AcousticEye G3 - User Manual - V6 PDF

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AcousticEye G3 Tube Inspection System User Manual Doc#: UTM00006 Rev: 6 Date: 6 June 2012
AcousticEye Dolphin G3 Tube Inspection System USER MANUAL
This manual applies to a complete testing system comprised of a Main Control and Analysis unit (AEMUN-30000) and an Acoustic Probe (AEPRB-30000)
CE Authorised Representative: Acoustic Eye International Attn: Gijs Cremer Eindhoven Mail address: PO Box 205 3830 AE Leusden, The Netherlands Visit address: Arnhemseweg 87 Leusden, The Netherlands Telephone: +31 33 4453114
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Revisions Record Rev. 1 2 3 4 5 6 Description of Change Initial release Add calibration tube Change CE authorized rep. Version 3.3 Release Minor changes Version 3.4 Release Revision Date 24-03-11 12-05-11 10-08-11 05-12-11 21-02-12 6-06-12 Revised By Roy Shtainman Roy Shtainman Roy Shtainman Roy Shtainman Roy Shtainman Roy Shtainman
Created By:
Roy Shtainman Willy Grunfeld
Tech Support Manager Quality Manager
15-Mar-11
Reviewed By:
24-March-11
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Table of Contents 1
1.1 1.2 1.3
INTRODUCTION .................................................................................................................... - 4 SCOPE ....................................................................................................................................... - 4 INTENDED USE ........................................................................................................................... - 4 ENCLOSURE ................................................................................................................................ - 4 -
2
2.1 2.2
TEST SYSTEM COMPONENTS. ........................................................................................... - 5 MAIN MEASUREMENT AND TEST UNIT .......................................................................................... - 5 OPERATOR INTERFACE ................................................................................................................ - 5 -
3
1.3
POWER CONSUMPTION ....................................................................................................... - 6 OVERVOLTAGE CONDITIONS ........................................................................................................ - 6 -
4
4.1 4.2
PHYSICAL AND ENVIRONMENTAL CHARACTERISTICS ............................................ - 6 DIMENSIONS AND WEIGHT ........................................................................................................... - 6 EQUIPMENT SPECIFICATIONS ...................................................................................................... - 7 -
5
5.1 5.2 5.3 5.4
QUICK START GUIDE ........................................................................................................... - 9 REMOVING EQUIPMENT FROM THE CARRYING CASE, SET-UP ......................................................... - 9 ATTACHING A TUBE ADAPTER TIP TO THE PROBE......................................................................... - 11 CONNECTING TO A POWER OUTLET ............................................................................................ - 17 TURNING THE SYSTEM ON .......................................................................................................... - 18 -
6
6.1 6.2 6.3 6.4 6.5
OPERATION INSTRUCTIONS ............................................................................................ - 20 PROBE LEDS ............................................................................................................................ - 20 PRELIMINARY TESTS .................................................................................................................. - 22 SETUP PRE MEASUREMENT ..................................................................................................... - 32 MEASUREMENT ......................................................................................................................... - 60 REPORT POST MEASUREMENT ................................................................................................. - 64 -
APPENDIX I PACKAGING INSTRUCTIONS, CABLE ARRANGEMENT ........................ - 77 APPENDIX II INSTRUCTIONS FOR ASSEMBLING EXTERNAL SEALING SPONGE ON ADAPTORS. ............................................................................................................. - 81 APPENDIX III MISCELLANEUOS ........................................................................................... - 87 APPENDIX IV PC HW BUTTONS ............................................................................................. - 87 APPENDIX V PROBE SCREEN NOTOFICATIONS .............................................................. - 87 APPENDIX VI SPECIFICATIONS AND STANDARDS ......................................................... - 87 -3-
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Introduction
1.1 Scope
This manual provides the specifications and instructions for the safe and effective operation of Acousticeyes Dolphin G3 Tube Inspection System, a NDT testing and evaluation solution for tubular systems using Acousticeyes proprietary Acoustic Pulse Reflectometry (APR) technology . The system consists of a main measurement and control unit referred to as the MCU, a hand-held measurement probe referred to as Dolphin Probe and a calibration tube. While it covers basic instructions for performing tests and generating a basic test report, it is intended to be used primarily as an installation and operation instructions manual, not a substitute for the operators training course offered by Acousticeye. This training offered by Acousticeye provides the skill and know-how necessary for analyzing and interpreting the data obtained from measurements and for obtaining the best possible assessment of the condition of the target tubing system. Note: Screen shots provided in this manual are based on version 3.0 of the application software (PTS) and may differ slightly from the actual screen shots in your particular version.
1.2
Intended Use
The system is designed for on-site inspection and evaluation of faults such as holes, pits, erosion, partial blockages etc. in tubular systems (material independent), in process industries such as power plants, refineries and the like, by means of the injection of acoustic pulses through one open end of the tube under test, and analysis of the reflected waves.
1.3 Enclosure
The test set is enclosed in one carrying case which provides protection for the contained system components during air and ground transportation, storage and handling. For operation the system components are removed from their carrying case (Refer to section 5) -4-
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Test System components.
2.1 Main Measurement , Test Unit and Calibration Tube

