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FLOORMAP3Di

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:

Floormap3Di Operating Manual Section 2


Manual Version combined version 1.0
Floormap3Di Data Acquisition Software

Copyright© 2014 by Silverwing (UK) Ltd

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

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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.

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3 Floormap3Di Data Acquisition software Installation


Instructions

IMPORTANT!
It is strongly advised not to install the Floormap3Di Data
Acquisition software during an inspection.

To install the Floormap3Di Data Acquisition software:


1. Create a back-up copy of the “FM3Tanks” or “FM3DiTanks” folder located on
the desktop of the Sitemaster2 computer.
2. Uninstall the current version of Data Acquisition software. Do not uninstall the
current version of software if inspections created with the current version are
still required for viewing and analysis. The Floormap3Di Data Acquisition
software cannot be to view and analyse data captured with previous versions
of software.
Note that it is possible for the Sitemaster2 to run three different versions of Floormap3D or
Floormap3Di software. A sitemaster2 may have:
a. Floormap 3D running software version 1.16.
b. Floormap3Di running software version 2.0.201 or earlier.
c. Floormap3Di running current release software.

To uninstall the current Data Acquisition software:


a. Navigate to Start -> Control Panel -> Programs and Features.
b. For Floormap3D and Floormap3Di versions on and before 2.0.201 right click on the
name Floormap3D Data Acquisition software and select Uninstall (Figure 1).

Figure 1 - Programs and Features Window

c. For current Silverwing release Floormap3Di software

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a. Left click on the name FM3Di/MFLi3000 Data Acquisition Software and select
Uninstall (Figure 1).

Figure 2a - Programs and Features Window

b. When prompted to remove all settings (Figure 2):


i. Selecting Yes uninstalls the FM3Di/MFLi3000 Software only and
retains the data.
ii. Selecting No removes all saved settings such as; calibration files,
inspection data and encoder calibration data.
iii. Selecting Cancel aborts the uninstall procedure.

WARNING –
Selecting No
removes all files
including the
license file. It is
recommended
to select Yes for
a basic
uninstallation

Figure 1b – Uninstall Wizard

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:

Figure 3 - Ethernet Connection Symbol

Note: The cap can be removed using a fine blade.

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5. Connect an Ethernet cable from an internet access point to the Ethernet


connection on the Sitemaster2.
6. Create a new account / log into an existing account to gain access to the
Floormap3Di Data Acquisition software.

To create a new account to gain access to Floormap3Di Data Acquisition software:


a. Go to the downloads section of the Silverwing website:
http://downloads.silverwingndt.com.
b. Select the Do not have an account? Register here link.
c. Enter all required details into the correct fields.
d. Select Next.
e. Select Floormap3Di from the Product drop down list, then enter the serial
number of the Floormap3Di scanner and click Insert.
f. Repeat previous step for all Silverwing products owned.
g. Click Finish.
h. Go to the email address that was entered during registration and click the link
in the email sent from registration@silverwingndt.com.
i. Allow up to 24 hours for access rights to be checked and updated.

To gain access to Floormap3Di Data Acquisition software for existing account


holders:
a. Log into the registered account using the username and password entered
during registration.
b. Select Add a Product under User Details.
c. Select Floormap3Di from the Product drop down list, then enter the serial
number of the Floormap3Di scanner and click Insert.
d. Allow up to 24 hours for access rights to be checked and updated.
7. Log into the account using the username and password entered during registration
and select Floormap3Di. Select the download button to download the Floormap3Di
Data Acquisition software.
8. Navigate to the folder storing the Floormap3Di Data Acquisition installation package
(this can be found under the Downloads folder).
9. Double click the setup executable (Figure 3).

Figure 4 – Setup Executable File Window

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10. Click Accept if prompted to install Microsoft XNA Framework 4.0 (Figure 4).

Figure 5 - Microsoft XNA Framework 4.0.

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11. Select Next on the install window (Figure 5).

Figure 6 - Floormap3Di Data Acquisition Setup Wizard

12. Select the I accept the terms in the License Agreement check box to accept the
licence agreement terms and click Next (Figure 6).

Figure 7 - Floormap3Di Data Acquisition Setup Wizard

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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).

Figure 8 - Floormap3Di Data Acquisition Setup Wizard

14. Uncheck the boxes labelled FM3Di and FM3Di Desktop and click Install (Figure 8).

Figure 9 - Floormap3Di Data Acquisition Setup Wizard

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15. Select Finish to complete the installation of the Floormap3Di Data Acquisition
software (Figure 9).

