ACFM Book

TSC ACFM course notes for use with
Level One
Training Course
To Recommended Practice SNT-TC-1A (2006)
Jim Sheppard & Martin Lugg
TSC Inspection Systems

6 Mill Square, Featherstone Road,
Wolverton Mill, Milton Keynes, MK12 5RB
UNITED KINGDOM
Document: TSC/MCL/1809
Date: 13 July 2010
Issue: 1.5
Revision: 5
© 2010. Technical Software Consultants Ltd.

Document Revision Approval Sheet
6 Mill Square, Featherstone Road, Wolverton Mill,

Milton Keynes, MK12 5RB
TSC INSPECTION SYSTEMS
KEYWORDS:
LEVEL1 TRAINING ACFM
Controlled Copy: Yes No

TITLE:

Level One
Training Course
To Recommended Practice SNT-TC-1A (2006)
Document: TSC/MCL/1809
HS MCL MCL Tidying up and 13th July 2010

1.5 (5) rewording to match
presentations
MCL JAS MCL Correction to 27th January 2010
1.4 (4) Fig 2.2
MCL JAS MCL Modifications 28th July 2009
1.3 (3) to suit new
questions for
PCN
JAS MCL MCL Miscellaneous 11th May 2009
1.2 (2) amendments
including new
pages 1-1 to 1-3
1.1 (1) JAS MCL MCL 7th October, 2008

Issue(Rev) Initiated by Checked by Approved by Date
Issued Document Revisions
© 2010. Technical Software Consultants Ltd.

Level One
Training Course
To Recommended Practice SNT-TC-1A
(2006)
6 Mill Square, Featherstone Road

Wolverton Mill, Milton Keynes
MK12 5RB
Copyright © Technical Software Consultants Limited

L1 Course Notes for ACFM Inspection of Welds
Contents for TSC ACFM Level 1 Course Notes

Title Page
Chapter 1 Introduction ....................................................................1-1

Requirement documents .......................................................................... 1-1
Present certification.................................................................................. 1-1
Standard Practice for the Examination of Welds using ACFM........... 1-2
ACFM Operator Level I .......................................................................... 1-2
ACFM Operator Level II ......................................................................... 1-3
ACFM Operator Level III ....................................................................... 1-3
Approved Training ................................................................................... 1-3
ACFM EQUIPMENT APPROVALS – Subsea ..................................... 1-4
EQUIPMENT APPROVALS - Topside ................................................. 1-4
A brief history of ACFM .......................................................................... 1-9
Introduction to NDT................................................................................. 1-4
Visual Inspection ...................................................................................... 1-5
Liquid Penetrants ..................................................................................... 1-5
Magnetic Particle Inspection ................................................................... 1-6
Ultrasonic Testing ..................................................................................... 1-7
Eddy currents............................................................................................ 1-8
Alternating Current Potential difference (ACPD) ................................ 1-9
Chapter 2 Electricity and Electro - Magnetism ............................2-1

Basic Units used in the measurement of electricity ............................... 2-1
Magnetic Theory ....................................................................................... 2-2
Magnetic Effect of Electric Current ....................................................... 2-3
Chapter 3 Basic Principles of Eddy Current Testing ...................3-1

Introduction .............................................................................................. 3-1
Eddy Current Generation and Detection ............................................... 3-4
Factors affecting Eddy Currents ............................................................. 3-6
Chapter 4 Principles of ACPD ........................................................4-1

Introduction .............................................................................................. 4-1
ACPD Principles ....................................................................................... 4-1
Copyright TSC 2008 ACFM\Notes\Chapter1

Issued September 2008
TSC ACFM Level 1 Contents Page 1
Title Page
ACPD Benefits .......................................................................................... 4-3
ACPD Disadvantages ............................................................................... 4-3
Chapter 5 ACFM Crack Detection .................................................5-1

Introduction .............................................................................................. 5-1
Limitations of ACFM for weld inspection.............................................. 5-7
Chapter 6 TSC ACFM Equipment Hardware ..............................6-1

Types of Equipment and Software.......................................................... 6-1
Software ..................................................................................................... 6-4
ACFM Probe Types .................................................................................. 6-4
Probe Connections .................................................................................... 6-8
Function Test Block .................................................................................. 6-8
Chapter 7 Operation of ASSIST Suite of Software ......................7-1

WINDOWS ............................................................................................... 7-1
Windows Explorer .................................................................................... 7-1
Drives and Directories .............................................................................. 7-1
Software Installation ................................................................................ 7-1
Probe File Installation .............................................................................. 7-2
Hotkeys ...................................................................................................... 7-2
Chapter 8 Assist Family Software ..................................................8-1

Introduction .............................................................................................. 8-1
ASSISTant Software for AMIGO U19 ................................................... 8-1
Software Description ................................................................................ 8-2
Overview .................................................................................................... 8-2
Task Screen ............................................................................................... 8-2
ACFM Data Screen .................................................................................. 8-6
Chapter 9 Bx - Bz and Butterfly Plot Relationship.......................9-1

Introduction .............................................................................................. 9-1
Crack like Signals ..................................................................................... 9-1
Other Signals ............................................................................................. 9-4
1809 rev 5.doc / Rev 1 Copyright TSC 2008

Contents Page 2
Title Page
Chapter 10 Briefing Requirements for Remote Scanning .........10-1

Introduction to remote probe operations ............................................. 10-1
General Introduction.............................................................................. 10-1
Safety awareness ..................................................................................... 10-1
Probe selection and features .................................................................. 10-1
Probe connections ................................................................................... 10-2
Cleaning requirements ........................................................................... 10-2
Marking up the component ................................................................... 10-2
Visual inspection ..................................................................................... 10-2
Scanning techniques ............................................................................... 10-3
Sizing for length ...................................................................................... 10-3
Probe Operator briefing check off sheet .............................................. 10-3
Chapter 11 Function and Operation Checks ...............................11-1

Function Check ....................................................................................... 11-1
Operations check .................................................................................... 11-2
Chapter 12 Scanning for detection - Summary ...........................12-1

Chapter 13 Scanning for Sizing ....................................................13-1
Introduction ............................................................................................ 13-1
Length sizing ........................................................................................... 13-1
Final Scan ................................................................................................ 13-2
Sizing for depth ....................................................................................... 13-3
Chapter 14 Reporting and Printing..............................................14-1

Report Sheets .......................................................................................... 14-1
Printing Data ........................................................................................... 14-1
Chapter 15 Routine Maintenance and Handling ........................15-1
Chapter 16 Glossary of Terms ......................................................16-1
Chapter 17 Course Exercises Detection .......................................17-1
Chapter 18 Course Exercises sizing..............................................18-1
1809 rev 5.doc / Rev 1 Copyright TSC 2008

Contents Page 3
Chapter One
Chapter 1 Introduction
Requirement documents
Present certification
Ø Certification Scheme for Welding Inspection Personnel (CSWIP). This
scheme is organised by The Welding Institute (TWI).
Ø Personnel Certification in Non-Destructive Testing (PCN). This scheme is
organised by the British Institute of NDT (BINDT).
Ø SNT-TC-1A Company specific certification. This scheme is organised by the
American Society of Non-Destructive Testing (ASNT).
The CSWIP and PCN schemes conform to EN 473: 2008 which establishes an
international system for the qualification and certification of personnel who perform
industrial non-destructive testing (NDT).
1809 rev 5.doc Copyright TSC 2010

Page 1-1
Standard Practice for the Examination of Welds using ACFM

ASTM E2261-07 sets out the standard practice for the inspection of welds using
ACFM.
The following includes sections taken from taken from Recommended Practice
SNT-TC-1A(2006) Section 4.
CERTIFICATION AVAILABLE
The categories of certification available are ACFM Operator Levels I, II and III.
NDT Operator Level I

An NDT Level I individual should be qualified to properly perform specific
calibrations, specific NDT, and specific evaluations for acceptance or rejection
determinations according to written instructions and to record results. The NDT
Level I should receive the necessary instruction and supervision from a certified NDT
Level II or III individual.
ACFM Specific
An ACFM Level I operator shall be capable of carrying out all data collection,
detecting and sizing simple fatigue cracks in simple geometries, reporting on any
anomalous signal and briefing a probe operator.
ACFM Level I personnel does not have competency in the choice of test probes or
inspection parameter settings to be used.

Page 1-2
NDT Operator Level II

An NDT level II individual should be qualified to set up and calibrate equipment and
to interpret and evaluate results with respect to applicable codes, standards, and
specifications. The NDT Level II should be thoroughly familiar with the scope and
limitations of the methods for which qualified and should exercise assigned
responsibility for on-the-job training and guidance of trainees and NDT Level I
personnel. The NDT Level II should be able to organize and report the results of
NDT tests.
ACFM Specific
An ACFM Level II operator shall be capable of creating new probe configurations,

detecting and sizing defects in complex geometries including transverse defects.
NDT Operator Level III

An NDT level III individual should be capable of developing, qualifying, and
approving procedures, establishing and approving techniques, interpreting codes,
standards, specifications, and procedures; and designating the particular NDT
methods, techniques, and procedures to be used. The NDT Level III should be
responsible for the NDT operations for which qualified and assigned and should be
capable of interpreting and evaluating results in terms of existing codes, standards and
specifications. The NDT Level III should have sufficient practical background in
applicable materials, fabrication, and product technology to establish techniques and
to assist in establishing acceptance criteria when none are otherwise available. The
NDT Level III should have general familiarity with other appropriate NDT methods,
as demonstrated by an ASNT Level III Basic examination or other means. The NDT
Level III, in the methods in which certified, should be capable of training and
examining NDT Level I and II personnel for certification in those methods.
Approved Training
Level I and II candidates will be required to have satisfactorily completed an
approved training course on the ACFM equipment type of not less than 40
hours.
Notes:
Candidates must provide evidence of training. A certificate of successful

attendance and a copy of the training syllabus, both authenticated by a senior
person in the candidate’s employing organisation or by an approved training
organisation will suffice.

Page 1-3
Experience for Levels I and II
Level I candidates will be required to show a minimum requirement of 400 hours

practical experience in NDT (including at least 210 hours in an electromagnetic
method). Level II candidates to show a minimum of 1200 hours in NDT (including at
least 630 hours in an electromagnetic method – preferably ACFM).
ACFM EQUIPMENT APPROVALS – Subsea

Ø LLOYDS- UK based world wide accepted
Ø DET NORSKE VERITAS- Norwegian based world wide accepted
Ø BUREAU VERITAS- French based world wide accepted
Ø GERMANISCHER LLOYDS- German based worldwide accepted
Ø ABS- US based world wide accepted
EQUIPMENT APPROVALS - Topside
Ø LLOYDS- UK based world wide accepted
Ø DET NORSKE VERITAS- Norwegian based world wide accepted
Ø BUREAU VERITAS- French based world wide accepted
Ø GERMANISCHER LLOYDS- German based worldwide accepted
Ø ABS- US based world wide accepted
Introduction to NDT
NDT is defined as the use of non-invasive techniques to determine the integrity of a
material, component or structure.
There are in excess of 50 NDT systems available for use at present time, not all of
which can sensibly be applied to the detection of surface cracks. Each of the
techniques will have advantages, disadvantages and applications. Some techniques are
used solely as crack detection methods others can be used for sizing. A few can
address some detection and sizing requirements. Common methods of NDT were
developed by the aerospace industries and adapted for automotive and ship building
industries. Some of these methods can be applied underwater.
The following is a list of the most common techniques that can be used for crack
detection:
Visual
Liquid penetrant
Magnetic Particle Inspection
Ultrasonic
Eddy Current

Page 1-4
The areas of application of a selection of the commonly used methods successfully

applied to surface fatigue crack detection and sizing are described in the paragraphs
below:
Visual Inspection
Visual inspection can locate visible defects and discontinuities. It will be used to
locate surface defects which can be quite small in the case of close visual inspection
of welds etc. Visual inspection can be backed up with a number of recording methods
such as video and digital photography.
Visual inspection gives an overall appreciation of the general condition of the

component or structure.
Weld inspection
Weld inspection is particularly important where weld defects may affect in-service inspection
results. It requires the removal of paint coatings to attain a more detailed assessment of damage
and weld condition. Datum reference points will normally be established at the onset of
inspection so that a defect can be monitored continuously. Video and digital photography will
normally record any areas of concern or damage.
Visual inspection will normally be carried out prior to the ACFM inspection in order
to find areas that could show up as non-relevant signals on the system.
Limitations of visual inspection are as follows:
Can only be used to assess surface breaking defects.

