Protective Equipment (PPE)
Safety footwear
Overalls
Hard hat
Safety glasses
Gloves
12
4
Lighting
Headlamps
Flood lamps
Marking out
Tape measures
Spray paints
Marker pens
Chalk sticks
13
Cleaning tools for both scanner and inspection surface.
Brushes
Scrapers
Industrial vacuum cleaner
14
Complementary Inspection Equipment:
Handscan – Inspection of areas not covered by the scanner.
Ultrasonic flaw detector / thickness gauge.
Coating thickness gauge (if inspecting coated floor plates).
Pit gauge.
Camera – Recording visual defects.
15
5
Tank Cleaning Requirements

The condition of the inspection surface can affect the
quality and accuracy of MFL inspection results.
Prior to the MFL inspection the tank product must be
drained and the tank floor cleaned so that it is free of any
product residue, scale, loose ferromagnetic material,
cleaning media and standing water from surface.
The floor plates must be clean enough to conduct a
thorough visual inspection.
Do not begin an MFL inspection of the tank floor if the
floor is not sufficiently clean.
Remember you can not inspect what you can not see!
16

Acceptable cleaning methods depend upon:
Type of product stored in the tank.
Duration since previous cleaning.
Presence of any coating / lining within the tank.
A tank floor good condition and contained light product
only a Jet wash may be required.
A tank floor in poor condition with extensive levels of
scale or history of extensive top side corrosion will
require grit, shot or ultra high pressure water blasting.
17

Acceptable for MFL Inspection
The following are examples of tank floors cleaned to a sufficient
standard to allow a meaningful MFL inspection to take place
Image 1 – Floor plates cleaned to bare metal using Image 2 – Top surface corrosion visible after
Ultra High Pressure water jetting cleaning
18
6

standard to allow a meaningful MFL inspection to take place
Image 3 – Generally acceptable coated surface. Image 4 – Floor cleaned to acceptable standard.
Some spurious results possible from blistered areas. Corrosion at bottom of dents would not be detected
accurately.
19

standard to allow a meaningful MFL inspection to take place.
Image 5 – Floor cleaned to acceptable standard Image 6 – Floor cleaned to acceptable standard
with some very thin scale remaining. with some very thin scale remaining.
20

Not acceptable for MFL Inspection
The following either limit an MFL inspection to certain areas of
tank floor or prevent an MFL inspection take place
Image 7 – 60mm thick layer of product residue Image 8 – Product residue masking top surface
corrosion
21
7

Image 9 – Heavy Scale Image 10 – Layer of hardened scale and product

residue
22

Image 11 – Thick build up of scale Image 12 – Uneven coated surface. The marked
area cannot be inspected.
23
Plate Setup for Scanning

How does the scanner determine which tank floor plate
it is inspecting and where on that plate is the scanner
located?
Before inspecting a plate the following information must
be entered:
Tank Datum.
Plate Numbering System.
Plate Reference.
Plate Size.
Plate Orientation.
Scanning Mode.
24
8

Tank Datum
It is a reference point that exists outside of the tank.
Referenced to Tank Datum are:
Plate Numbering System
Plate Reference
Plate Orientation
To position tank datum
1. View floor from above
2. Align plate row so they are
parallel
3. Look perpendicular to the rows
4. Tank Datum is located in the
bottom left corner of the tank
5. Mark location on the tank shell
25

Tank Datum
If the parallel rows are not obvious from looking from above
then rotate yourself when stood in the tank
26

Question: Where should tank datum be located?
Identify the parallel rows and stand perpendicular.
Here Here
?
Here Here
27
9

The system scans one plate at a time so must know which plate
is being inspected.
Reporting software relies on numbering to generate the layout.
During the inspection the Row / Plate layout must be used.
For reporting an alternative system can be selected.
Numbering begins in the top left hand corner, Tank datum is
located in the bottom left hand corner.
28

1. Identify tank datum.
2. Number rows from top to bottom.
3. Number plates from left to right.
4. Combine rows and plate numbers.
ROW 1 1/1
P1 1/2 P3 1/4
P2 1/3 P4 1/5 P6 1/7
P5 1/6 P7
ROW 2 P1
2/1 P2
2/2 P3
2/3
ROW 3 P1
3/1 3/2
P2 P3
3/3 P4
3/4
ROW 4 P1
4/1 P2
4/2 P3
4/3
ROW 5 P1
5/1 P2
5/2 5/3
P3 P4
5/4
ROW 6 P1
6/1 P2
6/2 P3
6/3
ROW 7 7/1
P1 7/2
P2 7/3
P3 P4
7/4
ROW 8 8/1
P1 8/2
P2 8/3
P3
ROW 9 P1
9/1 9/2
P2 P3
9/3 P4
9/4
ROW 10 P1
10/1 P2
10/2 P3
10/3
ROW 11 P1 11/2
11/1 P2 P311/4
P4 P511/6 P7
P6 11/7
11/3 11/5
29

What about numbering the tank floor layout below?
Issue with numbering the following rows:
Look closer ROW 1
ROW 2
ROW 3
ROW 4
ROW 5
ROW 6
ROW 7
ROW 8
ROW 9
ROW 10
ROW 11
30
10

The plates on Row 1, Row 2 and Row 4 are simple to number, as
the plates only lie left to right.
The plates in Row 3 cause problems due to having horizontal
and vertical plates in the same row.
There are various numbering orders.
Keep the numbering system
ROW 1 1/1 1/2 1/3 1/4 1/5 1/6 1/7 1/8
logical and the same for the
ROW 2 2/1 2/2 2/3
whole tank.
3/3
3/1
ROW 3 3/4 3/5 3/6 3/7 3/8 3/9 3/ 3/ 3/ 3/
3/2
3/1 10 11 12 13
3/1
3/2
3/3
ROW 4 4/1 4/2 4/3 4/4
31

The reporting software is unaware of the tank floor layout.
It relies on the row/plate numbering system to position the
plates in the correct order, working from left to right.
Manual adjustment of the plates is avaiable in the reporting
software using the Tank Layout Modification tool.
32

Plate Reference
It is a 90O corner of a plate where scanning begins.
It is identified relative to Tank Datum (bottom left).
Rectangular Plate:
There are 4 possible corners for Plate Reference. Choose a suitable
corner and mark the plate.
If possible select Bottom Left, since Plate Reference and Tank Datum
have the same orientation. However this may not always be possible
due to obstructions.
Top Left Top Right
Bottom Left Bottom Right

33
11

Plate Reference
Sketch Plate (non rectangular plates)
Consider following plates:
PR for 1/2
PR for 1/7 1/2 1/7
PR for 11/4 BL
TL TR
11/
BL BR 4
34

Plate Size
Every plate must be measured.
Enter the longest length and longest width for each plate.
Consider plates:
4/2 Width
1/2 4/2
11/4
1/2 4/2 Length
Width
Measurements are not always the plate weld
Longest side is always plate length
Longest
Plate width cannot be greater than length Length 11/4
Longest
1/2 Width 11/
4
Length
35

