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FLO

MFL floor Scanner with STARS Top & Bottom Defect Discrimination

FLOORMAP3Di
MFL Floor Scanner with STARS Top & Bottom Defect Discrimination

Floormap3Di
Safety Notes and
Specification

Silverwing UK Ltd Clos Llyn Cwm, Swansea Enterprise Park, Swansea, SA6 8QY Wales, UK
t: +44 (0) 1792 585533 f: +44 (0) 1792 586044 e: support@silverwingndt.com w: www.silverwingndt.com
MANUFACTURER:
Silverwing (UK) Ltd.
Clos Llyn Cwm,
Swansea Enterprise Park,
Swansea,
SA6 8QY
Wales, UK
Phone: +44 (0) 1792 585533
Fax: +44 (0) 1792 586044
Email: sales@silverwingndt.com
Web: www.silverwingndt.com

DISTRIBUTOR:

Floormap3Di Operating Manual


Manual Version combined version 1
Floormap3Di Safety Notes and Specification

Copyright© 2014 by Silverwing (UK) Ltd

The text, figures and programs have been worked out with the utmost care. However, we cannot
accept either legal responsibility or any liability for any incorrect statements which may remain,
and their consequences. The following documentation is protected by copyright. All rights
reserved. No part of this manual may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying and recording for any purposed without the
express written permission of Silverwing (UK) Ltd. The rights of reproduction through lectures,
radio and television are also reserved. The software and hardware descriptions referred in this
manual are in many cases registered trademarks and as such are subject to legal requirements.

Silverwing (UK) Ltd reserves the right to continue developing the system and software without
documenting each individual case. Silverwing (UK) Ltd will be happy to determine whether this
manual is up-to-date. Silverwing (UK) Ltd holds no responsibility for any damage or destruction
caused when following instructions within this manual.

This manual is part of the original documentation supplied with the Floormap3Di system.
Warranty
5.1 We warrant that on delivery, and for a period of 12 months for new equipment and 3 months
for spare parts/repairs/batteries from the date of delivery (warranty period), the Goods shall:

a. be free from material defects in design, material and workmanship;

b. be of satisfactory quality (within the meaning of the Sale of Goods Act 1979); and

c. be fit for any purpose held out by us.

5.2 Subject to clause 5.3, if:

a. you give notice in writing to us, including a written statement detailing the precise
nature of the fault and the operating conditions under which the fault occurred, within
a reasonable time of discovery that some or all of the Goods do not comply with the
warranty set out in clause 5.1;

b. we are given a reasonable opportunity of examining such Goods; and

c. you (if asked to do so by us) return such Goods to our place of business at our (or our
distributor’s) place of business at your cost and risk,

We shall, at our option, repair or replace the defective Goods and return them at our cost to you.

5.3 We shall not be liable for Goods' failure to comply with the warranty set out in clause 5.1 in
any of the following events:

a. you make any further use of such Goods after giving notice in accordance with clause
5.2;

b. the defect arises because you failed to follow our oral or written instructions as to the
storage, commissioning, installation, use and maintenance of the Goods or (if there
are none) good trade practice regarding the same;

c. the defect arises as a result of any software in the Goods being incompatible with any
other software used by you;

d. you alter or repair such Goods without our written consent; or

e. the defect arises as a result of fair wear and tear, wilful damage, negligence, or
abnormal storage or working conditions.

5.4 We do not warrant that any software in the Goods is error-free, but we will use our
reasonable endeavours to rectify any such error subject to the terms of this clause 5.

5.5 Except as provided in this clause 5, we shall have no liability to you in respect of the Goods'
failure to comply with the warranty set out in clause 5.1.

5.6 The terms implied by sections 13 to 15 of the Sale of Goods Act 1979 are, to the fullest
extent permitted by law, excluded from the Contract.

5.7 These Conditions shall apply to any repaired or replacement Goods supplied by us, but is
limited to 3 months from delivery and covers only those parts and labour necessary to make
the repair. For avoidance of doubt, any failure not directly related to the spare or repair is
excluded.
Floormap3Di Operating Manual combined version 1 Floormap3Di Safety Notes and Specification

Table of Contents

1 General Introduction .....................................................................................................................2