The main unit is contained within a metal enclosure with a removable top panel and contains the following main components: iEi Panel PC industrial computer iEi Lithium Battery Pack (BAT-LI-4S2P3800A) Rating: 14,8V DC, 3800 mAh, Maximum Charging Voltage/Current 16.8Vdc/2000mA
Amplifier Maya sound card
Dolphin Probe A formed plastic housing containing: Microphone Speaker LCD screen
Calibration tube: A 1.5 meter in length, faultless and plugged aluminum tube.
2.2 Operator interface

The operator interfaces with the tester primarily through the computer and specifically its GUI (Graphic User Interface), an integral part of the operation software. Hardware interfaces consist of a push button switch and 4 indicator LEDs located on the probe handle. The push button switch initiates the test by generating the acoustic wave and capturing of the reflected signals. The LED functions are as follows: -5-
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Blue: Ready for taking a measurement (or step to the next measurement) Yellow: Measurement in process Red: Last measurement was not taken properly probably due to a sealing problem. If applicable please repeat the measurement. There is also an indication on the SW interface. Green: Last measurement was taken properly.
Power consumption
Installation category II, IEC 60364-4-443 Power Input: Dual voltage system (110V/220V).
3.1 Overvoltage conditions

Overvoltage Category II type of supply for connection of equipment
4
4.1
Physical and Environmental characteristics Dimensions and weight Weight: Gross (In carrying case/trolley) MCU Probe: 18 kg (39.7 lbs) Net (Removed from carrying case) 8kg 1kg
4.1.1
4.1.2
Dimensions
Trolley: 56 x 45.5 x 26.5 cm The trolley incorporates built in wheels and 2 handles, one for lifting and another for pulling, to enhance portability and handling. 4.1.3 Accessory stowage The carrying case (trolley) has provisions for the stowage of all the accessories. -6-
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These are designed to prevent damage to the accessories and probe during transit. 4.2 Equipment Specifications
# 1.
Specification Overall size (L x W x H)
Spec Limits 33 x 28 x 14 cm (MCU) 25 x 14 x 12 cm (probe)
Tested to
Comments
Size of carrying case
56 x 45.5 x 26.5 cm
Weight :
8kg (MCU) 1 kg (probe) 18 kg (Inside carrying case) MIL-PRF-28822, Procedure: 4.5.5.1.1 for Class 2
2.
Temperature, Operating Temperature, Storage
-100C to +500 -200C to +700 RH: up to 95%
3.
Humidity
MIL-PRF-28822, Procedure 4.5.5.1.1.2 MIL-PRF-28822, Procedure 4.5.5.2
4.
Altitude Operating: Altitude nonoperating:
0 to 4000m (03123feet) 0 to 10000m (0-32800 feet) IPX0
5.
Ingress
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Specification Protection Enclosed in carrying case
Spec Limits IP67 (1 meter) submersion for 30 minutes) Class 2 :15-55 Hz. 15 min./axis cycling+10 min. dwell@ resonance frequency (or 33 Hz if no resonance found) for each of the 3 axis Drop height of 30 cms on each of the 6 faces and 4 corners for a total of 10 drops. N/A
Tested to
Comments
6.
Sinusoidal Vibration/ Transportability
MIL-PRF-28822 , 4.5.5.3.2 for Class 2
In carrying case
7.
Transit drop test
MIL-PRF-28822, 4.5.5.4.2 for Class 2, MIL-PRF-28822, Procedure 4.5.6.3 CISPR 11, CLASS 1 IEC 6100-3-2 , 3-3,4-2 , -4-3,-4-4, -4-5, -4-6 & -4-11 FCC Part 15, Subpart B, CLASS A
In carrying case
8. 9.
Explosive Atmosphere EMC
Detailed in Test Report EN 61326-1
10.
SAFETY
Detailed in Test Report EN 61010-1:01 IEC 61010 UL 61010-1 CSA C22.2 610101-04+GI1
Safety evaluated to +40 0 C max. ambient
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5 5.1
Quick Start Guide Removing equipment from the carrying case, set-up
Open the carrying case and remove the main unit.
Fig. 1
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Fig. 2
Fig. 3
Place the main unit on a suitable workbench or table top. In case no suitable table is available, place the main unit on the carrying case. - 12 -
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5.2
Attaching a tube adapter tip to the probe
The probe mechanically interfaces with the inspected tube by means of an adapter and a rubber sponge seal. According to the tubes to be inspected, select an adapter that matches the tubes diameter. Please use the get recommended adaptor wizard on the SW after inserting the inspected tube OD and wall thickness the application recommends the most fitted adaptor to be used can be identified by code: -RDP (Regular Diameter Probe): - Type AXX - cylindrical adaptors. - Type BXX - conical adaptors with perforated tips. -LDP (Large Diameter Probe): Type LDP_XXX Note: It is important to use only adapters and seals supplied by AcousticEye. See instructions for attaching the rubber sponge to the adapter in Appendix II. In order to choose the right adapter make sure that the adapters OD is a bit smaller then the measured tube ID.
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Attaching an adaptor to a RDP Probe:
Fig. 4
Fig. 5
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Fig. 6
Fig. 7
Fig. 8
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Attaching an adaptor to a LDP Probe:
Fig. 7a
Fig. 8a
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Fig. 9a
Fig. 7a
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Connect the probe to the main unit panel. Connect the probe cable to the probe. Pay attention to the connector orientation.
Fig. 9
Connect the other end of the cable to the main unit.
Fig. 10
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5.3
Connecting to a power outlet
Connect the power cord to the top panel of the main unit (next to the ON/OFF switch) See Fig. 11.
Fig. 11
Connect the power cord to the mains (Its important to ensure proper grounding!)
Fig. 12
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5.4
Turning the system on
Switch on the main unit power switch located on the upper panel
Fig. 13
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Launching the software Double click on the PTS icon located on the desktop using the supplied stylus.
Fig. 14
Make sure that the status line indicates that the software is ready (Fig 12A)
Fig 14A
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Operation Instructions
6.1.1 Probe LEDs