Will not detect fine fatigue cracks
Cannot depth size fatigue cracks.
Surface condition of the component must be taken into account.
Liquid Penetrants
A liquid with high surface wetting characteristics is applied to the surface of the part
and allowed time to seep into surface breaking defects.
The excess liquid is removed from the surface of the part.
A developer (powder) is applied to pull the trapped penetrant out of the defect and
spread it on the surface where it can be seen. Visual inspection is the final step in the
process. The penetrant used is often loaded with a fluorescent dye and the inspection
is done under UV light to increase test sensitivity.
Penetrants are normally applied on non-ferritic materials such as aluminium and
stainless steels.

Page 1-5
Liquid Penetrant advantages:
Can be used on metals and non-metals

Good on shallow defects
Gives a visual indication
Very sensitive on good surfaces
Good for complex cracks
Penetrant disadvantages:
Cannot be used underwater

Difficult to assess on rough surfaces like welds
No depth sizing
Written report only
Must have very clean surface
Magnetic Particle Inspection
The part is magnetized and finely milled iron particles coated with a dye pigment are
then applied to the specimen. These particles are attracted to magnetic flux leakage
fields and will cluster to form an indication directly over the discontinuity. This
indication can be visually detected under proper lighting conditions.
MPI can only be applied to ferromagnetic materials and will detect surface breaking
cracks only.
Fig 1.1. An example of MPI indications

Page 1-6
MPI advantages:
Good for assessment of complex cracking such as stress corrosion cracking

Shallow cracks can be detected
Transverse cracks are easy to detect
Easier for tight geometry
Easier when used in conjunction with remedial grinding.
Less complex and costly equipment.
MPI disadvantages:
Surface condition needs to be clean

Relatively slow compared to ACFM
Written reports only
Cannot be applied on non-magnetic materials
Requires real time interpretation
Ultrasonic Testing
High frequency sound waves are introduced into a material and they are reflected
back from surfaces or flaws. Reflected sound energy is displayed versus time, and the
inspector can visualize a cross section of the specimen showing the depth of features
that reflect sound.
initial
back surface
echo
crack
crack
0 2 4 6 8 10 plate
Fig 1.2. Ultrasonic A scan display
Ultrasonic Advantages
Detection of sub-surface imperfections

Portability
Able to penetrate thick sections
Measures depth and through wall extent
Ultrasonic Disadvantages
Not easy to detect surface defects.

Difficult to apply on large grain metals (such as austenitic stainless steel welds)

Page 1-7
Can be complex to interpret

Eddy currents
Eddy Current and ACFM are both electro magnetic detection techniques.
These methods can detect fine surface breaking defects through non conductive
coatings. In addition they can be used to size defects for length and ACFM can
accurately size for depth.
Eddy current inspection is based on inducing electrical currents in the material being
inspected and observing the interaction between those currents and the material. Eddy
currents are generated by coils in the test probe and monitored simultaneously by
Fig 1.3. Eddy Current equipment
measuring the coils' electrical impedance. As it is an electromagnetic induction

process, direct electrical contact with the component is not required but the material
must be an electrical conductor. Note that, when used underwater, the eddy current
and ACFM techniques still work by magnetic induction. The presence of water
between the probe and test piece has no effect.
Advantages
Can detect fine surface breaking fatigue cracks

Can detect through thin surface coatings
Accurate conductivity measurements
Can be automated
Minimal cleaning required

Page 1-8
Disadvantages
Very susceptible to permeability changes

Only on conductive materials
Not suitable for very complex geometries
Signal interpretation required
A brief history of ACFM

Alternating Current Field Measurement (ACFM).
ACFM is a technique, which can be used to find, and size surface breaking defects. It
can be used through non-conductive coatings.
The theory of ACFM was developed at University College London, funded by the
Wolfson Institute; it was developed as a non-contact development of ACPD.
Eventually Technical Software Consultants (TSC) marketed the system and the first
commercial system was released in 1991. In 1995 TSC marketed the first of their
Array probe systems.
Most recently, electromagnetic arrays for large area inspection have been introduced.
These have the advantage of not requiring a length measurement, or exact placement
of the probe, and have therefore been applied to automatic or robotic deployment.

Page 1-9
Alternating Current Potential Difference (ACPD)

The ACPD technique is used for depth sizing on a surface-breaking defect, which has
normally been found using another technique such as MPI. A high standard of
cleaning is required; the depth sizing obtained is usually reliable except when severe
closure occurs.
Both ACPD and ACFM techniques give a measurement of the depth along the face of
the crack, not the through wall thickness dimensions. ACPD is generally not used for
length sizing as the time scale would be impracticable. The principle of the ACPD
technique is covered later in the notes as ACPD relates to ACFM quite closely.
ACPD Advantages
Good for profiling the defect

Operator skill required is low
Good for monitoring crack growth
ACPD Disadvantages
Not good for detection.

A high standard of cleaning is required
Will not measure through thickness, but rather along the crack face
Not good for short deep defects. Length must be at least twice the depth (2:1)
ACFM or ACPD assessment

of crack depth, along the
face of the crack.
Figure 1.4: Measurements carried out by ACFM and ACPD.

Page 1-10
Technique Material Coatings Cleaning Typical Use on Equipment

Require- Detection Complex Complexity
ment Capability Geometries
(Minimum
defect depth in
mm)
MPI Magnetic None High 0.5-3 Good Low
Dye All None High - Good Low
Penetrant
Electro- Conduct- Insulating Low 1-2 Med High
magnetic ing
Ultrasonic All Adherent High 1+ Med Med
CW
ACPD Conduct- None High 1 Med Med
ing
Figure 1.5: Comparison of NDT techniques

Page 1-11
For your notes

Page 1-12
Chapter Two
Chapter 2 Electricity and Electro - Magnetism
Basic Units used in the measurement of electricity
Volt - A measure of electrical potential (the ability to carry out work)

Ampere - A measure of the electrical current flowing in a circuit
Ohm - A measure of the resistance of a circuit
Henry - A measure of the inductance in a coil
Watt - A measure of the output of a circuit (Power)
Ohms Law:
Resistance (R) in Ohms = Voltage (V) in Volts

Current (I) in Amperes
V = I x R; I = V/R; R = V/I
Resistance is measured in units called Ohms (Ω)
I R
Figure 2.1: Ohms law triangle

Page 2-1
Resistance (R)
Resistance is the opposition to electrical flow in a material, it is proportional to the

length of the conductor and inversely proportional to the cross sectional area.
The constant of proportionality is called Resistivity, and is different for each
conductive material.
Resistivity (ρ) is measured in ohms-metres
Total Resistance of a conductor = Resistivity x Length

Area
Conductivity is the ability of a material to conduct electrical current. Conductivity (σ)

is the inverse of resistivity (ρ). Conductivity is measured in Siemens per metre
(S/m). Conductance is the inverse of resistance and is measured in Siemens.
Conductance = Conductivity x Area

Length
The conductivity is the most frequently used parameter of a material measured by

eddy currents. Conductivity is mainly determined by the chemical composition of the
material, but can be affected by many other factors including, temperature, heat
treatment and hardening. Conductivity values are frequently expressed as a
percentage of the conductivity of copper (IACS=International Annealed Copper
Standard). Some typical values of materials are given below:
Copper = 100%
Aluminium = 40-60%(dependent on alloy)
Steels = 2-4%
Silver = 110%
Magnetic Theory
Some materials will strongly attract pieces of iron to themselves, this phenomena was
discovered in the ancient Greek city of Magnesia.
Oersted discovered the link between electricity and magnetism and Faraday
conducted a number of experiments in the 19th century that revealed electrical and
magnetic energy could be interchanged.

Page 2-2
Magnetic Effect of Electric Current

When an electric current flows in a conducting material it will cause a magnetic field
to flow in circles around the conductor, the direction in which this field will flow is
shown by the Right Hand Rule, where if the extended thumb points in the direction of
current, the curled fingers point in the direction of the magnetic field.
Fig 2.2 Magnetic field surrounding an electrical conductor
The strength of the field will be increased by wrapping the conductor into a coil or
increasing the current. Then all the fields from adjacent turns add together.
Flux flow
I I
Fig 2.3 Conductor wound into a coil increasing the magnetic field strength.
Field Strength (H).
The field strength is the strength of the external magnetising force that is applied to a
material. The units are Ampere Turns per Metre and the symbol is H.
Magnetic Flux Density in Magnetic materials (B).
The magnetic flux density is defined as the number of magnetic lines of force in a test
piece per unit area. It is given the symbol B and the units are Tesla (T).

Page 2-3
The applied field strength (H) and the resulting magnetic flux density in a material
(B) are related by the equation B=µH, where µ is the permeability of the material.
Permeability (µ).
Permeability is the ease with which a material can be magnetised or conduct a

magnetic field. If various materials are placed within a magnetic field it can be seen
that materials that experience a force (magnetic materials) always bend the magnetic
field towards themselves. This causes an increase of the number of lines passing
through the material compared to the number of lines of force that would be evident at
the same location in the field if the material were not present. The ratio of the number
of lines through the material compared to air is called the relative permeability and is
given the symbol µr. A typical value of µr for mild steel is 1000.
Total permeability, µ =µoµr, where µo is the permeability of free space (a constant).
The permeability of a material is the ease with which it can be magnetised i.e. High
permeability - Easily magnetised. Low permeability - Difficult to magnetise
High permeability materials will have less depth of penetration for eddy currents &
Vice Versa.
Permeability is mostly determined by the chemical composition of the material

(particularly the iron content), but is also affected by factors such as magnetisation,
magnetic history, heat treatment, hardening and stress.
Ferromagnetic: Strongly attracted by magnets

Examples: Mild steels, irons
Paramagnetic: Weakly attracted by magnets
Examples: Aluminium, Tungsten
Diamagnetic: Slightly repelled by magnets
Examples: Gold, Copper, Water
Magnetic Hysteresis
In non-ferromagnetic materials, magnetic permeability is constant, so a plot of B

versus H is a straight line. However, in ferromagnetic materials, permeability is not
constant. It varies with H, so a plot of B versus H is not a straight line. In fact,
permeability also varies according to whether H is increasing or decreasing. This
gives rise to a phase shift between B and H, known as hysteresis.
The word Hysteresis is derived from the Greek for delayed, and is used to describe
one thing lagging behind another, specifically in this case the flux density always lags
behind the applied magnetic field.

Page 2-4
Flux density (B) in Tesla

S N
3 2
7
4 1 Field strength
(H) in Ampere
turns/metre
5 6
N S
Figure 2.4: The Hysteresis loop
1 Material in the un-magnetised state.
An external field is then applied and the flux density starts to build.
2 Maximum flux density achieved in one direction (saturated).
No matter how much more external field is applied the material can hold no
more flux lines and so can be termed saturated.
3 Retentivity point (shows residual flux density).
This is the amount of flux left in the material once the external field has been
removed.
4 Coercive point (shows the force needed to reduce flux density in the
material to zero).
A magnetising force applied in the opposite direction to the original field will
tend to reduce the flux density in the material to zero.

Page 2-5
5 Saturation point (the poles in the material would now be reversed i.e.
what was the North Pole will now be the South Pole).
6 The second point of Retentivity.
7 The second point of coercive force.
1-2 Virgin curves (cannot be repeated once the material has been magnetised ).
1-3 Residual magnetism (a measure of the flux density left in the material after
the external field has been removed).
1-4 Coercive force (a measure of the amount of external magnetising force of

opposite polarity to that which was used for the initial magnetisation of the
material needed to reduce the flux density in the material to zero).
The Hysteresis shows that however much H increases B always reaches a saturation
value. This means that µr = 1 at this point and the material behaves non-magnetically.
If the applied field (H) is reduced to zero there will still be a value of B. This is called
residual magnetism. It can be relatively permanent, as in permanent magnets or be
small and decay quickly as in iron.