1.1 Purpose of this Operating Manual ........................................................................... 2
1.2 How this Operating Manual is Organised ................................................................ 2
1.3 Basic Safety Directions ........................................................................................... 2
1.4 Safety Warnings & Precautions ............................................................................... 3
1.5 Operator Training .................................................................................................... 4
1.6 Magnetic Flux Leakage Testing Limitations ............................................................. 4
2 Service and Maintenance ..............................................................................................................5
2.1 After Sales and Technical Support .......................................................................... 5
2.2 Return Policy ........................................................................................................... 6
2.3 Warranty and Liability .............................................................................................. 6
2.4 Legislative requirements ......................................................................................... 7
3 Transportation and Storage .........................................................................................................8
3.1 Receiving and Inspection ........................................................................................ 8
3.2 Unpacking ............................................................................................................... 8
3.3 Packing and Transportation..................................................................................... 9
3.4 Storage ................................................................................................................... 9
4 Floormap3Di Specification Sheet ..............................................................................................10
4.1 Detection capability table for defects created with 22mm ball end cutter ............... 12
4.2 Sizing capability table for defects created with 22mm ball end cutter .................... 12

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1 General Introduction

1.1 Purpose of this Operating Manual


This manual has been designed so that a person with a good knowledge of the basics of
magnetic flux leakage (MFL) testing may understand the operation and use of the features
offered by the Floormap3Di system.

Keep this manual safe and handle with care:


 It must be readily available throughout the use of the system.
 It must be provided to any individuals who assume responsibility for operating the system at a
later date.
 It must include any supplementary material provided by the manufacturer.
 The Manuals are also available on the Sitemaster2 computer in

Improper use of this instrument or failure to follow these instructions may cause injury or
equipment damage. All individuals responsible for operating this instrument must therefore be
properly trained and aware of the hazards, and must carefully follow these operating instructions
and the safety precautions detailed within. Contact Silverwing (UK) Ltd if you have any
questions on any part of this operating manual.

1.2 How this Operating Manual is Organised


This operating manual is organised into sections, with each section divided into various chapters.
 Section 1 refers to the mechanical Floormap3Di setup, hardware and operation.
 Section 2 refers to installation and operation of the Floormap3Di Data Acquisition software.
 Section 3 refers to SIMS (Silverwing Inspection Mapping Software) installation.
 Section 4 refers to the operation of SIMS.
 Section 5 refers to the Floormap3Di Calibration Example Traces.

1.3 Basic Safety Directions


 Do not operate the Floormap3Di system without reading, understanding and following this
operating manual, otherwise injury or damage may result.
 Observe all warnings, notes and instructions as marked on the packaging, on the equipment,
and detailed in the operating manual.
 The customer takes responsibility for the compliance to all appropriate safety measures.

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 Reliable and trained staff should only be authorised to work with the equipment.
 All users of the equipment must have undergone training by the manufacturer to operate and
control the system.
 The equipment must not be used for purposes other than those intended. Silverwing (UK) Ltd
assumes no responsibility for any damage resulting from such improper usage.
 The equipment must not be modified. In case of modifications the customer takes all
responsibility for any incidents due to such modifications.
 Ensure the equipment is always in safe operation condition. Qualified staff shall perform
functional tests and checks for damage at regular intervals. Authorised staff shall only do
disassembly, and according to operation instructions only.
 Maintenance of electrical components of the equipment must be performed by a professional
electrician, or under supervision of a professional electrician.
 Ensure, by regular checks, that working site, equipment and environments are kept in a clean
and clearly arranged state.
 Rules and regulations regarding the prevention of accidents that apply to the working site
should be observed.
 If the system does not operate normally, please contact Silverwing (UK) Ltd for assistance.

1.4 Safety Warnings & Precautions


During operation of the Floormap3Di system adhere to the following safety warnings and
precautions.

DANGER!
The Floormap3Di system is designed for a specific use. Using the
Floormap3Di system outside of its intended use is dangerous.
Severe injury or death could result. Read and understand this
operating manual before use.

CAUTION!
MAGNETIC MATERIAL. Due to magnetic material, consult IATA
documentation before air shipping.

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WARNING!
MAGNETIC MATERIAL. The Floormap3Di contains strong magnets
that produce an extremely strong magnetic field which may cause
failure or permanent damage to items such as watches, memory
devices, CRT monitors, and medical or other electronics devices.

WARNING!
PERSONEL SAFETY. Tools, magnets, and metal objects can cut,
pinch, or entrap hands and fingers. HANDLE WITH CARE. People
with pacemakers or ICD’s must stay at least 2m (79’’) away.

WARNING!
Damage to the Floormap3Di and/or cables during or prior to use
may cause explosion or fire.

1.5 Operator Training


All users of the Floormap3Di system must receive adequate training before using the system.
They must be trained to understand the operation, application and limitations of the Floormap3Di
system. Users must understand:
 Magnetic Flux Leakage and STARS technologies;
 Scanner components;
 Scanner setup and calibration;
 Scanner maintenance;
 Data acquisition software operation;
 SIMS operation.