Figure 10 - Floormap3Di Data Acquisition Setup Wizard

For any assistance regarding installation, please contact Silverwing directly:


Email: support@silverwingndt.com
Phone: +44 (0)1792 585533

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3.1 Activating the Floormap3Di Software with Internet


To activate the Floormap3Di software:
1. Ensure the Sitemaster2 computer is connected to the internet as described in
the Floormap3Di Data Acquisition Installation Instructions section.
2. Click on the Floormap3Di icon on the desktop.
3. Enter the activation key provided by Silverwing into the activation key box (Figure 10)
and select OK.

Figure 11 - Activation Key Window

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.

Figure 12 - Delete License Key Option Window

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Figure 13 - "FM3Tanks" Window

4. Ensure the Floormap3Di Data Acquisition software main screen can be seen (Figure
13).

Figure 14 - Floormap3Di Data Acquisition Software Main Screen

5. The Floormap3Di Data Acquisition software is successfully activated on the


Floormap3Di Sitemaster2 computer. Disconnect the Sitemaster2 computer from the
internet and refit the Sitemaster2 computer back onto the Floormap3Di scanner.

For any assistance regarding activation, please contact Silverwing directly:


Email: support@silverwingndt.com
Phone: +44 (0)1792 585533

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3.2 Activating Floormap3Di Software without Internet


In situations where the Sitemaster2 is unable to be connected to the internet to activate the
Floormap3Di Data Acquisition Software, there is an alternative solution to activating the
software. To activate the software a back-up license key is required which necessitates
contacting Silverwing and requires an internet connection to receive the License file (the
Sitemaster2 itself does not require internet connection). When contacting Silverwing you will
require:
1. Company name.
2. Serial Number of the Floormap3Di.
3. Hardware identification (see Figure 10).

Upon receipt of this information Silverwing will send:


1. license.xml.
2. An activation key (a unique number key).

To activate the Floormap3Di Data Acquisition Software with no internet connection:


1. Download the sent license.xml.
2. Open the FM3DiTanks folder located on the desktop.
3. Open the ConfigurationFiles folder.
4. Paste the license.xml file into the ConfigurationFiles folder.
5. Close down the ConfigurationFiles folder. This returns you to the desktop screen.
6. Double click on the Floormap3Di icon on the desktop to open the Data Acquisition
Software. The Floormap3Di Data Acquisition Software will now require the activation
key to be entered.
7. Enter the activation key what has been sent by Silverwing (this key is unique to the
hardware identification).
8. Press OK.

4 Loading the Data Acquisition Software


IMPORTANT!
The Floormap3Di Data Acquisition software cannot be to view and
analyse inspection data captured with previous versions of
software. If inspections created with previous versions of software
are still required for viewing and analysis, ensure the previous
version of software is kept and is used.

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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.

Figure 15 - Floormap3Di Data Acquisition Splash Logo

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:

Figure 16 - Scanner Busy Message Window

Attach the USB cable and ensure the Floormap3Di scanner is powered ON, and press OK.

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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).

Figure 17 - Main Menu Window (No inspection Loaded)

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.

5.1 New Inspection


The New Inspection button provides access to create a new inspection project.

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5.1.1 Creating a New Inspection


Note: Before a new inspection project can be created, the current inspection project must be
finished. Please refer to the Archive section for details on finishing inspections.

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.

Optional fields can also be customised if required, including:


 Metric (mm) or Imperial (inches) unit options – Select the units that are required
(selected units will be highlighted in green).
 Tank North – Rotate the tank to alter the tank angle altered to show which way is
north. It is worth noting that Tank North is of no scanning importance.
 Tank Diameter – Select the Diameter input box to enter the tank diameter.
 Annular plate information – Select the relevant boxes to input the number of annulars
/ annular width. It is also possible to add annular plate information later in the
reporting software if preferred. This annular information is not important to the
scanning process.
 Scan Overlap distance – The scan overlap distance is already set by default to
50mm. Select the Scan Overlap field to change the scan overlap distance. The
scanner must be positioned across the width of the plate at intervals of:

Interval Marks = Scan width (300mm) - Scan Overlap distance

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.

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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.

5.1.2 Creating a New Inspection – Quick Start-Up Flow


Figure 18 shows the process to follow for a quick set up of a new inspection.

Enter all relevant


Select the New Inspection details into
Start Click Continue End
Inspection Button the Inspection Details
window

Figure 19 - Creating a New Inspection: Flow Diagram

5.2 Load Inspection


The Load Inspection button provides access to load a previously saved inspection project. It
is also accessible in other locations. See the Loading an Inspection section below.

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5.2.1 Loading an Inspection


To load an inspection, the Load Inspection button must be selected. The Load Inspection
button can be accessed in three different ways:
1. Via the Load Inspection button in the Main Menu (Figure 16) – This applies if no
inspection has been loaded.
2. Via the New Inspection button in the Main Menu (Figure 16) followed by the Load
Inspection button in the Inspection Details window (Figure 17) – This applies if no
inspection has been loaded.
3. Via the Inspection Details button in the Main Screen (Figure 21) followed by the Load
Inspection button in the Inspection Details window (Figure 17) – This applies if an
inspection is already loaded.

