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MFL Floor Scanner with STARS Top & Bottom Defect Discrimination
Section 2
Data Acquisition
Silverwing UK Ltd Clos Llyn Cwm, Swansea Enterprise Park, Swansea, SA6 8QY Wales, UK
t: +44 (0) 1792 585533 f: +44 (0) 1792 586044 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 585533
Fax: +44 (0) 1792 586044
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.
This manual is part of the original documentation supplied with the Floormap3Di system.
Floormap3Di Operating Manual combined version 1.0 Section 2 – Data Acquisition Software
TABLE OF CONTENTS
1 Introduction ............................................................................................................................... 2
2 Overview................................................................................................................................... 2
3 Floormap3Di Data Acquisition software Installation Instructions ............................................. 3
3.1 Activating the Floormap3Di Software with Internet .......................................................... 10
3.2 Activating Floormap3Di Software without Internet ........................................................... 12
4 Loading the Data Acquisition Software .................................................................................. 12
5 Main Menu .............................................................................................................................. 14
5.1 New Inspection ................................................................................................................. 14
5.1.1 Creating a New Inspection ........................................................................................ 15
5.1.2 Creating a New Inspection – Quick Start-Up Flow ................................................... 16
5.2 Load Inspection ................................................................................................................ 16
5.2.1 Loading an Inspection ............................................................................................... 17
5.2.2 Loading an Inspection – Quick Start-Up Flow Diagram ............................................ 17
6 Main Screen ........................................................................................................................... 18
6.1 Inspection Details ............................................................................................................. 18
6.2 Calibrate ........................................................................................................................... 18
6.2.1 Pre-Calibration Requirements .................................................................................. 19
6.2.2 Performing a Calibration ........................................................................................... 19
6.2.3 Successful Calibration Attributes .............................................................................. 26
6.2.4 Exporting Calibration Images .................................................................................... 27
6.2.5 Exiting a Calibration .................................................................................................. 27
6.2.6 Loading a Calibration Before Scanning .................................................................... 27
6.2.7 Performing a New Calibration During Scanning ....................................................... 28
6.2.8 Loading a Calibration During Scanning .................................................................... 29
6.3 Scan ................................................................................................................................. 29
6.3.1 Tank Datum .............................................................................................................. 30
6.3.2 Creating a New Standard (Inner) Floor Plate to Scan .............................................. 33
6.3.3 Scanning Plates ........................................................................................................ 37
6.3.4 Viewing and Analysing Scanned Data ...................................................................... 40
6.3.5 Detection Above 13mm Plate Thicknesses .............................................................. 47
6.3.6 Deleting and Resuming Track Scans ....................................................................... 48
6.3.7 Transverse Scanning On a Plate .............................................................................. 49
6.3.8 Saving a Scanned Track on a Plate ......................................................................... 51
6.3.9 Scanning a New Plate............................................................................................... 51
6.3.10 Loading a Previously Scanned Plate ........................................................................ 51
6.3.11 Clear Plate – Clearing a Scanned Plate ................................................................... 51
6.3.12 Continuing an Inspection .......................................................................................... 52
6.3.13 Annular Plate Setup and Scan .................................................................................. 52
6.4 Archive ............................................................................................................................. 54
6.4.1 Backup / Archive to External Drive ........................................................................... 54
6.4.2 Finishing an Inspection ............................................................................................. 56
6.4.3 Closing the Archive Window ..................................................................................... 56
6.5 Options ............................................................................................................................. 56
6.5.1 Close ......................................................................................................................... 56
6.5.2 Palette Options ......................................................................................................... 57
6.5.3 Language .................................................................................................................. 57
6.5.4 Service - Altering the Encoder Ratio ......................................................................... 58
6.5.5 Simulating the Scanner ............................................................................................. 58
6.5.6 About - Contacting Silverwing, Acknowledgement / Developers Information........... 58
6.6 Exit ................................................................................................................................... 58
7 Spurious Indications ............................................................................................................... 59
8 Features ................................................................................................................................. 61
8.1 Desktop Data Acquisition Capability ................................................................................ 61
8.2 Advanced Mathematical Algorithm Capabilities ............................................................... 61
8.3 The Dynamic Cursor ........................................................................................................ 62
8.4 MFLi ................................................................................................................................. 63
8.5 Feature Support ............................................................................................................... 63
9 Combined MFLi3000 and Floormap3Di use .......................................................................... 64
1 Introduction
This section of the operating manual explains how to install and use the Floormap3Di Data
Acquisition software designed and manufactured by Silverwing (UK) Ltd.
