Beruflich Dokumente
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Operating Manual
Silverwing UK Ltd Clos Llyn Cwm, Swansea Enterprise Park, Swansea, SA6 8QY Wales, UK
t: +44 (0) 1792 798711 f: +44 (0) 1792 793481 e: support@silverwingndt.com w: www.silverwingndt.com
MANUFACTURER:
Silverwing (UK) Ltd.
Clos Llyn Cwm,
Swansea Enterprise Park,
Swansea,
SA6 8QY
Wales, UK
Phone: +44 (0) 1792 798711
Fax: +44 (0) 1792 793481
Email: sales@silverwingndt.com
Web: www.silverwingndt.com
DISTRIBUTOR:
The text, figures and programs have been worked out with the utmost care. However, we
cannot accept either legal responsibility or any liability for any incorrect statements which
may remain, and their consequences. The following documentation is protected by
copyright. All rights reserved. No part of this manual may be reproduced or transmitted in
any form or by any means, electronic or mechanical, including photocopying and recording
for any purpose without the express written permission of Silverwing (UK) Ltd. The rights of
reproduction through lectures, radio and television are also reserved. The software and
hardware descriptions referred to in this manual are in many cases registered trademarks
and as such are subject to legal requirements.
Silverwing (UK) Ltd reserves the right to continue developing the system and software
without documenting each individual case. Silverwing (UK) Ltd are happy to determine
whether this manual is up-to-date. Silverwing (UK) Ltd holds no responsibility for any
damage or destruction caused when following instructions within this manual.
General Introduction
Improper use of this instrument or failure to follow these instructions may cause injury or equipment
damage. All individuals responsible for operating this instrument must therefore be properly trained
and aware of the hazards, and must carefully follow these operating instructions and the safety
precautions detailed within. Contact Silverwing (UK) Ltd if you have any questions on any part of
this operating manual.
DANGER!
The Scorpion B-Scan system is designed for a specific use. Using the
Scorpion B-Scan system outside of its intended use is dangerous.
Severe injury or death could result. Read and understand this operating
manual before use.
CAUTION!
MAGNETIC MATERIAL. Due to magnetic material, consult IATA
documentation before air shipping.
WARNING!
MAGNETIC MATERIAL. The wheels of the Scorpion B-Scan contain
strong magnets that produce an extremely strong magnetic field which
may cause failure or permanent damage to items such as watches,
memory devices, CRT monitors, and medical or other electronics
devices.
WARNING!
PERSONEL SAFETY. Tools, magnets, and metal objects can cut,
pinch, or entrap hands and fingers. HANDLE WITH CARE. People with
pacemakers or ICD’s must stay at least 2m (79’’) away.
DANGER!
FALLING OBJECT HAZARD. Keep the area below an operating
Scorpion clear at all times. A NO ENTRY ZONE must be clearly
marked and cordoned off directly below the Scorpion. The NO ENTRY
ZONE must be a minimum of 6m (20ft) in all directions from the point
below the Scorpion.
WARNING!
Damage to the Scorpion and/or cables during or prior to use may cause
explosion or fire.
DANGER!
A suitable safety line must be attached to the attachment points of the
Scorpion at all times during operation. Attach the safety line BEFORE
placing the Scorpion onto the inspection surface.
CAUTION!
FINGER CRUSH. The wheels of the Scorpion contain
strong magnets that produce an extremely strong magnetic
field which could cause entrapment of hands and fingers.
HANDLE WITH CARE.
Operator Training
We advise that all users of the Scorpion B-Scan system receive adequate training before using the
system. They must be trained to understand the operation, application and limitations of the Scorpion
system. Users must understand:
Ultrasonic Testing;
Scanner components;
Scanner setup and calibration;
Scanner maintenance;
UT Lite operation;
Silverwing’s software operation.
More specific information about user training, qualification, certification and test specifications can be
obtained from technical societies, industry groups and government agencies.
Return Policy
If the Scorpion B-Scan system has been diagnosed as being faulty, or if it is in need of repair, it can
be returned to Silverwing (UK) Ltd. A Return Material Authorisation (RMA) number must be obtained
from Silverwing (UK) Ltd before it can be returned. To return the system:
1. Pack the system safely in the original transit case and ensure the product is shipped fully
insured.