Page 2-6
Differences in Permeability
B B
H H
Wide Slender
Loop Loop
Low Permeability (difficult to magnetise) High Permeability (Easily magnetised)
High Retentivity Low Retentivity

High Residual Magnetism Low Residual Magnetism
High Reluctance Low Reluctance
ddd(
High Coercive force needed to reduce the Low Coercive force needed to reduce the flux
flux density to zero density to zero
Figure 2.5: Hysterysis Loops showing differences in permeability

Page 2-7
Inductance
When a direct current is made to start to flow through a coil of wire, or to cease
flowing through it, or an alternating current flows, the flux lines around the coil will
respectively expand or collapse. This will induce a voltage in the coil itself (self
inductance). This induced voltage is out of phase with the original applied voltage.
Magnetic field from coil, B = N.I.A, so B is in phase with I.

Induced voltage from B-field, V = -dB/dt, so V is 90 degrees ahead of B (and hence
I).
Currents are induced by changing the magnetic field in a conductor. It is therefore

possible to create a current flow in an adjacent conductor either by moving a nearby
coil carrying a constant current, or by keeping the first coil fixed but changing the
current and so flux flow in the coil (mutual inductance).
Inductance is an electrical component which stores magnetic energy and the current
lags behind the voltage by 90 degrees.
Increasing the number of coil turns or the coil diameter increases the inductance
(Current has no effect)
Inductance will also increase by the addition of magnetic materials close to the coil
(by increasing B).

Page 2-8
For your notes

Page 2-9
Chapter Three
Chapter 3 Basic Principles of Eddy Current Testing
Introduction
Eddy Current inspection is widely used in industry for the inspection of metals. The
eddy current methods are sensitive to the following properties of metals:
Electrical Conductivity
Magnetic Permeability
Geometry
The capability of the technique in individual applications depends on the following:
The frequency of AC used

The sensor design
Distance of Sensor from Surface (Lift Off)
They will allow assessment of surfaces without need for contact (Through coatings).
Electrical Conductivity (σ)
Conductivity is the measure of the ease with which the electrons flow in a material
and will therefore determine the eddy current density; changes in conductivity will
affect the eddy currents produced in the material. Increased conductivity will
reduce the depth of penetration of eddy currents into the material and vice versa.
Magnetic Permeability (µ)
Permeability has the greatest effect on eddy current testing. The eddy current signals
created by permeability changes in ferrous welds can make eddy current techniques
difficult to apply, although ACFM technology has largely overcome these problems.
Some eddy current sets can provide useful information about materials by assessment
of permeability (e.g. metal type or condition).
Increased permeability will reduce the depth of penetration of eddy currents into
the material and vice versa.

Page 3-1
Frequency of the test (f)
One of the most important test variables is the frequency. Eddy current testing is
carried out at frequencies from a few Cycles Per Second (Hertz [Hz]) to several
million Cycles Per Second (Megahertz [MHz]). The most important effect of the
frequency is on the depth of penetration of the eddy current field in the test metal.
Increased frequency will reduce the depth of penetration of eddy currents into
the material and vice versa.
Depth of Penetration
All methods using alternating current are limited by the depth of penetration of such
currents into a conducting surface. Current density reduces with distance below the
surface and the theoretical depth of penetration, known as the skin depth (where the
current is reduced to approximately 1/3 of its surface value) is dependent on
conductivity, magnetic permeability and the frequency of operation.
Four examples are shown.
1 Ferritic steel has high permeability and low conductivity. The

permeability is the dominant effect and gives the smallest depth of penetration.
2 Aluminium has a high conductivity and low permeability giving a middle
depth of penetration.
3 Copper has a higher conductivity therefore less penetration than
aluminium.
4 Stainless steel has a low conductivity and low permeability giving the
deepest depth of penetration.
Figure 3.1: Frequency and Depth of Penetration

100
10
Standard Depth of Penetration (mm)
Stainless Steel
Aluminium
Copper
1
Steel
0.1
0.01
10 100 1000 10000 100000 1000000 10000000
Frequency (Hz)

Page 3-2
Applications for which electromagnetic systems can be used include:
Surface crack (defect) detection in conductors

Sub surface defect detection in non-magnetic conductors
Tube and bar inspection (production)
Tube inspection on site (e.g. Heat Exchangers and Condensers)
Metal sorting
Layer thickness measurement such as:
Insulator on conductor
Non-magnetic conductor on conductor
Conductor on Insulator
Electromagnetic Effects
In the first half of the nineteenth century it was discovered that there are three
electromagnetic effects. If a loop of wire connected to a current measuring device is
moved through a static magnetic field then the device measures a current flow. This
shows that electricity can be generated by magnetism and is the principle of the
dynamo or generator. A wire carrying an electric current experiences a force when
placed near a magnet. Also if the electric current reverses, the force changes
direction. This is the principle of the electric motor. The changing of a current in a
wire or the movement of this wire will cause another current to flow in an adjacent
but not touching wire. This is illustrated below:
Switch Meter
Circuit A Circuit B
Battery
Figure 3.2: Changing Current in circuit ‘A’ produces current in adjacent circuit B.
It should be noted that it is the closing of the switch in circuit A that causes a current
flow in circuit B (a steady direct current would have no effect). It is this phenomenon
that leads to transformers, radio and television transmission and eddy current testing.
If an A.C. current flows in circuit A, then one also flows in circuit B.

Page 3-3
Eddy Current Generation and Detection

Coils
A coil will increase the intensity of the magnetic field produced from an electric
current. The field from adjacent wires in a coil add to provide a new total magnetic
field dependent on the current and the number of turns in the coil. Coils are necessary
in eddy current testing to produce a sufficient magnetic field from limited current or a
sufficient current from a limited magnetic field. The shape of the magnetic field from
a coil is similar to that from a permanent magnet. This can be represented as a series
of lines or, for simplicity a single arrow. For D.C. current the arrowhead is at the
North Pole; for A.C. this only occurs at a certain point in time but is related to the
directions of currents flowing at the same point in time. The magnetic field varies at
the same frequency as the current in the coil. The coil windings are also sometimes
shown collectively. In practical eddy current probes a ferrite material is often used to
further concentrate and control the magnetic field. The ferrite is usually in the centre
of the coil, and in some applications (shielded probes) may also surround the coil.
Figure 3.3: Magnetic Field produced in a coil.

Page 3-4
Eddy Current Generation
If a coil carrying an AC current is brought in close proximity to a conductive material

the alternating magnetic field (primary field) will pass through the material. As
discussed above eddy currents will be induced in to the material. The eddy currents
generated will normally have circular paths at right angles to the primary field. The
flow of the eddy currents in terms of magnitude, phase and distribution depend on
several factors.
Primary
coil Ac current
Primary
magnetic field Metering
system
Alternating electrical
currents produced in the
plate (Eddy Currents)
Figure 3.4: Eddy Currents Flowing in a Material
These electrical Eddy Currents will induce a secondary magnetic field to flow in
opposition to the original primary field:
Ac current
Primary coil
Primary magnetic Metering

field system
Secondary
magnetic
Alternating
currents in the
plate (Eddy
Currents)
Figure 3.5: Secondary Field Produced By the Primary Magnetic Flow

Page 3-5
Eddy Current Detection
This situation can be balanced and so the display can be set to read zero in the normal
set of circumstances, (no crack) but if there is a change in the Eddy Current flowing in
the material this will then alter the secondary field, which in turn will affect the
characteristics of the primary coil. It is this change that will be monitored and so
displayed, normally, on either a meter or a cathode ray tube monitor.
Factors affecting Eddy Currents

There are several factors, which will affect the eddy currents, which have been
produced:
1. If a surface-breaking crack is encountered, the Eddy Current is forced to flow

under or around the crack. This will change the characteristics of the primary
coil and thus the metering system can indicate its presence.
Ac current
Primary coil
Primary magnetic Metering

system
Secondary
magnetic field
Alternating
electrical currents
in the plate (Eddy
Currents)
Figure 3.6: Eddy Current behaviour around a defect
2. If the probe lifts off from the material surface, then the results can be affected,
unless the probe has been specifically designed to limit the effects of lift off.

Page 3-6
3. Varying permeability of the test material can affect the resulting flux flow in
the test. The magnetic permeability of a metal affects the ease with which
magnetic lines will flow through it. In a material with high permeability a
larger density of these lines will be created from a given source, and the lines
will tend to concentrate in the material (particularly the surface). This has two
effects: firstly a greater amount of magnetic energy can be stored in the coil,
therefore increasing its inductance, and secondly more eddy currents are
generated which increases the lift off effects. High permeability materials
have a small depth of penetration of the eddy currents.
4. If the Eddy Currents come up against a plate edge then they will be
compressed and this will affect the results again.
Eddy
currents
deformed by
proximity of
plate edge
Figure 3.7: Edge effect or geometry
Geometry
The geometry of a component under test can cause difficulties in eddy current tests.
A curved piece of metal will obviously have a different lift off response to a flat one,
and the edge effect can distort the eddy current field and produce a large signal.
Geometrical effects can be reduced by designing a probe which fits the surface, or by
the use of shielded probes.

Page 3-7
For your notes

Page 3-8
Chapter 4 Principles of ACPD

Page 3-1
Chapter 4 Principles of ACPD
Introduction
ACPD is a well – established electromagnetic technique for sizing surface – breaking
defects in metals. It is particularly suited to obtaining detailed crack profiles and to
monitoring crack growth or initiation. It is a contacting method which requires a high
level of surface cleaning (At least ISO 8501 -1: 2001 SA 21/2 ) to achieve best results.
ACPD Principles
All methods using alternating currents are limited by the depth of penetration of these
currents into a conducting surface.
ACPD works by inputting an alternating current into the sample so it flows across the
defect. The current is normally directly injected, but can be induced. A voltage probe
then measures the surface potential differences.
By comparing the potential differences across the crack with a reference value, the
extra path length caused by the defect can be estimated, giving a value for crack
depth.
Figure 4.1: Alternating Current Potential Drop Assessment Method
100m
10 0
10mm

Page 4-1
10V 0V
2V
1V
Figure 4.2: Current flow around a crack
For a crack where the length is greater than approximately 10 times the depth, the
electric field strength can be considered constant (E). Then the voltage measured is
proportional to the path length taken by the current:
Vr = E.D and Vc = E.(D+2d)
where:
D = Distance between electrodes

Vc = Potential difference measured across the crack
Vr = Potential difference measured in the reference field adjacent to the crack
d = Crack Depth
and rearranging to eliminate E gives the crack depth by the formula:
Crack Depth, d=0.5D(Vc/Vr-1)
When the crack is shorter than 10 times the depth then a significant part of the electric
current flows around the ends. This means that the measured crack depth will be less
than the true depth. For a single semi elliptical crack correction factors have been
calculated which allow the true depth to be calculated from the measured depth and
length.
Note: The correction factors do not work for cracks deeper than semi-circular
(that is where the length to depth ratio is less than 2:1).

Page 4-2
ACPD Benefits
Can predict crack depth
Can predict crack shape
Easy interpretation of depth
No special interpretative skills required
No calibration
Very deep defects (>30mm) can be sized
ACPD Disadvantages
Difficult to set up in complex geometry
Requires removal of coatings or paint
Requires good electrical contact
Not easy to automate for field use
Poor technique for initial defect detection
Fig 4.3: ACPD 5mm and 10mm probe

Page 4-3
For your notes

Page 4-4
Chapter Five
Chapter 5 ACFM Crack Detection
Introduction
ACFM is an electromagnetic technique for detecting and sizing surface breaking
defects in metals and is particularly suited for inspecting painted and/or welded
structures.
A modern ACFM inspection system comprises of a field inducing probe with state –
of – the – art low noise analogue electronics coupled with a built in control system
and easy to use Microsoft Windows based analysis software. Frequencies used are
typically in the tens of kilohertz (5kHz to 50kHz).
Operation principles
An ACFM probe is placed on the surface to be inspected and an alternating current is

induced into the surface. When no defects are present the alternating current produces
a uniform magnetic field above the surface. Any defect present will perturb the
current forcing it to flow around and underneath the defect; this causes the magnetic
field to become non- uniform and sensors in the ACFM probe measure these field
variations. The probe is then moved along the surface, parallel to the weld (or similar
region where defects are likely to occur).
Two components (Bx and Bz) of this magnetic field are measured – one provides
information about the depth and aspect ratio of the defect(s) the other provides
information on the positions of the ends of each defect. The two signals are then used
together to confirm the presence of a defect and together with a sizing algorithm,
measure its length and depth.
Electric Field
Magnetic Field (B)
Figure 5.1: Current flow, Bx and Bz relationship

Page 5-1
Bx chart recorder trace Bx chart recorder trace

low on the graph higher on the graph
Low Current density High Current density

(Black lines) results in low (Black lines) results in
Bx flux density (Grey High Bx flux density
lines). (Grey lines).
Figure 5.2: Uniform Fields and currents on a surface
Electric Field
Magnetic Field
Fig 5.3 Bx Magnetism parallel to the plate surface

and perpendicular to the current flow.