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

Figure 20 - Load Inspection Window

Note: Loading an inspection is particularly useful when continuing the same inspection in a
different session.

5.2.2 Loading an Inspection – Quick Start-Up Flow Diagram


Figure 20 shows the process to follow to load an inspection.

Click the Load


Select the required
Start Inspection Click Open End
inspection
button

Figure 21 - Loading an Inspection: Flow Diagram

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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.

Figure 22 - Main Screen

6.1 Inspection Details


The Inspection Details button displays the inspection details window which contains all details
that were entered during the inspection creation. Fields which are not greyed out in the
inspection details window are modifiable.

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.

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6.2.1 Pre-Calibration Requirements


The Floormap3Di must only be calibrated using MFL reference plates manufactured to
the current Silverwing specification. The MFL reference plates manufactured by Silverwing
are specifically designed to meet current API standards and are required to be precision
made.

Before a calibration is performed, please ensure:


 The battery is fitted to the scanner correctly and is fully charged (See Section 1).
 Both the MFL and STARS sensor head are set at their correct heights as described in
Section 1 of the operating manual.
 The correct thickness reference plate is available to match the inspection surface plate
thickness - If the reference plate thickness does not match the inspection surface plate
thickness, it is acceptable to use a standard Floormap MFL reference plate provided
that the MFL reference plate used is, at most, 1mm thicker than the inspection
surface scanned. The resulting defects are oversized in this case, but not missed.
The reference plate thickness used for calibration must not be thinner than the
inspection surface to be scanned.
 The correct coating simulation sheet thickness is positioned on top of the reference plate
to simulate the coating thickness of the inspection surface.
 The reference plate is clean.

6.2.2 Performing a Calibration


Note: The Calibrate 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.

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).

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Load Calibration
button

Calibrate button

Figure 23 - Calibration Window

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.

Figure 24 - Reference Plate Thickness Options

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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).

Figure 25 – Top Surface Defects Message Prompt

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).

Figure 26 - Scanner Preparation Message Prompt

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.

Note: Resume is not required during calibration and so is greyed out.

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Figure 27 – Calibration Scan Acceptance Message Prompt

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).

Figure 28 – Scanner Preparation Message Prompt

6. Re-perform steps 3 and 4 to complete the second calibration scan.


7. Remove the Floormap3Di scanner from the reference plate. Turn over the calibration
plate so that the defects are on the bottom side of the plate and place any relevant
coating simulation sheet on the top side of the plate. Select OK to the message
prompt (Figure 28).

Figure 29 - Turn Calibration Plate Message Prompt

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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).

Figure 30 - Scanner Preparation Message Prompt


rd th
9. Re-perform step 2 to step 6 to complete the 3 and 4 calibration scan by following
the same process with the only difference being that the defects are now on the
bottom side of the plate, not the top side of the plate.
10. Enter a suitable file name into the Name field and select OK to continue.

Figure 31 - Calibration Name Window

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.

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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: It is recommended that verification scans are performed continually


throughout the day (e.g. at battery change intervals or after sensor head
impact) to ensure the calibration being used is correctly sizing defects.

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.

6.2.2.1 MFL - Calibration Trace


The view for the MFL sensors shows two different colour calibration traces:
 A red trace – The red trace represents MFL signals detected on the top side of the
plate. The trace increases in amplitude as it represents the 20%, 40%, 60% and 80%
defects in the reference plate.
 A green trace – The green trace represents the MFL signals detected on the bottom
side of the plate. The trace increases in amplitude as it represents 20%, 40%, 60%
and 80% defects in the reference plate.

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.

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MFL View

STARS View
Calibration Name
Scan Image View

Figure 32 – MFL Calibration Trace, STARS Calibration Trace and Scan Image View

6.2.2.2 STARS – Calibration Trace


The view for the STARS sensors shows one calibration trace. The trace increases in
amplitude to represent the 20%, 40%, 60% and 80% defects located on the top side of the
reference plate (Figure 32).

Figure 33 - Calibration Window Showing the STARS Trace

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6.2.2.3 Scan Image and Working Sensor Verification


Scan Image displays the raw data view for the MFL and STARS sensors for the scan
performed across the plate during calibration. The more distinct the indication, the stronger
the detected change in the magnetic field (greater % defects tend to show up bigger changes
in the magnetic field). This information is useful to check if all the sensors within the sensor
head function correctly. If there are no clear indications shown at 20%, 40%, 60% and 80%
please contact Silverwing and provide exported calibration images. (See Figure 33 for an
example of clear indications).