During system initialization, all the 4 LEDs at the back of the probe are turned on. A blue LED light on the gauge indicates that the initialization is over and the system is ready to take measurements.
Fig. 15
Notes about functions of the probe controls and indicators: The lower button initiates a measurement The upper button skips a tube (can be used in case of a plugged tube for example) and it increases the measurement counter by 1, all 4 LEDs flicker once when applied. - 22 -
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LED colors and their meaning: o BLUE: software is ready, press button at will o YELLOW: measurement in course, dont move o RED: Last measurement was not taken properly probably due to a sealing problem. If applicable please repeat the measurement (after deleting last measurement and reducing the counter). There is also an indication on the SW interface. o GREEN: Last measurement was taken properly.
6.1.2 Initial Templates

Upon initialization or when a new session is created, the user is prompted to choose a session template. The available templates are: Regular Diameter Probe - Standard Measurement Tube dimensions: 5/16 to 1.5 Tube length: Over 6 meters. Regular Diameter Probe - Short Measurement Tube dimensions: 5/16 to 1.5 Tube length: Up to 6 meters. Large Diameter Probe - Standard Measurement Tube dimensions: 1.5 to 4 Tube length: No limitation
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6.2 Preliminary Tests 6.2.1 Perform Hardware Test

In order to verify the system functionality, perform one test measurement in the air by clicking in the upper menu: Advanced -> Perform Hardware test.
Verify that you can hear the sound wave and that the test result was positive. In case the HW test failed
Try restarting the system. If the problem persists Dont use the system and contact AcousticEye Support promptly.
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6.2.2 Perform Calibration Verification

The second part of the inspection preliminary tests is verifying the probe calibration. This test should be performed following a successful Hardware test. The test is performed using the supplied calibration tube a 1.5 meter in length, Faultless and plugged from one side, aluminum tube. The non-plugged side has an interface to the system probe. This test verifies the probe calibration and if needed recalibrates it. This procedure must be performed on site before conducting any inspection session. Its recommended to climate the probe to the site environmental conditions 1 hour before performing the calibration (due to temperature changes between storing to operating locations). Connecting the calibration tube RDP: Open the probe bolt.
Fig. 16
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Fig. 17
Take off the probe membrane
Fig. 18
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Fig. 19
Attach the calibration tube to the probe (note the tube end orientation).
Fig. 20
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Connecting the calibration tube LDP: Take off the probe membrane
Fig. 16a
Fig. 17a
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Attach the calibration tube to the probe (note the tube end orientation).
Fig. 18a
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Back on the PTS application; go to Advanced->Probe->Probe Calibration
A note will be displayed
The procedure status is displayed at the bottom left status bar
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When done a completion note will be displayed
In case the probe calibration fails: a. Verify that the calibration tube is attached properly to the probe. b. Quiet any external noise or vibration sources. c. Repeat the calibration process. d. If fails again, Restart the main unit. e. Place the probe and the calibration tube tip on a soft (shock observing) ground f. Repeat the calibration process.
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Disconnect the calibration tube from the probe.
Dont forget to reinstall the probe membrane.
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The Set-up, Measuring and Report Workflow The PTS application is operated by means of the three main tabs and applicable sub-tabs described below. Main Tabs a) Setup for the pre-measurement steps. b) Measurement for taking measurements. c) Report for the post measurement analysis and report generation The basic workflow is to go through the tabs from left to right start with the main tab on the left (setup), go over all its sub tabs from left to right. When finished, move to the next main tab Measurement.
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6.3 Setup Pre measurement