Page 5-2
As far as the flow of current is related to the flux flow, the following are the important
principles. If a current is flowing in a surface (called the x-y plane) then:
1. The magnetic flux density in the x direction Bx is proportional to current in

the y direction.
2. The magnetic flux density in the y direction By is proportional to current in

the x direction.
3. The magnetic flux density in the z direction (out of the surface) Bz is

proportional to the curvature of current in the x-y plane.
The electrical currents will behave in a certain way when near a crack. These currents
give rise to magnetic flux density as shown below both on the surface (in the xy-
plane) and also perpendicular to the surface (in the z-direction).
Figure 5.4: Uniform Current flow in the surface of a plate being affected by a surface breaking crack.

Page 5-3
Because of the increase in flux density just outside the crack Bx will increase slightly
in this area, when actually over the centre of the crack the current density is reduced
and this will produce the following effects on the Bx trace:
Probe Movement Along Crack
Metal Surface
Crack
Bx
Current Density
Figure 5.6: Probe scanned along parallel to a crack showing the relationship of Bx to Current Density.
Because the current is being pushed around the ends of the crack, this will result in
circular current flow (Perturbation) around the crack ends, this will produce Bz just
inside the ends of the crack. Current flow is clockwise around one end, giving a
negative Bz, and anti-clockwise around the other end, giving a positive Bz. The result
of the position of Bz being just inside the ends of the crack will be that when the crack
is initially sized on the specimen by the probe operator, this size will be shorter than
that given by the ACFM program, which compensates for this problem by
mathematical algorithms.

Page 5-4
Figure 5.7: Magnetic flux density in the “Z” direction caused by curvature of currents
The result of the above will be that the specific relationship between Bx, Bz and
cracks will normally be produced as shown below:

Page 5-5
Figure 5.8: Combination of the two Bx & Bz, which come together to indicate the
presence to a crack.
Probe Design
Each probe has a magnetic yoke that is used to generate the initial magnetic field; this
in turn will create the currents of electricity in the surface of the plate. Coils or Hall
Effect sensors can be used to detect the magnetic fields. Normally, the coils are
concentric (one inside the other) to give simultaneous readings of field. However, in
probes containing small coils (for better sensitivity as in micro pencil probes) the coils
have to be placed side-by-side (as in Figure 5.9). This results in a lag between Bx and
Bz readings.
Bx
Bz
Figure 5.9: Sensing coils arranged to detect Bx & Bz above the surface of a plate.

Page 5-6
A C
Bx
Bz
Bx
Ey
Figure 5.10: Probe coil arrangement
Crack Sizing
The main feature of ACFM that distinguishes it from eddy current techniques is that
crack depth sizing is carried out by reference to theoretical models, using the
measurement of the surface magnetic fields in the X and Z plane in a uniform field.
The display produced is a direct representation of magnetic flux density, Bx and Bz.
Reduction of Lift off Effect
The use of a completely uniform field will in theory give a zero lift-off signal
(although in practice the finite field produced by a typical ACFM probe, will produce
some lift off signals).
Limitations of ACFM for weld inspection

Scanned Area
ACFM will be sensitive to the edges of components, (edge effects). These will
produce very large influences on the probe signal, which can obscure crack signals in
the vicinity of the edge. Because of this, special care must be taken when inspecting
close to plate edges. Micro and Mini probes with smaller induction coils which

Page 5-7
reduce the edge effect are normally used for the inspection of edges. The presence of
metal objects or magnets in the area of inspection may also produce unwanted signals.
Crack Sizing
The ACPD and ACFM techniques depend on theoretical models for their accuracy. It
must be assumed that the theoretical conditions may not be met operationally and so
corrections may need to be applied, if available. If this is not possible then some
inaccuracy must be accepted. ACFM relies on two basic criteria: it is assumed that
there will be a uniform field in the material and also that the crack will be semi-
elliptical in shape. Every effort should be maintained to ensure that the correct probe
is used for the position in which the test is being carried out, this should ensure a
uniform field as far as is possible. Fatigue cracks (caused by cyclic loading) typically
have a semi-elliptical shape, but other defect types (such as thermal cracks or stress
corrosion cracks) may not.
The eddy current method generally compares signals obtained from cracks to
machined slots. This will limit its accuracy because the signals obtained from
calibration slots can be very different from those obtained from real cracks.
Component Geometry
Component geometry will affect the ACFM signals. This is particularly true near to
tight or awkward geometries, corners and attachments. The signals from these
features will need to be taken into account when sizing, as the crack signals will be
superimposed on the geometric signals. This may make detection difficult, and care
will be needed when sizing.
Surface Condition
1. Non-conductive Coatings:
A non-conductive coating in good condition will not present problems for ACFM
provided that it is not more than 10 mm thickness (although sensitivity is reduced
with coating thickness). Coatings in poor condition might result in a poor scan or
produce lift off signals and reduce the accuracy of sizing.
2. Corrosion
If corrosion layers are light, this should not affect the ACFM technique, the main
problem could be if the scan becomes irregular or perhaps if there is heavy pitting,
which may introduce additional noise signals. Such signals will reduce the sensitivity
to small cracks and the accuracy of sizing. The standard weld probes are less
sensitive to pitting than other types.

Page 5-8
3. Material Changes
Metal differences and material changes that occur at weld repairs or where different
metals have been joined can produce strong signals, these may be difficult to separate
from crack signals and thus could obscure cracks.
Comparison of ACFM and Eddy Current for Weld Inspection
The following table shows some of the capabilities and properties of ACFM
compared to the most eddy current systems used today. Some generalisations have
been made and there could be times when some of the limitations may not apply.
Eddy Current ACFM
Probe Field Not quantified Produces a Uniform Field,

values used in calculations
Lift-Off Lift-Off Signal Suppressed Theoretically small lift- off

Compensation by Differential Probe signal passes unaltered
through the electronics
Calibration for Slot Signals used with Theoretical Models are

sizing compensation for geometry used. Crack depth
calculation done by
measurement of fields and
the use of Algorithms
Accuracy of Sizing Limited by accuracy of Limited by accuracy of

relationship between slot theoretical models and
and crack signals. validity of theoretical
assumptions
Gives greater variation of
signal at lower crack sizes
Optimum Portability/tight angles and Crack Sizing, arrays,

Application edges electronic recording
Capability
Main Restriction No electronic recording & Complex geometries

Complex Scanning
Figure 5.11: Variations between eddy current testing techniques and ACFM for weld
inspection.

Page 5-9
For your notes

Page 5-10
Chapter Six
Chapter 6 TSC ACFM Equipment Hardware
Types of Equipment and Software

Model U9b
This was a previous battery and mains operated instrument with a single channel
capable of being used for both ACPD and ACFM.. The battery life is 2-4 hrs and will
depend particularly on current settings. Re-charge time is 8 hours.
U9b is for use with QFM v2.0 software and can support up to three frequencies.
Note: This equipment is no longer supported by the manufacturers
Amigo (U19)
The Amigo is the current portable topside unit. It requires a PC to run it with ASSIST
software. Amigo does not support ACPD, however it can support Arrays and position
encoders. The probes are also different from those used on previous versions in that
they have electronics in the probe head. The Amigo operates at a standard frequency
of 5kHz, with 50kHz available as an option for higher sensitivity on non-ferrous
metals.
Figure 6.1: Amigo – U19 system

Page 6-1
Model U31
The U31 is the underwater version of the Amigo and represents a significant advance
in ACFM subsea inspection technology. The U31 is smaller in size and weight by
80% compared to the earlier U 21. Its compact size makes it much easier to deploy by
divers and a version is also available to fit in the framework of small ROV's. It can
also support faster scanning speeds than the U21.
Figure 6.2: U31
Model U21
The U21 is an older underwater version of the ACFM/ACPD equipment. The U21
unit is for use with WAMI 4 software only.
Figure 6.3: U 21
Note: This is no longer supported by the manufacturers.

Page 6-2
Array Equipment
Array probes require special software to collect and display the kind of data that is
produced by arrays.
Figure 6.4: Array probe and typical display.

Page 6-3
Software
QFM v3.0
QFM Version 3 software was produced for the U19 “Amigo”; for operators used to
using QFM v2 with the U9. It is superceded by ASSIST software.
Note: The above software is no longer issued by the manufacturer unless

requested.
ASSIST
The latest software for use with the current generation of ACFM instrumentation is
the ASSIST family (ACFM Software Suite for the Inspection of Structures). The
family consists of the following products:
ASSISTant Supports only standard manual probes (1Bx and 1 Bz).

ASSIST Lite Supports standard probes and small arrays of up to 3 rows
with or without encoders.
ASSIST Supports standard probes and all arrays.
ASSISTU Underwater version for use with U31.
ACFM Probe Types

All manually scanned ACFM probes have features, which must be brought to the
attention of the probe operator, these are:
1 Serial number of the probe

2 A or C direction markings
3 Centre or Index line
4 Connections
Standard weld Probe
This probe should be used for weld inspection whenever possible, as it has the largest
inducing coil for optimum crack sizing. It has a fairly large edge effect of
approximately 50mm. Note the yellow label colour, which indicates that the probe
contains larger concentric sensor coils.

Page 6-4
Figure 6.5: Standard Weld Probe
Tight Access Probe
The tight access probe was designed specifically for occasions when the area under
inspection is not accessible for the standard weld probe, in particular for angled
tubulars. It is not suitable for sizing in open geometries such as butt welds.
Mini Pencil Probe
Mini pencil probes are designed for tight access areas such as ratholes and cruciforms.
They have a reduced edge effect. They are available in straight, right angle or
transverse designs. Accurate sizing may be limited to shallow cracks only, and they
are more sensitive to lift off.
Figure 6.6: Mini straight probe

Page 6-5
Micro Pencil Probe
Micro probes are similar to mini pencil probes but are designed for higher sensitivity
crack detection in all areas. They are available in straight, right angle or transverse
designs. Accurate sizing may be limited to shallow cracks only, and they are more
sensitive to lift off. These have a blue label (for 5 kHz probes) to show they contain
smaller non-concentric sensor coils (or a red label for 50 kHz probes).
Figure 6.7: Micro right angled probe
Thread Probe
ACFM is particularly suited to detection and sizing of cracks in large threads (for
example drill collars). The universal thread probe is designed to be used with an
interchangeable shoe to fit the exact thread to be inspected.
Figure 6.8: Universal thread probe and shoes

Page 6-6
Encoder Weld Probe
Similar to Standard Weld Probe but contains:
Belt driven Position Encoder

Twin Fields
Control Buttons
Up to 8 Channel Sensor Array
Figure 6.9: Encoder weld probe – type 325
This probe features a position encoder to provide a continuous position reference and
the opportunity for rapid defect location, multiple sensor options for greater coverage,
option of twin field directions. Other new features significantly improve the usability
of the probe while at the same time probe wear has been significantly reduced.
Array Probes
A number of array probes have been made, for a variety of geometries. Array probes
have the advantage of quickly covering a large area.
Figure 6.10: Array Probe configured for inspection of tubes

Page 6-7
Probe Connections
Connections to all units are unique and are therefore unlikely to be confused. As with
all computer driven equipment all connections should be made prior to switching
units on. The ACFM instruments should be switched on before starting the software
or the computer may try to address a 'dead' instrument which will produce an error
message.
Figure 6.11 Lemo Connectors
Function Test Block

ACFM does not require calibration, however the operator does need to ensure that the
equipment is functioning correctly, for this a standard function check plate is used
made of the same material as that being inspected. Each plate is numbered (This
number must be recorded); each plate has a slot 50mm long x 5mm deep this slot
must be at least 100mm in from the edge.
100 mm 20mm x 2mm 50mm x 5mm
Figure 6.12: Function check plate

Page 6-8
A lighter test plate (Figure 6.13) s also available for use in demonstrations. This
checks that the equipment is working but does not check that instrument settings are
correct. It should not be used instead of a proper function check plate.
Figure 6.13: Light Weight Function check plate

Page 6-9
Ancillary Equipment needed when carrying out ACFM Inspection:
1 Magnetic marking arrows

2 Paintstick
3 Tape measures/ruler
4 Computer discs or memory sticks for backup and log sheets
Computer {PC} (Min 1 Gb, 256Mb RAM) Microsoft

Windows 2000 / XP- Vista
U19 AMIGO
Crack Microgauge
Comms
Lead (Max 30m)
Umbilical & Possible
extension cable 50 m max
ACFM Single probe
Weld to be Scanned
Figure 6.14: Block diagram for the topside ACFM system.
Computer {PC}
U21 or U31 ACFM Crack

Comms Microgauge topside unit
Lead (Max 30m)
Sea level
Umbilical (Up to 350m for

diver use, 1500m for ROV )
Underwater ACFM Single probe
Connector for Probe
Subsea Pot Weld to be Scanned
Figure 6.15: Block diagram for the subsea ACFM system.