Figure 34 - Scan Image Window

6.2.3 Successful Calibration Attributes


A successful calibration contains:
 An MFL top, MFL bottom and STARS calibration signal with four distinct peaks which
increase in amplitude over the X-Axis (to represent the 20%, 40%, 60% and 80%
defects).
 Ample height between each detected MFL top, MFL bottom and STARS peak.
 A calibration trace line that lies on each of the four detected MFL top, MFL bottom
and STARS peaks.
 Non-identical 60% and 80% MFL top and MFL bottom signals.

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.

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6.2.4 Exporting Calibration Images


Calibration images can be exported using the Export Curves button (Figure 33). It is advised
to export in .emf format (if supported) to ensure good image quality is met.

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.

6.2.5 Exiting a Calibration


To exit the calibration and return to the Main Screen, click the Close Button.

6.2.6 Loading a Calibration Before Scanning

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:

Figure 35 - Load Calibration Window

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.

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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:

Figure 36 - Not Loading Calibration from Current Inspection Warning

6.2.7 Performing a New Calibration during Scanning


During an inspection, a different calibration may be required to be performed to continue the
inspection. Reasons for performing a new calibration include:
 The plate and / or coating thickness has changed (i.e. from plates to annulars).
 The sensor head height for either the MFL or STARS heads has been altered since
performing the current calibration. The sensor height must be reset and a new
calibration must be performed to ensure system accuracy is not affected.

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.

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6.2.8 Loading a Calibration during Scanning

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.

To load a calibration during scanning:


1. Follow the steps in the Performing a New Calibration During Scanning section to
allow access to the Calibrate button in the Main Screen.
2. Select the Calibrate button from the Main Screen.
3. Select the Load Calibration button.
4. Load the relevant calibration (See Loading a Calibration Before Scanning for details
on loading a calibration).

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

Figure 37 - Scan Screen

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6.3.1 Tank Datum


When viewing a tank floor from above, the plates can be seen to align in both the vertical and
horizontal plane as illustrated in Figure 37 below.

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).

Figure 39 – Established Parallel Plate Rows

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2. Orientating to look perpendicular to the plate rows (Figure 39).

Figure 40 - Perpendicular Plate Rows

3. Positioning the tank datum point in the bottom-left hand corner (Figure 40).

Figure 41 - Tank Datum Position

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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).

Figure 42 - Row / Plate Numbering in Relation to Tank Datum

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

Figure 43 - Tank Datum and Reference Point Identification

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6.3.2 Creating a New Standard (Inner) Floor Plate to Scan


After an inspection project has been created / loaded, a new plate can be created via the
Scan button. If a calibration has not been performed / loaded within the created / loaded
inspection, the Scan button is greyed out. A calibration therefore needs to be created / loaded
within the software to enable the Scan button.

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.

Plate / Annular Tabs

Row / Plate number Secondary plate


selection reference identifiers

Length

Width Tracks

Primary plate reference

Plate Orientation

Scan Type

Figure 44 - New Plate Window: Plate Tab Selected

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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).

6.3.2.1 Row & Plate Number Selection


The row / plate number of the plate to be scanned is chosen by selecting the arrows either
side of the row / plate options (Figure 43). Row / plate numbers can be manually entered by
selecting the row / plate field and using the numerical keypad (Figure 44).

Figure 45 - Numerical Keypad

6.3.2.2 Entering Plate Dimensions


The length / width of the plate to be scanned must be entered into the relevant field prior to
scanning (Figure 43) so that a plate of those dimensions can be created. The values are
entered by selecting the length / width field and using the numerical keypad (Figure 44).
The plate width must always be greater than 300mm (the physical width of the Floormap3Di).
If a shorter dimension is entered, an error message will be displayed and the software will
restrict access to the scan mode.

The longest dimension must be the length and the shortest must be the width. This is
determined by the orientation of the plate.

6.3.2.3 Plate Orientation Selection


Vertical and horizontal orientation (Figure 43) is selected to correctly represent the physical
geometry of the plate to be scanned. The plate orientation can only be decided once the tank
datum is correctly chosen. This is not to be confused with the plate reference. The plate
reference needs to also be chosen with respect to the tank datum and the geometry of the
plate (see Start Corner (Plate Reference) Selection Section for details).

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6.3.2.4 Scan Type Selection


There are two methods to scan a plate:
Parallel Scanning (one direction scanning) - where each consecutive scan is made in the
same direction.
Raster Scanning (two direction scanning) - where each consecutive scan is made in the
opposite direction to the previous scan.

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.

6.3.2.5 Start Corner (Plate Reference) Selection


The plate reference determines the corner of the plate where the first scan will begin. It also
provides the direction and order of the tracks to be scanned in relation to tank datum. The
plate reference can be selected by clicking either corner of the plate or the red right angle
symbol (See Figure 43 for primary and secondary plate reference indicators). The secondary
plate reference identifier allows the plate reference to still be known when a plate is being
investigated using the zoom options available.

