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Scorpion B-Scan Manual Rev 6.0
Scorpion B-Scan Manual Rev 6.0
Scorpion B-Scan Manual Rev 6.0
Operating Manual
Silverwing UK Ltd Units 30 - 31 Cwmdu Industrial Estate, Carmarthen Road, Swansea, SA5 8JF Wales, UK
t: +44 (0) 1792 585533 f: +44 (0) 1792 586044 e: support@silverwingndt.com w: www.silverwingndt.com
Silverwing UK Ltd Units 30 - 31 Cwmdu Industrial Estate, Carmarthen Road, Swansea, SA5 8JF Wales, UK
t: +44 (0) 1792 585533 f: +44 (0) 1792 586044 e: support@silverwingndt.com w: www.silverwingndt.com
SCORPION B-SCAN
Dry Coupled Remote Access Ultrasonic Crawler
Operating Manual
Silverwing UK Ltd Units 30 - 31 Cwmdu Industrial Estate, Carmarthen Road, Swansea, SA5 8JF Wales, UK
t: +44 (0) 1792 585533 f: +44 (0) 1792 586044 e: support@silverwingndt.com w: www.silverwingndt.com
Scorpion B-Scan Operating Manual V 6.0
Table of Content
1. Introduction ................................................................................................................................... 3
2. General Description ...................................................................................................................... 4
2.1. Scorpion B-Scan Crawler .................................................................................................... 4
2.2. Sitemaster30 battery box ..................................................................................................... 5
2.3. Control Module .................................................................................................................... 5
2.4. Steering Control Pad ........................................................................................................... 6
2.5. Portable Ultrasonic Module (UT400) ................................................................................... 6
2.6. Netbook PC.......................................................................................................................... 6
2.7. Battery Extender .................................................................................................................. 6
2.8. B-Scan Software .................................................................................................................. 6
3. System Connections..................................................................................................................... 7
3.1. Short RG174U leads ............................................................................................................ 7
3.2. Connecting the Umbilical Cables to the Scorpion Crawler .................................................. 7
3.3. Control Module .................................................................................................................... 7
3.4. Connecting the Sitemaster 30 to the Control Module .......................................................... 8
3.5. Connecting the Umbilical cables to the Ultrasonic Module ................................................. 8
3.6. Connecting the Ultrasonic Module to the Netbook .............................................................. 9
4. System power ON ...................................................................................................................... 10
4.1. Setup of the Sitemaster 30 ................................................................................................ 10
4.2. Setup of Netbook ............................................................................................................... 10
4.3. Setup of Ultrasonic Module................................................................................................ 11
4.4. Set up of the Battery Extender........................................................................................... 11
5. Handling the Scorpion crawler ................................................................................................... 13
5.1. Placing the Scorpion crawler into the test surface ............................................................ 13
5.2. Removing the Scorpion crawler from the test surface ....................................................... 13
6. Driving the Scorpion Crawler ...................................................................................................... 14
7. Scorpion Crawler Adjustment ..................................................................................................... 15
7.1. Wheel Probe Normalisation ............................................................................................... 15
7.2. Wheel Probe Height ........................................................................................................... 16
8. Scorpion B-Scan Software ......................................................................................................... 18
8.1. Load the Scorpion B-Scan Software ................................................................................. 18
8.2. Menu Panel ........................................................................................................................ 18
8.3. Activating the Ultrasonic Module ....................................................................................... 18
9. Scorpion B-Scan Software – Setup Wizard ............................................................................... 19
9.1. Velocity Setup .................................................................................................................... 19
9.2. Ultrasonic Setup ................................................................................................................ 20
9.3. Gates Setup ....................................................................................................................... 22
9.4. Encoders ............................................................................................................................ 24
9.5. Inspection Details .............................................................................................................. 25
10. Scorpion B-Scan Software – Manual Ultrasonic Setup .............................................................. 26
10.1. Setting Transducer Mode .................................................................................................. 26
10.2. Setting Transducer Frequency .......................................................................................... 26
10.3. Adjusting Material Velocity................................................................................................. 27
10.4. Adjusting Ultrasonic Parameters ....................................................................................... 27
10.5. Adjusting the Measurement Gates .................................................................................... 28
10.6. Calibration checks ............................................................................................................. 28
11. Scorpion B-Scan Software – Manual Encoder Calibration ........................................................ 29
12. Scorpion B-Scan Software – Manual Inspection Setup ............................................................. 30
12.1. Entering Inspection Details ................................................................................................ 30
12.2. Units ................................................................................................................................... 30
12.3. Resolution .......................................................................................................................... 30
13. Scorpion B-Scan Software – Saving and Recalling settings ...................................................... 31
13.1. Saving Settings .................................................................................................................. 31
13.2. Recalling Saved Settings ................................................................................................... 31
14. Scorpion B-Scan Software – Acquiring and Saving B-Scans .................................................... 32
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1. Introduction
The Scorpion B-Scan system is a B-Scan profile imaging system. The Scorpion B-Scan
system has been developed to perform ultrasonic thickness measurements on ferrous
material. The crawler system can be used on vertical surfaces such as oil storage tank
shells, or towers and stacks. It can also be used on circumferential surfaces including
horizontal pressure vessels and spheres as well as above and below horizontal surfaces.