Page 6-10
For your notes

Page 6-11
Chapter Seven
Chapter 7 Operation of ASSIST Suite of Software
WINDOWS
Windows is a software operating system marketed by Microsoft for display and
simultaneous use of a number of programmes. Windows software versions are
regularly updated. Recent versions, all supported by ASSIST, are 2000, XP, Vista and
7.
Windows Explorer
Windows Explorer is one of the most useful of Windows programs. It can be used for
moving copying, re-naming as well as deleting files and creating and deleting
directories.
Drives and Directories

A:\ = “Floppy” disk or “Diskette”. This can be removed from the computer
for transport of files. New diskettes for data storage may need to be formatted.
Note: Most computers are now supplied without the ‘A’ drive
C:\ = This disk is not removable from the computer (commonly termed the
“hard drive”), it is the main storage area for data and programs within the computer
D:\ = Normally this will be reserved for a CD - ROM /DVD drive, on which
will be program information (Read only) or re-writable CD / DVD
E:\ = This will normally be another removable drive used for data storage
and export, it may be one of several types such as:
a) CompactFlashcard
b) Memory stick
c) CD ROM
Higher letters are used when required (e.g. external expansion ports, network
connections etc.
Software Installation
The software packages are usually supplied on a CD-ROM.
Insert the CD- ROM into the drive on the PC.
The instructions to install the software should appear automatically.

Page 7-1
If not using Explorer or My Computer, select the CD – ROM drive.

Double click on the ReadMe file.
Follow the onscreen instructions to install the software.
Probe File Installation

Before you can use a probe with the software, it is necessary to install the probes
configuration file.
Insert the CD (or other media) supplied with the probe. The installation program
should run automatically. Otherwise:
Copy the probe file ( < serial number > .QPC file
Paste it into the < programme directory >\ Mainstore \ Probes” folders.
These instructions are supplied on a readme text file with the disc.
Hotkeys
Hot keys are a method of reducing the number of operations necessary in order to
make a function occur. A list of the main hot keys available in ASSIST is given
below. The hot keys are also shown to the right of the command in a menu in the
ASSIST software.

Page 7-2
Key Function
A Set Anticlockwise scan direction
C Set Clockwise scan direction
D Sets Default display ranges
E End Current Replay
I Goes to the first page in the file
K Clears an area, swept in the Bz, of defect calls
L Goes to the last page in the file
M Mimics the action of pressing the Mark button on the
instrument
N Selects the Next data page in a file
P Selects the Previous data page in a file
(P) when Pauses the scan
running
R Runs a scan
S Stops a scan
T Set Transverse scan direction
V Centres the data in the windows
X Decreases the zoom level on a currently page width
zoomed section
Z Zooms the page width to fit a region selected in the Bz
window
ENTER Places general marker into scan data
SPACE Places numbered position marker into scan data
> Faster Replay
< Slower Replay
In addition to these single hotkeys, others have been added that are pressed while
holding down the Control (Ctrl) key to access frequently used dialog boxes.
Key Function
Ctrl + Opens the Info – Defects dialog
D
Ctrl + Opens the Info – Notes dialog
N
Ctrl + Opens the Info – Regions dialog
R
Ctrl + Opens the setup - markers
C

Page 7-3
For your notes

Page 7-4
Chapter Eight
Chapter 8 Assist Family Software
Introduction
The latest software for use with the current generation of ACFM instrumentation is
the ASSIST family (ACFM Software Suite for the Inspection of Structures). The
family consists of the following products:
ASSISTant Supports only standard manual probes (1Bx and 1 Bz) on Amigo.
This software version supersedes QFM3
ASSIST Lite Supports standard probes and small arrays of up to 3 rows with or
without encoders on Amigo.
ASSIST Supports standard probes and all arrays on Amigo.
ASSISTu Supports all probes on U31. Supercedes QFMu
The software has been developed to run on laptops or desktop PC's running Windows
2000 or later. Some devices now feature touch-screens so function buttons have been
used, in addition to menus, which can be selected easily with finger or stylus.
ASSISTant Software for AMIGO U19
Features available in ASSISTant are:

Automated file naming (with date/time stamp). Data files are stored by job code and
component description, making searching old data easier.
Profiles (use of any data page as a background to compare against other pages).
Useful when data is affected by geometric features.
Free entry Notes on each data page.
Ability to store sizing data from multiple defects on a page. Automatic location and
measurement of Bx minimum and Bz peak-trough values during sizing.
Defects marked in coloured bands on display after sizing.
User-controlled marking of anomalous features (such as seam welds, undercut) in
coloured bands.
Automatic fitting of data to screen width.
Easier switching between views, as well as new combination views (time-base and
contour plot). Single key centring of display, and zooming into marked region.
Improved print-outs for reports.
User-friendly ICON buttons.

Page 8-1
Easier transition to full ASSIST for array probes.
Software Description
Overview
The program can be started using a program icon on the desktop or from the Start
menu.
If an instrument is attached, this should be turned on before starting the software –
when the program starts it tries automatically to communicate with any attached
instrument.
The first program screen is the Task Selection Screen from which a job code and
method of inspection can be chosen. This links to the main Inspection Screen giving
you access to the inspection functions of the program. The program uses a
combination of buttons and drop-down menus to give access to its functionality.
Task Screen
The Task Screen is the first screen that you see when starting the program.
The left area enables the Job Code and your name to be entered or selected. It also has
two buttons that select the two different inspection modes Operations Check and
General Inspection. Below these are buttons for Help and program Exit.

Page 8-2
Function Check
This inspection method should be used to carry out functional checks of the
instrument and probes. The following panel is displayed:
If a probe is plugged into the instrument socket, and the instrument communications
are enabled, then the probe's serial number will automatically be displayed in the
Probe Serial No. box. If it is not then select the required number from the drop-down
list.
Select the configuration required for the inspection. The option will normally be
"ferritic steel" for most structural inspections.
For more recent instruments, the instrument serial number will be displayed
automatically.
If not, enter the serial number for the ACFM instrument in the Instrument box. Note
that if it has been entered previously then it will be available in the drop-down list.
Press Inspect to move on to the ACFM data screen.
Press Cancel if you want to return to the previous screen
Press Clear if you want to clear all the entries in the boxes.
Press Browse to look for a particular file already stored on the machine. Browse opens
a panel that displays all the Function Check files that match any entries in the
Function Check panel. For example, if you entered a particular probe serial number
but left the other boxes blank, then the panel would display all the files that were
taken with that particular probe. This can be very useful for finding a particular file.
Note that, when using Windows Explorer, all Function Check files start with an “O”
and are found in the directory ……\Assist\Main Store\Scan Data.

Page 8-3
Select one of the listed files and press OK. You will notice that this file's details will
appear in the Function Check panel. Simply press Inspect to review the data.
General
This inspection method should be used for all inspections. The following panel is
displayed:
If a probe is plugged into the instrument socket, and the instrument communications
are enabled, then the probe's serial number will automatically be displayed in the
Probe Serial No. box. If it is not then select the required number from the drop-down
list.
Select the configuration required for the inspection. This will normally be "ferritic
steel" for most structural inspections.
Enter a component description in the Component box, or select a previous item from
the drop-down list.
Press Inspect to move on to the ACFM data screen.
Press Cancel if you want to return to the previous screen.
Press Clear if you want to clear all the entries in the boxes.

Page 8-4
Press Browse to look for a particular file already stored on the machine. Browse opens
a panel that displays all the General files that match any entries in the General
Inspection panel. E.g. if you selected a particular component but left the other boxes
blank, then the panel would display all the files that were taken for that particular
component. This can be very useful for finding a particular file.
Select one of the listed files and press OK. You will notice that this file's details will
appear in the General Inspection panel. Simply press Inspect to review the data.
Note that, when using Windows Explorer, all General Inspection files start with a “G”
and are found in the directory ……\Assist\Main Store\Scan Data.
Probe Config Button
Note: This inspection method should ONLY be used for creating new probe
configurations. The creation of probe configurations should only be undertaken
by a Level 2 user who is completely familiar with the implication of probe file
configurations. See Level 2 course notes

Page 8-5
ACFM Data Screen

The ACFM Data Screen is the area where the ACFM data is displayed and analysed.
As such, it is the layout that will be seen most often by the operator. It consists of a
control area, file information area and defect details/page notes area at the top and a
data display area underneath with a scroll bar at the very bottom. The control area
comprises two rows of buttons and a central information bar. The top row is used to
select the type of view that the data is displayed with, such as butterfly plot or line
traces, and the lower buttons select groups of actions or information.
ACFM Data Screen

Page 8-6
defects
seam weld
Combined Plot
The combined plot shows both the line traces and butterfly plot at the same time. This
is the same view displayed when collecting data. You can use all of the functionality
associated with the individually displayed plot types.
Probe Configuration (Level 2 Function)
Contour Plot Button
This button displays the ACFM data as a 2D map that is coloured according to the
reading value. Two separate panes contain Bx and Bz data.
Note: This plot is usually only useful when looking at array data.
Replay Button
This button allows you to replay a scan and watch the data appear in a similar way to
live collection. This can be particularly useful for observing the direction of the
butterfly loop for example. The speed of reply can also be adjusted.
Below is a screen shot of the replay functionality at work.

Page 8-7
When running a replay additional buttons are enabled to control the replay functions:
Repeatedly replays data in a style similar to when the data was

collected.
Replays the data once in the normal view style.
HotKey: < - Slower replay.
HotKey: > - Faster replay.
HotKey: E – End current replay.

While replay is enabled all other program functionality is disabled until the replay is
ended.
Field Display Button
OR
Not supported in ASSISTant
Note: Y field data is only applicable to array probes with twin fields
This button selects which field's data to display. When the X field logo is showing,
the data corresponding to the X field excitation coil is shown, i.e. the conventional
field direction when using manual probes. This field is sensitive to defects lying in the
same line as the scan direction. Alternately when the Y field logo is showing, the data
represents that collected in the Y field which is at right angles to the X. This field is
sensitive to transverse defects that run across the line of the scan.
Battery Level
Pressing this button sends a query to the instrument and displays the reported
instrument battery level.
The following icons indicate a particular battery state:
Battery full.
Battery 2/3 full.
Battery 1/3 full.

Page 8-8
Battery voltage getting low - recharge soon or connect power.
Battery too low for the instrument to operate. Change for full
battery pack, switch off and recharge or connect power.
Battery status could not be determined. Try pressing the button

again. If this remains then check that the instrument is switched on and
that the communications lead is connected. (Also appears when running
with no instrument attached).
Information bar
This area separates the two rows of buttons and displays various pieces of information
about the data.
When switching between pages it shows the page number against the total number of
pages.
When a data view type button is pressed it shows the Bx and Bz ranges along with the
scan length (for encoder probes).
When sizing a defect it shows the Bx and Bz values selected.
Scan Direction Button
This button sets the direction for the next scan:
HotKey: C - Scan will be performed in the C direction.
HotKey: A - Scan will be performed in the A direction.
HotKey: T - Scan will be performed in a transverse (sideways)

direction i.e. normal to the standard A-C direction.
Manual probe direction undefined.
If the run button is pressed when the direction is undefined a warning message is
given and the scan cannot begin until a valid direction is entered.