Plate Orientation
Identified relative to tank datum.
Determined by the longest length of a plate.
Consider plates:
4/2 Horizontal
11/4
4/2
Length
Vertical
Vertical
Length
11/
4
Horizontal
36
12

Scanning Mode
Begin scanning at plate reference and scan along length of plate
Plates can be scanned in one of two modes:
Raster Scanning Parallel Scanning
The plate must have four 90O corners. A plate with at least one 90O corner.
Most efficient way of scanning a plate. Always return to plate reference edge.
Preferred method for plates with no 4/2 Preferred method for plate with
obstructions. obstruction.
11/
4
37

Plate setup details are entered into the plate tab in the
new plate window before inspecting a plate.
Plate
Numbering
Plate Size Plate

Reference
Orientation
Scan Type Tank Datum
38
Annular Plate Setup for Scanning

Annular plate setup does not require Tank Datum.
Each annular is in a different orientation to the tank datum.
The system is provided with the following information:
Annular Numbering System.
Annular Plate Size.
Annular Plate Reference.
Scanning Mode.
Typically annular plates are thicker than the floor plates
in a tank.
Ensure the correct calibration is used before inspecting.
39
13

In order for the system to map annular plate correctly:
Every Annular plate must be identical in size and shape.
Straight edge annular plates are easier for scanning.
Parallel edge annular plates are difficult to scan because the
scanner does not travel in curves.
Manual scanning will be required.
Possibility to skip the first track.
Annular shape with parallel edge Annular shape with straight edge
No straight edge Straight edge
40

Annular Numbering System
Numbered in a clockwise direction beginning at A1.
Location of A1 is not important as Annular plates can be
rotated.
41

Annular Plate Size
Every annular plate must be measured.
The following measurements are required for each annular:
A: Annular length, inner straight edge distance
B: Annular width, weld between two annular plates
C: Maximum overall length
D: Maximum overall width
42
14

Annular Plate Reference
Annular Plate Reference does not consider Tank Datum.
The Plate Reference requires a right angle corner so by looking
at tank shell it is either:
Bottom Left Corner.
Bottom Right Corner.
BL BR
Annular Scanning Mode

Parallel Scanning only.
43

Annular plate setup details are entered into the annular
tab within new plate window before inspecting a plate.
Plate
Numbering
Plate
Plate Size
Reference
44
Tank entry with the scanner

What must be done before entering into a storage tank?
Ensure the correct safety measures have been taken and permit
to work within the storage tank obtained.
Safety measures must comply with client / site specific safety
regulations and Local legislation.
Ensure the tank is gas free and is safe to enter.
Establish if Scaffolding is required in order to gain access to the
man-way.
45
15
Tank entry with the scanner

Minimum man-way entry for scanner is 500mm [20inch].
The entry process required two people.
One person inside and one person outside of the tank.
Lift and pass the scanner though the man-way without causing
damage.
Remove the battery and Sitemaster before entry.
46
In-tank preparation before scanning

Erect suitable lighting to illuminate the working area.
Assess the cleanliness of the inspection surface.
Visually inspect each plate and mark potential hazards
such as obstruction, weldments and repair plates.
DONOT scan across these. They can cause damage and lead to
false indications. If possible weldments should be ground down.
47

Identify a suitable Tank Datum Position.
Mark on every tank floor plate:
Plate Number.
Plate Reference.
Plate Length.
Plate Width.
Track Width Interval.
Recommended to mark up a few plates in the first row
and begin scanning in a logical order.
Avoid having to stop scanning in order to mark up the
next plate. Ensure someone is marking ahead of the
scanner so the plates are ready to be scanned.
48
16

Correct positioning of the scanner is important to ensure
that the location of detected corrosion can be found.
Track width intervals must be marked at either end of the
plate, measuring away from plate reference.
Add further marks near obstructions and on long plates.
Marks are dependant upon scan overlap.
Interval = Scan Width – Scan Overlap
= 300 – 50 (default)
= 250mm [10inch]
1750mm
1500mm
1250mm
1000mm
750mm
500mm
250mm
49

Marking can be done using a tape measure but can be
difficult to identifying the correct measurement.
Recommended to have a purpose made pre-marked tool
as this can increase the speed of marking the floor.
Remember to mark away from plate reference, at either
end of the plate, mid plate and around any obstructions.
50

To mark the track width intervals on an annular plate a
right angle corner is required at the plate reference.
The track width intervals are marked along the right
angle edge at either side of the annular and around
obstructions, measuring away from plate reference.
Spacing is identical to floor plates, 250mm [10inch].
51
17

When scanning Annular plates with a parallel edge it is
important to determine the straight edge between the
two inner corners.
Use a large square to help draw the right angle line.
Mark the track width intervals and determine which
tracks cannot be scanned.
52
Locating and prove up of MFL results

In order to prove up results it is important to correctly
locate the detected MFL indications on the plate.
The onscreen cursor displays the X and Y co-ordinates
measured from Plate Reference of that particular plate.
The X and Y directions are taken relative to the tank view.
X is measured along the horizontal length
Y is measure along the vertical length
Co-ordinates for the plates below: y – vertical
x
y y
x x - horizontal
53
Locating and prove up of MFL results

Once the correct location on the plate has been
identified then methods used to prove up MFL
indications include:
Visual Inspection.
Pit gauging.
Ultrasonic Inspection.
The tank floor surface condition can make the prove up
difficult especially on highly pitted tank floors.
54
18
Inspection Process
The following flow chart shows the sequence of work
required to perform a successful inspection with the system.
In Office Site Obtain

Obtain (hot)
Check for induction if confined space
Equipment work permit
required permits
latest check
version of including Arrival
software spares Organise Arrange for Safety man,
access to tank electrical gas monitor
for equipment & power
Tank cleaning Risk team
requirements Assessment
Work
Arrange for
safety man
Out of Tank
Procedures
(confined space) Check all Check Input
Battery
cables are sensor inspection
check
Tank history, secure heights details
Electrical power
floor plate
requirements &
thickness &
tank access
coatings
Carry out Conduct Calibrate on If required use
Ensure personnel have current safety gas verification suitable coating
passports / confined space / BA monitoring scan reference plate simulation sheets
certificates (if required)
55
Inspection Process
In Tank
Setup Investigate Verify Mark
Check tank Identify Tank Verify Plate
suitable tank coating weldments &
cleanliness Datum Thickness
lighting environment thickness obstructions
Ensure all floor Measure

Mark out Select &
plates & annular Analyse plate
scan mark plate
have been data width &
tracks reference
scanned length
SCAN
Identify areas of
Backup data interest, verify
to USB indications (UT
visual)
Out of Tank Leave site