The minimum outside diameter the crawler can inspect both circumferentially and axially are
1.5m. The minimum internal diameters the crawler can inspect are 1.5m axially and 3m
circumferentially. The maximum surface temperature the Scorpion B-Scan crawler can
continuously operate on is 80oC.
Upon receipt of the Scorpion B-Scan system ensure that all battery powered equipment, are
fully charged. These including:
Sitemaster 30
Ultrasonic Module (UT400)
Netbook PC
Battery Extender
Failure to comply may result in serious system failures.
2. General Description
On top of the main chassis is the umbilical cable connector box. In front of this box are two
SMC bulkhead connectors, to which the two short transducer leads connect to the dual
elements of the wheel probe. At the rear of the box there is one Fischer connector to which
the umbilical cable is connected and two colour coded BNC connectors to which the
umbilical UT cables are connected. At the rear of the chassis is a cable restraint pillar that is
used to anchor the Umbilical cable restraint clip on the umbilical cable. The cable restraint
must always be used to prevent premature damage to the Umbilical cable or connectors.
The Scorpion B-Scan crawler utilises the Silverwing UK Ltd TWP12 dry-coupled wheel
probe. The wheel transducer assembly is attached to the main chassis by a parallelogram
hinge system to keep the transducer normal to the surface. The wheel transducer itself can
be normalised using the adjusting nuts on the top arm of the parallelogram. The two small
nylon wheels mounted towards the front of the transducer assist in lifting the wheel probe
clear of welds. The two larger nylon wheels mounted each side of the wheel probe
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transducer are designed to minimise compression of the wheel probe tyres over uneven
surfaces. Compression of the wheel probe tyres may result in irregular B-scan traces.
The forward magnet maintains sufficient contact pressure between the wheel probe and the
test surface. The wheel transducer is kept clean and free of dust by the cleaning pad,
housed in a container mounted above the forward magnet.
Operational Safety
Personnel must keep clear of area immediately below the Scorpion B-Scan crawler at
all times during operation.
A suitable safety line must be attached to the attachment point at the front of the
Scorpion B-Scan crawler at all times during operation.
Safety Line
Attachment Point
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2.6. Netbook PC
A Netbook is supplied, pre-installed with Microsoft Windows operating system and the
Scorpion B-Scan software for data capture and analysis. The battery powered Netbook
provides up to 6 hours continuous operation (model dependant).
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3. System Connections
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Connect the steering control pad to the socket at the left side of the control module. Connect
the 9-Way D-type encoder cable to the socket at the right side of the control module.
Do not over tighten the securing posts of the connector
The two BNC connectors are required for the UT signal, one for TX (Transmit) and the other
for RX (Receive). These connectors are colour coded to ensure they are connected
correctly. The red colour connector must be connected to the BNC connector marked TX, as
shown in Figure 5.
Failure to observe the Red / Black colour codes when connecting the umbilical cable
to the UT400 will prevent any back-wall echoes being displayed.
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4. System power ON
Connect the system as described in section 3 before powering on the Sitemaster30, UT400
or Netbook.