2 Overview
The Floormap3Di Data Acquisition software is used to view and analyse Magnetic Flux
Leakage (MFL) data that has been obtained by the Floormap3Di scanner. The Data
Acquisition software is primarily used on a Sitemaster2 touch screen computer but can also
be used on a desktop / laptop computer.
IMPORTANT!
It is strongly advised not to install the Floormap3Di Data
Acquisition software during an inspection.
a. Left click on the name FM3Di/MFLi3000 Data Acquisition Software and select
Uninstall (Figure 1).
WARNING –
Selecting No
removes all files
including the
license file. It is
recommended
to select Yes for
a basic
uninstallation
3. Unscrew the 4 bracket mounting screws situated at the rear of the Sitemaster2. Once
complete, remove Sitemaster2 from the rest of the scanner.
4. Remove the cap at the bottom of the Sitemaster2 computer that shows the Ethernet
connection symbol. See below for Ethernet connection symbol:
10. Click Accept if prompted to install Microsoft XNA Framework 4.0 (Figure 4).
12. Select the I accept the terms in the License Agreement check box to accept the
licence agreement terms and click Next (Figure 6).
13. Select the Activate fullscreen mode check box and click Next if installing the
Floormap3Di Data Acquisition software on the Floormap3D Sitemaster2 computer. If
installing the Floormap3Di Data Acquisition software on a desktop or laptop
computer, leave the box unchecked and click Next (Figure 7).
14. Uncheck the boxes labelled FM3Di and FM3Di Desktop and click Install (Figure 8).
15. Select Finish to complete the installation of the Floormap3Di Data Acquisition
software (Figure 9).
Note: If an incorrect activation key has been entered at this point, a message will
appear with the option to “Delete License Key?” (Figure 11). Select the option Yes to
delete the incorrect licence key. If the “FM3Tanks” file appears after selecting the Yes
button (Figure 12), select the Cancel button. Return to step 3 and re-perform the
activation process.
4. Ensure the Floormap3Di Data Acquisition software main screen can be seen (Figure
13).
Before loading the Data Acquisition software, ensure that the Floormap3Di scanner is:
Connected to the Sitemater2 via the USB cable
Powered ON
To load the Data Acquisition software, either double click on the Floormap3Di icon on the
Sitemaster 2 desktop, or navigate through the windows start menu:
Start → All Programs → Silverwing (UK) Ltd → Floormap3Di → Floormap3Di
The software displays a Splash logo as it initialises (Figure 14) then opens into the Main
Menu window.
If the software is loaded without the USB cable connecting the Floormap3Di scanner to the
Sitemaster2 or without the Floormap3Di scanner powered ON, the software allows all
functions to operate as normal until the Scan button is selected. Upon pressing the Scan
button, the following message appears:
Attach the USB cable and ensure the Floormap3Di scanner is powered ON, and press OK.
5 Main Menu
If no inspection has been loaded or created, the Floormap3Di Data Acquisition initial Main
Menu is seen. The Main Menu consists of four buttons across the top of the screen (Figure
16).
Note: Located in the bottom left hand corner of the Main Menu Window is a status indicator.
The status indicator displays the connection status between the software and the scanner.
The status indicator should read Idle. If the status indicator reads Disconnected, it is likely the
Floormap3Di scanner is either not powered on or is not connected properly. If this is the case,
restart the Floormap3Di Data Acquisition software ensuring the Floormap3Di scanner is
powered on and is connected to the Sitemaster2 computer.
To create a new inspection, select the New Inspection button from the Main Menu (Figure
16). The Inspection Details window then appears (Figure 17) where the following information
must be entered into the correct fields:
Service Company
Customer
Location
Tank ID
Operator Name
To enter details into a field, select the blank white area next to the field and use the on screen
keyboard.
Note: This option exists to ensure total plate coverage. No Scan Overlap is required if
there is confidence that each scan is adjoining (boundary sharing).
The Inspection Date and Hardware Serial are automatically generated pieces of information.
However if an incorrect date is displayed (prior to inspection creation), the date can be
changed by selecting the Get Date button.
Close window
without saving
Load Previously
Saved Inspection
Details
Save Inspection
Details and
close window
Figure 18 - Inspection Details Window for New Inspection Setup
Once all required details have been entered, the Continue button becomes available to
select. The Continue button opens up all options available related to the inspection that has
been created.
Note: When creating a new inspection using the Inspection Details window, any greyed out
areas cannot be modified. When a new inspection has been created the Customer, Tank ID
and Inspection Date fields are greyed out and unchangeable, so care must be taken when
entering these details.