More specific information about user training, qualification, certification and test specifications can
be obtained from technical societies, industry groups and government agencies.

1.6 Magnetic Flux Leakage Testing Limitations


Magnetic Flux Leakage (MFL) systems are heavily reliant on the inspection surface, on which
they operate. It is important to understand that as the conditions of the inspection surface
deteriorates, so can the effectiveness of any MFL system.

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MFL systems interpret a leaking field and any influencing factors that affect this leaking field must
be understood and factored into the inspection process. In order to maintain detection
capabilities, it must be understood that as plate thickness increases, the detection sensitivity
must increase. As the detection sensitivity increases, the likelihood of spurious defects increases
accordingly.
It must also be understood that MFL is one of the many available NDT inspection techniques. To
improve the accuracy and confidence of any inspection it is important to incorporate the use of
other NDT techniques such as Pit Gauging and Ultrasonic Testing (the limitations of these
techniques must also be understood).

As MFL can chiefly be considered as a volumetric detection technique, it is important to


understand the relationship between the calibration defects and defect depth.

2 Service and Maintenance


 The specified calibration and maintenance work should be performed promptly according to
the maintenance schedule.
 After completion of maintenance work test all functions and all safety devices.

2.1 After Sales and Technical Support


Silverwing (UK) Ltd provides after sales and technical support and is available from Monday
through Friday from 9:00 AM to 5:00 PM GMT (excluding UK public holidays). Contact us either
by:
Phone: +44 (0) 1792 585533
Fax: +44 (0) 1792 586044
Email: support@silverwingndt.com

Please provide the following information when contacting:


 Your name and your company name.
 The technical point of contact (name, phone number, email).
 System serial number, equipment type and any software versions.
 A detailed description of the issue.

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2.2 Return Policy


If the Floormap3Di system has been diagnosed as being faulty, or if it is in need of repair, it can
be returned to Silverwing (UK) Ltd. A Return Material Authorisation (RMA) number must be
obtained from Silverwing (UK) Ltd before it can be returned. To return the system:
1. Pack the system safely in the original transit case and ensure the product is shipped fully
insured (for a guide on how to pack the system, please refer to Section 1 – Hardware, Setup
and Operation).
2. Include the following:
a. The RMA number supplied by Silverwing (UK) Ltd. Clearly mark this on the outside of
the box.
b. A return address where the system can be shipped.
c. A contact telephone number / email address to be reached during work hours.
d. A detailed description of the problem.
3. Ship the unit prepaid to the address specified by Silverwing (UK) Ltd.

2.3 Warranty and Liability


All warranty and liability claims in case of damage to persons or material are excluded, if they are
caused by one or more causes stated below:
 Usage of equipment other than that according to the intended purpose.
 Work on equipment by persons other than those authorised to work with the equipment.
 Improper transport, storage, assembly, commissioning, operation or maintenance of
equipment.
 Operation of equipment containing faulty safety devices, or safety devices not fitted properly,
or safety and protection devices that are out of function.
 Disregarding instructions regarding safety, transport, storage, assembly, operation,
maintenance and setting-up, as stated by the operations manual.
 Modification of equipment not authorised by the Silverwing (UK) Ltd.
 Insufficient monitoring of equipment parts which are subject to wear.
 Repairs executed improperly, use of spare parts from other suppliers.
 Catastrophic impacts, e.g. by external matters or force majeure risks.

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2.4 Legislative requirements


The Floormap3Di system is designed to meet the safety requirements in accordance with
electrical safety and electromagnetic compatibility. It has been tested and has left the
factory in a condition in which it is safe to operate. The equipment is in conformity with the
statutory requirements of the EC directive and complies with the following provisions of
Low Voltage Directive 2006/95/EC and the Electromagnetic Compatibility Directive
2004/108/EC.

The Waste Electrical and Electronic Equipment Directive (WEEE Directive) aims to
minimise the impact of electrical and electronic goods on the environment by increasing
re-use and recycling and by reducing the amount of WEEE going to landfill. It seeks to
achieve this by making producers responsible for financing the collection, treatment, and
recovery of waste electrical equipment, and by obliging distributors to allow consumers to
return their waste equipment free of charge.

Silverwing (UK) Ltd offers its customers the possibility of returning unused and obsolete
equipment for correct disposal and recycling. The Dustbin Symbol indicates that when the
last user wishes to discard this product, it must be sent to appropriate facilities for
recovery and recycling. By not discarding this product along with other household-type
waste, the volume of waste sent to incinerators or landfills will be reduced and natural
resources will be conserved.