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During operation should an audible alarm sound then the UT400 must be charged. Refer to
section 19 for Hardware Charging information.
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5. Once connected to the Netbook the battery extender can be switched ON. The
Battery Charge LED on the Netbook will illuminate, indicating the charge status.
DANGER
Care MUST be taken whilst positioning the crawler on the test surface to avoid
jarring the carriage or transducer.
Never attempt to hold, touch or reposition the Scorpion crawler during use.
The crawler has an extremely powerful attractive force towards any ferromagnetic
object. Serious injury can result if limbs or tissue become trapped between such
objects and the crawler.
Place the rear wheels of the crawler on the test surface first then gently lower the front
wheels to the surface. Finally allow the wheel transducer to lower onto the surface.
Connect a suitable safety line to the Safety line attachment point on the lid of the crawler, as
shown in section 2.1.
Always remember there are very strong magnets located on the underneath of the crawler
and inside the rear wheels which will attract and be attracted to any ferrous material.
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Reverse Drive
(Latching)
When selecting a scan line, check to see that there are no obvious obstructions. Check that
the driving wheel tyres, all four are driven, have not become polished. If necessary roughen
the rubber by a gentle rub with 120 grit emery cloth.
On painted vertical surfaces, check the surface condition. It is common for the paint to
bloom with age creating a powdery deposit on the surface. Rain tends to wash this deposit
to the lower courses and the thicker layers of powder can be quite slippery, especially when
wet. If the surface is slippery it may be wise to set the crawler on a diagonal course,
straightening up as the top courses are reached.
The system will be able to take a straight, vertical run on the descent.
Before climbing, ensure the safety line has been attached to the front of the crawler and
ensure the wheel probe has been lowered onto the surface and that UT signals are being
received by the software.
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To carry out normalising adjustments, the system needs to be mounted on a steel plate,
connected and powered on, as described in section 3 and 4. The software must be initialised
with the A-Scan backwall echoes displayed on screen as described in section 8 through 10.
With the system set up as above:
1. Obtain at least two back wall echoes, and adjust the system gain so that the first
back wall echo is about 60% full screen height.
2. Slacken the rear-adjusting nut four or five turns then slowly tighten the front adjusting
nut whilst observing the ultrasonic signals.
3. If the first backwall echo immediately begins to FALL – STOP TIGHTENING THE
FRONT NUT. Immediately re-tighten the rear nut and then slacken the front nut four
or five turns.
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4. Then slowly tighten the rear nut and observe the ultrasonic signals, which should be
RISING.
5. When the first backwall echo reaches a maximum and starts to fall, Stop adjusting
the rear nut and lock up the front nut.
The transducer is now normalised and the wheel probe height should now be checked.
WHEEL PROBE
CLAMP SCREWS
2. Turn the wheel probe height adjustment screws until the correct height has been
achieved. Both height adjustment screws must be turned equal amounts to ensure
the wheel probe does not point to one side.
If the wheel probe is set too high, there will be insufficient pressure between the
wheel probe and the test surface resulting in low amplitude back wall echoes.
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If the wheel probe is set too low, the nylon guide wheels will not make contact
with the test surface which may cause irregular B-scan images due to changes in
wheel probe tyre compression.
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1. Place the Scorpion B-Scan crawler onto the thicker of the two test samples
2. Click Auto Adjust to set the gain such that the first back-wall echo peak is set to
80% full screen height. The + and – buttons can be used to manually adjust the gain
value if required.
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3. Using the onscreen number pad, enter the thickness in mm of the test sample which
the Scorpion B-Scan crawler is placed on. Once entered press the number pad enter
key.
Figure 25: Thickness entered into number pad for the thicker test sample
4. Place the Scorpion B-Scan crawler onto the thinner of the two test samples
5. Using the onscreen number pad, enter the thickness in mm of the test sample which
the Scorpion B-Scan crawler is placed on. Once entered press the number pad enter
key.
Figure 26: Thickness entered into number pad for the thinner test sample.
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Gate 1
This gate is active by default and the software calculates wall thickness by measuring from
the zero point on the time base up to the first echo that crosses the gate. The digital
thickness measurement is displayed in red to the right of the gate settings.