6.3.1 Tube sheet map creation In the PTS application there are several methods of creating a tube sheet map and choosing the tube ordering. Here is a description of the most common method using a digital photo: Take a digital photo of the measured equipment and place it on the systems computer. TIPS FOR TAKING PICTURES OF TUBE SHEETS Use a good quality camera, having at least 5 mega pixels resolution with optical zoom capabilities Use flash photography under all circumstances, even at full sunlight, unless there are safety limitations. Position the camera in front of the tube sheet, holding the camera centered (in line with the tube sheet center) The distance between the camera and the tube sheet should be at least 45 times the diameter of the tube sheet. Make sure that most of the picture frame is occupied by the tube sheet. Come closer to the tube sheet or use optical zoom if necessary to achieve that goal.
Open the Map builder sub application
Go to file->New
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Double click on the path at the Picture File Name field to open a browse window. Navigate to the image taken, open it, and then double click on the Create Map button. The equipments photos will be shown on screen.
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There are 2 ways of performing the tubes detection on the digital image manually or automatically. 6.3.1.1 Manual tube detection on the MapBuilder Check the add button at the bottom left corner. Then start clicking on the tubes, according to the tube ordering you want to use. Note: The circle size can be adjusted by changing the value of the Radius field, right to the Mode field. To delete or select a certain tube use the Delete/Add/Select menu at the Mode field. To zoom in or out, use the keyboard +/- keys or the mouse scroll wheel. To move the picture, use the arrow keys.
After the tube map is ready, choose file->save to custom, then choose a map name.
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Close the Map builder application. The tube map is set.
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6.3.1.2 Automatic tube detection on the MapBuilder While preparing a map in Map Builder, it is possible to automatically detect the tubes holes in the map, without clicking on them one by one: Load the equipment map Choose the Path selection mode:
On the top menu, click Tube detection -> Custom
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Click on the map to create a region of interest for the searching process.
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Click on the Set button in Region of interest Zoom in onto the map, and select 2 points on the diameter of some tube.
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Click on the Set button in Diameter Click Search
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Note: if a message that there is not enough memory for the operation is displayed, try selecting smaller portions of the map at a time, until the map is completed The Search further button can be clicked to perform a deeper search. Remaining tubes may be filled in manually by changing the Mode at the lef tbottom part of the screen to Add, and changing the selection mode to Rectangle by right clicking on the map, and choosing Selection type - > Rectangle Note: The tube radius may be changed to see if the tubes are obscuring some suspicious area. Note: Using the Tube detection mechanism obliges the use of Tube Ordering (Row-Column-Zone ordering) before saving the map.
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6.3.2 Row Column Zone Annotation 6.3.2.1 Row Column Zone Support - Map Builder After building the tubes map, the tubes can be ordered by rows, columns and zones. There are 2 methods to set Row Column Zone info for a given picture: A) Automatic B) Manual 6.3.2.1.1 Automatic In the top menu, click Tube ordering -> Custom
For regular maps as the above one, using the Automatic tube ordering should be enough. By looking at the above map, the user can see that it is best to divide it by Columns (vertical), so the Advance at angle by parameter should be set to columns as well as the colorized by parameter.
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Mark the first tube (the tube you want to define as (0,0)) and press set. The first tube ID box should be filled in with a number.
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Select two adjacent tubes (select the second one by pressing and holding the ctrl button). Then press the set button. A number representing an angle should appear in the angle box.
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Press the apply button. The presented coloring help verify that the ordering was done properly. Zoom in the better verify it. Once done, go to file->save to custom, and specify a name for the map.
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Note: If the tube set in First tube ID is not located in one of the maps corners, the program will display a message and select on the map the tubes that can be set as the first tube.
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6.3.2.1.2 Manual If the Automatic method didnt provide the desired results, the Row Column Zone properties can be set using the Manual method.
For example, in the following map, select the first column, then in the bottom Orientation panel set the C field to 1, select the desired starting point (Top at the above example) and click Apply. To determine the coloring orientation, on the top menu, click Tube ordering -> Custom and set the Colorize by parameter. By leaving the R field empty, the user indicates to the software to automatically fill in the R values into the selected tubes. After setting the first column, select the second column, set the C field to 2 and click Apply. - 46 -
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Repeat the procedure for the entire map. If the map is at a certain angle, the tubes for each row or column can be chosen by the Path selection mode.
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Then click several times to bound the desired Row or column:
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Then right click again and choose Select from path
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Once the user has selected the desired column, he can click Apply and repeat the action for the remaining columns. Note: To set different zones to the map, select the tubes at the needed zone, clear the R, C fields, set the Z value, and click Apply
Once done, go to file->save to custom, and specify a name for the map.
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6.3.2.2 Row Column Zone Support PTS
PTS supports Row Column Zone tube identifiers. If a user wishes to work without Row-Col-Zone, he can only use the R ( row ) values, by right clicking on the ,measurements list and choosing Measurement name format
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The N value at the 2D map tube drawings represents the order by which the tubes need to be measured. This order will change if the user changes the Advance by field at Measurements name control panel. The Advance by field at Measurements name control panel will also determine the way that the defect tables and measurement list are sorted. As always, there is a backward compatibility which means PTS can load older sessions. The user can also use the D field (Description) to type free text at certain measurements. By selecting tubes in the 2D map, the corresponding tubes in the measurement list will be selected. If tubes selected in the 2D map dont exist in the measurement list, they will be immediately unselected. By clicking on a single tube in the 2D map, the tube Zone-Row-Column information will be set at the Measurement name control panel. An existing measurement can be renamed by right clicking on it and selecting Rename. The Zone-Row-Column-Description info in the Measurement name control will be set in the measurements name. After the map is finalized, use file->save to custom in order to save the map to the main application. Close the map builder.
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Back on the main application, the first step is to open a new session and to name it. Go to file->new and then file->save as; choose a unique name and location for this session. Note: The measurements are saved automatically to the hard-drive as they are taken (no data is lost due to a crash/outage problem). By default all measurements are saved to a temporary directory on disk as they are made Path\TempDir_XX In order to avoid overwriting this temporary directory use the Rename or the Save As options. The Save As button can be used to make a copy of the measurements, but will entail copying large amounts of data to the new directory, cluttering the disk and taking some time to execute.
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6.3.3 Setting the tube map Go to Setup tab, then Map sub tab. Under Facilities drop down menu, choose custom. Then at the System Type drop down menu, choose the map you have created. Click the Apply bottom. Note: To Zoom in/out or move the map use the relevant keyboard keys.
