2_HydroFORM - Mechanical Setup R2

8/13/2019 2_HydroFORM - Mechanical Setup R2

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HydroFORM Phased Array Corrosion Mapping System

Part 2 Mechanical Setup


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HydroFORM Corrosion Mapping System Mechanical SetupThe HydroFORM Phased Array System is designed to perform corrosion mapping in two possibleconfigurations.

Manual Encoded One Line Scans (1 axis)

Semi-Automated Encoded Multiple LineScans (2 axis)


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HydroFORM Mechanical Setup Probe Installation

Ensure that the probe is installed into the

HydroFORM scanner where elementnumber 1 is positioned correctly for theC-scan that will be created. The normalposition for this is 1-64 left to right whenscanning forward as pictured.When the Omniscan Start button isselected, the 0,0 position will set 2mm tothe right of element number 1 as

pictured.The Index axis will increment in thedirection below indicated by the greenarrow. (1mm focal law resolution and61mm total width)The Scan axis will increment below in thedirection indicated by the blue arrow atthe resolution entered into the Omniscan.


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Loosen the knob (pictured at right),apply light pressure on the probe toensure the foam seal is secureagainst the inspection surface andtighten the knob.The HydroFORM wedge used bythe focal law calculator has adefault height (Water column) of12mm. This can be visualized onthe Omniscan display prior totightening the probe knob andadjusted by applying light pressureuntil the interface signal is at 0.It is also acceptable to modify theHydro wedge parameters to the

current position.


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The phased array probe will alignparallel and level with the pipewhen secured with the one-knobpatent pending probe carriage.Minor differences in the watercolumn due to the scannerCrabbing will not affect thickness

readings when the interface gate(Yellow) is set to A-scan Syncro I/To achieve the intended focalpoint, the real water column heightmust match the Hydro wedgeheight in the Omniscan database.Differences in the water column

and calculator will not affect beamangle at 0 degrees for corrosionmapping and thickness readings.


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HydroFORM Mechanical Setup Probe Installation - Foam

Pressure applied to the probeduring installation is directlyrelated to the foam insertposition and will affect the abilityto maintain the water column.Care should be taken to ensurethat the probe is not installed

with too much or too littletension on the foam.To optimize both the position ofthe probe and tension of thefoam the interface echo betweenthe water and componentsurface should appear at 12mm.This is the default height of the

Hydro wedge in the Omniscandatabase and when positionedcorrectly will result in theinterface signal appearing atzero mm using the default set upfile. (With gate I Syncro onPulse, not \ I)


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HydroFORM System Manual Encoded One Line Scans

In the manual encoded one line scan configuration, the position of the data is maintained and

recorded using the encoder integrated in the HydroFORM carriage.The integrated encoder has a resolution of 8 steps\mm that is entered into the Omniscan MXUsoftware in the Scan-Encoder-Resolution for Encoder #1.In this configuration with the default aperture of 4 elements (4mm per A-scan), the HydroFORM willprovide a one line scan of 61 A-scans (61mm) up to the limit of either the 160 megabyte file size(Standard) or 300 megabyte file size (Optional).

For the 160 megabyte standard Omniscan, thelimit would be a C-scan of 61mm X 7680mm at aresolution of 1mm in both axis.For the 300 megabyte optional Omniscan, thelimit would be a C-scan of 61mm X 14,400mm ata resolution of 1mm in both axis.To piece multiple one line scans together in one

data file, the probe can be indexed manually inthe Omniscan software or indexed by use of aclicker (Olympus P/N: OPTX674) and index of theC-scan entered manual.


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HydroFORM System Manual Encoded One Line Scans

For manual encoded one linescans, plug the Mini-Wheelencoder cable to the Lemo-DE15encoder cable extension. The

DE15 connector will connect tothe OmniScan.


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HydroFORM System Semi-Auto Raster Scanning (2 Axis)Use of the HydroFORM system in the 2 axis semi-automated mode requires the

Olympus CHAIN Scanner (Chainscan-XY38) or similar.The HydroFORM adaptation kit includes all of the required hardware to adaptthe HydroFORM HD Mapper to a standard Olympus CHAIN Scanner XY38.Included in the adaptation kit is the crank handle, encoder junction with Lemoconnector, reversed spring loaded arm for HydroFORM scanner attachment,four plastic wheels and parts to allow the CHAIN Scanner to inspect Flatsurfaces.


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HydroFORM System Semi-Auto CHAIN Scanner

In the CHAIN Scanner manual, locate therequired number of short links and long links forthe diameter of pipe to be inspected and connectthem in accordance with the manual.Insure the adjustment screw is set so that whenclamped on the pipe the scanner is snug to thepipe and does not move freely.

Make sure you use a small link with dovetail on itfor installation of the umbilical attachment device.


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Install the HydroFORM on the index arm as pictured below. The probe knob

should be on the far side of the HD Mapper from the CHAIN Scanner wheels.The probe should be installed with element 1 closest to the CHAIN Scannerwheels.The umbilical should be configured with slack to allow a full range of movementon the index arm.

Index Axis

S c anAxi s


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The HydroFORM assembly is connected to theCHAIN Scanner by a spring loaded arm that has3 possible positions.

1. Locked up (for HydroFORM manipulation)2. Locked down

3. Free moving

When acquiring data and manipulating thescanner the arm should be in the freemoving position.

Acquiring data when the arm is in a locked

position results in poor data quality andscanner operation.


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HydroFORM System Semi-Auto CHAIN ScannerPosition the scanner so that 0,0 (XY position) on the probe is in the intended

position on the pipe.Using the default aperture of 4 elements, this puts 0,0 (Focal law 1) 2mm fromthe element 1 position line.

0,0


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Semi-Auto Chain Scanner Position of 0,0 for C-scan

To assist in positioning the HydroFORM at the correct 0,0 position a magnetictemplate is provided.Place the magnetic template on the component with the 0,0 position of the C-scan under the window below indicated by the red arrow.

After the magnetic template is in place the HydroFORM can be put in placeprior to locking down the chain scanner.


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Semi-Auto Chain Scanner Position of 0,0 for C-scan

The chain scanner has a arm length (Index or Y axis) that will allow the probefive revolutions or Strokes around the pipe. Using the default set up thisresults in a C-scan acquisition of 305mm X pipe circumference. (61mm X 5strokes)For multiple acquisitions, the chain scanner must be repositioned every305mm. The magnetic template is used to set the original 0,0 position and tomaintain the correct position for successive scanner positions every 305mm.

See Omniscan Setup Power Point for encoder preset position and C-scan areacreation for consecutive repositioning of the chain scanner for inspectionslarger than five strokes (305mm)


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HydroFORM System Semi-Auto CHAIN ScannerMove the scanner to the side slightly and open the water control valve until thewater chamber is flooded and all bubbles have disappeared from the S-scan

display. After initially flooding the water chamber and clearing the bubbles, the waterpressure can be reduced to a light flow during scanning.The surface condition of the pipe will determine how much water is required.Best results and fastest scan speed will be achieved with an electric pump dueto constant consistent pressure.

Be sure to move the scanner back to 0,0 prior to starting the acquisition.


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2_HydroFORM - Mechanical Setup R2