IRTS MFL Work Procedure

IRTS Robotic
Department
Revision: 1.0
Issue Date: Oct 2016
MFL Tank Floor Inspection Procedure
MFL Tank Floor Examination in accordance with manufacturer’s guidelines.
International Robotic Tank Solutions
MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 1 of

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CONTENTS
1. SCOPE
2. DEFINITIONS
3. REFERENCES
4. PERSONNEL
5. SAFETY
6. TECHNIQUE
7. EQUIPMENT
8. FUNCTIONAL TESTS
9. SURFACE PREPARATION & PRE-PLANNING
10. SCANNING PROCEDURE

10.1 Calibration of MFL Test Unit
10.2 Detection
11. PRESENTATION OF RESULTS
12. EXAMINATION RESTRICTIONS & LIMITATIONS

12.1 Pipework
12.2 Welds
12.3 Plate Geometry
12.4 Previous Remedial Work
12.5 Floor and Annular Plate Thickness
Figure 1 – Principle of Technique
Figure 2 – Standard MFL Reference Plate
Figure 3 – Sample Scan Pattern
Figure 4 – Restricted Scanning Areas

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1.0 SCOPE
This procedure defines the inspection method to be utilized when performing MFL
tank floor inspection utilizing the Silverwing Floormap unit or equivalent MFL units.
The under-noted items will be agreed by the contracting parties prior to
commencement of testing:
a) Acceptance Standard
b) Tank floor preparation
c) Operator approval
d) Procedures
e) Scope of inspection
f) Reporting
2.0 Definitions
2.1 Linear Indication. A relevant indication with a length greater than three times its
width that is due to a crack or other discontinuity.
2.2 General Pitting. Any area that displays multiple pits in close approximation to one
another over a large section of individual floor plates.
2.3 Local Pits. An isolated pit or small number of pits in an otherwise clean section of floor
plate.
2.4 MFL - Magnetic Flux Leakage
3.0 REFERENCES
IRTS relevant QA/QC procedures latest edition.

SNT-TC1A
Equipment manufactures operating manual
IRTS-UTM Procedure
4.0 PERSONNEL
The Technician must be qualified and certified in accordance with the manufacturers
written practice, which will, as a minimum, comply with the requirements of SNT-TC-
1A’s latest Code accepted edition for Level 2 and Level 3 personnel and meet the
current requirements of EN 473 or PCN were relevant.
Lead Technician will have a minimum of 3 years’ experience of tank survey projects
previously, have some form of Electromagnetic testing qualification and have been
trained on the specific equipment be utilized. They will also be qualified in any
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additional supporting techniques required for confirmation of corrosion ie. (magnetic

particle or ultrasonics)
5.0 SAFETY
All work is to be carried out in accordance with any statutory and local safety
requirements and also in accordance with the requirements of any applicable hazard
assessment. IRTS personnel will submit relevant Method Statement and Risk
Assessment (MSRA) before starting any project to discuss local site requirements with
regards to work permits; lockout/tagout procedures. All personnel will attend site
safety inductions.
Special attention is required for continuous monitoring of atmosphere in all confined

spaces. Where lead paint is involved operators should use supplied air and must be
qualified to do so.
Note: MFL system use strong magnets and therefore poses a threat to any person
fitted with a pace maker and should be kept a safe distance from unit. Also special
handling procedures are required to prevent any potential pinch point.
Minimum Permits: Work Permit/Confined Space/Hot Work if required.
6.0 TECHNIQUE
The MFL Floormap system and equivalent MFL units use a Magnetic Flux Leakage
technique. The method only performs on low alloy carbon steels, which have a high
relative magnetic permeability.
The technique is based on the principle of magnetizing the floor plate under test to a
relatively high level without saturation using a permanent horseshoe magnet.
This magnetization of the area under test generates a uniform magnetic flux between
the two poles in a defect free plate in contrast to a plate with local corrosion
(pitting/local corrosion) the uniformity of the magnetic flux is distorted around the
discontinuity allowing flux lines to break the plate surface as shown in Figure 1.
An array of Hall Effect sensors placed between the poles of the magnet is used to
detect extent of this local flux leakage.
The system response to the detection of these changes in flux leakage is transferred to
unit display where typically illumination of the corresponding LEDs occurs to help
evaluate type of defect observed.
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7.0 Equipment
Silverwing MFL Floormap comprises of the following parts:
1. The magnet carriage, magnet and Hall effect sensor module