Sign off site
Calibration Equipment Pack up all permits, ensure
verification check equipment all paperwork In Office
complete
Ensure ALL Analyse
equipment is clean collected data &
ready & available prepare report
56
Practical Session
Identifying the plate setup information
Tank Datum
Layout 1
Answer a
Tank Datum
Plate Number Plate Reference Plate Orientation Scanning Mode
a 2/2
4/2
Top Left Top Right Horizontal X
Bottom Left X Bottom Right Vertical X
b 3/1
3/4
Bottom Left X Bottom Right X Vertical X
57
19
Practical Session
Layout 2
Answer Tank Datum
b a
Tank Datum
a 16/4
2/1
Top Left Top Right Horizontal X X
Bottom Left X Bottom Right X Vertical
b 10/4
8/2
c 17/4
1/6
Top Left Top Right X Horizontal X
58
Practical Session
Layout 3 Tank Datum
Answer a
Tank Datum c
Top Left Top Right Horizontal
a 5/13
3/7 Bottom Left X Bottom Right Vertical X X
b 5/19
3/1
c 1/6
7/4
59
Practical Session
Layout 4
Answer Tank Datum a
Tank Datum
c

a 2/15
b 3/6
1/9
c 2/2
2/20
60
20
Practical Session
Layout 5
Answer Tank Datum c
Tank Datum
b

a 2/10
b 3/28
c 2/16
4/6
Top Left Top Right X Horizontal X X
Bottom Left X Bottom Right Vertical
61
Practical Session
Reviewing the Learning Outcomes
Identify the roles within the inspection team and additional
equipment required for a successful tank floor inspection.
Demonstrate the correct plate setup required for scanning,
identify the tank entry requirements and in-tank preparation.
62
21
MFL Tank Floor Inspection - Learning Outcomes Review Questions

1. Where can corrosion occur on a tank floor?
2. Name the three types of corrosion?

3. What prevents 100% inspection of the floor plate?
4. What is the size of the minimum non inspected area in the corner of the plates?
5. Why is it not possible to inspect over a patch repair plate?
6. What is minimum distance that must exist between the two floors of a double floored tank?
7. What must be conducted in areas where the scanner is unable to inspect?
Identify the roles within the inspection team and additional equipment required for a
successful tank floor inspection.
8. What is the minimum number of personnel required for the MFL inspection?
9. What is the most important tool required when operating the scanner?
10. List additional equipment required for the inspection and its purpose.

11. Why does the tank floor require cleaning before the inspection?
12. What condition must the tank floor be cleaned too?
13. If the tank floor is not cleaned sufficiently what must not be done?
Demonstrate the correct plate setup required for scanning, identify the tank entry
requirements and in-tank preparation.
14. Define Tank Datum.
15. What must the plate have in order to Raster scan?
16. What is the minimum man-way diameter required for scanner entry?
17. List the details that must be marked on every plate?
18. How is the spacing of the track width intervals marks determined?
19. When conducting prove-up what location are the measurements taken from?

20. Why is the inspection process required?
Doc Ref:
Rev: 1
Page 1 of 1
Section 4 – Scanner components and maintenance – Rev 1
Scanner components and

maintenance
Scanner components and maintenance

Aim
To familiarise technicians on scanner health and safety, identify
the components of the scanner and correct maintenance of the
system.
Learning Outcomes
Establish the operational hazards of the scanner.
Demonstrate correct manual handling of the scanner.
Demonstrate correct placement of the scanner onto a plate.
Locate and describe the components of the scanner.
Identify maintenance required during and after an inspection.
Examine key areas of the scanner to check for any damage.
Establish how to correctly store the scanner when not in use.
Scanner Health and Safety

The scanner is fitted with powerful permanent magnets
and a continuous magnetic field flows around the bridge.
Keep all body parts clear of magnetic bridge when
moving scanner around the tank.
Correct safety footwear must be worn when operating
the scanner.
1
Scanner Health and Safety

Magnetic field can destroy magnetic media such as hotel
room keys, ATM / credit cards, watches, cell phones,
computers etc.
Any person fitted with a pacemakers must not come
within 3 meters [10 feet] of the scanner. This must be
written into the method statement.
The scanner is not ATEX intrinsically safe.
Risk of explosion if a spark occurs.
Hot Work Permit is required.
Transportation and Manual Handling

The scanner is supplied in a purpose build transit case.
Scanner is held securely via handles.
Meets IATA regulations allowing it to be flown by airfreight.
Storage shelves for systems accessories.
Keep plate controlling magnetic field.

Handling the Scanner.
Scanners weight is 60kg (130lbs).
Be aware of the magnetic field at all times.
Carry the scanner using the correct carry handles.
Two handles either side of the chassis:
Right handle: Drive handle.
Left handle: Removable handle.
One handle in front of the battery cover.
2

Important to use the correct technique for placing and
removing the scanner from a plate.
Magnetic attractive force increases as scanner approaches plate.
Do not twist the motor handle ON and allow the drive wheels to
rotate when placing the scanner onto the plate.
Incorrect technique will cause damage to the scanner.
System and Component Overview

Component Location
Removable Handle
Sitemaster Computer
Drive Handle
Computer Power & Data

Connectors
Battery
Damper
Magnet Bridge Drive Motor
Encoder
STARS Sensor Head MFL Sensor Head

Magnetic Bridge
300mm [12inch] wide mounted on a roller carriage.
64 sensor channels.
Neodymium Iron Boron Permanent Magnets.
No loss of magnetic force.
Generate a ton pressure on a 6mm [1/4inch] plate.
Thicker the plate, stronger the magnetic pull.
Front Rollers
Front Magnet
Rear Magnet
Rear Rollers
64 Channels
300mm [12inch]
9
3

MFL Sensor head
Located in the centre of the magnetic bridge.
Detachable MFL sensor head cable.
Sealed unit but not fully waterproof.
Spring mounted to minimise damage.
Sensor height must be correctly set.
Periodically checked during inspection.
Sensor head removal required for cleaning.
Removal after completing every inspection.
Recalibration required if MFL sensor head.
Has been removed for cleaning.
Height has been altered during inspection.
MFL Sensor head
10
System
Scanner Setupand Component Overview
MFL Sensor head
Old method New method
Adjustable height sensor head Fixed height sensor head
4 brass thumbnuts Red and silver bushes
Fixed height MFL sensor head reduces any setup errors by the
operator.
During the systems annual calibration the adjustable height
MFL sensor head are changed to the Fixed height sensor head.
11

STARS Sensor head
Located underneath rear magnetic pole.
Integrated STARS sensor head cable.
Sealed unit but not fully waterproof.
Sensor head is bolted in place
Sensor height must be correctly set.
Periodically checked during inspection.
Recalibration required if STARS sensor head.
Position has been altered during inspection.
STARS Sensor head
12
4

Battery
12 Volt, 25 Amp hour sealed lead acid gel filled battery.
Powers the system electronics, motor and Sitemaster.
13.5 Volts (approx.) – Fully charged battery.
11.5 Volts (idle) – Battery requires charging.
Disconnect battery from scanner when not in use.
System is supplied with 4 batteries,
cycle batteries during use.
Keep batteries out of direct sunlight.
13