Other mapping options will be introduced in the hands-on training part of the course.
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6.3.4 Setting up tube parameters Go to the Parameters sub tab. Insert the temperature, tube length, outer diameter, wall thickness and probe adaptor code in the corresponding fields. Note: - Pay close attention to the units in each parameter. - The unit type (metric/US) can be changed using the preferences->units in the menu bar. - When moving to the measurement tab for the first time, the system will ask you to fill in the 5 parameters mentioned above. Filling in these parameters correctly is crucial for proper system performance. These parameters affect the final analysis (report generation). However, they dont affect the raw data acquisition meaning that in order to perform a measurement you can insert dummy values, but before generating a report you must insert the parameters accurately. The tube length should be taken from the measurements signals after finishing the job, go to report->signals, right click ->select all measurements. The average tube length is the one you should use. When inspecting U-Tubes set the U-Tubes parameter to yes.
- Checking the show advanced box, opens a list of all the advanced parameters. Dont change those values without consulting with AcousticEye support first! - Restoring the parameters list (both basic and advanced) to its default values, can be done by choosing Advanced-> Database -> Restore default values, in the upper menu.
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6.3.4.1 Choosing the proper adaptor The application has a wizard that assist the user in choosing the proper adaptor. After inserting the tube OD and Wall Thickness, choose the Get recommended adaptor button. The system will suggest the proper adaptor code to be picked from the system set.
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6.3.4.2 Measuring the inspection temperature Since the speed of sound is affected by the air temperature inside the tube, it is important to measure and update it on the software. Measuring the temperature inside the tube can be performed simply by measuring the temperature of the tube wall with a surface thermometer (under the assumption that on steady state conditions both should be equal).
The requirements from the thermometer are: Note: The temperature update affects only the location reporting accuracy and not the system sensitivity. The thermometer is not supplied with the system. Accuracy: Up to 5 degrees Celsius variation (2.5 Celsius). Surface thermometer: the measurement is done on the tube wall. Time to a steady reading: 1 minute.
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After taking the trouble to enter all setup parameters, you might like to export them to a file of their own Next time you start a session you can save time by importing previous settings Heres how to do it:
o Export:
Import:
Note: these parameters are saved with all the measurements of a particular session
6.3.5 Inspection details Fill in the relevant fields to appear in the final report. Free text summary can also be edited. The name of the company performing the inspection and its logo can be applied both will appear in the header on top of each report page.
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6.3.6 License update
In order to operate, the program requires a valid license that needs to be updated every 90 days. There are two ways to update the license: When internet connection is available, clicking the Update button will cause the program to connect to the AcousticEye server and retrieve a 90 days license and a software update if available. 21 days before the license expiration date a proper message will be displayed to the user. If the license expires, the program will cease to work until the license is updated. When internet connection is not available, clicking the Import license button will prompt the user for a license file. Such .lic file can be sent to the user by email.
6.3.7 Export Click DB When Internet connection is not available, and the user wants to send an activity report to AcousticEye, an activity file can be exported to be later sent by mail.
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6.4
Measurement You should keep 3 goals in mind as you make measurements: You probably want to go through measurements of as many tubes as possible in a given time You definitely want to synchronize the measurement label in the software with the actual tube that has been measured Finally you should use the built in safeguards to make sure that the measurements are good (this will be explained below in detail)
6.4.1 Conducting a reference measurement Move to the Measurement tab. Insert the probe tube adaptor into the tube marked as 1 in the tube map, verifying a good seal. When ready press the lower button on the probe or use the software button. The reference measurement is much longer then all the others (about 45 seconds), and during it the system performs a volume optimization to the excitation signal. Once done the volume parameter will be updated by the chosen value. After getting the blue LED indication (meaning that the reference is done), press the push button again or use the software Measure button to take another measurement of the first tube (marked with red circle).
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6.4.2 Taking the tubes measurements Go over all the tubes you wish to measure using the probe push button or the software Measure button. Wait for the blue LED indication before moving on to the next tube. The system gives an indication whether the measurement was taken properly (sealing considerations). 2 indications are given in parallel: 1. Probe indication Green indication stands for a good measurement; red indication together with a "bad sealing" error message stands for a bad measurement. 2. GUI indication at the measurements window on the right, under the QC column. Stands for a measurement taken properly. measurement. Stands for a bad
In case of a bad measurement a warning message appears:
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In case of a bad measurement indication, if applicable improve the sealing and repeat the measurement.
Example (Bad Sealing):
During work it is recommended to use the 2D sub-tab in order to validate your position on the tube map. To view the acoustic signal, just switch to the Signals sub-tab.
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6.4.2.1 Deleting a measurement To delete a measurement, mark it with the cursor then right click->delete selected. The counter value will be decreased automatically.
Note on labeling: Measurements can be are labeled as follows: [R] = Row [C] = Column [Z] = Zone [N] = Tube number (a continuous counter following the measuring sequence) If a user wishes to work without Row-Col-Zone, he can only use the R ( row ) values, by right clicking on the ,measurements list and choosing Measurement name format
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6.5
Report post measurement
In the report main tab you will see the following sub-tabs:
Options: Analyzing all the measurements or only selected tubes Signals: On this screen signals can be Displayed and analyzed using several important features Noise margins, Thresholds (per defect type), Subtract of calibration. Defects table: All detected defects are listed in separated tabs based on their type. Filtering can be done as well. Final report: Printing a report and 3 dimensional representations. 6.5.1 Before report generation Before generating an inspection report, you need to verify that the following steps were completed: 1. Parameters All the tube and adaptor parameters were inserted correctly. If needed, the relevant advanced parameters (primarily detection thresholds), were adjusted.
2. Optimal visual reference was selected Before running a final analysis we need to choose an optimal visual reference. If a good reference tube is available we can just use it as a reference. In order to do so just measure it as was explained in section 6.4.1. Or just click on the tube measurement, then right click ->change reference to>the selected measurement.
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Since in most cases a reference tube will not be available, we need to choose a different reference method averaging. To do so, in the measurement tab, click on one of the tubes ->right click->select all measurements, then clear off the bad measurements from the group (bad sealing, plugged tubes). Once done: right click->change reference to->the average of selected measurements. Since the measurement quality status depends on the reference tube, the system will ask whether to recalculate the tubes QC status.
Note: Indications of the measurements that participated in the creation of the Reference and Noise can be seen in the R N columns.
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6.5.2 Generating a report

