Baugh & Weedon TruFlux

Baugh & Weedon TruFlux

High Resolution Digital Tank Floor Plate Scanner

Overview

The TruFlux is a new concept in Magnetic Flux Leakage (MFL) tank floor plate inspection, delivering a new level of user sophistication with innovative design. As a fully self-propelled high-resolution digital scanner, the TruFlux is capable of producing highly accurate topographical images of 6-20mm storage tank floor plates. Particular attention has been paid to the mechanical design, notably it's physical size, weighing in at just 32kg, inclusive of its slip-in-slip-out lithium ion battery pack. The system is easy to use and highly practical; with the use of just one lever the TruFlux folds down into a locked transport position. With reduced physical size and lower weight, handling and set-up requires little effort.

Key Features:

  • Efficient & Effective Mechanical Design
  • Superior Digit Resolution: 0.2" x 0.04" (5.2 x 1 mm) - Readings from 48 hall effect sensors are captured and digitized every 0.04" (1mm) of forward travel at a scanning speed of 20" (500mm) p/sec.
  • Lightweight, 71lbs. (32kg) including battery
  • Easy to transport, total shipping weight under 132 lbs. (60 kg) (not including laptop)
  • Easy reporting via Laptop, USB.
  • Semi-rugged laptop upgradeable to a fully rugged option
  • Unique damping system provides easy lift off and placement in one easily controlled motion reducing any high levels of mechanical loading.
  • High resolution optical encoder. Positional accuracy of +/- 0.04" (1mm) over a 65.6 ft. (20m) scan track.
  • Fast track-to-track scanning images
  • USB connectivity means the Truflux effectively works as a simple "plug and play" unit
  • Uses Lithium-ion battery technology with push pull hot swappable capability. Fast recharge and 4 batteries per unit provide 24 hr. utilization.

 

How It Works

Calibration

It is vital that the TruFlux is calibrated on a known test plate before an inspection of a tank floor is carried out. If using the software for the first time a calibration file must be produced for the material thickness you intend to inspect. Calibration files are stored for a maximum of 30 days, where after a new calibration will be required. The software will always use the most recent calibration file.

Allow the motor to move the instrument from the start point to end point, on the plate, in one continuous smooth operation. It is important for the instrument to run the entire length of the calibration plate, including the first 300-400mm before the first indication; this part of the plate is used to capture data where there are no indications and general noise levels are eliminated. Once stopped, unlatch or re-press the calibrate button.

Once satisfied with the signal display, you can move each cursor bar onto its corresponding indication. You will notice that each moveable bar has a number that corresponds to each indication. Pick up the bars individually and place into the center of each indication – bisecting the indication through its center. The bars are used to register the signal amplitude that corresponds to each percentage loss indication. This then sets the reference amplitude curve for the software when scanning. Once this has been done the calibration can be accepted by pressing the accept button. Now the calibration has been completed, inspections relating to that particular plate thickness, can begin.

Inspection

Pre-Inspection

Before commencing any inspection program the operator should ensure the following information is available.

  1. All floor plate thicknesses including annular plate
  2. If any floor plate coatings are present and their thickness; simulation of coating thickness will have to be simulated during calibration
  3. General condition of plates – floor plates need to be free from loose scale and relatively clean
  4. Presence of heater coils and other obstructions
  5. Floor plate numbering system to be used

Inspection Procedure

Step 1: Click Inspect

From the front panel click inspect

Step 2: Inspect Panel - 'Project' Tab

The inspect panel comprises of three parts: project, tank and plate. Navigation between the panels can be done by either – clicking on the tab control, or when project, tank and plate data has been added, by using the drop-down lists.

Work through each element on the inspect panel; project tab, survey date, operator, location, outline, grid, padding, offset, dead-zone, blanking, threshold & comments. After working through each element create a report to generate a full file output of the entire inspection.

Step 3: Inspect Panel - 'Tank' Tab

Once the project has been created, you can create tanks within the project. Type the tank name or description into the box and press enter. When the enter key is pressed, you be transported to the tank panel. Within the tank panel you can add the tank diameter.