All positional information, including any corrosion, is measured from the plate
reference.

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6.3.2.6 Listing Scanned Plates


The List Plates button in the New Plate window (Figure 43) displays a list of all plates
scanned in the current inspection. It also shows the maximum discontinuity found for each
plate, and the total percentage covered for each plate.

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.

Plate number and plate information

Select a plate to
load

Load a
selected
plate
Figure 46 - Scanned Plates Window

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6.3.3 Scanning Plates


Once a standard plate is set up and created, all information entered during set up is reflected
within the Floormap3Di Overview window (Figure 46). The track to be scanned is outlined in
red.

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.

Exit to the Main Screen


Scan Direction
Indicator
Setup New plate

Overlapping Open View Menu


track Indicator
Open Track Menu

Next Scan Highlighted

Transverse Scans
Plate Reference Indicator

Begin scan
Tank Datum Indicator

Figure 47 - Floormap3Di Overview Window

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).

Figure 48 - Start Offset Window

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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).

Scan Progress Bar

Initial Start Offset

Figure 49 - Scan Progress Window

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.

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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).

Total Distance Travelled

Scanning Progress Bar –


Increases
When Scanning

Figure 50 - Scanning Complete Window

Scanned Plate Data

Figure 51 - Scanned Track Data and Next Track to be Scanned

6.3.3.1 Changing the Start Offset


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 available in the software when the Scan button is pressed.
In some cases, obstructions occur during scanning e.g. heating pipes lying across the
beginning of a track. A different start offset is therefore required to overcome the obstacle. To
enter a different start offset:
1. Select the Scan button to begin scanning a plate.
2. Select the white Enter Offset area within the Scan Start Offset window.
3. Enter the required offset using the numerical keypad.

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6.3.3.2 Resuming a Scan


The Resume option is used whenever it is required to resume scanning on the same track i.e.
resuming a scan after an obstacle. The Resume function can be used as many times as
required providing there is enough room on the track.

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.

A scan can be resumed at any time. To resume scanning a previous track:


1. Select Track Menu in the Floormap3Di Overview window.
2. Select the track required to be resumed using the arrow keys.
3. Select the Resume button.
4. Enter any offset (if an obstacle is present) into the Enter Offset section of the Scan
Start Offset window.
5. Turn the drive handle and the scan is resumed.

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.

6.3.4 Viewing and Analysing Scanned Data


When a scan is complete the scanned plate data becomes available (Figure 50). The
scanned data can be viewed and analysed comprehensively with the various tools that are
available. The information detailed within this sub-section explains the various different types
of viewing and analytical options.

Note: If any viewing or analytical options detailed within are not understood, or more
information is required, please contact Silverwing for details.

6.3.4.1 Cursor Information


The on-screen cursor can be hovered over a defect / indication for initial analysis. When the
cursor is over a defect, the coordinates of the defect (in relation to plate reference) and the
Estimated Percentage Loss of the defect (with respect to the calibration) is seen.

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6.3.4.2 Defect Quick View Box


The defect quick view box is displayed in the bottom right-hand corner of the Floormap3Di
Overview screen (Figure 51). The quick defect view box allows a quick analysis of the plate /
track being currently worked on. The following information can be found in the defect quick
view box:
1. Plate percentage coverage (how much of the plate has been scanned).
2. Maximum % discontinuity on the plate.
3. Maximum % discontinuity on the current track.
4. Maximum % discontinuity on the previous track.

Defect Quick View Box

Figure 52 – Defect Quick View Box

6.3.4.3 Detailed Defect / Indication Information


Detailed defect / indication information (Figure 52) is found by selecting the View Menu button
in the Floormap3Di Overview window. When hovering over a defect / indication, the following
information is seen:
1. X / Y coordinates – These are the coordinates of the defect that is being currently
viewed / analysed.
2. EPL - This is the Estimated Percentage Loss of each defect. This value can range
from 0 - 100% dependant on the intensity of the MFL signal received.
3. STARS – This is used to establish if there is top side corrosion within a plate. View
the STARS results to determine if an indication is higher than the background noise.
If so the STARS sensors are triggered meaning there is a high possibility of top side
corrosion or a large bottom side indication.
4. MFLi - This displays the raw MFL intensity value. The greater the value, the higher
the MFL volume, of MFL intensity, that has been found by the MFL sensors.

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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.

6.3.4.4 Zoom Control


The zoom controls (Figure 52) provide the option to zoom in or out on a particular area of
interest for more precise analysis. The purple (crossed arrow) indicator at the center of the
zoom control can be selected to reset the zoom level and the position of the plate.