Page 8-9
Run Button
HotKey: R
As its name suggests, this button sends an instruction to the instrument to begin
collecting ACFM data. While a scan is in progress, the whole lower buttons change:
Pressing the Stop button (HotKey: S) will stop the scan.

Pressing the Pause button (HotKey: P) will pause the scan - press unPause button (or
P again) to resume the scan.
Pressing the Pos. button places a numbered position marker in the data. The numbers
can be set up using the Setup Markers panel.
Pressing the Mark button places a general marker in the data.
Note that markers can also be placed in the data using the instrument mark button.
The type of marker that this button generates is controlled in the Setup Markers panel.
Analyse Button
The Analyse button accesses certain functions required in analysing the data. The
following panel is displayed:
Press one of the following buttons or press the Cancel button to leave this screen.
Note that if the screen scalings are altered using the zoom or fit options the Analyse
button changes to alert you to the fact that you are not seeing the traces at the correct
level of "magnification".
Default
HotKey: D
Pressing this button sets the screen scalings to those in the probe file (to be used after
zooming into or out of the data, and prior to collecting new data).

Page 8-10
Centre
HotKey: V
Pressing this button centres the traces in the windows. The hotkey: V can also be used
at any time.
Zoom
This allows you to change the data display scalings and effectively "zoom" in or out
on any particular feature. The following panel is displayed to allow you to set the
required display ranges:
Fit
Pressing this button will cause the screen scalings to change so that the data fills the
screen. The Bx and Bz are scaled in the same proportions as the default probe scalings
so that butterfly loops appear with the correct ratio.
As a side effect the Analyse button changes and the message “Scalings lost” appears
on the bottom of the screen to alert you to the fact that you are not seeing the traces at
the correct level of "magnification" set in the probe file.
Size Defect
This button is used to size a defect manually using data points you have previously
marked on the line traces.

Page 8-11
Add Region
This button enables you to mark a specified region onto the data, to represent a seam
weld for example.
To add a region:
Mark the area required by sweeping in the Bz trace.
Choose Analyse and press the Add Region button.
Drop down the types box and select the required region type. Note that the colour
produced on the trace will depend on the option chosen. The options are:
Defect - Red
Unclassified - Blue
Anomalous – Blue
Undercut – Green
Seam weld - Green
Clear - Green
Press OK
The new region will be added to the list of regions and the area will be displayed in
the corresponding colour in the Bx trace.
Standardise
Note: This option is only available in Probe Configuration mode. See Level 2
Course Notes

Page 8-12
Info Button
As its name suggests, the Info button accesses inspection information. The following
panel is displayed:
Notes
HotKey: Ctrl + N
This button opens a panel where you can type in any information relating to the
current data page. This could be the meaning of marker locations or any other notes
that would be helpful when reviewing the file. The date and time that the page of data
was collected on is shown at the bottom of the panel.
The contents of the notes page can be found to the top right of the data screen. This
can be changed to show the defects list by pressing the adjacent button.
There eight buttons that can be pre – configured by accessing
C:\programmes\ASSIST. Click on “NoteInserts” and edit buttons in “Notepad”.

Page 8-13
Defect Info.
HotKey: Ctrl + D
This button produces a panel that shows details of the defects identified on the page.
Any defects that have been sized are displayed in the main list box which shows their
ID number, location, length and depth in mm and row number which the defect was
sized on. When in probe configuration mode there is another column which shows the
coil factor used when sizing the defect.
Region Info.
HotKey: Ctrl + R
Various parts or "Regions" of the traces can be highlighted and assigned a particular
classification e.g. Seam welds, Anomalous etc. Viewing and editing this information
is performed by pressing the Region info button. Note: if you delete a previously
marked defect, the red defect region remains highlighted until it is removed using this
panel.
Settings
This button displays a panel that shows the instrument settings in operation when the
data page was collected. These settings are therefore fixed and you cannot edit them.
Print
It allows you to print out any page of data from a data file.
Note: See chapter 14

Page 8-14
Setup Button
The Setup button allows certain software or instrument properties to be altered. The
following panel is displayed:
Scan Rate
This allows you to adjust the rate at which data is collected and, as a result, the speed
at which the traces appear on the screen. The following panel is shown.
Setting Scan Speed, Communications rate or sample rate
Sometimes the traces may be moving across the screen either too fast or too slowly
for the particular inspection conditions, this can be altered by changing the Scan Rate
by clicking on the Setup button.

Page 8-15
What the scan Move the slider towards the top to increase the scan rate or move it towards the
rate number bottom to decrease. The actual scan rate is shown in the box. Note that zero is
actually the fastest scan rate and 1000 the slowest.
represents is Note that the Scan Rate does not affect the collection of data when a probe with
the amount of an encoder is used and the Setup Software panel is in the distance based mode.
time (in 1/100 The encoder controls the resolution of data collected.
of a second)
between
successive
data points.
The ASSIST software sets the scan speed at default setting of 0.03 seconds (i.e. Scan
Rate = 3). The scan interval is the amount of time between consecutive reads of the
probe data and effectively controls the rate at which the readings are passed from the
instrument to the PC. This has the effect of changing the speed at which the traces
cross the display screen during scanning. A scan interval of 0 will produce the fastest
data collection rate and a scan speed of 10 seconds will produce the lowest.
Display where scan rate set too low Display where scan speed is set correctly
Markers
This button displays a panel that allows you to alter the marker parameters.

Page 8-16
For inspecting a cylindrical geometry, where markers are to be clock points, the Max
Value should be set to 12. This is the number at which the marker numbers are reset.
If the incrementing box is ticked, numbers go up (i.e. clockwise on a clock face), if it
is un-ticked, numbers go down.
Software
This button displays a panel that allows you to alter the software settings that are
specific to inspecting. These functions are somewhat advanced and it is therefore
unlikely that a level 1 operator would need to access this screen.
Instrument
Note: Changing values in this panel may seriously affect the inspection
configurations. As such, it should not be used by a level 1 operator. See level 2
Course notes.
Coating
This button displays a panel that allows you to alter the coating thickness or liftoff
that the probe is operating through.
More Button
This button displays the following panel.

Page 8-17
Press one of the following buttons to make a selection or press Cancel to close the
panel.
Previous
Hotkey: P
Displays the previous page of data in the current file.
Next
Hotkey: N
Displays the next page of data in the current file.
Delete
Note: Deleted pages cannot be restored
Task Screen
This button returns you to the task screen with the Inspection information
panel still showing for the current file.

Page 8-18
For your notes

Page 8-19
Chapter Nine
Chapter 9 Bx - Bz and Butterfly Plot Relationship
Introduction
Bx and Bz signals are presented as traces on a timebase which shows levels of flux
density in the X and Z directions. When plotted against each other they form what is
termed as the butterfly plot. This plot is called the butterfly plot because the shape of
the signal produced by a defect is that of butterfly wings. It is important to understand
the relationship between the scans and this is shown in below.
Bx
Increasing
Bz Start point
Increasing
Figure 9.1: Bx and Bz in the Butterfly plot
By removing time from the display, the butterfly plot is independent of the speed of
probe movement. It also helps the operator distinguish signals due to a crack from
other signals.
Crack like Signals

Semi Elliptical Crack along scan
The classic butterfly shape from a crack-like indication from a detection scan is
shown below in figure 9.2.
The direction in which the butterfly plot is orientated may be either in the clockwise
or anti-clockwise direction. This will be dependant on the direction in which the
probe approaches the crack; this is determined by the direction of movement of the
probe. Every probe has letters A and C on either side of the label. The probe operator
reports which of these letters is leading in a scan. The ACFM operator enters the
direction in the software so that the direction of the probe will be indicated on the
ASSIST Data screen.

Page 9-1
Figure 9.2: Cracklike indication showing relationship between Bx & Bz
The above shows Bx, Bz and butterfly plots for a fatigue crack. In the case of the
micro probe and thread probe the sensing coils are slightly displaced from each other.
This results in a skewed butterfly plot as shown below.
C - direction scan
Figure 9.3: Appearance of ACFM crack signals for micro and thread probes.

Page 9-2
Crack at angle to scan
If the crack is at an angle to the scan it is likely to produce a signal as shown below.
The Bz is reduced because the sensor probe passes some distance away from the Bz
trough. This type of signal can appear when a crack turns a corner at the end of an
attachment or rathole.
Scan passes over this Scan passes this end of the

end of the crack crack at a distance
Weld
Scan passes this end of the

Scan passes over this crack at a distance
end of the crack
Weld
Figure 9.4: Crack at angle to scan
Figure 9.5: Example of crack signal from opposite toe of weld

Page 9-3
Line Contacts and multiple cracks
When contacts occur within a crack, loops of the butterfly plot occur within the main
loop of the crack which indicates areas where the current is bridging the crack. If
more than one crack occurs in the scan then there will be a number of loops but the
Bx will return to the background between loops.
Line contact indication
Figure 9.6: Example of scan showing line contact
Other Signals
Signals from other features can distort crack signals and make detection and
identification more difficult. It is very important for an ACFM operator to be able to
quantify the effect of non-relevant signals such as geometric effects. Visual inspection
may be needed to help quantify some types of signals.
Lift-Off
Small amounts of lift-off may not affect the ACFM probe, however substantial
movement of the probe will produce large signals. These can usually be identified
because Bx and Bz move together rather than at different times as they do for most
defects. Lift-off due to deep grind repairs and /or seam welds can produce crack like
signals. The probe operator should inform the ACFM operator that there is a ground
out area or seam weld in the vicinity of the scan.

Page 9-4
Operators should also be aware of a gradual change in the noise level when scanning
the weld toe. This could be due to scanning onto or off the weld cap or because as the
scan progresses the joint geometry is changing.
Geometry
When a probe scans into tight geometry the Bx signal will tend to gradually increase.
This will occur on all tubular joints to some extent as the geometry is continually
changing.
Figure 9.7: Scan into tightening geometry
If a crack indication is found when scanning into a tightening geometry, then the
crack indication will be superimposed on the geometry effect, see figure 9.8.
Figure 9.8: Effects of scanning into tightening geometry on Crack indication.

Page 9-5
Materials
The use of ACFM to scan materials other than steel is not considered in this course.
However the presence of different materials in and around the weld area in steel can
cause unwanted signals, which may or may not be like crack signals. Material
changes such as different materials in a weld repair can also produce signals. Suitable
scanning procedures can sometimes help to distinguish the signals.
Seam Welds
Signals from seam welds can be very similar to cracklike indications. Seam welds
normally produce upward forming butterfly plots but occasionally downward forming
butterfly plots can be produced from some seam welds. It is important when
scanning over seam welds that the signals are verified. This can be achieved by
simply marking the beginning and the end points as the probe transverses the weld. If
the signals correlate with the markers then there is a good probability that the signals
are produced by the weld and not a fatigue defect. This can be confirmed by making
further scans across different parts of the seam weld. If the signal is produced solely
by the seam weld, the same size signal will be observed (see Fig 9.10).
A C 1
25mm
A C 2
Figure 9.9: Verifying cracklike indications

Page 9-6
A C 1
25mm
A C 2
Seam Weld
Figure 9.10: Verifying indications from seam welds
If a crack like signal is encountered, but for some reason there is some doubt and it is
thought that maybe the signal is due to an inclusion then the following procedure
could clear up any doubt:
Initially the screen shows a crack like signal when scanned in the normal way:
Figure 9.9: This cracklike signal will be repeated if another scan is carried out parallel to the first but
5mm away from the toe.

Page 9-7
Figure 9.10: In fact the same cracklike signal will be evident until the scan line takes the probe past
the inclusion and thus there is no effect from it.
Figure 9.11: Turn the probe through 900 and scan across the inclusion there will be a cracklike
indication produced.