2. Include the following:
a. The RMA number supplied by Silverwing (UK) Ltd. Clearly mark this on the outside of the
box.
b. A return address where the system can be shipped.
c. A contact telephone number / email address to be reached during work hours.
d. A detailed description of the problem.
3. Ship the unit prepaid to the address specified by Silverwing (UK) Ltd.
Legislative requirements
The Scorpion B-Scan system is designed to meet the safety requirements in accordance with
electrical safety and electromagnetic compatibility. It has been tested and has left the factory
in a condition in which it is safe to operate. The equipment is in conformity with the statutory
requirements of the EC directive and complies with the following provisions of Low Voltage
Directive 2006/95/EC and the Electromagnetic Compatibility Directive 2004/108/EC.
The Waste Electrical and Electronic Equipment Directive (WEEE Directive) aims to minimise
the impact of electrical and electronic goods on the environment by increasing re-use and
recycling and by reducing the amount of WEEE going to landfill. It seeks to achieve this by
making producers responsible for financing the collection, treatment, and recovery of waste
electrical equipment, and by obliging distributors to allow consumers to return their waste
equipment free of charge.
Silverwing (UK) Ltd offers its customers the possibility of returning unused and obsolete
equipment for correct disposal and recycling. The Dustbin Symbol indicates that when the last
user wishes to discard this product, it must be sent to appropriate facilities for recovery and
recycling. By not discarding this product along with other household-type waste, the volume of
waste sent to incinerators or landfills will be reduced and natural resources will be conserved.
The European Union’s RoHS (“Restriction of the use of certain Hazardous Substances”)
Directive (2002/95/EC) came into effect on July 1, 2006. All of the systems manufactured by
Silverwing (UK) Ltd fall under Category 9, Measurement and Control Equipment. Currently
this category is exempt from RoHS compliance until at least 2018, when it and other
exemptions will be reviewed. Regardless of this, all products manufactured by Silverwing
(UK) Ltd are compliant with the RoHS Directive.
Transportation and Storage
Unpacking
Care should be taken when unpacking the Scorpion B-Scan system, any markings or warnings shown
on the packaging should be observed prior to opening. The following steps should then be taken:
Unpack the Scorpion B-Scan system in a dry area.
If a knife is used to remove packaging care should be taken not to damage the Scorpion B-
Scan system or cables.
Check the contents of the Scorpion B-Scan system against the packing list supplied and any
missing items are to be reported immediately.
The package and contents of the Scorpion B-Scan system should be checked for signs of
damage during transport and any problems reported immediately.
Silverwing (UK) Ltd accepts no responsibility for damage or injury caused during the unpacking
of the system supplied.
Storage
If storage of the Scorpion B-Scan system is required then all components must be packed correctly.
The Scorpion B-Scan should be stored;
In a clean, dry and secure location.
Away from water and harsh environment conditions.
In such a way as to avoid damage to the system.
Table of Contents
1. Introduction ................................................................................................................................... 1
2. General Description ...................................................................................................................... 2
2.1. Scorpion Crawler ................................................................................................................... 2
2.2. Sitemaster30 Battery Box ...................................................................................................... 3
2.3. Control Module ...................................................................................................................... 3
2.4. Steering Control Pad ............................................................................................................. 3
3. Scorpion Pre-Inspection Setup.................................................................................................... 4
3.1. Preparation of the Inspection Equipment .............................................................................. 4
3.2. Charging the Sitemaster30 Battery Box ................................................................................ 4
3.3. Preparation of the Inspection Surface ................................................................................... 4
3.4. Scorpion B-Scan Inspection Area .......................................................................................... 5
4. Scorpion B-Scan Hardware Setup and Operation ..................................................................... 5
4.1. Short RG174U leads .............................................................................................................. 5
4.2. Connecting the Scorpion ....................................................................................................... 5
4.3. Connecting the UT Module .................................................................................................... 6
4.4. Connecting the Control Module ............................................................................................. 6
4.5. Sitemaster30 Battery Box Operation ..................................................................................... 7
4.6. Scorpion Steering Control Pad .............................................................................................. 7
5. UT Lite Software - Inspection Setup ........................................................................................... 8
5.1. Loading the UT Lite Software ................................................................................................ 8
5.2. Inspection Setup in UT Lite Software .................................................................................... 8
5.2.1 Encoder Calibration ............................................................................................................... 9