After the Load Inspection button is selected, a list of all created inspections becomes
available. The inspections can be sorted by date via the Order By Date tick box (Figure 19).
Ordering the inspections by date makes it easier to load the last inspection created.
Once the required inspection is known, select the inspection and press the Open button
(Figure 19). The loaded inspection details are then displayed in the Inspection Details
window. Select the Continue button in the Inspection Details window and the inspection is
loaded into the Floormap3Di Data Acquisition software.
Order by
date tick box
Note: Loading an inspection is particularly useful when continuing the same inspection in a
different session.
6 Main Screen
The Main Screen is available when a new inspection has been created or a previous
inspection is loaded. The tabs that make up the Main Screen can be seen in Figure 21. Note
that Scan is greyed out / not available until a calibration has been loaded.
6.2 Calibrate
The Calibrate button includes options to:
Perform calibration scans.
Save calibrations.
Load previously saved calibrations.
Export calibrated images.
Analyse calibration scans.
Check the operation of the scanner head.
Before beginning the calibration procedure, please firstly ensure the Pre-Calibration
requirements have been carried out accordingly as previously described in the Pre-Calibration
Requirements section above.
To begin a calibration:
Select the Calibrate button on the Main Screen to open up the calibration window
(Figure 22).
Select the Calibrate button in the calibration window (Figure 22).
Load Calibration
button
Calibrate button
Note: Within the calibration window there is an option to load a previous calibration via the
Load Calibration button (See the Loading a Calibration Before Scanning section).
Upon selecting the Calibrate button in the calibration window the plate and coating thickness
drop-down boxes are automatically displayed (Figure 23). Select the correct plate and coating
thicknesses to be used for calibration.
Once the correct plate and coating thicknesses have been selected, the Floormap3Di is ready
for calibration. The software provides easy to follow calibration instructions at this point to
make the calibration process simple. The following steps describe how a calibration should
take place:
1. Ensure the defects are on the top surface of the plate and any relevant coating
simulation sheet is placed on the top side of the plate. Select OK to the message
prompt (Figure 24).
2. Position the scanner to scan from the smallest to the largest defect (20% -> 80%)
with defects on the top surface of the plate. Select OK to the message prompt
(Figure 25).
3. Turn the drive handle to simultaneously start the scanner drive motor and the data
collection functions. Drive the scanner along the full length of the plate from the 20%
defect towards the 80% defect. Release the drive handle before the drive wheels
reach the far end (the 80% defect end) of the plate. Care must be taken to ensure
that the Floormap3Di is not driven off the edge of the plate.
4. Select Accept to the Calibration Scan prompt after the drive handle has been
released (Figure 26) to complete the first calibration.
5. Disengage the Floormap3Di scanner magnets from the end of the reference plate.
Ensure the magnets do not interfere with the reference plate surface. This can
be achieved by placing the Floormap3Di on its back rollers. Re-position the
scanner to the same position as detailed in step 2. Select OK to the message prompt
(Figure 27).
8. Position the scanner to scan from the smallest to the largest defect (20% -> 80%)
with defects on the bottom surface of the plate. Ensure the Floomap3Di is centrally
aligned with the defects. Select OK to the message prompt (Figure 29).
Note: The software does not allow a new calibration file name to be the same as
one which already exists in the current inspection or in any other inspection. A
unique name is therefore required (this is to allow calibration files to be easily
traceable). It is suggested to include the inspection date into the file name i.e.
“6mm cal 27 May”.
Calibration is now complete and the MFL calibration traces, the STARS calibration trace
and the scan image can all be seen by selecting the relevant tabs across the top of the
calibration view (Figure 31). The name of the calibration is also shown on the right (Figure
31).
Note: Example calibration traces for all plates and coating thicknesses as well as
incorrect calibration examples can be found in Section 5 Example Calibration Traces.
11. Calibration Verification: After a calibration has been completed, it is important to verify
the calibration with two verification scans; one top side scan and one bottom side
scan. To perform the two verification scans:
a. Create a new plate to scan (See section 6.3.2) - Enter the dimensions of the
reference plate as the verification scans must be performed on this
plate.
b. Scan the reference plate with defects on the bottom side of the plate –
Confirm the 20%, 40%, 60% and 80% defects are well sized. When
performing this verification scan, it is important to scan from the 20%
defect toward the 80% defect.
c. Scan the reference plate with defects on the top side of the plate – Confirm
the 20%, 40%, 60% and 80% defects are well sized. When performing this
verification scan, it is important to scan from the 20% defect toward the
80% defect.
