UNDERWATER ACFM CRACK MICROGAUGE MODEL U21

PRODUCT INFORMATION

Underwater ACFM Crack Microgauge (Model U21)

FIGURE 1 : Underwater ACFM Crack Microgauge Model U21

INTRODUCTION
The Underwater ACFM Crack Microgauge (Model U21) represents a significant advance in inspection technology. Based on the alternating current field measurement (ACFM) technique, the system enables reliable crack detection and crack depth measurement on welded structures. Advanced software aids the operator in the interpretation of the inspection data to provide crack detection with low likelihood of false calls. Crack depth predictions are based on mathematical modelling and the system therefore requires no calibration procedure, significantly reducing the possibility of operator error. TSC offer full support from our engineering staff who have broad experience in platform design, analysis and inspection. Underwater ACFM inspections were first conducted in the North Sea in 1991. Since that time the system has been adopted by many major operators around the world for the inspection of offshore platforms, subsea structures and pipelines. Originally introduced for deployment by diver, the Underwater ACFM Crack Microgauge is now available for interfacing to ROV's. In this mode, the system makes use of the very latest ACFM array technology to avoid the need for scanning around the weld. In this case, the probe is simply placed in a series of overlapping positions around the weld enabling deployment by basic workclass ROV's without the need for complex manipulators.

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Underwater ACFM Crack Microgauge (Model U21)

The ACFM system provides:

Reliable crack detection and crack sizing without the need for calibration, ie Crack LENGTH and Crack DEPTH Ruggedised topside and subsea units successfully proven in the North Sea Reduced cleaning requirements with no need to clean to bare metal Capability of inspection through metallic and non metallic coatings State of the Art software operating under Windows 95 for ease of operation and compatibility with other reporting software packages 'Replay' facility for review of data Fully automated back-up facilities for data storage Rapid scanning around weld toes using diver held probe Access to a wide range of geometries by using TSC's range of underwater probes

When deployed by ROV the system provides:

Fully integrated communications via the ROV umbilical Rapid inspection without the need for weld scanning

BACKGROUND TO ACFM
Alternating Current Field Measurement (ACFM) is an electromagnetic inspection technique and relies on the fact that an alternating current flowing in a component will be disturbed by the presence of a crack. The ACFM probe introduces an electric current locally into the structure and measures the associated electromagnetic fields close to the surface. The presence of a defect disturbs the associated fields and the information is graphically presented to the system operator. The ends of a defect are easily identified to provide information on defect location and length. The significance of a defect, in terms of structural integrity, generally depends on the depth of the defect. Using mathematical models, the system also provides the depth of the defect, thus allowing an immediate evaluation of the significance of the indication. This is a major advantage compared to other techniques that only give detection or at best, length information. ACFM systems have been used for a range of applications where rugged inspection systems are needed. The speed of scan provides a rapid and cost effective means of inspecting welded connections with reduced cleaning requirements compared to conventional techniques.

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Underwater ACFM Crack Microgauge (Model U21)

The probes have been developed to minimise signals from features that are not cracks, eg corrosion, undercut, HAZ, material property changes, etc, thus overcoming the problems often associated with other electromagnetic systems and minimising false calls. The ACFM technique has been approved for subsea weld inspection by major authorities around the world, including Lloyds, ABS, Bureau Veritas, DNV and OCB Germanischer Lloyd.

BACKGROUND TO THE COMPANY

Established in 1984, TSC are leaders in the application of ac field measurement techniques to industrial applications. The ACFM technology has been developed in-house from the successful ACPD technique to provide a system for crack detection and sizing without the need for any electrical contact. The crack sizing capability has resulted from theoretical studies at the Wolfson NDE Centre at University College London, which allows the prediction of crack depth from a knowledge of the surrounding ac electromagnetic fields. The hardware developments make use of state of the art low noise analogue electronics and the control system has been developed using the very latest Windows software techniques. The result is a system that provides reliable inspection of welded structures that has been developed by a Company specialising in structural inspection and structural integrity assessment. TSC are therefore in a unique position and able to provide customers with not only the inspection system, but also the back-up in terms of procedural development, customisation to suit specific applications and even an evaluation of the significance of any defects found.

SYSTEM LAYOUT - Diver Deployed (U21-Diver)

Topside Printer PC Module

110v

350m Umbilical

ACFM Probe

Subsea Module

FIGURE 2 : Model U21 - Diver Deployed

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Underwater ACFM Crack Microgauge (Model U21)

Figure 2 shows the system layout for diver deployment. The system comprises a topside PC, which acts as the system controller as well as a data acquisition unit, a topside unit providing all power to the system, a 350m umbilical and a subsea unit. The complete system is operated from a single 110V supply to ensure maximum safety for the operator both subsea and topside. The topside computer is a standard PC and requires no additional cards. The computer is provided with full battery back-up facilities to ensure that in the event of a power failure no data is lost, and operation can continue for at least an hour to allow data to be reviewed / replayed if required.