Gate Trigger
Set the gate Trigger point to either Flank or Peak.
When set to Flank the software will measure up to the point where the gate meets
the left hand flank of the back wall echo.
When set to Peak the software will measure up to the highest point (peak) of the
back wall echo crossing the gate.
The Start, Length and Level of the gate can be adjusted by using the arrow buttons.
By default the gate colour is red but can be changed by clicking on the colour box at the top
of the window
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Once the gate has been set, the Delay can be adjusted until correct thickness
measurements are obtained.
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9.4. Encoders
The encoder must be calibrated to ensure correct distance measurements are recorded. It is
possible to save encoder calibrations and recall them at a later date.
Before calibration is performed the system must be connected and powered on as described
in section 3 and 4, and the UT400 must be initialised as described in 8.3.
The calibration can be saved for later use by clicking Save then entering a suitable file name
and save location.
To recall the encoder calibration, click Open and select the relevant file.
Click Next to continue the though the setup wizard.
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The Today button automatically enters the date, according to date set in the operating
system into the Test Date field.
The Clear Details button clears any text from all fields.
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Each parameter can be changed either by adjusting the slider bar, using the + / - buttons, or
by entering a value using the number buttons on screen. If a number has been entered using
the onscreen number buttons the Enter button, as circled in Figure 35, must be pressed to
apply the change.
Click the green tick button to close the parameter adjustment panel.
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Typical Ultrasonic parameter values expected when using the Scorpion B-Scan system:
Gain – Typical values for gain are between 3dB to 10dB. This is due to the Scorpion
B-scan system being fitted with 2 pre-amplifiers.
Delay – Due to the unique nature of the material used for the Wheel Probe tyres, it
will be necessary to set a larger delay value than that of a “normal” ultrasonic probe.
Typical values for delay are in the region of 20000 units.
Range – When calibrating the system it is recommended that the time-base range is
initially set at 100mm so that all back wall echoes are visible. Once a suitable delay
value has been set, choose a time-base range more suitable to the thickness of
material to be tested.
Position the Scorpion B-Scan crawler on each plate in turn and check that the ultrasonic
system indicates the correct thickness. If necessary adjust the UT Parameters to obtain the
correct values.
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The Encoder calibration window, shown below in Figure 37, also allows a calibration to be
performed or saved calibration file to be loaded. To open this window:
Click System
Click Encoder Calibration
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12.2. Units
The Scorpion B-Scan software is only set to display thickness reading in millimetres, mm.
12.3. Resolution
A scan resolution can be set to capture between every 1mm up to 10mm that the crawler is
moved. A resolution of 4mm is suitable for most applications when using the Scorpion B-
Scan system.
The resolution can be set prior to beginning a scan, or if required be adjusted during a scan.
To set or adjust the resolution:
Click System
Select Resolution
Set the resolution by moving the slide adjuster or using the + / - buttons
Once set, click the green tick in the corner of the screen.
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Click Cancel to close out from, and not begin the B-scan data acquisition.
Click No to continue scanning the previous scan. Scanning begins from the current
encoder position in the software. This is illustrated by a white vertical line along the
black bar above the B-Scan profile image.
Click Yes to clear any open scans and begin a new scan.
If Yes is selected then a warning box may appear asking if the required B-Scan profile image
required saving.
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If a new scan is to be started then an Enter Start Offset box appears, as shown in Figure 42.
Here an offset measurement from a physical starting location to the actual position of the
Scorpion B-Scan crawler‟s wheel probe can be entered if required. Use the keypad to enter
the start offset, in mm then click OK to begin.
The Scorpion B-Scan software is now “Live” and the B-Scan profile image will be generated
from the A-scan as the Scorpion B-Scan crawler is driven in a forward direction. During the
inspection the crawler can also be driven backward to re-profile any areas. Once the scan is
completed click End.
Check the length of the scanned distance against the X axis to ensure the distance covered
is correct. If the distance covered is not correct then the encoder must be re-calibrated, refer
to section 11.