Note: If during calibration the distance screen is not counting please cancel the
current calibration and turn the power switch off on the machine (not on the
Sitemaster2 computer). Then turn the machine back on and press Calibrate to
begin the calibration again. If problems persist ensure that the encoder is
working correctly. If problems still persist please contact Silverwing support.
Figure 31 is a good example of how the MFL calibration traces should look for a 6mm plate
with no coating. See the Successful Calibration Attributes section for details on correct
calibration trace characteristics.
MFL View
STARS View
Calibration Name
Scan Image View
Figure 32 – MFL Calibration Trace, STARS Calibration Trace and Scan Image View
Note: Each calibration trace varies depending upon which calibration setting has been
selected e.g. A 12mm plate with 2mm of coating shows a different calibration trace to a 12mm
plate with a 3mm coating. In some instances e.g. 12mm plates, the 20% defect indication can
get ‘lost’ in the noise. If you are unsure whether a calibration was successful please contact
Silverwing for verification.
If exporting the curves to send to Silverwing for verification, please provide as much
information as possible regarding the calibration process e.g. plate thickness, coating
thickness, coating quality (bumpy, variable thickness) etc.
IMPORTANT!
It is never recommended to load an existing calibration. If a
different calibration is required, it is always advised to perform a
new calibration to ensure the calibration being used is accurate
and applicable.
Prior to scanning, a calibration can be loaded by selecting the Calibrate button in the Main
Screen followed by the Load Calibration button in the calibration window. The following
screen appears once the Load Calibration button is selected:
As Figure 34 shows, the calibrations are presented in a folder manner. The folders are
structured as follows:
1. Current Inspection folder – This current inspection folder is displayed at the top of the
calibration screen. All calibration files related to the current inspection can be seen in
its sub folder.
2. Calibration Files folder - This folder is displayed in the middle of folder list on the
calibration screen. This shows all calibrations in its sub folder.
3. Inspections folder – This folder shows all created inspections in its sub folder. The
relevant calibration files can then be seen within each created inspections sub folder.
Calibrations can be selected from other inspections. Once the relevant calibration is selected,
the Load button can be selected.
Inspections with a purple highlight have calibrations associated with them. These calibrations
can be accessed and included into the current inspection.
Note: If a calibration has been loaded, it now exists within the current inspection. This
calibration can only be re-loaded from the current inspection. If the calibration is not loaded
from the current inspection, the software produces the following error message:
As a calibration is already loaded for the current plates being scanned, the Calibrate button in
the Main Screen is greyed out and so a new calibration cannot be performed. To enable
access to the Calibrate button to perform a new calibration:
1. Click the Scan button in the Main Screen.
2. Complete scanning the current plate using the existing calibration when in the Scan
Overview window (Figure 36). Ignore this step if not applicable.
3. Click New Plate in the Scan Overview window (the plate settings are irrelevant and
do not need to be altered).
4. Make note of the row / plate number in the Floormap3Di Overview window and select
Create. Ensure no scan is performed on this plate.
5. Click Close in the Floormap3Di Overview window. The Main Screen is now available
and the Calibrate button is now accessible.
6. Perform a new calibration. Refer to Pre-Calibration Requirements and Performing a
Calibration sections.
7. Select New Plate in the Scan Overview window and clear the row / plate that was
created in step 4 using the Clear Plate button. This step ensures the created
plate is not included in the inspection mistakenly.
IMPORTANT!
It is never recommended to load an existing calibration. If a
different calibration is required, it is always advised to perform a
new calibration to ensure the calibration being used is accurate
and applicable.
6.3 Scan
The Scan button consists of options to scan, edit, analyse, delete and create tracks. Figure 36
shows the different options available:
Close
New Plate
View Menu
Track Menu
Transverse
Scan
Vertical
Horizontal
Figure 38 - Vertical and horizontal Plates
Tank datum is important as the plate numbering system, the plate reference and the
plate orientation are all referenced to the tank datum. The tank datum position is
established within a tank by:
1. Looking at the tank floor from above and establishing the plate rows that run
parallel (Figure 38).
3. Positioning the tank datum point in the bottom-left hand corner (Figure 40).
Figure 41 shows the row / plate numbering system in relation to the tank datum. The row
number increases downwards and the plate number increases from left to right (the plate
number resets on each new row).
In the Flormap3Di Data Acquisition software, the tank datum is displayed in the bottom left
hand corner of a plate to be scanned. Figure 42 shows the plate reference in relation to the
tank datum.