2. The motor unit and battery compartment
3. The electronics module housed within the main chassis/handle unit
4. The detachable Sitemaster 1000 computer.
5. 12V 30Ah sealed lead acid gel battery and battery charger
6. Reference plate containing a set of accurately machined defects (see Figure 2).
8.0 Functional Test
Press startup on the unit and allow to "warm up" for approximately ten minutes.
Ensure plate thickness selector switch is set to the correct position
Ensure sensor height is correct and the auto stop is enabled.
Set the threshold to 15 and scan over the 40% artificial defect on the reference plate.
Check that the appropriate LEDs turn red and the unit stops automatically.
9.0 Surface Preparation & Pre-Planning
Quality of inspection results are directly related to surface preparation performed on tank
floors prior to inspection they should be free from product, scale, water, and residue from
cleaners (e.g.: after shot blasting, scale etc.).
If the tank floor has been shot blasted a minimum acceptable finish of SA 2 / SA 2.5 will be
required depending upon initial surface condition. As with all inspection test methods lighting
within the tank should be bright enough to perform a detailed visual inspection.
Prior to inspection labelling or mapping of tank floor plates must be agreed with client, if
previous floor maps exist then these should be maintained to improve record keeping and
future trending of deterioration. This map should then be transferred to actual floor plates
with paint marker to allow easy recording of defects during inspection. First course shell
plates should also be marked at this time.
Note any limitations/restrictions, e.g. strike plates, heating coils etc.
Plate orientation is defined as “vertical” or ”horizontal” with respect to the tank datum
(manway).

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10.0 Scanning Procedure
After tank floor plates numbering system is in place a thorough visual inspection should be
performed for 100% of tank floor plates, annular ring and first course shell plates. All visible
areas of heavy pitting and corrosion should be highlighted at this time.
Perform manual ultrasonic thickness readings with a correctly calibrated UT set on each
individual plate and record results to ensure the documented plate thickness is consistent
with that observed in field.
10.1 Calibration of MFL Test Unit:
Assemble and place the MFL Floormap on a defect free area of the reference plate, ensuring it is
of the same thickness as those to be tested. (Diesel Tank 8mm)
Switch unit on and allow a "warm up" period of ten (10) minutes. Set the plate thickness
selector switch to the correct position:
To acquire calibration data the unit needs to be driven along the full length of the MFL
reference plate in both directions: The first scan must be made from the largest calibration
defect. The second scan must be made from the smallest defect. Check the sensor head height is
set up correctly using the 0.5mm shims.
Table 1.0 - System settings (Sensor height related to plate thickness and coating)