Battery Charger
Mains input: 100 to 240 AC Volts 50/60Hz.
Only use the battery charger supplied with the system.
Charging time of up to 6 hours.
3 chargers supplied with the system.
Power switch at rear of charger.
Red LED – Charger Power
Orange / Green LED – Charging Status
Fuse protecting charging circuit (6A 12V)
BLOWN FUSE!
IF the Green LED is lit after connecting a flat
battery check the fuse.
Replace with same rating fuse.
14

Top Panel
Power Switch
Switch illuminated BLUE when ON.
Battery Voltage
DO NOT operate the scanner below 11.5 Volts idle.
Battery Voltage
Power Switch Indicator
15
5

Drive Motor
Speed of 500mm/sec [19.7inch/sec].
Motor is activated via drive handle.
If the scanner becomes stuck never
turn the motor on.
Correctly place the scanner onto
the plate otherwise damage can
occur to the drive motor.
Always fit the battery and motor
cover during inspection to avoid
damage to drive motor and battery.
16

Sitemaster
Ruggedized touch-screen computer.
Microsoft Windows Operating System.
Data acquisition software.
Powered by Floormap3Di battery.
UPS battery allows up to 15 minutes of power after battery disconnected.
Communication to scanner by USB.
Data transfer by high speed USB drive.
Desktop power supply included.
17

Encoder
Measures distance travelled during a scan.
Encoder pickup via brass gear attached to the front roller axle.
Encoder
Encoder pickup
18
6

Damper Strut
Located at the rear of the scanner.
Helps overcome the scanners magnetic pull from the floor.
Allows the drive wheels to be raised and push the scanner.
Never lift or carry the scanner by it.
Never put your foot against it.
Do not damage when passing through the manway of a tank.
19
Maintenance during an Inspection

Conduct periodic cleaning around the magnetic bridge
during inspection.
Remove magnetic dust, debris and foreign objects that
are attached to the magnetic bridge.
20
Maintenance during an Inspection

Remove any magnetic debris around rollers as this can
prevent the scanner from moving.
Remove any foreign object that become embedded
within the rollers.
21
7
Post Inspection Cleaning

After each inspection remove the MFL sensor head in
order to clean any magnetic debris from behind it.
22
Check for scanner damage

Damage caused to the Motor / Gearbox.
Loose fixing or a broken gearbox mounting.
Leaking gearbox
Cracked motor cap.
Loose or sticky drive handle.
23

Damage caused to the Encoder assembly.
Encoder assembly rubbing front axle.
Loose grub screw on the encoder gear causing movement.
24
8

Damage cause to either the MFL and STARS sensor head.
Scraping across the bottom of the sensor head.
Broken sensor head connectors.
25

Results of a damaged MFL and STARS sensor head.
In the RAW view the a faulty sensor creates a line on the track.
During the inspection check the raw views, MFL, MFLi and
STARS, because it is clear to see if any damage has occurred.
Replace the sensor head immediately as the captured data is
unreliable and the inspection results are compromised.
A dent in the STARS sensor After damage has occurred a faint As the fault becomes worse during
head affects the scanned data grey line appear on each track the inspection the line get white
26

Damaged caused to the damper strut.
Leaking or bent strut.
Snapped damper strut.
27
9

Damage caused to the scanners chassis
Chassis pivot bolts and bushes.
Any loose, missing or snapped bolts.
Broken motor or front covers.
28

Scanner Rollers
Corrosive product attaching wheels.
29
Recommended Spares
Motor
Damper strut
MFL Sensor head
STARS Sensor head
Wired Encoder
30
10
Packing and storage of the scanner

Store the scanner in the transit case when not being
used.
Before storage of the system ensure:
The system is cleaned and free from debris.
All the batteries are fully charged.
Correct storage of the scanner.
Scanner and components are packed correctly into transit case.
In a clean, dry and secure location.
Away from water and harsh environment conditions.
Store in such a way to avoid damage to the system.
Within temperature limits of -35⁰C to 75⁰C (-31⁰F to 167⁰F).
31
Packing and storage of the scanner

Examples of incorrectly packed systems.
Arrived strapped and taped onto a pallet, no transit case!
Scanner the wrong way around in the transit case.
32
Practical Session
Practical Exercises
Removing the scanner from the transit case.
Correct manual handling of the scanner.
Correct technique for placing and removing the scanner from a
plate.
Battery Charging.
Removal of the MFL sensor head.
Packing the scanner back into transit case.
33
11
Practical Session
Review of Learning Outcomes
34
12
Scanner Components and Maintenance – Learning Outcome Review Questions

1. What is the major health and safety risk of the scanner?
2. Is the scanner intrinsically safe?
3. What permit is required when operating the system inside a tank?

4. Why is it important to handle the system by the designated carry handles?
5. What potential hazard exist when carrying the system?

6. What happens when the correct method of placing the scanner onto a plate is not followed?
7. How could this affect an inspection?
8. Why must the battery cover be fitted during use?
9. At what voltage does the battery require charging?
10. How long does it take to charge a battery?
11. Why must the charging LED be checked when a flat battery is connected and charging?
12. What is the purpose of the Encoder?

13. During an inspection what locations of the scanner require constant cleaning?
14. Why is it important to remove any foreign object that become embedded in the rollers?
15. After completing an inspection what component requires removal to aid cleaning?

16. What components must be checked for damage?
17. How can faulty sensors in a damaged sensor head be identified?
18. What are the recommended spare parts and why are they important to have?

19. Why must the system be stored and transported in the transit case?
20. What must be done before storing a scanner?
Doc Ref:
Rev: 1
Page 1 of 1
Section 5 – Inspection Setup and Calibration – Rev 1
Inspection Setup and Calibration
Inspection Setup and Calibration

Aim
To ensure the system is correctly setup for an inspection. To
identify the requirements and demonstrate how to conduct a
calibration with the scanner.
Learning Outcomes
Demonstrate how to setup the scanner for an inspection.
Demonstrate how to create a new inspection.
Describe the purpose of the scan overlap function.
Establish what information is required for scanner calibration.
Performing a calibration and evaluating the calibration trace.
Conducting a verification scan and establishing if the calibration
is acceptable.
Scanner Setup
The scanner must be setup correctly before use and
involves:
1. Battery fitment.
2. Attaching the Sitemaster.
3. MFL Sensor head height setup.
4. STARS Sensor head height setup.
5. Powering ON the system.
1
Scanner Setup
1. Battery fitment.
The battery must be positioned in the scanner so that it is lying
on its back with the terminals to the front, and to the top.
Incorrect battery position could cause the terminals to short
against the chassis.
Secure using the battery strap.
Always fit the battery and motor
cover during inspection to cover
the battery terminals.
Check hot work permits for
battery changing.
Scanner Setup
2. Attaching the Sitemaster
Brackets are used to secure the Sitemaster to the scanner.
Connect Sitemaster cabling to the scanner.
USB connector
on scanner
Sitemaster2
Power connector
Thumbscrews
Scanner Setup Scanner Setup