Zoom Controls

Detailed Defect
Information

Sizing View Options

Analysis View Options

Threshold Menu

Palette menu
Pan control Window
Back to main
scanning screen

Figure 53 - View Menu Screen

6.3.4.5 Defect View Selection


There are two different types of view which can be selected; Sizing view and Analysis view.
Sizing view displays EPL data by cross referencing the raw data signals with the calibration
within the inspection, whereas Analysis view only displays raw data obtained from the
inspection surface (i.e. does not use a calibration).

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Sizing (Calibrated) View


Sizing view cross references all received raw MFL signals with the current inspection
calibration. As a result of this process, a percentage loss between 0% and 100% is
established, dependent on the MFL signal received (the higher the MFL signal received, the
greater the % loss). This % loss (EPL) is then represented by a certain colour banding to help
categorise defects which in turn can be seen as a defect / indication on the Sitemaster2
computer. If a defect detected during an inspection is similar in geometry to the calibration
defect, sizing is expected to be within tolerance. Variation in defect sizing is a consequence of
variations in defect geometry.

Sizing view consists of three different options:


Top and Bottom View:
This option shows the calibrated MFL indications
from both the TOP side and BOTTOM side of the
plate.
Top View Only:
This option shows the calibrated MFL indications
from the TOP side of the plate only.
Bottom View Only:
This option shows the calibrated MFL indications
from the BOTTOM side of the plate only.

These options are useful for viewing top and bottom side defects in a calibrated view. See
Figure 52 for sizing view options.

Analysis (Uncalibrated) View


Analysis view displays the raw data directly on screen (i.e. no inspection calibration is used).
MFLi, MFL and STARS view are all different types of analysis view options (Figure 52). These
analysis views can be considered as great detection and verification tools as the data is
displayed as it is received from the inspection plate. A description of each analysis tool is
given below:
 MFL - The MFL view shows the pure raw signals received from the MFL sensor array
(Figure 53). MFL view is capable of detecting edges of large defects. Spurious
defects may also be identified as in this view they tend to show as a straight line.

Figure 54 - Uncalibrated MFL View

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 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.

Figure 55 - Uncalibrated MFLi View

 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

Figure 56 - Uncalibrated STARS View

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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.

6.3.4.6 Threshold Control


Indications are represented on screen by a certain colour. The colour of each indication
depends on the % loss of the indication. The Threshold button (Figure 52) is used to gain
access to the colour scale being used to represent indication % losses (Figure 56). This
colour scale can be easily altered to control what percentage loss are seen on a plate. For
example, the threshold level can be set to 35% to only allow indications of 35% and above to
be seen. This is a useful tool when only certain % losses are of particular interest.

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

Figure 57 – Threshold Control Window

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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.

6.3.4.8 Pan Controls and Screen Lock


The pan controls are activated when a finger is placed on the Sitemaster2 and is moved
around. The purple indicator at the center of the + and – zoom controls (Figure 57) can be
selected to reset the zoom level and show the complete plate within the window.

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

Figure 58 - Lock Screen Example

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.

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6.3.5 Detection above 13mm Plate Thicknesses


The Floormap3Di is capable of sizing defects with a high degree of accuracy up to plate
thicknesses of 12mm with 3mm coatings. However, when inspecting plates of larger
thicknesses i.e. 16mm, sizing accuracy is not guaranteed. In this case, the Floormap3Di is
primarily used as a detection tool (with sizing a possibility depending on certain
circumstances). To ensure the most capable degree of accuracy is available for scanning
larger plates, there are two options available:
1. Calibrate the Floormap3Di on a 12mm plate with 3mm coating – By calibrating on the
maximum plate and coating thickness specified for the Floormap3Di, it ensures the
Floormap3Di is at its absolute maximum sensitivity when looking at any plates thicker
than 12mm with 3mm coating. A decrease in detection and accuracy with an increase
in inspection plate thickness is expected using this method.
2. Calibrate the Floormap3Di on a Silverwing specified reference plate of the same
thickness as the surface to be inspected – By calibrating the Flooramp3Di on the
same surface thickness to be inspected (ensuring the maximum settings have been
entered during calibration setup), accuracy of defect sizing is likely to be better for
this case, however detection is expected to decrease with increased plate
thicknesses.

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.

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6.3.6 Deleting and Resuming Track Scans


The Track Menu button provides tools to resume track scans and delete tracks on the current
plate (Figure 58):
 Resume – Tracks can be selected using the Track arrows. The Resume button can
be used to resume a scan on a selected track (if room permits). The scan can be
continued either from the end of the selected track or from the opposite edge of the
track (by selecting the Scan From Opposite Edge button – software will prompt). Any
applicable offsets can also be inputted to the system using the Enter Offset window.
Once the OK button has been selected, scanning can be resumed as normal.
 Delete Track – Tracks can be selected using the Track arrows. When the relevant
track is selected (outlined in red), it can be deleted through the Delete Track button.

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.