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Position the scanner at the end of the calibration plate closest to the 80% defect and press the
Calibrate button. A message will appear instructing the operator to scan from the largest
defect to the smallest defect. Turning the drive handle will simultaneously start the scanner
and data collection functions. Drive the scanner along the full length of the plate and release
the drive handle before the drive wheels reach the end of the plate. Releasing the handle ends
the first calibration scan. A message will appear instructing the operator to scan from the
smallest defect towards the largest defect. Drive the scanner along the full length of the plate
and release the drive handle before the drive wheels reach the end of the plate. Releasing the
handle ends the second calibration scan. Press accept to view the calibration trace. The
calibration must be saved if the calibration trace is acceptable.
Note:
The reference plate must not be in contact with any ferromagnetic material while the
calibration operation is carried out.
If there is a coating in excess of 0.5mm on the tank floor to be tested, a piece of nonmagnetic
material of same thickness as the coating on the floor must be placed between the unit and
the reference plate during the calibration procedure.
Method of Operation
Due to the strong magnet care must be taken when placing the unit in the tank to avoid
accidents. After switching on allow the unit to stabilize and calibrate system as previously
discussed. Position the MFL Floormap unit at the corner (datum) of the first plate to be
scanned. Enter the plate length and width into the relevant boxes on the computer screen.
Once all details have been correctly entered, click on the Create button and this will open the
scanning window.
Scanning Plates:
To begin a scan, click on the scan button. Once clicked, an on-screen numeric keypad appears
allowing the user to enter a "Start Offset". The "Start Offset" represents the area at the start
of the scan that is not accessible by the Floormap sensor head. Once the measurement is
entered, click on the enter key to begin a scan. Turning the handle will simultaneously start
the scanner and data collection functions, the handle is held on until the required scan length
is reached. Once the handle is released, the Floormap will stop the data collection. The "Scan
Summary" window will appear. Press the "Accept" button to save the track scan. The
computer automatically prepares the software to start scanning the next track. Continue this
process until the whole plate is scanned (Figure 3). Carry out a transverse scan at each end of
the plate to ensure maximum coverage of the plate. The inspection shall be carried out row by
row, each plate being scanned in turn. The maximum scan length shall be restricted to one
plate length.
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10.2 Detection
When a flaw is encountered the MFL Floormap all indications are captured by the computer,
sized, in real time, against a correlation curve created from a calibration plate with known
artificial defects and then stored with the location and plate details on the hard drive. This
information is subsequently downloaded into the graphical reporting software and a colour
coded map of the tank floor can be created showing the location and severity of all corrosion.
All defects detected on the tank floor plate are crosschecked with manual ultrasonics.
The positions of defects are to be marked on the floor plates as follows: An area containing
significant internal defect indications shall be marked with a circle. An area exhibiting
significant external defect indications shall be marked with a square.
If the condition of the top surface of the plates is such that realistic testing is not possible (due
to cleanliness, corrosion products, scale, severe top surface pitting etc.) re-calibrate the MFL
Floormap unit as per Section 9.2, but replacing the 40% reference defect with the 50% to
obtain the inspection threshold. Re-scan the areas that have been scanned with 40%
threshold using the new threshold settings to allow for poor surface condition.
If the response is still unsatisfactory the floor shall be considered unfit for testing and the client
informed.
In the absence of either a reference plate with the machined defects as per drawings in Figure
2 it is permissible to adjust the sensitivity against a natural defect of approximately 12.5mm
diameter and 40% deep (or a percentage loss agreed with the client).
It is not allowed to adjust the sensitivity against a natural defect with a diameter greater than
15mm.
10.3 Ultrasonic Verification of Defects Indications
A manual ultrasonic examination shall be carried out on all areas identified by the MFL
Floormap unit to confirm extent and severity of under floor corrosion.
The examination shall be carried out as per procedure IRTS UTM procedure.
The extent of the ultrasonic examination shall be as follows:
External indications shall be mechanically measured with a pit gauge to evaluate the depth
and diameter of the pits. A minimum area of 300mm shall be checked at each position
identified by the MFL Floormap unit. Any area not covered by the MFL Floormap scan shall be
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subject to a manual ultrasonic survey. The extent of coverage shall be agreed with the client.
11.0 Presentation of Results
Unless otherwise agreed with the client, all indications identified with MFL Floormap unit and
verified as 40% or greater by manual ultrasonic examination shall be recorded on individual
plate diagrams, showing location, area and remaining wall thickness.
These areas shall be marked up on the floor plate.
A preliminary report shall be submitted to client prior to leaving site containing as a minimum:
a) Floor diagram showing layout, numbering system used and datum points.
b) Individual floor plates, which exhibit significant corrosion.
c) A list or drawing containing any areas not inspected and restriction noted.
Within an agreed time frame with the client a final report shall be prepared and issued this will
contain detailed findings to include the following:
a) Floor plate diagram showing, layout, numbering system employed and datum points.
b) A list of plates exhibiting significant top surface pitting.
c) A list of plates exhibiting significant under floor corrosion.
d) Plate drawings showing position, extent of flaws and ultrasonic examination results.
e) A drawing and /or list showing plates not inspected and reasons.
f) Any comments or recommendations.
12.0 Examination Restrictions & Limitations
12.1 Pipework
Any area not covered by the MFL Floormap scan due to restricted access by pipe work, strike
plates, heating coils shall be subject to a manual ultrasonic survey. The extent of coverage
shall be agreed with the client
12.2 Welds
At welds between adjacent plates the MFL Floormap unit is able to scan to the edge of the
weld on the upper plate, but is not able to scan closer than 30 mm in the lower plate.
12.3 Plate Geometry