6.5.2.1 System interpretation Go to Report -> options Choose the measurements that you want to analyze (All/selected only). Choose whether the inspected tubes are U-Tubes When the U-Tubes analysis mode is selected, the automatic analysis splits the tubes into length based groups (marked "GXX"):
Choose whether to impose reference tubes on small statistics sessions, creating a reference tube by averaging is meaningless. The visual reference is imposed to be used in the automatic analysis as well.
Press the
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In the defects table tab you can see all the detected defects, separated into tabs based on their type. Filtering based on the column attribute can be done as well.
In the Signals tab, measurements can be displayed and analyzed manually using several features Thresholds, noise, subtract calibration, Filter view.
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6.5.2.2 User interpretation

Now comes the final part of the analysis the user reviews the system report and verifies the findings. Go to the signals tab, choose the measurement you want to analyze, its signal will appear on the screen. All the defects that were detected in this tube will be listed below the signal on separated tabs, based on their type.
Clicking on an indication will zoom in on its location on the signal.
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Now, the user can decide whether to approve or decline the system classification and add its graph to the final report
And simply continue to the next indication by using the dedicated arrow key
The tube condition can be classified as well if needed.
Free text can be inserted in the comments column. Notes: Assigned keyboard buttons to improve usability during the analysis. The list is shown when clicking on the button.
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Load last saved in Defects Table screen: o Clicking this button will load the last saved defect table. o The defect table is saved automatically every few minutes or when the Apply button is clicked, or when the session is closed.
At any defects table scheme, right clicking on an indication will enable the following options: o Approve/Decline Selected indications can be applied simultaneity using the Ctrl key. o Delete to delete the indications o Add new insert a new defect to the marked tube, based on the user manual analysis. o Move to Move the current classification to any of the other options. o Approve/Decline all All the indications in the same tube/class (depends on your viewing scheme) will be approved/declined. o Add/Remove graph from all o Approve without adjacent fault filtering - approve very close faults. o Properties Defect ID, tube ID and the defect location and amplitude attributes are displayed
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Filters views: In order to increase defect delectability while using the automatic analysis, the system applies 5 types of filters Low/Low_BP/High/High_BP/None. In order to let the user verify the defect using the same filter that was used by the system the filter at which this defect was detected is listed at the detection filter column and the user can toggle between the filters to optimize the defect verification.
The same defect will look totally different under different filters: A hole:
LPF:
HPF:
BPF: - 71 -
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In order to know how a certain defect type looks under a certain view filter, the user can apply the theoretical defect signatures at the right click options menu:
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Signals screen options: o Displaying multiple signals can be done using the Ctrl key (one by one), or the shift key (selecting a group of signals). o Zooming can be done using the + - keys; panning can be done using the arrow keys. o Right click on a line (signal or a threshold) will color it orange momentarily and display its text o Other right click options: View all will zoom out to the entire signal length Undo zoom will return to the last zoom step Save as image save the current screen capture
Show holes/Pitting/Erosions/Blockages signatures Shows the theoretical defect type signatures under the selected view filter with various sizes. Hide defect signatures Hides the selected signatures. Deselect from measurement list unselect the tube from the highlighted measurements list.
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6.5.2.3 Printing the report