Plate
Reference
Tank
Datum
When the Scan button is available and is selected, the New Plate window is displayed (Figure
43). Within this window there are two inspection surface tab options that can be selected,
Plate and Annular. The plate tab is for creating standard (inner) floor plates to scan and the
annular tab is for creating the outer annular plates to scan. To create a standard (inner) floor
plate to scan:
1. Select the Plate tab.
2. Select the required row / plate.
3. Enter the relevant plate dimensions (length > width).
4. Select the relevant orientation.
5. Select the intended scanning method.
6. Select the plate reference.
7. Select the Create button once all relevant information has been entered / selected.
Note: Any unintentionally created, un-scanned plates are shown in the reporting software. To
avoid these plates being shown in the reporting software, the plates in question have to be
cleared. See Clear Plate – Clearing a Scanned Plate for details.
For information on creating and scanning annular plates, see the Annular Plate Setup and
Scan section.
Length
Width Tracks
Plate Orientation
Scan Type
Note: The green arrows on the plate represent the number of scans that are available. When
present, dark grey areas on the tracks represent overlapping tracks (see Figure 46).
The longest dimension must be the length and the shortest must be the width. This is
determined by the orientation of the plate.
The relevant scan type image (Raster or Parallel) must be selected prior to scanning (Figure
43).
Note: Prior to making a scan, there is also an option to Scan From Opposite Edge. Selecting
this feature allows a scan to take place from the opposite end of the track, dependent on what
type of scan has been selected (parallel or raster scan) during setup. See the Scanning
Plates section for details.
All positional information, including any corrosion, is measured from the plate
reference.
It is possible to load a plate directly from the list by selecting the plate followed by the Load
Plate button. See Figure 45 for details.
Note: Please allow time for the list of scanned plates to appear.
Select a plate to
load
Load a
selected
plate
Figure 46 - Scanned Plates Window
Note: The Scan button is greyed out on the desktop version of the Data Acquisition
software as the desktop version of the Data Acquisition software is solely for viewing
and analysing inspection data.
Transverse Scans
Plate Reference Indicator
Begin scan
Tank Datum Indicator
Note: The figure above shows no defects as the plate has not yet been scanned.
To begin a scan at the indicated position, select the Scan button. Once selected, the Scan
Start Offset window appears (Figure 47).
The start offset accounts for the area at the start of the scan that is not accessible by the
Floormap3Di sensor head due to its physical position within the system. The area that is not
covered initially by the Floormap3Di is 160mm. By default, the 160mm offset is
automatically input as the scan start offset when the Scan button is pressed. See Changing
the Start Offset section for details on when and how to change the start offset.
At this point there is also an option to Scan From Opposite Edge. Selecting this feature allows
a scan to take place from the opposite end of the track, dependent on what type of scan has
been selected (parallel or raster scan) during setup.
Once the correct start offset measurement has been entered and the OK button has been
selected in the Scan Start Offset window, the scan progress window appears to allow a scan
to begin (Figure 48).
The scan progress window displays any initial start offset entered (Figure 48) before the drive
handle on the Floormap3Di has been turned. Turning the drive handle simultaneously starts
the Floormap3Di drive motor and data collection functions. The scan progress bar in the scan
progress window can then be seen to increase from the initial start offset (Figure 49).
The drive handle must be held in the ON position until the required scan length has been
reached. Releasing the drive handle at any time ceases all Floormap3Di data collection
operations. If releasing the drive handle is unintentional, the Cancel button must be selected
and the scan process must be restarted.
Note: If during calibration the distance screen is not counting please press cancel and
turn the power switch off on the machine (not on the Sitemaster2 computer). Then turn
the machine back on and continue scanning. If problems persist ensure that the
encoder is working correctly. If problems still persist please contact Silverwing
support.
Once the drive handle is released intentionally, the Floormap3Di stops and the data collection
is paused. The Scanning Complete window then appears (Figure 49) and displays the
following options:
1. Resume - This allows the scan to continue along the same track. See Resuming a
Scan section for further details.
2. Accept - This saves the current scanned track data and displays it in the Floormap3Di
Overview window. The next track is then highlighted in red for scanning (Figure 50).
3. Cancel - This discards any data collected from the track and allows the scan process
to be restarted.
The total distance travelled during the scan can also be seen within the Scanning Complete
window (Figure 49).
When the Resume button is selected, an offset measurement window opens. If an obstacle
is met, the offset measurement entered needs to be the distance from the Floormap 3Di
sensor head before and after the obstruction. Once this measurement is known and has
been entered, the scanner is ready to resume scanning the track. The scan resumes once the
drive handle is turned. The non-scanned (offset) area is displayed in white.