5.3. Handling the Scorpion ......................................................................................................... 10
5.4. Placing the Scorpion onto the Test Surface ........................................................................ 10
5.5. Attaching the Safety Line ..................................................................................................... 11
5.6. Removing the Scorpion from the Test Surface.................................................................... 11
5.7. Wheel Probe Normalisation ................................................................................................. 11
5.8. Wheel Probe Height ............................................................................................................. 13
6. Scorpion A-Scan Calibration ..................................................................................................... 14
6.1. Automatic A-Scan Calibration .............................................................................................. 14
6.2. Manual A-Scan Calibration .................................................................................................. 15
7. Scorpion B-Scan Setup .............................................................................................................. 16
7.1. Scorpion Resolution ............................................................................................................. 16
8. Scorpion B-Scan Operation ....................................................................................................... 17
8.1. Scorpion Scan Path ............................................................................................................. 17
8.2. Ready for Operation Checklist ............................................................................................. 17
8.3. Encoder................................................................................................................................ 18
8.4. Scanning Head Wheel Magnets .......................................................................................... 19
8.5. Scanning Operation & Missing B-Scan Data ....................................................................... 19
9. Viewing / Analysing B-Scans ..................................................................................................... 20
10. Scorpion Care & Maintenance ................................................................................................... 21
10.1. Scanning Head Component Identification & Location ......................................................... 21
10.2. Wheel Probe / Transducer ................................................................................................... 22
10.2.1 Wheel Probe Removal ........................................................................................................ 23
10.2.2 Wheel Probe Servicing ........................................................................................................ 23
10.2.3 Wheel Probe Replacing ...................................................................................................... 24
10.3. Cleaning Pad ....................................................................................................................... 25
10.4. Scorpion Drive Wheels ........................................................................................................ 25
10.5. Encoder................................................................................................................................ 25
Scorpion B-Scan Operating Manual Rev 7.2
1. Introduction
The Scorpion system is a B-Scan imaging system that is used with Silverwing’s UT Lite system. The
Scorpion has been developed to perform ultrasonic thickness measurements on ferrous material. The
Scorpion can be used on vertical ferrous surfaces such as oil storage tank shells, towers and stacks.
It can also be used on circumferential ferrous surfaces including horizontal pressure vessels and
spheres as well as above and below horizontal surfaces.
The minimum outside diameter the Scorpion can inspect both circumferentially and axially is 1.5m
(59”). The minimum internal diameter the Scorpion can inspect is 1.5m (59”) axially and 3m (118”)
circumferentially. The maximum surface temperature the Scorpion can continuously operate on is
o o
80 C (176 F).
Note: We advise that users read the UT Lite Operating Manual before continuing with the
Scorpion B-Scan Operating Manual. Alternatively ensure the UT Lite Operating Manual is
readily available as some sections of this manual refer to sections of the UT Lite Operating
Manual.
2. General Description
Mounted within the rear wheels are ring magnets which assist with traction while inverted. The
combined clamping pressure of the magnets is approximately 22.7kgs (50lbs) when used on flat
plate. The Scorpion is fitted with a single axis encoder, which provides positional information of the
Scorpion to the UT Lite system along with the UT data.
On top of the main chassis is the umbilical cable connector box. In front of this box are two SMC
bulkhead connectors, which the two short transducer leads connect to the dual elements of the wheel
probe. At the rear of the box there is one LEMO connector to which the umbilical cable is connected
and two colour coded BNC connectors to which the umbilical UT cables are connected. At the rear of
the chassis is a cable restraint pillar that is used to anchor the Umbilical cable restraint clip on the
umbilical cable. The cable restraint must always be used to prevent premature damage to the
Umbilical cable or connectors.
The Scorpion B-Scan utilises the Silverwing UK Ltd TWP12 dry-coupled wheel probe. The wheel
transducer assembly is attached to the main chassis by a parallelogram hinge system to keep the
transducer normal to the surface. The wheel transducer itself can be normalised using the adjusting
nuts on the top arm of the parallelogram. The two small nylon wheels mounted towards the front of
the transducer assist in lifting the wheel probe clear of welds. The two larger nylon wheels mounted
each side of the wheel probe transducer are designed to minimise compression of the wheel probe
tyres over uneven surfaces. Compression of the wheel probe tyres may result in irregular B-Scan
traces.