After the user has finished going over all the reports and verifying the system classification, its time to print the report. Under report->Final report->Issue report, the user can: Choose some report printing options Add pictures to the report to appear after the 2D colored map (Usually this option is useful for displaying some zoomed in zones of a big heat exchanger.
In order to print the report, all you need to do is press the Issue report button.
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A report (at the chosen format) will be displayed; the chosen signal graphs will appear in the report as well.
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Pie charts summarizing the malfunctions can be viewed at the final report tab.
The pie chart is also added to the HTML/PDF report.
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APPENDIX I PACKAGING INSTRUCTIONS, CABLE ARRANGEMENT

There are two cables: the external power cord and a second cable for the connection of the main control unit (computer) to the probe. The cables are packaged in the carrying case, inside a cell located under the main control unit. In order to re-pack the cables follow the instructions below. STEP 1: open (lift) the cell plastic cover. STEP 2: probe-main unit arrangement. components: cable, plastic cable drum (Fig. 2.1).
Fig. 2.1 A. Place the connector in its place using the cable locator bracket (Fig.2.2)
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Fig. 2.2 B. Start rolling tightly the cable on the internal drum tube (Fig. 2.3)
Fig. 2.3 C. Final configuration of the rolling cable should be as shown (Fig.2.4)
Fig. 2.4
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STEP 3: place the cable in its place as shown (Fig. 3)
Fig. 3
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STEP 4: Internal Suitcase arrangement Is displayed at the image below (Fig. 4.1)
Fig. 4.1
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APPENDIX II INSTRUCTIONS FOR ASSEMBLING EXTERNAL SEALING SPONGE ON ADAPTORS.

STEP 1: clean the adaptor tip & tip base (sealing sponge bonding surface) with ethanol as shown in Fig. 1.
Fig. 1
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STEP 2: find the right sealing sponge on the sealing sponge plate and remove it from the plate. As shown in Fig. 2.1 & 2.2
Fig. 2.1
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Fig. 2.2 STEP 3: remove the internal part of the sealing sponge ring. As shown in Fig. 3
Fig. 3 STEP 4: remove the adhesive protective wrapping. As shown in Fig. 4
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Fig. 4
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STEP 5: place the sponge ring on the adaptor tip. As shown in Fig. 5
Fig. 5
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STEP 6: turn the ring clockwise till the bonding surface touches the tip base. As shown in Fig. 6 Notice: You must turn the sponge ring on the adaptor tip in order to make the sponge come closer to the adaptor bonding surface.
Fig. 6
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APPENDIX III MISCELLANEUOS

1. Report -> Signals screen
Check here to see a graphical representation of the noise margin Check here to order to get the exact estimation for a specific fault
Check here to see a subtraction of the calibration from the measured signal
Check here to see a graphical representation of the various defect types thresholds
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2. File menu
New Open a new session file (under Path\TempDir_0), need to be renamed in order not to be over written by a later session. Load Load an existing session file Save As File is copied and saved to a chosen name. Compress to zip is used for reducing raw data size before sending on the net. Use default setting (without checking any box) unless asked otherwise. Rename renaming current session name.
Import/Export setup parameters Is used to import/Export an existing parameter file from/to an external folder for future use. Note that the parameters file must be named ArgumentsDB.xml
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APPENDIX IV PC HW Buttons
From right to left: Screen on/off Increase brightness Decrease brightness Increase volume (not in use) Decrease volume (not in use) Auto screen brightness Mute power alert buzzer
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APPENDIX V Probe screen notifications