Note: When resuming a track scan, care must be taken to align the lateral position of the
scanner with the first part of the track.
Note: If any viewing or analytical options detailed within are not understood, or more
information is required, please contact Silverwing for details.
5. Display – This is the type of display that has currently been selected. The MFL, MFLi
and STARS displays can be selected in View Menu.
Note: The ‘u’ after the STARS and MFLi values is the abbreviation for ‘unit’. This is because
MFLi and STARS do not have dedicated units, as they are raw values.
Zoom Controls
Detailed Defect
Information
Threshold Menu
Palette menu
Pan control Window
Back to main
scanning screen
These options are useful for viewing top and bottom side defects in a calibrated view. See
Figure 52 for sizing view options.
MFLi – MFL intensity (MFLi) view uses the raw data received from MFL and shows
an enhanced view of the raw data signal received from the MFL sensor array (Figure
54). This tool results in a clearer representation of the signals received. MFLi can be
used:
o As a verification tool.
o As a defect shape identifier.
o As a tool to assist in sizing.
o To distinguish between real and false corrosion.
o To reveal areas of interest (particularly narrow pipe-like defects) before a
threshold is set.
STARS - The STARS sensor array is used in the Floormap3Di to detect top side
indications. The STARS view displays the raw signals received from the STARS
sensor array. Indications will only be seen at a given point on screen if the STARS
sensor array has been triggered. The trigger point of the STARS sensor tends to be
6.00u and above on calibration plates and must be determined on inspection
surfaces. If the STARS sensor is triggered and Indications can be seen on screen,
there is a high probability that the indications originate from the topside of the plate. If
the indication is on the bottom side of the plate, there will be no indications
shown when in STARS view. STARS view is generally used for determining if the
indications originate from the top side or not. In the example of Figure 55, top side
defects are shown as the STARS sensors have been activated.
Note: If the STARS view is selected and the defect of interest is seen then the defect
is a top side defect regardless of what the sizing views say.
Top Side
defects
shown with
STARS
option
enabled
Note: It is important to understand that the MFLi, MFL and STARS views are regarded
as Uncalibrated MFL Signals as the MFL signals received are cross referenced against
a colour palette ranging from 0-256. In particular for the STARS sensors if no defect is
present (i.e. a perfect inspection surface) then the STARS value exists between 5.00
and 6.00u on a calibration plate.
Note: As the % loss of each indication is estimated, care must be taken when setting a
threshold so that certain indications such as small pipes are not missed. Before a threshold
is set it is advised that MFLi view is used so that any areas of concern can be
investigated.
+ and - Controls
Selected Threshold
Palette Button
Back Button
6.3.4.7 Palette
The Palette button allows indications to be represented by different colour palettes. This is a
useful option to have as certain types of indications are displayed in more detail than others
by using a different palette scheme, therefore allowing improved detection, viewing and
analysis.
The lock screen option is activated by double-tapping the Sitemaster2 screen with a finger, or
double clicking on a desktop computer. This feature is particularly useful for analysis
purposes as it allows the screen to be frozen and viewed. It is clear the screen is locked as
four red highlighted bars enclose the Floormap3Di Overview window (Figure 57)
Locked screen
6.3.4.9 Back
The Back button (Figure 57) will return to the screen the software was on previously. For
example, if the Threshold button or the Palette button is selected, the Back button will return
to the Floormap3Di Overview window etc.
Whichever option is used, it must be re-emphasised that detection is now the main capability
of the Floormap3Di.
It is known that for bottom side defects, detection decreases with increasing plate thickness.
An important feature of the Floormap3Di STARS technology is its ability to detect top surface
defects in plates that are thicker than 13mm. It is important to check the STARS view option
when scanning thicker plates to check for top side defects. Internal tests have revealed that it
is possible to detect 20%, 40%, 60% and 80% defects on a 16mm reference plate with 10mm
of coating.
Note: For further information regarding detection capabilities for thicker plates, please contact
Silverwing.
These functions can also be performed on a previously scanned plate but the plate is required
to be loaded first (see Loading a Previously Scanned Plate section).
Note: The Resume button is greyed out on the desktop version of the Data Acquisition
software as the desktop version of the Data Acquisition software is solely for viewing
and analysing inspection data.
Transverse Scans
To perform a transverse scan, select the Transverse button. The Transverse Scan setup
window then appears which includes all available transverse scan options in relation to the
plate reference (red circle) that was previously selected during plate creation (Figure 60).
