Magnetic Flux Leakage (MFL) Inspection Limitations
API 2009 Storage Tank Conference
Presentation
Aaron Lund
Regional Sales Manager of Gulf Coast
HMT Inc.
Dont Discard the Technology and go backwards
MFL is the Best
method to
evaluate a
tank bottom
condition
quickly and
cost effectively
All Limitations
Technology
Human (Training and experience)
Physical
Information on Technology Limitations
A lot of information has been available and presented on in
regards to technology limitations. However, the information
is not common to all brands and types of scanners, so it is
not without some controversy.
API has been trying to quantify these technology limitations
through a task group performing the re-write of nonmandatory Appendix G in API Standard 653 which call for
operator qualification testing and certification. This effort is
on-going but still has not happened thus far.
This presentation will identify most of the physical limitations
and offer some solutions to overcome those physical
limitations
Lets Talk about the Physical Limitations
Tank Bottom inspection preparation
Bottom Plate Lap Welds seams
Bottom Plate Shapes and Sizes (sketch plates)
Shell (corner weld) radius
Patch Plates
Tank Bottom Obstructions (columns / re-pads, internal
piping, etc.)
Edge Settlement
Uneven Bottom Plates peaks and valleys
Thick Reinforced Coating
Thick Annular Plates
Magnet and Sensor location
Bottom Plate Lap Weld Seams
Typical Full Sized MFL Scanner
Front to base
sensor = 10
Overall
Length = 36
Bridge Width = 12
Overall scanner width = 14
Limitation Zone
Corner Weld No Scan Zone
Sketch Plate Example
Typical Patch Plate
Typical Column with repad
Floating Roof Leg Striker Pad
Tank Bottom Obstructions
Solutions/Options
Following an informed risk assessment on limitations what
are your best options:
Do Nothing!!
Extensive Visual Exam (should already be standard in
any scope of work)
Vacuum Box Testing (leak detection only)
Helium Testing (leak detection only)
Manual Ultrasonic Scrubs (corrosion locator)
Hand/ Mini MFL Scanner (corrosion locator)
ACFM Crack Detection / Magnet Particle Examination
(surface breaking crack-like indications on welds only)
Patch Plate near lap seam hole/extensive visual exam
Vacuum Box Testing
Helium Testing - Equipment
Helium Testing Weld Seam Scanning
Manual/Mini Scanner Solution
Overall Scanner
length = 9
Front to back of
sensor bar = 6
Hand scanner width = 6
Scanner width = 6
Manual/Mini Scanner for Near Corner Weld
ACFM Crack Detection Equipment
HISTORY
This Technology was introduced in 1991.
The method was initially developed for offshore structures
Since then it has been applied to:
Theme Park Rides
Bridges
Ships
Petrochemical/Refinery Equipment
Tanks
APPLICATIONS
Weld inspection
Detection of Crack-like indications
Depth Sizing
Monitoring Dimensional Propagation
SURFACE PREPARATION
With the Magnetic Particle (MT) and Dye Penetrant Testing
(PT) Methods, the quality of the surface preparation is
critical to the ability of the method to detect
discontinuities.
This level of preparation is not required for electromagnetic
techniques as the method of detection is not based on the
migration of inspection media to the site of discontinuities.
SURFACE PREPARATION-Contd
Reduced surface preparation does not imply no preparation
The presence of ferromagnetic scale will impair the ability
of the method to identify discontinuities
However, the presence of surface rust will not significantly
impair the sensitivity of the test
Coatings-less than .200 does not need to be removed
ADVANTAGES
No set up Calibration required
Single direction deployment unlike MT
Inspection time is reduced
Data can be recorded for later comparison, review, or audit
CONCLUSION
ACFM has proven effective for:
Coated Components
Internal/External Shell-to-Bottom Welds
Internal Lap Welds
Sump Welds
After tank bottom replacement
When Stress Corrosion Cracking is suspected
This techniques provides consistent results - at a lower cost
In Summary
Be aware of real world Limitations that exist everyday
Make an informed risk assessment
Revise or develop a work scope for your inspection vendor
that addresses either:
All tanks
or
Specific to particular tanks based upon tank
characteristics, risk analysis or tank condition
Be informed of the technology/tools that can help
QUESTIONS?