14.2. Resolution
The scan resolution can be adjusted whilst scanning. During a scan if vertical white lines
appear, as shown in Figure 43, it could indicate that the scan resolution is set too low for the
crawlers speed. It is possible to re-profile any of these areas by driving the scanner
backward the area or by increasing the resolution of the scan. Refer to section 12.3 for
resolution adjustment.
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When a B-Scan is saved, the following information is saved along with a B-scan file:
The captured A-scan signals
The Gate Settings used to create the B-scan profile
The Inspection Details
The Ultrasonic Parameters
The Scan Resolution
A *.CSV file is also saved into the same directory as the B-Scan file and is given the same
file name. This *.CSV file containing all the stored measurements relating to the B-Scan
which were generate when using the measurement tool.
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The Play, Pause, and Speed controls can be used as required. The Rewind and Fast
Forward buttons can be held down to proceed quicker through the scan. The speed at
which the replay runs can be adjusted by altering the Replay Speed value.
During replay the captured A-scan signal is displayed in the upper section while a vertical
white line above the B-scan indicates the current location on the B-Scan as the scan is
replayed.
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15.6. Statistic
The Scorpion B-Scan software can display statistical thickness information for the minimum,
maximum and mean thickness of the B-Scan profile. To display the statistics:
Click Edit
Select View Stats
The location of the minimum and maximum thickness found for a scan can be displayed on
the B-Scan profile as vertical line by ticking Show. Each line colour can be changed by
clicking on the colour box below the thickness name.
Click the green tick in the corner of the screen to close Statistics.
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Figure 49: Marker Lines control and display on the B-scan profile view
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Placing the cursor on any part of the magnified B-scan displays both the distance and depth
value at that point. Also displayed in the bottom section of the zoom window is statistical
thickness information
The zoomed area of interest can either be printed direct from the software, by clicking Print
or be saved as an image, by clicking Save As Bitmap.
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The length of the measurement line is displayed in the Result portion of the Measurement
window, see Figure 53. Individual measurements can be saved by clicking the Store button
in the Measurement window.
To add additional measurements click the relevant arrow representing Horizontal, Vertical
or Diagonal measurements, as shown in Figure 53.
To view saved measurements go to Edit and click View Measurements to reveal the table,
shown in Figure 54 with all the stored B-Scan measurements.
To remove any stored measurements, highlight the required measurements then click
Delete.
A *.CSV file containing any stored measurements is created when the B-Scan file is saved.
The *.CSV file will be saved in the same directory and have the same file name as the B-
Scan file.
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A confirm window will appear asking to Copy Axis with the image. If it is required
select Yes
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However this can cause issues with computers that are setup for countries that use a
comma as a decimal separator. For example 2,5mm will be opened in excel with 2 in the left
hand column and 5mm in the next column. This problem can be overcome by changing the
symbol used to separate 2 fields within the *.CSV file. This symbol is known as the Delimiter.
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Browse to the location of the saved Exported *.CSV thickness file from the Scorpion B-Scan
software. Select the file and click Open.
Select Delimited
Click Next
Figure 65: Select Import Data location Figure 66: Microsoft Excel display for data
recorded using Scorpion B-Scan Software
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Uninstalling the Scorpion B-Scan software will not remove any saved settings or scans.
To install the updated version, double click on the Scorpion BScan.msi icon.
Follow the onscreen instructions to install the application.
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5. Navigate to the driver folder by clicking Browse. Depending upon the version of
windows select either 32bit or 64bit. This can be found in the same location as the
installed software.
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Once the Scorpion B-Scan software is loaded all the values are reset to their default values.
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Figure 76: Battery pack and inline battery connector for the UT400.
4. Disconnect the inline white battery connector then pull the orange strap to remove
the battery pack from the UT400 module.
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5. Connect the battery charger to the inline white connector of the battery pack.
The charging of the UT400 battery pack will be complete once a green LED is displayed on
the UT400 charger. Once charged the battery pack must be returned back into the UT400.
1. Fully remove the orange battery strap and position on the top of the UT400.
2. Slide the battery pack into the UT400 ensuring the battery strap is positioned across
the top of the pack.
3. Reconnect the battery pack to the UT400 electronics and push the cables inside the
UT400.
