Development of Automated Electromagnetic Techniques for Inspecting Inner Cracks of LPG Tanks

Yung-How Wu, Feng-Ju Hsieh, Mu-Chung Peng, Hsing-Jeng Yang

Materials Research Laboratories, Taiwan Email:700606@mrl.itri.org.tw

Objective
To integrate an automated ElectroMagnetic Array based system for inspecting inner surface cracks on LPG Tank.

Background
LPG tanks were frequently subjected to SCC on inner surface during service and must be inspected from inside regularly. Conventional ISI by MT or PT is toilsome and costly.
Extremely hot in summer Scaffolding & Coating removal

ACFM has been used to detect surface breaking cracks without removing coating on components.

Electromagnetic Array Techniques

ACPD
V2/V1 = (2d + ) / d =/2((V2/V1) 1)
Surface current Span =
V1 V2

EMA or ACFM
Crack tip Current perturbation

Surface current

Surface crack

Crack Detection and Sizing

EMA System Data Display
CP Abs Corr. Display

Crack

Solo Handheld Probe

SDDPU

Abs

CP

Probe for Automation

Samples with Artificial Cracks

Notches
41210 Plate-1

Cracks

150

A group

C group

B group

Defect(mm) Defect(mm)
Type/Positn Depth 2 Notch/A 2 2 Length 40 20 10 Width 0.25 0.25 0.25 Weld-9 Centerline Crack ~2mm 13 38 Weld-6 Toe Crack

Block

Type

Depth ~2mm

Lengt h 12

Positn

30

Characteristic Defect Signals

A single defect was detected by three successive channels. Defect could be clearly identified by various displays.

Signals in Various Conditions

8

6 4 2 0 0 20 38
o

1
5
15

50

90

Weakest response at 380 Amplitude decreased exponentially with Lift-Off Measuring error could be controlled down to 25%

10mmx1mm

1_Plate1_Plate2

(Max/Min)

(mm)

10 5 0 0 10 20 30
1

6 5 4 3 2 1 0 0 1 2 3 4 5 6 7

(mm)

Automated Inspection System

EMA System
Lizard solo 64 channels SDDPU

Scanner Control Console

PC + TFT monitor Motor control module Motion control & monitoring package

CCD camera and 2-axis stage Scanner

With 4 magnetic rollers Carrying 32-channel probe

Automated Inspection Method

Weld and Plate regions were Inspected individually
Weld: along the weldment Plate: as shown

Scanner was moved to the top position and then scan automatically on each path. Scanning route was monitored by CCD camera and full coverage was assured.

Field Trials
Scanning is controlled and
monitored through CCD camera by inspector operating below the LPG tank.

Inspection Process

or

Yes

CCD Camera No

EMA EMA

Scan a Line

EMA Control Console

Conclusions
Laboratory and preliminary field trials proved the method satisfactory in detecting real cracks down to 10mm in length and 1mm in depth in both regions. However, minor improvement on the scanner manipulation is required before practical application.