3. Fixed height MFL sensor head setup
Bushes are colour coded as they might be different thicknesses.
Red is Left hand side Silver is Right hand side
Ensure the correct thickness bushes are used since they are
scanner specific and that the bush surface is clean.
To set the height of the sensor head turn both thumb nuts fully
clockwise onto the flat washer located on top of the bush.
Thumb nut Thumb nut
Flat washer Flat washer
Red bush Silver bush
Marking on
bridge to
identify
location of
red bush
6
2

3. Adjustable height MFL sensor head setup – old method
Scanner must be placed on a ferrous plate e.g. reference plate
Sensor height is determined between the bottom of MFL
sensor head and top surface of the ferrous plate.
The MFL sensor head height must always be set at 2mm.
Ensure the MFL sensor head is set so that is it level.
IMPORTANT!
It is recommended that the sensor head height is regularly checked throughout an
inspection. If at any point the MFL sensor head permanently moves, then the sensor head
should be reset and a recalibration is required. After the sensor head height has been set ensure
that the height has not altered after locking. Also check that the sensor can move freely if it were
to be impacted. i.e. check that the springs are as expected.

3. Adjustable height MFL sensor head setup – old method
MFL sensor head height is adjusted using the brass thumbnuts
located on the top of the magnetic bridge.
Upper is the Locking thumb nut.
Lower is the MFL sensor Height adjusting thumb nut.
Clockwise: Raises the MFL sensor head.
Counter-Clockwise: Lowers the MFL sensor head.
Upper locking thumb nut
Lower Height adjusting thumb nut
Scanner Setup
4. Setup of STARS sensor head height
The height is determined by the position of the retaining bolts
in the slots of the side plates.
Upper position is the recommended location.
A 4mm Allen key is required to alter the STARS sensor height.
Ensure the STARS sensor head is set so that is it level.
Lower position at the bottom of the slot Upper position at the middle of the slot
3
Scanner Setup
5. Powering ON the system
Check all cables are connected and secure before powering on.
Once powered check the battery voltage displayed on the
scanner is above 11.5v.
Sitemaster power button is located on the right hand side.
Increase the screen brightness control if the screen stays black.
Sitemaster2 Screen brightness

Power button control (+/-)
10
New Inspection Setup

Load the Floormap3Di software using the
desktop icon.
A new inspection must be created in order to perform a
tank inspection.
Enter the detail relating to the inspection.
! indicates Mandatory Fields, so these must be entered.
Set required scan overlap for the inspection

Note: If the tank name has the letter A followed by a number, add
a dash between them i.e. BA12 becomes BA-12.
If an existing inspection is loaded it must be finished
before a new inspection can be created.
Any finished inspection can be loaded.
11
Scan overlap during inspection

Scan Width of each track is 300mm [12inch].
Overlapping of scanned tracks allows no areas to be
missed.
Default overlap value is 50mm [1.97inch].
Set between 0mm and 250mm [9.84inch].
Identical overlap used for every track.
250mm Track
Track11
Track
[9.84inch]
50mm
0mm
Overlap
[1.97inch]
Track
Track22
300mm
300mm[12inch]
[12inch]
12
4
Pre-calibration requirements
Questions to ask before the tank floor inspection:
What is the thickness of the tank floor?
Is there a coating on the tank floor?
What thickness is the coating?
Determine the nominal thickness for each floor plate.
Check and record a minimum of 3 Ultrasonic thickness reading
per plate.
Ideally 5 Ultrasonic readings per plate.
13
MFL reference plate thickness must match the tank floor
plate thickness.
Available reference plate thicknesses are:
6mm – CP30 [1/4inch – CP72]
8mm – CP28 [5/16inch – CP74]
10mm – CP29 [3/8inch – CP75]
12mm – CP31 [1/2inch – CP76]
Acceptable to use a MFL reference plate within 1mm
[0.04inch] of the tank floor and preferably thicker than
the tank floor.
The reference plate must be clean of any debris.
14
Tank Floor Coating thickness must be simulated using the
correct thickness coating simulation sheets.
Coating simulation sheet pack contains thicknesses of:
0.5mm [0.02inch]
1mm [0.04inch]
2mm [0.08inch]
3mm [0.12inch]
Coatings above 0.5mm [0.02inch] must be simulated.
Ensure a fully charged battery is fitted to the scanner.
The MFL and STARS sensor heights are correctly set.
15
5
Performing a Calibration
Ensure the calibration is conducted in a similar
temperature range or climatic condition as the inspection.
The reference plate must not come into contact with any
other ferrous plates such as the tank floor plates.
Perform the calibration outside of the tank.
If calibrating inside tank raise the reference plate up above tank
floor by a minimum distance of 150mm [6inch].
Never pull the scanner back across the reference plate.
To calibrate select the correct plate and coating thickness
options then follow the onscreen instructions.
Save the calibration with a unique name.
Plate / Coating thickness, date, etc.
16
Viewing the calibration trace

MFL Calibration trace
Green is the MFL bottom signal, Red is the MFL top signal.
Four distinct peaks increasing in amplitude over the X-Axis.
Ample height between each peak.
Y-axis is a unit ‘u’ value associated to the amount of leaking
magnetic field.
X-axis is distance.
80% MFL PEAK
Heights of the peaks will 60% MFL PEAK
vary depending upon 40% MFL PEAK
plate / coating thickness
20% MFL PEAK
and MFL sensor height.
17

STARS Calibration trace
Four distinct peaks increasing in amplitude over the X-Axis.
Ample height between each peak.
Y-axis is a unit ‘u’ value
associated to the
amount of change in
magnetic field.
80% STARS PEAK
X-axis is distance.
60% STARS PEAK
Height of peaks will vary
40% STARS PEAK
depending upon plate /
20% STARS PEAK
coating thickness and
STARS sensor height.
18
6

Section 5 booklet shows example calibration traces.
Do not compare calibration traces in too much detail as
there are differences in machine tolerances.
Use as reference / guidance only.
Valid calibration trace should be similar.
If calibration trace are different ensure
correct procedure was followed.
Common oversights include:
Selection incorrect plate /coating thickness.
Not turning reference plate over.
Calibrating with reference plate on tank floor.
19
Exporting calibration images

Once the calibration is complete click Export to save an
image for both the MFL and STARS calibration trace.
These can be included into the tank report and area also
helpful when analysing the inspection data.
20
Calibration Verification Scans

Verification scans performed on the reference plate are
required to check the validity of the calibration.
Create a plate with a row / plate number that exists
outside of the tank floor.
Perform four scans all in the 20% to 80% direction.
Checks are performed to ensure the correct EPL value
and surface origin for the scans on the reference plates.
The EPL tolerance should lie within +/- 4% to 5%.
i.e 80% lie between 75% to 85%.
21
7
Loading a calibration
Only load calibrations that are still valid for the current
sensor height position and performed for the current
inspection.
If the sensor height position has moved then perform an
new calibration.
A greyed out Calibrate button indicated the current
calibration is associated with the current scanned plate.
To access the calibration window, click Scan and create a
new plate then close before performing a scan.
IMPORTANT!
It is never recommended to load an existing calibration. If a different
calibration is required, it is always advised to perform a new calibration to
ensure the calibration being used is accurate and applicable.
22
Why calibrate in one direction only?