SMC Connector
RG174U Leads
Umbilical Connections
Restraint Clip
During operation if a buzzer alarm sounds it indicates that the battery pack has limited power
remaining.
After the Sitemaster30 buzzer alarm sounds drive the Scorpion back to ground level immediately.
With a fully charged battery the Sitemaster30 can operate continuously for up to 8 hours.
Do not allow the Sitemaster30 battery to completely discharge as this will shorten its service life
considerably.
Note: Extended use during the alarm period can damage the battery pack.
Stop
Forward Drive
Steer Left Steer Right
Reverse Drive
Start
No
Has an encoder calibration been
performed recently?
End
Start
Select Start
Yes
End
Figure 13 – Scorpion Encoder Calibration Flowchart
Doc Ref: OM-SB
Rev: 7.3
Date of Release: 19/02/2016
9
Scorpion B-Scan Operating Manual Rev 7.2
The mobility of the Scorpion is affected by one or more of the following variables:
Condition of the Scorpion drive wheels (e.g. quality of maintenance, wear and any ferrous
materials attracted to the magnetic wheels).
Condition of the inspection surface (e.g. wet, dirt, rust and loose ferrous materials).
To load an encoder calibration, select the Load Encoder Calibration button then open the required
encoder calibration file.
WARNING!
Care MUST be taken whilst positioning the Scorpion on the test surface
to avoid jarring the carriage or transducer.
Never attempt to hold, touch or reposition the Scorpion during use.
The Scorpion has an extremely powerful attractive force towards any
ferromagnetic object. Serious injury can result if limbs or tissue become
trapped between such objects and the Scorpion.
Place the rear wheels of the crawler on the test surface first then gently lower the front wheels to the
surface. Finally allow the wheel transducer to lower onto the surface.
DANGER!
FALLING OBJECT HAZARD. Keep the area below an operating
crawler clear at all times. A NO ENTRY ZONE must be clearly
marked and cordoned off directly below the crawler. The NO
ENTRY ZONE must be a minimum of 6m (20 ft) in all directions
from the point below the crawler.
Note: Always remember there are very strong magnets located on the underneath of the
Scorpion and inside the rear wheels, which will attract and be attracted to any ferrous material.
To carry out normalising adjustments, the system needs to be mounted on a steel plate, connected
and powered on. The software must be initialised with the A-Scan back-wall echoes displayed on
screen as described in Section 7 – A-Scan Setup of the UT Lite Operating Manual. With the system
set up as above:
1. Obtain at least two back wall echoes, and adjust the system gain so that the first back wall
echo is about 60% full screen height.
2. Slacken the rear-adjusting nut four or five turns then slowly tighten the front adjusting nut
whilst observing the ultrasonic signals.
3. If the first back-wall echo immediately begins to fall – stop tightening the front nut.
Immediately re-tighten the rear nut and then slacken the front nut four or five turns.
4. Then slowly tighten the rear nut and observe the ultrasonic signals, which should be rising.
5. When the first back-wall echo reaches a maximum and starts to fall, Stop adjusting the rear
nut and lock up the front nut.
The transducer is now normalised and the wheel probe height should now be checked.
2. Turn the wheel probe height adjustment screws until the correct height has been achieved.
Both height adjustment screws must be turned equal amounts to ensure the wheel probe
does not point to one side.
If the wheel probe is set too high, there will be insufficient pressure between the wheel
probe and the test surface resulting in low amplitude back wall echoes.
If the wheel probe is set too low, the nylon guide wheels will not make contact with the
test surface which may cause irregular B-scan images due to changes in wheel probe
tyre compression.
3. To complete the adjustment, re-tighten the wheel probe clamp screws.
Start
Press Calculate
End
Figure 19 – Automatic A-Scan Calibration Flowchart
After completing the Automatic A-Scan Calibration, perform calibration checks on some known
thicknesses to ensure the B-Scan is reporting the correct thickness measurements. If the
measurements are incorrect, manually adjust the UT flaw detector settings and gates until the correct
measurements are displayed.