The MFL Floormap unit is unable to examine annular plates adjacent to the shell if the width
of the plate is less than approximately 400mm as the unit becomes wedged against the tank
shell (see Figure 3).

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12.4 Previous Remedial Work

Any previous welding on the plates gives rise to spurious readings, as the MFL Floormap unit
interprets the changes in the flux field as defects. A visual and/or an ultrasonic inspection shall
be used to confirm results.
The MFL Floormap unit is unable to distinguish between top surface and bottom surface
corrosion. The results from the MFL Floormap unit are accurate to +/- 10%.
12.5 Floor and Annular Plate Thickness

The maximum floor plate thickness that can be inspected is 12.5mm.
The design of the magnet carriage allows coverage up to the "lap welds" when inspecting
thinner plates.
It is not possible to get closer than 60 mm adjacent to the shell to annular weld.
Along the axis of the weld, a 30 mm wide strip will not be inspected by the MFL Floormap unit
(see Figure 5).
13.0 NON-COMPLIANCE
If the inspection is unable to be performed in accordance with the requirements of this
procedure, for any reason, then the team leader shall seek guidance from his supervisor or the
client.
Any agreed deviation from this procedure shall be documented for the inspection record.

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FIGURE 1.0 PRINCIPLE OF TECHNIQUE

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FIGURE 2 Standard MFL Reference Plate

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FIGURE 3 Sample Scan Pattern

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FIGURE 4 Restricted Scanning Areas

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IRTS Robotic

International Robotic Tank Solutions

MFL Tank Floor Inspection Procedure

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 1 of

9. SURFACE PREPARATION & PRE-PLANNING

10. SCANNING PROCEDURE

11. PRESENTATION OF RESULTS

12. EXAMINATION RESTRICTIONS & LIMITATIONS

Figure 1 – Principle of Technique

Figure 2 – Standard MFL Reference Plate

Figure 3 – Sample Scan Pattern

Figure 4 – Restricted Scanning Areas

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 2 of

IRTS relevant QA/QC procedures latest edition.

additional supporting techniques required for confirmation of corrosion ie. (magnetic

Special attention is required for continuous monitoring of atmosphere in all confined

Minimum Permits: Work Permit/Confined Space/Hot Work if required.

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 5 of

Silverwing MFL Floormap comprises of the following parts:

1. The magnet carriage, magnet and Hall effect sensor module

8.0 Functional Test

9.0 Surface Preparation & Pre-Planning

Note any limitations/restrictions, e.g. strike plates, heating coils etc.

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 6 of

10.0 Scanning Procedure

10.1 Calibration of MFL Test Unit:

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 7 of

10.3 Ultrasonic Verification of Defects Indications

The extent of the ultrasonic examination shall be as follows:

11.0 Presentation of Results

These areas shall be marked up on the floor plate.

12.0 Examination Restrictions & Limitations

12.3 Plate Geometry

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 10 of

12.4 Previous Remedial Work

12.5 Floor and Annular Plate Thickness

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 11 of

FIGURE 1.0 PRINCIPLE OF TECHNIQUE

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 12 of

FIGURE 2 Standard MFL Reference Plate

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 13 of

FIGURE 3 Sample Scan Pattern

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 14 of

FIGURE 4 Restricted Scanning Areas

MFL Tank Floor Inspection Procedure Revision 1 IRTS-COPYRIGHT 2016 Page 15 of

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