Full magnetic saturation is not achieved for all reference
plate and coating thickness combination.
Saturation is not achieved in reference plates typically
greater than 10mm [3/8inch] with no coating.
The thicker the coating becomes the less likely full plate
saturation can occur in thinner reference plates.
When saturation is not achieved we must reach a
maximum fixed level of magnetism in the reference plate
to allow repeatable results.
This is only applicable for reference plate. A tank floor
can be considered as an un-scanned ‘virgin’ plate
containing no magnetism.
23
Practical Session
Practical Exercises
Battery fitment and removal. Performing a calibration and
Attaching the Sitemaster to viewing the trace
the scanner. Accessing calibration when
Setup of the MFL sensor button is greyed out
head. Loading an existing calibration
Setup of the STARS sensor Performing a Verification scan.
head. Calibration Exercise.
Powering the system ON and Effect of a Plate thickness
OFF. change.
Creating a New Inspection. Effect of a Coating thickness
Finishing an Inspection. change.
Loading an Inspection. Effect of an MFL sensor lift off.
24
8
Practical Session
Conducting a verification scan and establishing if the calibration
is acceptable.
25
9
Inspection Setup and Calibration - Learning Outcomes Review
Questions

1. What might happen if the battery is fitted incorrectly to the scanner?
2. What happens if the USB cable is not correctly between the Sitemaster and the scanner?
3. What must be done if the Sitemaster screen stays black after powering ON?
4. What side must is the Red bush located on the Fixed MFL sensor head setup?
5. What sensor height must the Adjustable MFL sensor head be set at?
6. What must be done before a new inspection can be created?
7. What information can be altered after creating an inspection?
8. Why would an inspection be loaded?
9. What is the benefit of overlapping scans?
10. What is decided by the scan overlap?
11. What must be known about the tank floor inspection before calibrating the system?
12. What decides which reference plate is used to calibrate the system on?
13. What is used to simulate tank floor coatings?

14. What must not be done on a calibration plate?
15. What does the red and green traces on the MFL calibration represent?
16. What must be checked on the calibration trace?
17. What steps must be taken if the calibration button is greyed out?
18. How can a calibration be deemed successful?
Conducting a verification scan and establishing if the calibration is acceptable.
19. What must be checked on the verification scan?
20. What is the acceptable tolerance for the EPL values?
21. What must be done if results are outside of the required tolerance?
Doc Ref:
Rev: 1
Page 1 of 1
Section 6 – Scanning the tank floor – Rev 1
Scanning the tank floor
Scanning the tank floor

Aim
To demonstrate correct positioning and scanning on tank floor
or annular plate. To implement the appropriate scanning
method around tank floor obstructions.
Learning Outcomes
Demonstrate correct scanner positioning during the inspection.
Identify what data captured during a scan is shown on screen.
Demonstrate how to transverse scan correctly.
Demonstrate how to resume scans around obstructions.
Explain the practical limitations of scanning annular plates.
Locating where scan data is stored and when the data is saved.
Identify how to remove old inspection data.
Correct positioning of the scanner

Position the scanner so that the side plate closest to
plate reference edge is on the track width interval mark.
On the first and last track position the scanner as close to
the plate weld as possible. An increased overlap area
always occurs on the last track. Align the scanner as
close to the plate weld.
Align side plate

closest to plate
reference
1
Incorrect positioning of the scanner

When the scanners roller is positioned over the track
width interval the software is unaware and so positions
the track at the correct track width interval.
This can cause a duplicate indication on the track as well
as incorrect positional information of indications.
Same indication
indication
An Indication found
found on track
on track 1 2 A duplication of the same indication
Incorrect scanner position

4
Incorrect positioning of the scanner

When the scanner is positioned away from the track
width interval the software is unaware and positions the
track at the correct track width interval.
This can cause missed indication as well as incorrect
positional information for indications.
Missed
Missedindication
indicationbetween tracksIndication
not shown Indication
incorrectly
found during
locatedscan
on plate
Indication found
during scan
Incorrect scanner position

5
Scan Start Offset Measurement

Once in-line with Track Width Interval position rear rollers
so that they are against the start edge or weld of plate.
Start offset is 160mm [6.3inch] when against the weld.
When not against the weld measure from the start edge
to the MFL sensor and change the offset value.
Lap Weld
Lap Weld
Start Edge
Start Offset Distance:

Measure 160mm
Start Offset [6.3inch]
Distance
6
2
Annular Scan Start Offset Measurement

This measurement is from the Annular plate reference to
the MFL sensor head. The value is different for each track.
Position the scanner back as far as possible then check the
measurement as it may be less that 160mm [6.3inch].
Negative offset values are possible if the MFL sensor head
is behind the plate reference.
Positive Offset value in Positive Offset value less Negative Offset value
front of plate reference than 160mm [6.3inch] behind plate reference
7
Track data captured during a scan

Twist the handle to scan then release to end data capture.
Track data is a combination of both MFL and STARS data,
STARS only and MFL only data is removed.
The scan direction can be identified by the
white scanner slowdown area at the end
of the track.
Distance travelled is from the plate edge to the
Entered Scanner slowdown is
Start
stop location of the scanner Scanner slowdown is
displayed in white
displayed
Release of drive handlein white
Offset ends data capture
Release of drive handle
MFL Data ends data capture
Position
scanner
STARS Data
stops at
Track Data
Transverse Scanning
Transverse scans are performed to minimise the non
scanned areas located at either end of the plate.
Scan direction is made perpendicular to normal plate
scans and is taken relative to Plate Reference.
Scan direction away

Scan direction away
from Plate Reference Scan direction towards
from Plate Reference Plate Reference
Plate
Reference
marker
Non scanned
Scan direction areas
towards Non scanned areas
located
Plate at the start
Reference located at the end
of the plate of the plate
3
Transverse Scanning
Scan location can be either at the:
Start plate edge which is against the plate reference.
End plate edge which is against the opposite edge to plate
reference.
Mid plate which is anywhere except the against the plate edges.
Measurement is from the plate reference to the damper.
Damper location
Plate
Reference
marker
Start Plate Edge Mid Plate Scan End Plate Edge

Scan location Location Scan location
10
Scanning around obstructions

There are two ways to resume a track:
1. During the scan of a track.
2. Select a completed scanned track.
The scanning direction for the resuming track is either:
In the same direction of travel.
From the opposite edge of the plate. (Rectangle plates only)
When resuming choose the most efficient option to help
minimise the inspection time.
Remember to mark the track width intervals on the plate
around the obstructions to help position the scanner.
Transverse scans cannot be resumed.
11