In order improve the system usability by decreasing the use of the main unit during the measurement acquisition phase Most of the measurement control process was mirrored to the probe screen. Almost all the user notifications appear on the probe screen and the user can operate the system using the probe only. Here are the complete scenarios and the handling from the probe: Legend: Low = lower probe button Up = Upper probe button -> = Pressing a probe button
HW TEST During hardware test - on the probe: performing hardware test. At the end: Hardware test succeeded / hardware test failed. CALIBRATION During calibration: calibrating probe. At the end: Ready. REFERENCE During Reference: measuring If a Reference exists: Ref exists. Low=OK -> Perform new Ref? Low=OK UP=NO Regular measurement Measuring: R[ ]C[ ] At the end: SNR:___. Next: R[ ]C[ ]. Repeating an existing Measurement - meas exists. Low = OK-> Remeasure ? Low=yes UP=NO Problematic measurement - problematic meas. Low=OK -> UP=Continue. Low=Repeat
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Bad sealing - Bad sealing. Low=OK - > UP=Continue. Low=Repeat
Bad measurement - After 3 attempts: Meas failed. Low=Ok -> Next: R[ ]C[ ] -> Measuring
Example (Bad Sealing):
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APPENDIX VI - REFERENCED EC DIRECTIVES, SPECIFICATIONS AND STANDARDS

The following documents referenced in this manual are pertinent only in the quoted context and to the extent specified. UNIVERSAL SERIAL BUS REVISION 2.0 SPECIFICATION IEC 61010-1EDITION 2.0 200102 SAFETY REQUIREMENTS FOR ELECTRICAL EQUIPMENT FOR MEASUREMENT, CONTROL AND LABORATORY USE PART 1: GENERAL REQUIREMENTS ELECTRICAL EQUIPMENT FOR MEASUREMENT, CONTROL AND LABORATORY USE EMC REQUIREMENTS PART 1: GENERAL REQUIREMENTS SAFETY INFORMATION TECHNOLOGY EQUIPMENT, INCLUDING ELECTRICAL BUSINESS EQUIPMENT GENERAL SPECIFICATION FOR TEST EQUIPMENT FOR USE WITH ELECTRICAL AND ELECTRONIC EQUIPMENT Department of Defense Test Method Standard for Environmental Engineering Considerations and Laboratory Tests
IEC 61326-1EDITION 1.0 200512
UL 1950
MIL-PRF-28800F
MIL-STD-810F
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EU DIRECTIVE 2006/95/EC EU DIRECTIVE 2004/108/EC EU DIRECTIVE 2002/95/EC
Low Voltage Directive EMC RESTRICTION ON HAZARDUOUS SUBSTANCES - ROHS
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Product Management

AcousticEye Dolphin G3 Tube Inspection System USER MANUAL

Roy Shtainman Willy Grunfeld

Tech Support Manager Quality Manager

POWER CONSUMPTION ....................................................................................................... - 6 OVERVOLTAGE CONDITIONS ........................................................................................................ - 6 -

Test System components.

2.1 Main Measurement , Test Unit and Calibration Tube

Amplifier Maya sound card

2.2 Operator interface

3.1 Overvoltage conditions

Specification Overall size (L x W x H)

Spec Limits 33 x 28 x 14 cm (MCU) 25 x 14 x 12 cm (probe)

Size of carrying case

Temperature, Operating Temperature, Storage

-100C to +500 -200C to +700 RH: up to 95%

MIL-PRF-28822, Procedure 4.5.5.1.1.2 MIL-PRF-28822, Procedure 4.5.5.2

Altitude Operating: Altitude nonoperating:

0 to 4000m (03123feet) 0 to 10000m (0-32800 feet) IPX0

IEC 60529 -7-

Specification Protection Enclosed in carrying case

Sinusoidal Vibration/ Transportability

MIL-PRF-28822 , 4.5.5.3.2 for Class 2

Transit drop test

Explosive Atmosphere EMC

Detailed in Test Report EN 61326-1

Safety evaluated to +40 0 C max. ambient

Open the carrying case and remove the main unit.

Attaching a tube adapter tip to the probe

Attaching an adaptor to a RDP Probe:

Attaching an adaptor to a LDP Probe:

Connect the other end of the cable to the main unit.

Connecting to a power outlet

Turning the system on

6.1.1 Probe LEDs

6.1.2 Initial Templates

6.2 Preliminary Tests 6.2.1 Perform Hardware Test

6.2.2 Perform Calibration Verification

Take off the probe membrane

Back on the PTS application; go to Advanced->Probe->Probe Calibration

A note will be displayed

The procedure status is displayed at the bottom left status bar

When done a completion note will be displayed

Disconnect the calibration tube from the probe.

Dont forget to reinstall the probe membrane.

6.3 Setup Pre measurement

Open the Map builder sub application

Close the Map builder application. The tube map is set.

On the top menu, click Tube detection -> Custom

Click on the Set button in Diameter Click Search

Then click several times to bound the desired Row or column:

Then right click again and choose Select from path

6.3.2.2 Row Column Zone Support PTS

6.3.6 License update

In case of a bad measurement a warning message appears:

Report post measurement

6.5.2 Generating a report

6.5.2.2 User interpretation

Clicking on an indication will zoom in on its location on the signal.

The tube condition can be classified as well if needed.

6.5.2.3 Printing the report

The pie chart is also added to the HTML/PDF report.

APPENDIX I PACKAGING INSTRUCTIONS, CABLE ARRANGEMENT