There are two types of transverse scanning options available:
1. End plate transverse scanning - There are four options for end plate scanning. All
four options are for carrying out transverse scans on plate welds immediately
adjacent to the left hand side and right hand side of the plate, dependant on the plate
reference selected (Figure 60). Any required offset values can be entered using the
Scan Start Offset window.
Mid Plate
Mid Plate
2. Mid-plate transverse scanning - There are two options for mid-plate transverse
scanning. These options are for making a transverse scan at any position other than
the beginning or end of the plate e.g. at either side of an obstruction, such as a patch
plate.
For mid-plate scanning, an offset can be entered to allow transverse scans to take
place along the plate in relation to the reference. It is important to note that, for
mid plate scanning, the offset is measured from the plate reference to the
center of the scanning head. The required offset can be entered into the top right
Distance from Reference area (Figure 61). Once this offset has been entered, the
Scan Start Offset screen is displayed and any scanning offset (other than the
automatic 160mm offset) can be entered prior to scanning.
Once the required transverse option is selected and any offsets have been entered, it is
important that the Floormap3Di is then placed in the correct relative position. Transverse
scanning can then commence by turning the drive handle. The Accept or Cancel button can
then be pressed to confirm or reject the scan.
Note: There is no Resume option for transverse scans. If a transverse scan needs to be
resumed, the Scan Start Offset feature must be used (not the Distance from Reference
feature).
Offset location
If for any reason (to leave site) the Floormap3Di and the Sitemaster2 are turned off, the
inspection that was last open is still available when the Floormap3Di software is reloaded.
It is worth noting the following annular plate fundamentals prior to set up:
Plate Reference - When scanning annular plates, there are only two possible options
for the Plate Reference:
o Bottom left of the plate (when facing the tank shell / wall). See Figure 63.
o Bottom right of the plate (when facing the tank shell / wall). See Figure 63.
Annular Width -The annular width is always measured at the joint between two
annular plates. See Figure 63.
Start Offset - A start offset line should be marked on the annular plate as a reference
for the scanner to scan from. The line should be perpendicular to the Annular Plate
base line. It is referred to as the zero line and is represented on-screen by a red or
blue dotted line (depending on plate reference). See Figure 63.
The start offset of the scanner is measured from the Zero Line to the center of
the scanning head. If it is required to begin scanning behind the Zero Line, a
negative start offset should be used and visa-versa.
Scan direction – The only scan direction option for annular plates is parallel
scanning. However, a scan from opposite edge function is available.
Annotated annular
diagram
Annular width
Annular Plate
Measurement Input
Boxes
Plate Reference
Indicator
The dimensions of each annular needs to be correctly entered in order into the four
measurement input boxes provided (Figure 63). The annotated annular diagram is available
for easy referencing. Once the annular plate number and dimensions are set, the Create
button can be selected and the normal scanning procedure can be followed (See the
Scanning Plates section).
If dimensions have been entered that do not result in an annular, the following error message
is displayed:
Error
message
If the above error message is still visible after all dimensions have been entered, re-check
physical measurements. If the error still remains please contact Silverwing support.
Note: Transverse scanning cannot be carried out when scanning annular plates.
6.4 Archive
The Archive button opens the archive window and is used for listing scanned plate
information, backing up data to an external hard drive and finishing an inspection project
(Figure 67).
The scan data can be transferred to a USB storage device when connected to the
Sitemaster2 computer. The transferred data can then be analysed using the Data Acquisition
software on the desktop / laptop or the data can be imported into the reporting software to
create a final report. To transfer the data onto a USB storage device:
1. Select the Archive button.
2. Connect the USB storage device to the Floormap3Di.
3. Select the Backup button (Note: the Backup button will be greyed out if no USB
storage device has been connected to the Sitemaster2). See Figure 67.
4. Select the Yes button (Figure 65) to allow the data to be compressed (to .zip format)
and sent to the USB storage device (the data is automatically compressed to
maximise data transfer efficiency). Refer to Figure 67 for size of uncompressed data
and the destination (file name) on the USB storage device.
Note: If the No button is selected to the message above, the data is not backed up to
the external storage device.
Note: The USB storage device must only be connected to the Floormap3Di when data
needs to be transferred. Once the data is transferred the USB storage device must be
removed. Leaving the USB storage device connected to the Sitemaster2 may result in
software loading issues.
Total
(uncompressed)
data
6.5 Options
The Options button provides access to various additional options including:
Close
Palette Options
Language
Service – for Silverwing personnel only (contains encoder ratio)
Simulated Scanner
About
Close
Palette Options
Language
Service
Simulated Scanner
About
6.5.1 Close
Selecting the Close button allows the software to return to the Main Screen.