Page 9-8
Magnetism
Residual Magnetism can affect the magnetic properties of the material and this will
therefore affect the ACFM traces. For most structural steels residual magnetism
decays within a few hours, but where MPI or other magnetic devices have been
recently used the area should be demagnetised.
Edges and Corners
An edge can produce a signal as shown below for a standard probe (although usually
the change in Bx is larger than that in Bz).
Figure 9.12: Edge Effect shown by the oval window

Page 9-9
START
Yes Signal dies quickly
Downward Butterfly ? 25mm away
No Yes
Other feature CRACK

No
No Yes
Crack Unlikely
Any Significant Possible Crack
Loops ?
Any Dips in Bx
No Below the Trend ?
Yes
No
Any peaks in Bx
Any Associated peaks If it is possible that the probe was not
above the trend
with upward and troughs on Bz? following the weld, rescan.
butterfly?
Otherwise, NO CRACK
Yes
Probably a long CRACK.

Possible
transverse crack Scan a large section and look for crack-like
or material trends, especially on Bx, to confirm.
inclusion?
Figure 9.14: Signal Interpretation

Page 9-10
For your notes

Page 9-11
Chapter Ten
Chapter 10 Briefing Requirements for Remote Scanning
Introduction to remote probe operations

The remote probe operator has a very important role in the detection and sizing of
fatigue cracks using ACFM technology. It is therefore imperative that the probe
operator is thoroughly briefed with regard to his duties. Probe operators should have
an inspection background, either welding inspection or Non-Destructive Testing
(NDT). For subsea inspections the diver carrying out the remote probe operations
should at least have a current CSWIP 3.1U or equivalent diver qualification.
General Introduction
It is likely that the probe operator will not be familiar with ACFM technology and in
some cases will not have met the ACFM operator. The briefing should always
commence with a general introduction followed by an overview of the system. This
should include the systems capabilities and a general description on how it works.
Safety awareness
Briefing on the aspects of site safety is of utmost importance. Probe operators should
be made aware of local site safety rules, instructions and guidance. This will include
safe to work permits and PPE requirements. He should also be aware of any electrical
safety requirements.
Probe selection and features

For optimum performance it is important that the best probe for the application should
be chosen. Although the probe operator does not choose the probe he needs to be
aware of the different types of probe available and their application. All manually
scanned probes have features that must be brought to the attention of the probe
operator, these are:
Serial number of the probe

A or C direction markings
Centre or index line
Connections

Page 10-1
Scribed line Serial Number A and C markings

Probe Connection
In addition the probe operator should be informed that the ACFM probe contains a
main induction coil and two sensor coils, Bx and Bz.
Probe connections
Probes are connected to either the Subsea Unit or Topside instrument by a single
connector. Probes should never be changed underwater without switching off the
Subsea Unit simply by switching the, ‘Probe Off’ button in the software and
recovering the unit to the topside.
Cleaning requirements
The inspection area will need to be cleaned of marine growth if underwater; however
paint removal is not necessary. The surface needs to be cleaned of loose flaking paint
or corrosion. The important point is that cleaning should be sufficient to allow smooth
probe travel.
Marking up the component

Once the cleaning has been carried out, the area must be marked up. This may require
the use of clock or marker positions or increments of 100 - 50mm. This should be
done using a paint stick or similar marker. Incremental or clock markings should
always refer to a datum or fixed reference point.
Visual inspection
Visual inspection should identify any visual irregularity which will be likely to affect
probe movement, or alternatively the ACFM signal produced. These should all be
reported prior to the ACFM inspection. The following is a list of some of the
reportable items:

Page 10-2
seam welds
areas of grinding
spatter
bolt heads
nearby stiffeners etc.
Scanning techniques
When scanning, the probe operator should avoid any rocking, yawing, or lifting off of
the Probe. Similarly any deviations from the weld toe, either away from the toe or
riding up onto the weldcap, should be reported.
When holding the probe light pressure only should be applied. Heavy handed probing
will result in unnecessary probe wear and possibly expose the sensor coils. Often
electrical PVC tape is used to cut down the wear of the probe sensor housing.
Scanning speed should ideally be smooth and at an even constant speed of up to
around 50 mm per second. This speed should be decreased on rough surfaces, or in
tight geometries.
Always start the scan with an ops check to identify long defects (see chapter 12).
To ensure that 100% of the weld is inspected and that defects are not missed at the
beginning and the ends of scans at least 50mm overlaps should be included between
the detection scans.
Sizing for length

Once the detection scans have been completed sizing for length will be covered in
chapter 13 of this manual.
Probe Operator briefing check off sheet

1 qualification
2 general introduction
3 safety awareness
4 probe selection and features
5 probe connections
6 cleaning requirements
7 marking up the component
8 visual inspection
9 scanning techniques
10 sizing for length
11 any questions

Page 10-3
For your notes

Page 10-4
Chapter Eleven
Chapter 11 Function and Operation Checks
Function Check
Function Test Plate
The test plate supplied by TSC should include a 50mm long by 5mm deep slot and a
20mm long by 2mm deep on one side of a weld. This slot should be at least 100mm
from the edge of the plate.
100 mm 20mm x 2mm 50mm x 5mm
Figure 11.1 Function test plate
Plastic Test Plate
This plate should only be used for checking the functionality of the equipment and not
for checking depth sizing capabilities.
Figure 11.2 Lightweight portable function test plate

Page 11-1
Probe Scalings
Most TSC probe files use scalings based on a 50mm long x 5mm deep slot. The
20mm long x 2mm deep slot is for micro probes only. The scalings are chosen to give
a suitable size signal to be displayed on the screen. These are adjusted to give a
butterfly plot signal, which extends for 50% of the screen in the Bx scale (vertical)
and 175% of the screen in the Bz scale (horizontal). Also check that the background
Bx falls between 700 – 1600 range. This appears on the screen as below:
Figure 11.1: Display from Standard probe scanned over the function test plate
Operations check
The Operations Check

Page 11-2
Figure 11.2: Operations check to check for full-length defect.
Figure 11.2 shows the signal expected from a scan up to a weld with no large defect.
The Bx trace will increase, or stay flat.
If the Bx trace decreases significantly, this could indicate a large defect. Note that a
defect running the full length of a weld will have no “ends”, so no Bz peak or trough
will be produced. Such a defect can be detected by repeating the operations check at
different locations along the weld.

Page 11-3
For your notes

Page 11-4
Chapter Twelve
Chapter 12 Scanning for detection - Summary
1 A function check should be carried out using the function test block. All
probes should be checked prior to an inspection shift.
2 The displayed signal from a 50mm x 5mm slot be 50% Bx (screen height) and
175% Bz (screen width) for a standard or mini probe. The display will apply
from a 20mm x 2 mm slot for a micro probe. (See chapter 11).
3 Brief the probe operator.
4 Deploy the equipment ensuring:
Watertight integrity (for subsea use)

All ancillary equipment is provided
All probes secured
5 Identify the component.
6 Ensure the correct level of cleaning has been carried out as follows:
All marine growth removed (subsea only)

Scale removed
Flaking paint removed
7 Mark up component in 50mm or 100mm increments or clock positions from a

fixed datum point.
8 Visually inspect component.
9 Demagnetise if required.
10 Carry out operations check (See chapter 11).
11 Set up direction of scan. Either A or C direction.
Figure 12.1: Click for direction or use Hotkey C or A

Page 12-1
12 Setup Markers
Figure 12.2: Setup markers
13 Scan for detection ensuring overlap at the ends of scans.
14 Repeat detection scans along the opposite weld toe and at 15mm increments
across the weld cap.
15 If a defect indication is detected at a toe, carry out a further scan 10-20mm

away from toe to ensure signal not caused by seam weld or other large change
in material property.
16 If defect confirmed, carry out further scans parallel to and 5mm either side of
original scan to determine where the maximum signal variation occurs – this
will be when the sensors pass directly over the top of the defect.
16 Sizing scans (See chapter 13).
17 Ensure all data pages have notes entered up (e.g. on chord toe, cap etc).
18 Exit software, all data files will be automatically saved. Copy data files to
media via windows explorer.
19 Recover equipment and carry out the following:
Wash with freshwater (subsea inspection only)

Carry out any maintenance
Store safely
Recharge batteries (4 hrs approx for Lithium Ion battery pack )

Page 12-2
For your notes

Page 12-3
Chapter Thirteen

Page 12-1
Chapter Thirteen
Chapter 13 Scanning for Sizing
Introduction
There are three measurements required from the data for ACFM software to be able to
manually size a defect.
The distance from Bz peak to trough (measured on the component).

The probe reading at the minimum point of the Bx trough.
The background Bx level reading.
Both length and depth sizes are then obtained by comparison with look-up tables of
theoretically-derived values.
Length sizing
Carry out normal detection scanning methods for initial crack detection
Place the probe 50mm from the beginning of the crack
Scan slowly into the crack beginning and stop the scan when the butterfly plot reaches
its maximum deflection at the start of the defect. Place a mark on the component next
to the index line of the probe. This will invariably mean some forward and backward
adjustment with the probe. Repeat this procedure to find the other crack end.
Crack beginning
Figure 13.1: Finding crack beginning (for C direction scan).

Page 13-1
Crack End
Figure 13.2: Finding crack end (for C direction scan).

Final Scan
Position the probe one marker from beginning of crack and scan through the crack
calling out the crack markers and 50mm – 100mm increments. Press <space bar > for
increments and <enter key> for crack markers. The final scan should show that the
purple lines placed on the screen by the <enter key> should align with the positive
and negative Bz peak and trough. If that is the case the probe operator should take the
physical measurement between the two markers which should be recorded in the
“notes”. If this is not the case then another sizing scan should be carried out until the
markers are aligned.
Figure 13.3: Final scan

Page 13-2
Sizing for depth

Left Clicking
This is the most common form of data marking and can be used to mark regions in the
Bz window and generally for sizing. Click and hold the left mouse button in the Bz
window then move the mouse to the left or right. Two vertical lines are drawn in the
window, one marks the originally clicked position and the other will follow the mouse
cursor. To leave the second line in place, simply release the mouse button.
If you do a similar operation by left clicking and hold in the Bx window and move the
mouse up and down, then horizontal lines will appear. The Information Bar displays
the Bx readings at the two levels of the lines.
If the butterfly window is displayed then the horizontal Bx lines are also shown on the
butterfly. This can be useful when selecting the background level before sizing a
defect.
Bz selection
Left click in the Bz plot area and by dragging the mouse encompass the positive and
negative Bz peak and trough.
Bx selection
Left click in the Bx plot area and by dragging the mouse upwards from below the
minimum Bx point and ending on the background noise level. This is where the Bx
signal flattens our either side of the defect. It is usually best to select the centre of the
area of “noise” in the butterfly plot, or the point where the two sides of the butterfly
loop cross.
Analyse the data
Press the Analyse Button and choose Size Defect. If an encoder was used to collect
the data, the distance between the Bz peak and trough is calculated automatically and
a message is displayed showing the calculated defect length and depth. In ASSISTant,
or with a probe without an encoder, this distance must be entered manually. You will
first be asked if you have carried out extra scans to determine the location and
orientation of the defect then you will be asked to enter the Bz length. After
processing the Recalculate button to obtain the defect size you have the option to
keep the sizing by pressing the Yes button, which will store the defect in the page's
defect list.
Note that, (except for very short defects), the defect length reported by the software is
slightly larger than that measured on the component. This is because the Bz peak and
trough occur slightly inside the physical ends of the defect.

Page 13-3
Examine the Bz trace again. You will notice that a grey band is drawn between the
peak and trough positions indicating the defect location. If the band does not coincide
with the required peak and trough, repeat the sizing.
Figure 13.4: Correct Bx and Bz selection for depth sizing

Page 13-4
For your notes

Page 13-5
Chapter Fourteen
Chapter 14 Reporting and Printing
Report Sheets
Report sheets may be the responsibility of the employer or the client, they come in
many forms. Always ensure that the report sheets are completely filled in.
In ASSIST software, report sheets are generated automatically so it is important that

all the dialogue boxes are completed and that the notes have been entered up correctly
before printing the report.
Printing Data
There are various ways of obtaining hard copy print out of the scans carried out:
Windows Print Screen
Use of Print Screen command (Normally shown as PrtSc). This loads the available
screen into the clipboard. From there it may be transferred to Word or other Windows
documents or perhaps to a drawing program. Note that this method requires large
memory availability.
Info Button
Press Info button to access print icon
Figure 14.1: Information panel

Page 14-1
Print Button
It allows you to print out any page of data from a data file, providing the PC has at
least one printer driver installed.
You can view different pages in the file by pressing the left / right arrow buttons or
change the size of the page on the screen using the magnifier button.
Press page setup to configure your printer or paper type then print the report using the
Print button.