The European Union’s RoHS (“Restriction of the use of certain Hazardous Substances”)
Directive (2002/95/EC) came into effect on July 1, 2006. All of the systems manufactured
by Silverwing (UK) Ltd fall under Category 9, Measurement and Control Equipment.
Currently this category is exempt from RoHS compliance until at least 2018, when it and
other exemptions will be reviewed. Regardless of this, all products manufactured by
Silverwing (UK) Ltd are compliant with the RoHS Directive.

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3 Transportation and Storage

3.1 Receiving and Inspection


For transport purposes the Floormap3Di system is supplied within a black transit case strapped
to a non-wooden pallet. Any transport work may only be carried out by appropriately trained
personnel. Transportation instructions on the packaging must be followed (refer to Section 1 –
Hardware, Setup and Operation).

On receipt of the system, carefully check it for any damage that may have occurred during
shipping. The transport company is responsible for damage that occurs during transport. If there
appears to be damage, carefully inspect the system components for any further damage and
check that all components correspond to the packing list. In the event of damage, notify the
transport company immediately and keep the packaging as evidence. A full report describing the
damage in detail must be submitted to the Transport Company and serves as the basis for the
damage claim.
Damage or loss of goods delivered must be reported immediately to Silverwing (UK) Ltd and
confirmed by a copy of the above-mentioned report. If the operating manual is removed, do not
lose or misplace.

3.2 Unpacking
The Floormap3Di system is packaged in a black transit case. Care should be taken when
unpacking the Floormap3Di system, any markings or warnings shown on the packaging should
be observed prior to opening. The following steps should then be taken:
 Unpack the Floormap3Di system in a dry area.
 If a knife is used to remove packaging care should be taken not to damage the Floormap3Di
system or cables.
 Check the contents of the Floormap3Di system against the packing list supplied and any
missing items are to be reported immediately.
 The package and contents of the Floormap3Di system should be checked for signs of
damage during transport and any problems reported immediately.
 Silverwing (UK) Ltd accepts no responsibility for damage or injury caused during the
unpacking of the system supplied.

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CAUTION!
FOUR MAN LIFT. Lift the Floormap3Di transit cases at its four
handles with the aid of 4 people. Alternatively a forklift can be
used.

3.3 Packing and Transportation


Before packing the Floormap3Di system into the transit cases ensure:
 Each component of the system is clean and dry;
 The small case carrying the Sitemaster2 is firmly secure using the supplied straps;

Each component of the Floormap3Di system must be correctly packed into the correct transit
case. Refer to the supplied packing list.
The large black transit case is designed to hold the Floormap3Di system and mounted to the
base of the transit case is a keep plate. When packing the Floormap3Di scanner the magnetic
bridge must be in contact with the keep plate.

CAUTION!
FINGER CRUSH. The magnetic bridge contains strong
magnets that produce an extremely strong magnetic
field which could cause entrapment of hands and
fingers. HANDLE WITH CARE.
If the Floormap3Di system is to be shipped elsewhere, the original packaging and transport
protection inserts MUST be used.

CAUTION!
MAGNETIC MATERIAL. Due to magnetic material,
consult IATA documentation before air shipping.

3.4 Storage
If storage of the Floormap3Di system is required then all components must be packed correctly.
The Floormap3Di should be stored;
 In a clean, dry and secure location.
 Away from water and harsh environment conditions.
 In such a way as to avoid damage to the system.

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4 Floormap3Di Specification Sheet

Physical Characteristics

Operating Principal Magnetic Flux Leakage & Magnetic Field Reluctance


IP rating IP 4x
Scan width 300mm (12”)
Floormap3Di weight 57.5 kg (126lbs)
Height: 98.5cm (38.7”) - Width: 51cm* (20”) - Length: 69cm
Physical dimensions
(27.1”)
Minimum man-way
500mm diameter man-way for Floormap3Di entry
size
Meets IATA requirements for transporting magnetisable
Transit case
material
Operating Conditions

1 x 12V, 25 amp-hour sealed lead acid battery (x4 supplied)