Identify which of the following types the obstruction is
because the scanning approach will be different.
Isolated Obstruction Pipework or heating coil
Blocking one or two tracks Running across many plates
Always set to scan type to parallel when the

obstruction runs across one or more plates.
12
4

Isolated Obstruction.
1. Scan to the obstruction then mark the MFL sensor position.
2. Position the scanner around the other side of the obstruction

and measure the offset distance from the mark to the MFL
sensor.
3. Select resume, enter the offset measurement then continue

scanning.
13

Pipework or heating coils
1. Scan one side of the obstruction, marking the MFL position.
2
1
3
2. Position the scanner around the other side of the obstruction

on the track to resume. Measure the offset distance from the
mark to the MFL sensor.
2
1
3
3. Select the track number to resume, enter the offset

measurement then continue scanning.
14

Resuming from opposite edge.
1. Position the scanner on around the other side of the
obstruction and to scan in the opposite direction.
2. Measure the offset from the opposite edge of the plate to the
MFL sensor head position.
2
1
3
3. Select the track number to resume, select the Scan From

Opposite Edge? so that is it green, enter the measurement
then continue scanning.
15
5

Annular plate obstruction can only be resume in the
same direction of travel.
Do not scan from opposite edge.
16

Multiple Obstructions
If a plate has more than one obstructions it is possible to use a
combination of resumes methods to scan around.
Look at the obstruction and decide the best approach.
1 2 3 1 2 3
1 3 2
17

Multiple Obstructions
Consider the tank section below with the various obstructions,
there are many routes to scan around these obstructions.
Look at the plates surrounding the obstructions to determine a
suitable scanning path.
Use load plate together with resuming tracks to scan efficently.
A2 A3
1/3 1/4 1/5
1/1 1/2 1/6 1/7
2/1 2/2 2/3
A1 A4
3/1 3/2 3/3 3/4
4/1 4/2 4/3
18
6

Delete Track removed the data for the scanned track.
Deleting a resumed track removed the entire track data.
Clear plate deletes all scanned data and the plate setup
information.
Do not skip any tracks, perform a short ‘false’ scan on the
track that requires skipping.
Skipping tracks cause issues within the reporting software.
19
Saving and Exporting scanned data

When a new inspection is created it generates a folder to
save the inspection data. The folder name is based on
the entered inspection details: Date-Customer-TankID
By selecting these software buttons it affects the
scanned data in the follow way:
Automatically saves the scanned track data
Clears the scanned track data
Permanently deletes the track data
Permanently clear all the scanned plate data
20

Backup, in the Archive menu, copies and compresses the
current inspection folder which contains the scanned
data onto an external USB drive.
Backup button is only available when a external USB
drive is connected to the Sitemaster.
Ensure the USB drive has enough free space available.
To close the completed inspection click Finish Inspection.
21
7

The file structure, folder names, file names of the
inspection data is important and must not be altered.
Data format found within the inspection folder include:
An inspection file: Date-Customer-TankID.fm3insp
Calibration files: calibration name.fm3cal
Plate details file: R*- P*.fm3rectangular
Plate Track files: R*- P*_*.fm3track
Annular details file: A*.fm3rectangular
Annular Track files: A*_*.fm3track
DO NOT CHANGE OR RENAME THE FILING STRUCTURE

22
Removing old inspection data

Ensure the current inspection has been completed and
all data archived before removing any unwanted data.
A typical inspection folder, depending on the tank
diameter, can vary between 200 MB and 3 GIG.
Remove a completed Inspection by deleting it from the
Inspections folder.
Remove unwanted calibration files by deleting them from
the Calibration Files folder only.
DONOT remove unwanted calibrations from the inspection file.
23
Practical Session
Practical Exercises
Positioning, scanning, transverse and locating for prove up
Start scan offset with an obstruction
Resuming during the scan of a track
Selecting a completed scanned track to resume
Scanning around multiple plate obstructions
Using the load plate function when scanning around
obstructions
Annular plate scanning
Backup of inspection data
Removing old inspection data from the Sitemaster
24
8
Practical Session
Establish correct selection of transverse scan based on position.
Discuss the practical limitations when scanning annular plates.
Locate where scanned data is stored and when data is saved.
25
9
Scanning the tank floor – Learning Outcomes Review – Questions

1. What is required in order to correctly position the scanner?
2. What happens when the scanner is positioned incorrectly?
3. What is the start offset value when the scanner is against the plate weld?
4. When the scanner is not against the plate weld how is the start offset value determined?
5. What data is displayed onscreen by the system?
6. When does the data capture end?
7. What does the white section at the end of a track represent?
Demonstrate how to transverse scan correctly.
8. What is the purpose of a transverse scan?
9. What position is used to reference both location and direction of the transverse scan?
10. When the scanner is not against the plate edge how is the location determined?
11. What two ways are there to resume a track?
12. What type of plate is required when using scan from opposite edge?
13. When scanning around an obstruction what must be done once the scanner stops?
14. What scan type must be selected when an obstruction crossing the one or more plates?
15. What must be checked before finishing the inspection?
Explain the practical limitations of scanning annular plates.
16. When scanning annular plates what is the major limitation?
17. Why will the start offset value be different for each track?
18. How is the start offset value determined for each track?
19. What direction must you resume in when scanning around obstructions on an annular plate?
Locating where scan data is stored and when the data is saved.
20. What details are used to generate the folder name of the inspection?
21. When does the scanned data get saved?
22. Where is the Backup button located?
23. Why must the filing structure of the inspection data not be change?
24. How are old inspection removed?
25. What other information required removal?
Doc Ref:
Rev: 1
Page 1 of 1
SECTION 7 – Data Analysis and Reporting – Rev 1
Data Analysis and Reporting
Data Analysis and Reporting

Aim
To determine if indications detected by the system are relevant
or spurious and how to identify spurious indications. To
evaluate scanned data and produce a report.
Learning Outcomes
Compare different methods of data analysis whilst inspecting.
Differentiate between the types of detectable indications.
Identify the appearance of relevant indications.
Establish possible causes of spurious indications.
Demonstrate how to analyse scanned data.
Demonstrate how to use the software to generate a report.
Data Analysis methods during inspection

Two approaches of data analysis exist:
Data Acquisition Software Desktop Analyser Software
Approach depends upon the inspection duration and

number of personnel and their experience.
Any area identified for further investigation must be
confirmed by re-checking the location on the tank floor.
1
Types of detectable Indications

Not all detected MFL leakage fields are caused by defects
Relevant Indications.
These are un-designed imperfections that can be classified as a
defect when they affect the fitness for purpose.
It is dependant upon the defect reporting requirements.
Non-Relevant Indications.
Are caused by design features to the structure, such as scores
or scratches on the plate, heat affected zones (HAZ) near edge
of plates or a change of permeability of the floor plates
Spurious Indications.
Can be caused by scale or dirt, weld spatter, sensor impacting
or vibration of the scanner.
Identifying Relevant Indications