Page 14-2
Figure 14.2 Example of print format

Page 14-3
For your notes

Page 14-4
Chapter Fifteen
Chapter 15 Routine Maintenance and Handling
The AMIGO instrument is NOT waterproof and must never be submersed in water or
other fluid. The AMIGO is rated to IP54 providing that the battery pack is installed
and all connectors or blanking plugs are in place. Ensure water does not enter the
connectors.
The instrument can only be charged indoors as the charger is NOT IP54 rated.
Never put strain on the probe or connectors and always keep connectors covered when
not in use to avoid contamination by dirt.
If the probe is to be used in an environment where the cable could be damaged by
dragging along sharp objects, it is recommended that the cable be protected using
additional sheathing.
Probes generally have a ceramic nose containing the sensor coils. This is hard wearing
if the probe is used properly. The pencil probe noses can be protected further with
electrical insulation tape to reduce wear. A single strip over the end of the nose
followed by a wrap around the nose to hold it in place should suffice. Replace when
the tape becomes torn.
The instrument may be cleaned with a damp cloth. A mild detergent may be used or
foam computer cleaner, however, do not allow ingress into the connectors.
The instrument should not be left on continuous "trickle-charge" whilst in use as this
can lead to the battery over heating and reduces subsequent battery life. The
instrument should be run from battery power then recharged when the battery level is
low. Recharge time should be 4 – 5 hours from empty.
The laptop can be run continuously from mains power, but again this will reduce
subsequent battery life.
Neither instrument or laptop should be connected to a mains supply if the probe is
being deployed by a diver. The system must be operated on battery power to avoid
any risk of shock to the diver.
Refer to the instrument Maintenance Manual for further information.
** IF IN DOUBT, REFER TO MANUFACTURER **

It is recommended that the unit and probes be returned to the manufacturer annually
for a routine check and issue of new Certificate of Conformance.

Page 15-1
For your notes

Page 15-2
Chapter Sixteen
Chapter 16 Glossary of Terms
ACFM
Alternating Current Field Measurement - the patented NDT technique for
electromagnetic inspection of surface breaking defects, developed by TSC Inspection
Systems.
ACPD
Alternating Current Potential Drop. Contacting technique for sizing crack depth
through surface voltage measurement
ASSIST
ACFM software for use with the AMIGO
Crack Microgauge
Generic name for TSC's ACFM equipment.
Job Code
Identifying code to group together different inspection types. This must be entered
before beginning an inspection.
Probe File
A computer configuration file that automatically sets up the hardware and software
for a particular probe. The probe file is usually supplied on a floppy disk with each
new probe. It's name is <probe serial No.>.QPC and it should be copied to the Probes
folder inside Mainstore.
RS232
Communications protocol used between the PC and AMIGO.

Page 16-1
For your notes

Page 16-2
Chapter Seventeen
Chapter 17 Course Exercises Detection

References:
UCL ACFM Data Bank

Page 17-1
ACFM TRAINING COURSE-EXAMPLES
LEVEL 1 DETECTION
File: l1d001
Sample Information: Tubular Joint 100mm increments
D = 650mm
d = 324mm
Circ=1130mm
Scan Details
Page Probe Dir Clocks Notes

1 Check
2 A 1-5
3 A 4-8
4 A 7-12
Questions
1 Have all scans been correctly carried out? Comment
2 Indicate cracks detected
3 Indicate signals other than cracks

Page 17-2
LEVEL 1 DETECTION
File: l1d002
D = 650mm
d = 324mm
Circ=1130
Scan Details
Page Probe Dir Clocks Notes

1 A 1-5
2 A 4-8
3 A 7-1
Questions

Page 17-3
LEVEL 1 DETECTION
File: l1d003
D = 750mm
d = 450mm
Circ=1545mm
Scan Details
Page Probe Dir Position Notes

1 A Datum-5
2 A 4-9
3 A 8-13
4 A 12-15-1
Questions

Page 17-4
LEVEL 1 DETECTION
File: l1d004
D = 500mm
d = 450mm
Circ=1630mm
Scan Details

1 A Datum-9
2 A 9-datum
Questions

Page 17-5
LEVEL 1 DETECTION
File: l1d005
Sample Information: Tubular joint 100mm increments
D = 750mm
d = 450mm
Circ=1600mm
Scan Details

1 A 1-4
2 A 4-8
3 A 8-14
4 A 13-2
Questions

Page 17-6
LEVEL 1 DETECTION
File: l1d006
Sample Information: Section of Tubular Joint. 50mm increments
Scan Details

1 A 1-11 Bottom Toe
2 A 9-12 Bottom Toe.
3 C 1-10 Top Toe
4 C 9-12 Top Toe
Questions

Page 17-7
LEVEL 1 DETECTION
File: l1d007
Sample Information: Flat Plate 2mm coating. 50mm increments
Scan Details

1 A 1-7
Questions

Page 17-8
LEVEL 1 DETECTION
File: l1d008
Sample Information: Flat Plate 50mm increments
l = 300
Scan Details

1 A 1-6
2 A 1-6
Questions

Page 17-9
LEVEL 1 DETECTION
File: l1d009
Sample Information: Flat Plate 50mm increments
l = 300
Scan Details

1 C 1-6 Side A
2 A 1-6 Side B
3 C 1-6 Side C
(underside)
4 A 1-6 Side D
(underside)
Questions

Page 17-10
LEVEL 1 DETECTION
File: l1d010
Sample Information: Tee Butt 50mm increments
Scan Details

1 C 1-5
2 C 1-5
Questions

Page 17-11
LEVEL 1 DETECTION
File: l1d011
Sample Information: Flat Plate 50mm increments 20mm width toe
l = 300mm
Scan Details

1 A 1-5 Toe A
2 A 1-5 Toe B
3 A 1-5 Cap
Questions

Page 17-12
LEVEL 1 DETECTION
File: l1d012
Sample Information: Flat Plate 50mm increments Weld cap ground off
Scan Details

1 A 1-5
Questions

Page 17-13
LEVEL 1 DETECTION
File: l1d013
Sample Information: Flat Plate. Weld Cap Ground off
Scan Details

1 A
4 A.
Questions

Page 17-14
Chapter Eighteen
Chapter 18 Course Exercises sizing

References:
UCL ACFM Data Bank

Page 18-1
LEVEL 1 SIZING
File:l1s001
Sample Information:Tubular Joint
D =650mm
d =324mm
Scan Details
Page Probe Dir Position Comments Length(mm)

1 Check
7 A 2-3
8 A 2-3 40mm
9 A 8-9 35mm
Questions
1 Have all scans been correctly carried out and cracks correctly marked?
Comment
2 Give Crack Sizes

Page 18-2
LEVEL 1 SIZING
File:l1s002
Sample Information: Tubular Joint
D = 650
d =324
Scan Details

1 A Datum-5 Detection Scan
5 A 3-5 40
Questions
Comment
2 Give Crack Sizes

Page 18-3
LEVEL 1 SIZING
File: l1s003
Sample Information: Section of Tubular Joint
Scan Details
1 A 1-11 bottom toe Detection Scan
2 A 9-12 bottom toe Detection Scan
3 C 1-10 top toe Detection Scan
4 C 9-12 top toe Detection Scan
7 C 4-9 top toe
8 C 4-9 top toe 130
Questions
Comment
2 Give Crack Sizes

Page 18-4
LEVEL 1 SIZING
File: l1s004
Sample Information: Flat Plate
Scan Details
1 A 1-7 Detection Scan
2 A 1-3 35
3 A 4-6 Both markers out same 16
amount
Questions
Comment
2 Give Crack Sizes

Page 18-5
LEVEL 1 SIZING
File: l1s005
Sample Information: Flat plate
Scan Details
1 C 1-6 Detection Scan
4 C 3-5 16
Questions
Comment
2 Give Crack Sizes

Page 18-6
LEVEL 1 SIZING
File:l1s006
Sample Information:Tubular Joint
D = 500
d =324
Scan Details
11 A 1-4 105
Questions
Comment
2 Give Crack Sizes

Page 18-7
LEVEL 1 SIZING
File:l1s007
Sample Information: Tubular Joint
D = 500
d =324
Scan Details

12 C 1-4 120
Questions
Comment
2 Give Crack Sizes

Page 18-8
LEVEL 1 SIZING
File: l1s008
Sample Information:Flat Plate
Scan Details

13 A 2-4 12
14 A 3-5 28
Questions
Comment
2 Give Crack Sizes

Page 18-9
LEVEL 1 SIZING
File: l1s009
Sample Information: Flat Plate
Scan Details

1 C 1-10 Toe A Detection Scan
4 A 1-9 Toe B Detection Scan
6 A 1-3 53
Questions
Comment
2 Give Crack Sizes

Page 18-10
LEVEL 1 SIZING
File: l1s010
Sample Information:Flat Plate
Scan Details

1 C 1-10 Toe A Detection Scan
2 A 1-9 Toe B Detection Scan
8 C 7-9 Toe A 77
Questions
Comment
2 Give Crack Sizes

Page 18-11

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TSC ACFM course notes for use with

Jim Sheppard & Martin Lugg

TSC Inspection Systems

© 2010. Technical Software Consultants Ltd.

6 Mill Square, Featherstone Road, Wolverton Mill,

Controlled Copy: Yes No

TSC ACFM course notes for use with

HS MCL MCL Tidying up and 13th July 2010

1.1 (1) JAS MCL MCL 7th October, 2008

© 2010. Technical Software Consultants Ltd.

6 Mill Square, Featherstone Road

Copyright © Technical Software Consultants Limited

Contents for TSC ACFM Level 1 Course Notes

Chapter 1 Introduction ....................................................................1-1

Chapter 2 Electricity and Electro - Magnetism ............................2-1

Chapter 3 Basic Principles of Eddy Current Testing ...................3-1

Chapter 4 Principles of ACPD ........................................................4-1

Copyright TSC 2008 ACFM\Notes\Chapter1

Chapter 5 ACFM Crack Detection .................................................5-1

Chapter 6 TSC ACFM Equipment Hardware ..............................6-1

Chapter 7 Operation of ASSIST Suite of Software ......................7-1

Chapter 8 Assist Family Software ..................................................8-1

Chapter 9 Bx - Bz and Butterfly Plot Relationship.......................9-1

1809 rev 5.doc / Rev 1 Copyright TSC 2008

Chapter 10 Briefing Requirements for Remote Scanning .........10-1

Chapter 11 Function and Operation Checks ...............................11-1

Chapter 12 Scanning for detection - Summary ...........................12-1

Chapter 14 Reporting and Printing..............................................14-1

Chapter 15 Routine Maintenance and Handling ........................15-1

Chapter 16 Glossary of Terms ......................................................16-1

Chapter 17 Course Exercises Detection .......................................17-1

Chapter 18 Course Exercises sizing..............................................18-1

1809 rev 5.doc / Rev 1 Copyright TSC 2008

1809 rev 5.doc Copyright TSC 2010

Standard Practice for the Examination of Welds using ACFM

NDT Operator Level I

1809 rev 5.doc Copyright TSC 2010

NDT Operator Level II

An ACFM Level II operator shall be capable of creating new probe configurations,

NDT Operator Level III

Candidates must provide evidence of training. A certificate of successful

1809 rev 5.doc Copyright TSC 2010

Experience for Levels I and II

Level I candidates will be required to show a minimum requirement of 400 hours

ACFM EQUIPMENT APPROVALS – Subsea

1809 rev 5.doc Copyright TSC 2010

The areas of application of a selection of the commonly used methods successfully

Visual inspection gives an overall appreciation of the general condition of the

Limitations of visual inspection are as follows:

Can only be used to assess surface breaking defects.

1809 rev 5.doc Copyright TSC 2010

Liquid Penetrant advantages:

Can be used on metals and non-metals

Cannot be used underwater

Magnetic Particle Inspection

Fig 1.1. An example of MPI indications

1809 rev 5.doc Copyright TSC 2010

Good for assessment of complex cracking such as stress corrosion cracking