Power requirements
with 3 chargers for continuous use
Typical battery
Up to 2 hours
operational time
Operating
-30⁰ C to 55⁰ C (-22⁰ F to 131⁰ F)
temperature
Storage temperature -35⁰ C to 75⁰ C (-31⁰ F to 167⁰ F)
Humidity 10-95% RH
Scanning Capabilities
Method of detection 256 Hall Effect sensors, 64 channels
Minimum defect
2mm (0.08”) diameter pipe type 50% deep **
detection sensitivity
Minimum defect
20% material loss (ball type) under floor and top surface **
sizing sensitivity
Test through
Yes, if non magnetic
coatings
6mm (1/4”) coating on 6mm (1/4”) plate
Maximum coating
5mm (3/16”) coating on 8mm (5/16”) plate
thickness for
3mm (3/32”) coating on 10mm (3/8”) plate
accurate sizing **
1mm (1/16”) coating on 12mm (15/32”) plate
Top and bottom
Yes, using STARS technology
discrimination
Supporting plate
Rectangle, annular and sketch
types
Scan overlap 0 to 250mm (9.8”) with transparent tracks to show all defects
10mm (3/8”) from plate weld, 160 x 160mm (6.3 x 6.3”) corner
Un-scanned area
dead zone
Defect size, x / y position, plate view, top/bottom, MFL, MFLi,
Real time analysis
STARS

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Drive Capabilities

Method of propulsion DC motor, anti-static drive wheels


Rollers Heavy duty, multi compound rollers
Speed 500mm / second (19.7” / second)
Positional accuracy ±0.04% (±3mm over 8 metres) (±3/32” over 315”)
Scan coverage 9m² / minute (354”² / minute)
Maximum single
32 metres (1,260”)
scan length
Software and Computing Specifications

Computer system Sitemaster2 ruggedised touchscreen computer


IP rating IP 65
Operating system Microsoft Windows 7 Pro
Processor Intel® Core™ i7
Memory 8GB DDR 3
Display 12.1” XGA touchscreen LED
Storage 120GB SATA internal SSD with anti-shock protection
Power supply 9-36V DC
Uninterruptable Internal battery for up to 30 minutes of power (10 minutes with
power supply (UPS) default settings)
Interfaces 4x USB 2.0, 1x Ethernet 10/100/1000, 1x RS232, 1x COM port
Data Acquisition 1x pre-installed version on Floormap3Di unit (Field updatable)
System Software*** 3x desktop versions
3x user licenses for full desktop versions
SIMS ***
Unlimited read only desktop versions for client use

* = Removing the detachable handle can reduce this value to 40.5cm (16”).
** = This value is based on a clean ferrous inspection surface.
*** = Operating system requirement – Microsoft Windows Vista, 7 or 8.

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4.1 Detection capability table for defects created with 22mm ball end cutter
(using MFL and STARS)

Plate Thickness
Coating 6mm 8mm 10mm 12mm 16mm
Thickness (0.24”) (0.31”) (0.4”) (0.47”) (0.63”)
No Coating          40%+

0.5mm          40%+

1mm          40%+

2mm          60%+

3mm        40%+  60%+

4mm      40%+  40%+  60%+

5mm      40%+  60%+  80%+

6mm      40%+  60%+  80%+

7mm      60%+  60%+ 


8mm  40%+  40%+  60%+  80%+ 
9mm  40%+  40%+  60%+  80%+ 
10mm  40%+  40%+  60%+  
Bottom

Bottom

Bottom

Bottom

Bottom
Top

Top

Top

Top

Top
 = 20%+
4.2 Sizing capability table for defects created with 22mm ball end cutter (using
MFL – STARS used for surface origin only)

Plate Thickness
Coating 6mm 8mm 10mm 12mm
Thickness (0.24”) (0.31”) (0.4”) (0.47”)
No Coating        
0.5mm        
1mm        
2mm      
3mm      
4mm     N/A N/A

5mm     N/A N/A

6mm   N/A N/A


Bottom

Bottom

Bottom

Bottom
Top

Top

Top

Top

 = 20%+
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Notes:

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Silverwing UK Ltd - (Head Office) Silverwing Middle East LLC Silverwing Africa (PTY) Ltd Silverwing USA Inc
Clos Llyn Cwm P. O. Box 75950 Private Bag X1 Suite 120
Swansea Enterprise Park Dubai Postnet Suite 419 2911 South Shore Blvd
Swansea United Arab Emirates Melkbosstrand League City
SA6 8QY t: + 971 4 360 6751 7437 Texas
Wales, UK f: + 971 4 360 6124 South Africa 77573
1
t: +44 (0) 1792 585533 e: sales@silverwingme.com t: + 27 21 557 5740 USA Ref: OM-FM3Di-S0
Doc
f: +44 (0) 1792 586044 w: www.silverwingme.com f: + 27 21 557 4354 t: + 1 832 531 0092
Rev:4.0
e: sales@silverwingndt.com e: sales@silverwingafrica.com Date
e: of Release:30/05/2014
sales@silverwingndt.com
w: www.silverwingndt.com w: www.silverwingafrica.com w: www.silverwingndt.com

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