Start
Yes
Are two thickness Setup Gate 1 over the first
measurements required? A-Scan signal
No
No
Setup Gate 1 and Gate 2 Is the reported thickness of Gate 1
over the first and second A- the same as the known inspection
Scan signals respectively surface thickness?
Yes
No
Is the reported thickness of Gate 1
Adjust the velocity so Gate 2
and Gate 2 the same as the known
reads the correct thickness
inspection surface thickness?
End
Start
End
Figure 21 – B-Scan Setup Flowchart
Note: The colour scheme displaying data within the B-Scan Window can be changed under the
Utilities tab in the Main Menu Window.
Note: In some rare circumstances the Scorpion B-Scan can miss data due to surface
conditions. These blocks of missing data are shown by vertical white lines within the B-Scan.
If this occurs the Scorpion B-Scan can be moved backward and forward to fill in the missing
data.
On painted vertical surfaces, check the surface condition as it is common for the paint to bloom with
age creating a powdery deposit on the surface. Rain tends to wash this deposit to the lower courses
and the thicker layers of powder can be quite slippery, especially when wet. If the surface is slippery it
may be wise to set the Scorpion on a diagonal course then straightening up as the top courses are
reached.
Note: Before climbing, ensure the safety line has been attached to the front of the Scorpion
and ensure the wheel probe has been lowered onto the surface and that UT signals are being
received by the UT Lite software.
Refer to Section 10 – Capturing, Saving and Loading Data in the UT Lite Operating Manual before
capturing a B-Scan. Follow the steps below in order to capture B-Scan data:
Start
Place the Scorpion at the
start of the required
inspection path
Yes
Is a scanning offset Enter the scan offset value
required? into the Enter Offset field
No
Select OK
No
Continue scanning
Is the scan completed?
inspection surface
Yes
Select the End B-Scan
button
End
Figure 22 – Capturing B-Scan Data Flowchart
8.3. Encoder
The Scorpion B-Scan is fitted with a single axis bi-directional encoder, which is gear driven by the
front wheels. Ensure no debris becomes stuck between the meshing of the gear teeth as this could
cause damage to the teeth and report incorrect distance measurements.
Doc Ref: OM-SB
Rev: 7.3
Date of Release: 19/02/2016
18
Scorpion B-Scan Operating Manual Rev 7.2
Start
Capture B-Scan
View Statistics
Yes
Adjust B-Scan View?
Yes
Save area as bitmap?
Export data
Yes
Save entire B-Scan?
Save file
No
End
Discolouration of the Wheel Probe tyres suggests they be cleaned using a cloth moistened with
Acetone. This will help restore the tyre to their original ‘tacky’ condition. The frequency of cleaning
will depend upon the condition in which the unit is being used, for example where the paint surface is
particularly dusty (or coated with a thick 'bloom'), it may be necessary to clean the tyres after each
scan.
IMPORTANT!
ONLY USE SILICONE OIL TO MOISTEN THE CLEANING PAD. ANY
OTHER FORM OF MINERAL OIL MAY DAMAGE THE WHEEL PROBE
TYRES.
THE USE OF ANY “OIL” OTHER THAN THAT SPECIFIED BY THE
MANUFACTURER INVALIDATES THE WARRANTY ON THE WHEEL
PROBE TYRES.
Inspect the tyres for any signs of splitting, cracking, excessive abrasion or any evidence of swelling
due to contact with mineral oil. Check the condition of the cork insulating washer and ensure that it
sits snugly and turns freely in the groove. Check that the ball bearings in the side plates turn freely.
Use acetone to clean all components and surfaces. Take extra care that all traces of film and dirt are
removed, especially around the outer circumference and Perspex plug over the crystal and the inner
face of the wheel probe tyres.
If new tyres are to be fitted, it is very important they are first cleaned with acetone to remove
protective film.
Once reassembled, check that there is only slight resistance when rolling the wheel probe. Do this by
holding the wheel probe ends between finger and thumb of each hand.
Once replaced check the system to ensure UT signals are being received.
Cleaning Pad
Reservoir Screws
10.5. Encoder
The Scorpion B-Scan is fitted with a single axis bi-directional encoder on the side of the crawler.
Ensure no debris becomes stuck between the meshing of the gear teeth as this could cause
damage to the teeth.
Ensure the optical encoder does not get damaged during use as it could cause distance
measurement inaccuracies.