Figure 59 - Track Menu

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6.3.7 Transverse Scanning On a Plate


The Transverse button in the Floormap3Di Overview window (Figure 46) is used to perform
transverse scans once all horizontal / vertical tracks are scanned. Transverse scans cover the
area missed by the scanner due to the physical limitations of the scanner. Transverse scans
are made perpendicular to normal scans and will cover the areas not inspected at each end of
the plate (Figure 59).

Transverse Scans

Figure 60 - 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

End Plate End Plate

Mid Plate

Figure 61 - Transverse Scan Window

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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

Figure 62 - Distance from Reference Offset Location

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6.3.8 Saving a Scanned Track on a Plate


After a track scan has been performed on a plate (transverse or standard scan), the Accept
button must be selected to save the scan.

6.3.9 Scanning a New Plate


The New Plate button (Figure 46) is selected when a new plate requires scanning.
The software automatically increments the plate number, however, the row needs to be
updated where necessary as the software does not update this automatically. All plate
options must then be appropriately customised. The Create button is selected to create the
new customised plate and scanning can continue.

6.3.10 Loading a Previously Scanned Plate


To return to a plate which has already been scanned, scroll through the row and plate number
in the New Plate window (Figure 43). The plate / row required can also be manually entered
using the numeric keyboard. The image of the plate is then updated accordingly and the
Create button can be selected to load the plate into the Floormap3Di Overview window.

6.3.11 Clear Plate – Clearing a Scanned Plate


To clear all data from a plate which has been scanned:
1. Scroll through the row / plate number in the New Plate window (Figure 43) to find the
desired plate to clear.
2. Select the Clear Plate button (Figure 62)
3. Select Yes to the on-screen prompt.
Once the Clear Data button has been selected, the data on that plate cannot be
recalled.

Clear Plate Button

Figure 63 - Clear Plate Option

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6.3.12 Continuing an Inspection


Any previous inspection can be continued at any time by closing the current inspection and
reloading the desired unfinished inspection back into the software when required (see
Finishing an Inspection and Loading an Inspection sections for further details).

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.

6.3.13 Annular Plate Setup and Scan


In addition to scanning standard plates, the Floormap3Di can be used to scan annular plates.
To scan annular plates when in the New Plate window (Figure 43), the Annular tab must be
selected. This will then display all annular set up options (Figure 63).

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.

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Annotated annular
diagram
Annular width

Zero Line Indicators


(Dependent on plate
reference)

Annular Number Bottom Left Plate


Selector Reference

Bottom Right Plate


Reference

Annular Plate
Measurement Input
Boxes
Plate Reference
Indicator

Figure 64 - Annular Scanning Window

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

Figure 65 - Invalid Dimensions 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.

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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).

6.4.1 Backup / Archive to External Drive


All scan data is automatically backed up to the ‘FM3Ditanks’ file when new data is collected. It
is important that this filing structure is not altered in any way.

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.

Figure 66 - Archive to External Storage Device Message

Note: If the No button is selected to the message above, the data is not backed up to
the external storage device.

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5. Select OK to accept successful transfer of data:

Figure 67 - Successful Archive to External Storage Device Message

6. Remove the USB 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.

Exit to Main Screen

List scanned plates

Location in ‘FM3Di tanks’


folder

Total
(uncompressed)
data

Destination of Backup to an external


the file on the drive button
USB storage
device Finish current
inspection project

Figure 68 - Archive to External Drive Window

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6.4.2 Finishing an Inspection


The Finish Inspection button (Figure 67) finalises the current inspection by closing the project.
The system is reset and made ready for a new inspection project. If the inspection is required
to be resumed it can be loaded back into the software (See Loading an Inspection section for
details).

6.4.3 Closing the Archive Window


The Close button (Figure 67) closes the Archive To External Drive window and returns the
software back to the Main Screen.

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

Figure 69 - Options Window

6.5.1 Close
Selecting the Close button allows the software to return to the Main Screen.

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6.5.2 Palette Options


The Palette Options button (Figure 68) has the same functionality as previously described in
the Palette section. To re-iterate, Palette Options allows indications to be represented by a
range of different colour palettes (Figure 69). 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.

Figure 70 - Palette Options Window

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:

Figure 71 - Language Options

When a different language is selected, the software automatically shuts down and restarts.
Upon restart, all instructions are in the selected language.

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6.5.4 Service - Altering the Encoder Ratio


The Service (Figure 68) button is password protected and is for Silverwing personnel only
(Figure 71).

Figure 72 - Encoder Ratio Message

If a faulty encoder ratio is suspected e.g. due to a newly installed motor or a worn encoder
gear, please contact Silverwing.

6.5.5 Simulating the Scanner


The Simulated Scanner button (Figure 68) provides the option to simulate the Data
Acquisition software from a desktop or laptop computer and is always greyed out. It is worth
noting that this option is for computer work only, not for actual scanning.