Corrosion indications tend to be circular or random in
nature when viewing in the percentage sizing view and
MFLi analysis view.
Identifying Spurious Indications

All indications should be considered relevant unless
proven otherwise.
The system can display percentage indications when
there is no equivalent corrosion present.
One major contributing factors is the higher sensitivity
levels on thicker inspection surfaces and coatings.
Spurious indications can be caused by:
Vibrations from a rough or poorly cleaned inspection surface.
Uneven applied coatings.
Senor head impact.
Near weld joints of the floor plates.
Scanning over weldments.
6
2
Identifying Spurious Indications

They can be easily identified and are likely to:
Straight lines perpendicular to the direction of scan.
Located along the edge of the tracks
Reduce in value as they moved inwards from the track edge.
Spurious indications must be removed from the report
Examples of
spurious
indications
detected at
a high EPL
value
Possible causes of Spurious Indications

Identifying a Weldments.
A key factor is the parallel lines across the tracks in analysis
views. This is the sensor head vibrations as the rollers travelling
over the weldment.
The distance between the lines is always 260mm [10.25inch]
which is identical to that of the scanners wheelbase.
STARS displays an indication as a White -> Black change so it
indicates the indications is coming up and out of the plate.
Indications
Notice
Note
Clear the high
White ->signal
thevisible
top
seenside intensity
along
indications
track
parallel
Black change line.
linesedge
atparallel
45%
at the
across
and 100%.
track.
lines.
8

The ‘T’ joints between plates.
When viewing plates within the reporting software it can be
clear to identify these joints.
3

Identifying an old bracket support covered by coating.
The STARS view can provide a clear outline of what is hidden
beneath the coating.
10

Identifying repair plates covered by coating.
The STARS view can provide a clear outline of what is hidden
beneath the coating.
11

Identifying welds covered by coating.
An image of writing by a welder hidden under coating and is
clearly seen in STARS view.
12
4
Identifying plate undulations

Plate undulations can be identified in STARS view by the
gradual changes between white and black.
13
Identifying plate undulations

Undulations around repair plates and roof support plates
can be identified in STARS view by the sudden colour
change.
14
How to analyse scanned data

Analyse data on a plate by plate basis.
Determine the maximum % loss indication for each track.
View the plate in STARS view.
View the plate in MFLi view.
View the plate in MFL view.
Identify a background MFL ‘u’ level for the tank floor.
Identify a background STARS ‘u’ lever for the tank floor.
Identify the calibration used to scan the plate and view.
Determine the Suggested Minimum Operational
Threshold level based on the background ‘u’ level to
report above.
15
5
What to identify for each indication

X & Y location - For prove up and visual inspection.
Percentage value.
MFLi ‘u’ value.
STARS ‘u’ value.
Surface origin based on ‘Sizing view’.
Top Bottom
Surface origin based on ‘Analysis view’.
Top Bottom
Is the indication circular or random in nature?
Yes No
16
What to identify for each indication

Does it appear merged with other indication?
Yes No
Colour gradient of indication in ‘Sizing View’.
Monochrome (one colour) Varicoloured (multicolour)
Indication size using Dynamic Cursor in ‘Sizing View’.
Larger Within Smaller
Is the indication located at the edge of a track?
Yes No
What is the STARS colour representation?
Black to White White to Black
Additional comments on indication.
17
Decisions based on data analysis

What is the surface origin of the indication?
Top Bottom Both
What is the expected indication geometry?
Lake Conical Pipe
Does the indication appear to be spurious?
Yes No
Is further prove-up on the indication area required?
Yes No
What action is required during report generation?
18
6
Practical Session
Practical Exercises
Data Analysis Exercises
Data Analysis Tutorials Plates
Data Analysis Exercise Plate A
Data Analysis Exercise Tank 1
Reporting Software
SIMS Tutorial Guide
SIMS Tutorial Tank
SIMS Tank Layout Modification Tutorial Layout
SIMS Exercise Tank A – F
SIMS Tank Layout Modification Exercises 1 – 5
19
Practical Session
20
7
Data Analysis and Reporting – Learning Outcomes Review Questions

1. What are the two approaches of data analysis during the inspection?
2. What factors can decide the analysis approach?
3. What must be done when any area of interest has been identified?
4. What are the three types of detectable indications?
5. Which of these types can be detected by MFL?

6. What shape do relevant indication typically appear as?

7. What is one of the major factor for the increased detection of spurious indications?
8. List other causes are there for spurious data?
9. How can spurious indication be identified?
10. What must be done to spurious indications?

11. Why must all views be checked during data analysis?
12. Where are the alteration made to the data once analysis has completed?

13. What software option is used to input the scanned data into the reporting software?
14. What software option is used to add more data into a tank file?
15. What software tool is used to reposition tank floor plates around?
Doc Ref:
Rev: 1
Page 1 of 1

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Operators Training Course

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Improving Inspection Through Technology

Floormap3DiM Training Course

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Floormap3DiM System Overview

Floormap3DiM System Overview

Floormap3DiM System Overview

Floormap3DiM System Overview

Floormap3DiM System Overview

Floormap3DiM System Overview

Detection of indications Sizing of indications

Floormap3DiM System Overview

Detection of indications above

MFL and STARS technology

Improving Inspection Through Technology

MFL and STARS technology

Magnetic Flux Theory

Magnetic Flux Theory

Magnetic Domain Theory

Magnetic Domain Theory

Magnetic Flux Leakage Principle

Bridge Permanent Magnets

Pole piece Pole piece

Magnetic Flux Leakage Principle

Magnetic Flux Leakage Principle

40% EPL 60% EPL 60% EPL

Magnetic Flux Leakage Principle

Difficult to discriminate -0.05

as there is a 7% difference -0.1

in the peak to peak. 0 10 20 30 40 50 60 70 80 90 100

Another technique is required for surface discrimination.

Pole piece Pole piece

POLE PIECE POLE PIECE

If there is a protrusion on the surface (weld spatter), the

MFL Reference plate

MFL Reference plate

Plate 20% defect 40% defect 60% defect 80% defect

MFL Reference plate

Purpose of the calibration

Defect Volume Estimated Percentage Loss depth

The magnetic leakage signal is identified for defects

Calibration trace and the unit ‘u’ value

Calibration trace and the unit ‘u’ value

Calibration trace and the unit ‘u’ value

u = 105 40% u = 109 40%

BOTTOM TRACE TOP TRACE

Calibration trace and the unit ‘u’ value

Background low STARS higher STARS

Calibration trace and the unit ‘u’ value

Surface Origin and Percentage Loss

Surface Origin and Percentage Loss

Surface Origin and Percentage Loss

Top EPL View Bottom EPL View

Surface Origin and Percentage Loss

The diameter of the cursor is determined by the MFL

1. Accurately Sized 2. Oversized Indication 3. Undersized Indication

Indication colour gradient

Compare this to the know geometry of the calibrated

Signal to Noise Ratio

Signal to Noise Ratio

3:1 ratio is 45u