Step 4: Inspect Panel - 'Plate' Tab

To create plates, enter a plate number into the plate field. You can enter as many plates as needed, dimensions will be identical to the first plate, however you can change their dimensions any time prior to collecting data. Within the plate screen you can enter plate dimensions, type (thickness) and choose to scan the end zones. If end zones are selected, this will place one or two transverse scans at one or both plate ends.

Step 5: Scanning Mode

Press the scan button. The instrument should now be in position to start scanning runs, with the first track starting from the selected datum point. Once the instrument is in position to start scanning, you may commence a track run. Depress or latch the collect button, start the track run by moving the instrument, continue to end point and stop. Press the collect button to unlatch, and you will see the track data appear on the screen. If you are satisfied with the results, proceed to the next track run by clicking accept. If not happy with the results move instrument back to start point and repeat.

Step 6: View the Results

You will now see a scanned plate image. To view in greater detail; right click on image and select full screen.

Step 7: Create a Report

The create report button, will be used at the end of an inspection to produce a full printable PDF file output, of all plate images within the project selected.

image54

Example of Defect Data & Locations

Rasterscan

Software

Auto-Drawing, Scaling, & File Handling

The software produces a full-scale drawing of the tank floor, with auto numbering of plates and tracks including annular rings. Scanned plots of tracks are auto-positioned onto plates; as are the plates into the tank image. All file and directory handling is produced automatically, resulting in significantly faster track-to-track scanning speed. Unrivalled data image display reveals any material loss as a high-resolution corrosion map with additional controls or zooming, panning and saving images. Threshold sensitivity can be adjusted to client requirements along with color choice, so if required, any indication over a set percentage loss can be set to a single indicative color.

Once operator inputs have been selected an automatic plate scan strategy is generated. The operator has then only to follow the on-screen guidance, whilst also being able to choose and select end zone scanning. The DAQ software has a Preliminary PDF report output function, enabling the on-site operator to leave a first draft report upon inspection completion. This enables the client to be immediately reactive to possible issues.

Technical Specifications

TruFlux Specifications

Principle of Operation Magnetic Flux Leakage
Detection 48 Hall Effect Sensor
Scan Width 11.8" (300mm)
Method of Propulsion DC motor
Speed 20in./s (500mm/s)
Thickness Range 0.24" -0.79" (6 - 20mm)
Test Through Coatings Yes
Maximum Coating Thickness 0.24" (6mm)
Maximum Sensitivity 20%
Auto-Stop No
Power Requirements: 24V
Transit Case: Meets IATA requirements for transporting magnetizable material
Operating Weight: 71 lbs. (32kg)
Stop on Defect: No
Real Time Analysis: Yes
Real Time Averaging: Yes
Real Time Digital Signal Processing: Yes
Freeze Screen Alarm: No
Linear Resolution: 0.02" (0.5mm)
Speed Compensation Algorithm: Yes
Digital Data Storage: 48 channels x 0.02" (0.5mm)
Scan Length: Unlimited
Scan Plate End Zones: Yes
Adjustable Sensitivity Range: Yes
Laser Guide: Yes - Optional
Fully Dampened Magnetic Contact: Yes
Assisted Magnetic Lift-Off: Yes. Minimal effort required to break magnet contact resulting in considerably less operator fatigue.
Scan Length Alignment (whilst in magnetic contact): Yes. The scan track can be fully aligned when the magnet is in contact with the plate, alleviating the need to break contact if track alignment was not achieved.

TruFlux Kit Includes:

  • TruFlux MFL Tank Floor Scanner System - 1 Head Unit and 1 Handle & Laptop Platform Assembly
  • Laptop for operation of software with additional external battery
  • TruFlux Software fully loaded onto the laptop
  • 2 Batteries
  • Cable for attaching battery to unit
  • Hard Transport Case for TruFlux and laptop
  • Hard Transport Case for batteries
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