4. Refit the lid of the battery cover using the thumb screws. Secure figure tight.
The UT400 must not be switched on for at least 15 minutes to allow a battery cool down
period. The battery charger MUST be disconnected from the mains power supply so the
green LED is no longer lit before charging another UT400 battery.
DO NOT power the Ultrasonic Module whilst charging. The battery charger is not a
power supply.
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LED MODE
Yellow Battery not connected
19.2. Netbook
Connect the Netbook AC power adapter to the Netbook and a suitable mains power supply.
Whilst charging the AC power LED and charging LED will be lit.
Doc Ref:OM-BS
Rev: 6.0
Date of Release:30/05/2013
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Scorpion B-Scan Operating Manual V 6.0
Before charging the Sitemaster30 battery box, the module must be switched off so as to
allow for a battery cool down period of at least 15 minutes. Disconnect the output power
supply cable from the side of the box. After the 15 minutes have elapsed, the charging can
begin. To charge:
Connect the charging cable to the connector inside the lid of the Sitemaster30
Connect the battery charger cable to a suitable mains power supply
Switch the power switch to Charge. The Red charging LED will light.
Once fully charged the Green charged LED will light. This will take approx 5 - 7
hours.
Doc Ref:OM-BS
Rev: 6.0
Date of Release:30/05/2013
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Scorpion B-Scan Operating Manual V 6.0
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1
Discolouration of the Wheel Probe tyres suggests they be cleaned using a cloth moistened
with Acetone. This will help restore the tyre to their original „tacky‟ condition. The frequency
of cleaning will depend upon the condition in which the unit is being used, for example where
the paint surface is particularly dusty (or coated with a thick 'bloom'), it may be necessary to
clean the tyres after each scan.
ONLY USE SILICONE OIL TO MOISTEN THE CLEANING PAD. ANY OTHER FORM OF
MINERAL OIL WILL DAMAGE THE WHEEL PROBE TYRES.
THE USE OF ANY “OIL” OTHER THAN THAT SPECIFIED BY THE MANUFACTURER
WILL INVALIDATE THE WARRANTY ON THE WHEEL PROBE TYRES.
Doc Ref:OM-BS
Rev: 6.0
Date of Release:30/05/2013
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Scorpion B-Scan Operating Manual V 6.0
For comprehensive cleaning and servicing the Wheel Probe must be removed.
To remove the wheel probe:
1. Disconnect the two SMC connectors on the short leads which connect the wheel
probe to the lid of the crawler.
2. Slacken both wheel probe clamp screws so that the wheel probe can be removed
from the carriage from the bottom.
3. Disconnect the two 90o SMC connectors at either of the wheel probe axle.
WHEEL PROBE
CLAMP SCREWS
Doc Ref:OM-BS
Rev: 6.0
Date of Release:30/05/2013
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Scorpion B-Scan Operating Manual V 6.0
Inspect the tyres for any signs of splitting, cracking, excessive abrasion or any evidence of
swelling due to contact with mineral oil. Check the condition of the cork insulating washer
and ensure that it sits snugly and turns freely in the groove. Check that the ball bearings in
the side plates turn freely.
Use acetone to clean all components and surfaces. Take extra care that all traces of film and
dirt are removed, especially around the outer circumference and Perspex plug over the
crystal and the inner face of the wheel probe tyres.
If new tyres are to be fitted, it is very important they are first cleaned with acetone to remove
protective film.
Once reassembled, check that there is only slight resistance when rolling the wheel probe.
Do this by holding the wheel probe ends between finger and thumb of each hand.
Once replaced check the system to ensure UT signals are being received.
Doc Ref:OM-BS
Rev: 6.0
Date of Release:30/05/2013
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Scorpion B-Scan Operating Manual V 6.0
CLEANING PAD
RESERVOIR
SCREWS
20.5. Encoder
The Scorpion B-Scan is fitted with an optical encoder on the side of the crawler. Ensure no
debris becomes stuck between the meshing of the gear teeth as this could cause damage to
the teeth.
Ensure the optical encoder does not get damaged during use as it could cause distance
measurement inaccuracies.
Doc Ref:OM-BS
Rev: 6.0
Date of Release:30/05/2013
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