SYSTEM LAYOUT - ROV Deployed (U21-ROV)

Topside Printer PC Module 110v

RS232

RS485

1500m ROV Umbilical

ACFM Probe

ROV umbilical termination

Subsea Module

FIGURE 3 : Model U21 - ROV Deployed Figure 3 shows the system layout for ROV deployment. The ROV system makes use of an ACFM array probe which avoids the need for any scanning around the structure welds. Like the diver version, the system is controlled from the surface by a PC. The major differences between the diver system and the ROV system are that the ROV system communicates via the ROV umbilical and has the capability for a number of array probes to be connected simultaneously.

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Underwater ACFM Crack Microgauge (Model U21)

SYSTEM SPECIFICATION
Standard Maximum operating depth Umbilical Length Operating temperature range Operating temperature range Maximum power consumption Electrical supply Subsea Unit Topside Unit 300m 350m 0-250 0-350 1A @ 110V 110V (+10%) 45-65Hz Special 500m 1000m

SYSTEM FEATURES - Model U21

Hardware (General)

Rugged Topside Unit with illuminated system checks Earth Leakage Trip protection for complete system Rugged subsea housing

Diver System

Subsea connections allowing probe change out underwater Grab rails for easy handling and protection against damage Range of probe configurations to cover different geometries:i) ii) iii) iv) Standard probe for general weld inspection Tight access probe for angles down to 350 Pencil probes for difficult access of grinds Edge effect probes

ROV System

Up to three array probes simultaneously connected Easy interfacing to ROV for power and communications

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Underwater ACFM Crack Microgauge (Model U21)

Software (General)

Windows 3 or 95 software environment supporting simultaneous running of word processor package / spreadsheet, etc, and interface to all common printers Graphical display of raw data Graphical display of processed data for crack detection Multiple screen facility for comparing consecutive scans Real time adjustment of trace position on screen Moveable cursors for use during data review Crack depth calculation including recording of crack size on screen Multiple page facility in a single file Automated back-up at end of session onto diskette and hard disk Full system status reports for hardware checking Graphical printout of user screens Data transfer into standard spread sheets eg Excel

Diver System

Real Time data display Clock points and marking to indicate position on scan Variable speed time base to suit application Replay facility of recorded data

ROV System

Colour contour plots of probe area Free format text input associated with each scan Computer aided calculation of crack sizes Automated crack length measurement Data merging facilities to combine scans of adjacent areas of weld

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Underwater ACFM Crack Microgauge (Model U21)

OPERATOR TRAINING FOR DIVER DEPLOYMENT

The diver is required to move the probe around the component under inspection, under instruction from the topside operator. The diver has no display of data from the instrument and thus does not require any training in terms of interpretation or operation of the system. However, moving the probe correctly is a requirement of the system and the topside operator should be trained to ensure that the diver is performing the probe movement correctly. The topside operator is therefore responsible for all aspects of the inspection and TSC recognise that quality in training leads to quality in results. TSC have therefore co-operated with TWI who have prepared a training course for topside operators, part of which includes training on how to train the diver. The one week course is run at regular intervals at TWI Norths diving facility in Middlesborough. It involves practical and theoretical training of all aspects of ACFM inspection. An examination is given at the end of the training and those passing obtain a certificate. The course is approved by Lloyds Register. Training and examinations are also available within the CSWIP scheme. TWI also run courses, on request, in different parts of the world and will provide training at customer sites if required.

OPERATOR TRAINING FOR ROV DEPLOYMENT

In addition to the training for manual deployment, operators of ROV systems require additional ROV system training on the use of ACFM array probes. This training is provided by TSC and can be provided on customer sites if required.

AVAILABILITY
The Underwater ACFM Crack Microgauge is available from TSC for sale and rental. Trained topside operators are also available to operate the system offshore if required.

ENQUIRIES
Sales and Technical Enquiries: Dr David A Topp Technical Software Consultants Limited 6 Mill Square, Featherstone Road Wolverton Mill, Milton Keynes MK12 5RB UNITED KINGDOM Tel No: Fax No: Email: Web: Please Note: +44 (0) 1908 317444 +44 (0) 1908 220959 dtopp@tscinspectionsystems.com www.tscinspectionsystems.com

As part of its continuing programme of product improvement, TSC reserve the right to alter specification without prior notice.
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