6.5.6 About - Contacting Silverwing, Acknowledgement / Developers


Information
Silverwing contact details are available under the About button (Figure 68). Acknowledgment
and developer information can also be seen under this section.

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.

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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:

 An inspection surface that is not suitably clean.


 Inappropriate use of the Floormap3Di
 Sensor head impact – warped plates, obstacles etc.
 Uneven coating surface – causing Floormap vibration and sensor head
impact.

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.

Regarding Spurious Defects, the main things to remember are:-


• The initial stance should be that all defects are real unless proven otherwise. Some
false recordings will be less obvious to detect as false and will require further
verification.
• If the Floormap3Di is operated as per Silverwing specifications spurious indications
(false defects) are unlikely.
• In practice, it has been found that if the inspection plate does not meet certain
preparation standards, spurious defects are more likely on:
o 10mm+ plates with no coating
o 6mm plates with 5mm of coating
o 8mm plates with 2mm+ of coating
• A fluctuating air gap is also a common cause of spurious defects. This can occur as a
result of plate warping, variable coating thickness, unsmooth Floormap rollers etc.

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

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Spurious
Defects

Figure 73 - 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.

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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.

8.1 Desktop Data Acquisition Capability


The Floormap3Di system contains a desktop version of the Data Acquisition software. The
desktop version of the Data Acquisition is identical to the version on the Floormap3Di
Sitemaster2 computer with the only difference being that data cannot be captured using
the desktop version (as there is no Floormap3Di system available). This means the
Calibrate and Scan buttons are not available for use.

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.

8.2 Advanced Mathematical Algorithm Capabilities


The Floormap3Di contains complex mathematical algorithms which:
 Reduce the number of spurious / false defects.
 Provide improved data representation.
 Improve defect sizing.

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8.3 The Dynamic Cursor


Given the Floormap3Di is calibrated with respect to API specifications, faults sizing errors in
the Data Acquisition software occur as these calibrated faults do not account for the entire
range of possible fault types.

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

Figure 74 - Dynamic Cursor

It must be stated that to fully utilise the Dynamic Cursor, experience and
understanding of MFLi and calibration traces is required.

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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.

8.5 Feature Support


For further any information regarding the Floormap3Di Data Acquisition software features,
please contact Silverwing directly:
Email: support@silverwingndt.com
Phone: +44 (0)1792 585533

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9 Combined MFLi3000 and Floormap3Di use


It is possible to upgrade the MFLi3000 to run the Floormap3Di software. The Floormap3Di
and MFLi3000 software can then be used in one inspection. When the Floormap3Di and the
MFLi3000 software are used in one inspection there are the following considerations:
 The MFLi3000 and the Floormap3Di software cannot be run at the same time.
 When performing an inspection it is possible to switch between the MFLi3000 and the
Floormap3Di software.
Note: When creating a new inspection ensure that the newly created inspection must be
unique. See Figure 76 for an example of the Floormap3Di and MFLi3000 software being
used in the same inspection.
 To avoid any conflicts the inspections created in the Floormap3Di and MFLi3000
software will remain independent.
 If the MFLi3000 or the Floormap3Di software is closed when either software is
opened the Main Screen window is displayed with the current inspection loaded.
 Floormap3Di inspections cannot be opened in MFLi3000 mode. If a Floormap3Di
inspection is loaded during an MFLi3000 inspection the following error message is
displayed.

Figure 75 – MFLi3000 Error Message

 MFLi3000 inspections cannot be opened in Floormap3Di mode. If an MFLi3000


inspection is loaded during a Floormap3Di inspection the following error message is
displayed.

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Figure 76 – Floormap3Di Error Message

 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.

Figure 77 – Recommended Inspection Details

 If the inspection Details are entered as above then the created inspections appear as
in Figure 69 below.

Figure 78 – File Structure

 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.

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Notes:
Silverwing UK Ltd - (Head Office) Silverwing Middle East LLC Silverwing Africa (PTY) Ltd Silverwing USA Inc
Clos Llyn Cwm P. O. Box 75950 Private Bag X1 Suite 120
Swansea Enterprise Park Dubai Postnet Suite 419 2911 South Shore Blvd
Swansea United Arab Emirates Melkbosstrand League City
SA6 8QY t: + 971 4 360 6751 7437 Texas
Wales, UK f: + 971 4 360 6124 South Africa 77573
t: +44 (0) 1792 585533 e: sales@silverwingme.com t: + 27 21 557 5740 USA
f: +44 (0) 1792 586044 w: www.silverwingme.com f: + 27 21 557 4354 t: + 1 832 531 0092
e: sales@silverwingndt.com e: sales@silverwingafrica.com e: sales@silverwingndt.com
w: www.silverwingndt.com w: www.silverwingafrica.com w: www.silverwingndt.com

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