6.5.3 Language
The Language button (Figure 68) is available to change the language of the Data Acquisition
software. When selected, the following menu is provided:
When a different language is selected, the software automatically shuts down and restarts.
Upon restart, all instructions are in the selected language.
If a faulty encoder ratio is suspected e.g. due to a newly installed motor or a worn encoder
gear, please contact Silverwing.
6.6 Exit
The Exit button is the final option on the Main Menu / Main Screen and can be found in the
top right hand corner of the screen. When pressed, this closes the Floormap3Di Data
Acquisition software.
7 Spurious Indications
‘Spurious Indications’ is a term used to describe noise, false calls, or instances where the
software displays an indication where there is no equivalent corrosion present. Spurious
indications / defects are generally created by:
It is important to understand that spurious defects do occur but generally they can be easily
identified and removed.
As inspection surface thickness and coatings increase, so must the sensitivity levels of the
Floormap3Di. Increasing the sensitivity levels is a major contributing factor to the appearance
of spurious defects. As sensitivity levels increase, so does the probability of recording
spurious defects.
Spurious indications do not look like natural corrosion see figure 72. A spurious defect
detected by the Floormap3Di is likely to
1. Appear on the edge of tracks
2. Be horizontal starting at the edge of the scanned track
3. Decrease in intensity with the edge of the scanned track being the highest value
Spurious
Defects
If after an initial visual inspection, the Floormap3Di operator believes spurious indications are
likely then the Operator must be particularly gentle with the machine i.e. the operator should:
Remove or account for anything that could result in sensor head impact – for example
grind down weldments, treat warped plates as obstacles.
Guide the machine instead of holding it tightly between both hands as this will
minimise Floormap3Di movement (a major cause of noise).
Minimise wherever possible sudden movements i.e. wobbles or sharp stops need to
be avoided.
Possibly raise the sensor head to the highest height (to reduce sensor head impact)
and recalibrate. If this option is selected it must be understood that detection and
accuracy will be affected.
8 Features
There are several different features associated with the Floormap3Di Data Acquisition
software, including:
1. Desktop Data Acquisition Capability.
2. Advanced Mathematical Algorithm Capabilities.
3. The Dynamic Cursor.
4. MFLi.
The desktop version of the Data Acquisition version is intended for analytical and viewing
purposes. It can be used in conjunction with the SIMS reporting software to produce a
comprehensive final report.
To help overcome possible sizing inaccuracies, the Dynamic Cursor (DC) has been
developed. The DC is a cursor used to hover over defects during the inspection process to
provide further information of how correctly sized a defect is. The more experience with the
DC (and MFLi), the better the defect classification (and hence sizing).
After a calibration is performed, the DC automatically appears in the software. The DC knows
how a defect of a given estimated percentage loss EPL should be displayed. The Dynamic
Cursor consists of two circles connected by a mesh. The area between the circles (the
meshed area) is the tolerance (Figure 73). There are three possible cases the DC can
display:
1. The defect is between the inner and outer circle – This means the defect is likely to
be sized within specified tolerances.
2. The defect is within the inner circle (is small) – This means the defect is likely to be
undersized.
3. The defect is outside of the outer circle – This means the defect is likely to be
oversized but can also be undersized. If a defect does exist outside of the outer
circle, care is required to determine the exact nature of the defect.
It must be noted that the Dynamic Cursor is an inspection tool and should be used as part of
an inspection procedure to determine a defects true nature.
Tolerance
It must be stated that to fully utilise the Dynamic Cursor, experience and
understanding of MFLi and calibration traces is required.
8.4 MFLi
Please refer to Analysis (Uncalibrated) MFLi, MFL and STARS View for details on MFLi and
other related information. The main advantages of MFLi are:
1. A different search option that may reveal previously overlooked areas of concern.
2. Reduction of the visual impact of spurious defects making true corrosion easier to
see.
3. Defect geometry information.
Each created inspection is saved within the same FM3DiTanks folder found on the
desktop of the Sitemaster2 computer. If data from the MFLi3000 is to be included
within a Floormap3Di inspection then it is possible to name the inspections
accordingly. For such a scenario it is recommended that the following inspection
details are entered for the Floormap3Di and MFLi3000 software.
If the inspection Details are entered as above then the created inspections appear as
in Figure 69 below.
If MFLi3000 data is to be included into a Floormap3Di report then this must be done
manually. For example MFLi3000 exported images and description logs can be
included into a final report manually.