Development of Automated

Electromagnetic Techniques for

Inspecting Inner Cracks of LPG Tanks

Yung-How Wu,
Feng-Ju Hsieh, Mu-Chung Peng, Hsing-Jeng Yang

Materials Research Laboratories, Taiwan

Email:700606@mrl.itri.org.tw
Objective

To integrate an automated
ElectroMagnetic Array based system for
inspecting inner surface cracks on LPG
Tank.
Background
 LPG tanks were frequently subjected to SCC on
inner surface during service and must be
inspected from inside regularly.
 Conventional ISI by MT or PT is toilsome and
costly.
 Extremely hot in summer
 Scaffolding & Coating removal
 ACFM has been used to detect surface breaking
cracks without removing coating on components.
 Electromagnetic Array
Techniques
ACPD EMA or ACFM
V2/V1 = (2d + △) / △
∴ d =△/2((V2/V1) – 1) Crack tip Current
perturbation
Surface current
Span = △

V1 V2

Surface d
current Surface crack
 Crack Detection and Sizing
EMA System Data Display

CP Abs Corr.
Display

Crack

離距

Abs CP
Solo SDDPU

Handheld Probe Probe for Automation

 Samples with Artificial Cracks
Notches Cracks
41210

Plate-1

150 A group

C group B group

Defect(mm)
Defect(mm) Block Type Lengt Positn
Depth
Type/Positn Depth Length Width h
2 40 0.25
Weld-6 Toe Crack ~2mm 12 30
Notch/A群 2 20 0.25
Centerline
2 10 0.25 Weld-9 ~2mm 13 38
Crack
Characteristic Defect Signals
 A single defect was detected by three successive channels.
 Defect could be clearly identified by various displays.
 Signals in Various Conditions
8
 Weakest response at 380
6 1張
振幅

4 5張  Amplitude decreased exponentially

2 15張 with Lift-Off
0
 Measuring error could be
0 20 38 50 90
controlled down to ±25%
角度 o

10mmx1mm 裂縫 實驗1_Plate1_Plate2
振幅(Max/Min)

6
10 5

量測深度(mm)
4
5 數列1 3

0 2

1
0 10 20 30 0
0 1 2 3 4 5 6 7

投影片張數 實際深度(mm)
Automated Inspection System
 EMA System
 Lizard solo
itio
nS
ens
e

CCD Camera
 64 channels SDDPU
Pos
NTSC Standard
 Scanner Control Console
 PC + TFT monitor
Motor Control  Motor control module
 Motion control &
Control Console monitoring package
Direct Cable Connection  CCD camera and 2-axis
stage
EMA Signal  Scanner
 With 4 magnetic rollers
EMA System  Carrying 32-channel
probe
 Automated Inspection Method
 Weld and Plate regions were
Inspected individually
CCD Camera  Weld: along the weldment
ns e
Se
Po
siti
on
 Plate: as shown
NTSC Standard

Real Scan Path  Scanner was moved to the top

Field of View
position and then scan
automatically on each path.
Ideal Trajectory  Scanning route was
monitored by CCD camera
and full coverage was assured.
Frame GrabberCard
LPG Tank Steel Plate
 Field Trials
 Scanning is controlled and
monitored through CCD camera
by inspector operating below the
LPG tank.
Inspection Process
掃瞄動作
流程

焊道區
掃瞄區塊選擇 or
鋼板區
繼續掃瞄
下一條 Yes
CCD Camera
架設
No

機器人手動
移至初始位置

EMA資料擷取 機器人啟動
影像擷取 EMA資料傳送至 停止影像
開始 Scan a Line 機器人復歸
Control Console 擷取顯示

EMA資料擷取
機器人停止 影像處理 資料分析
結束
缺陷研判

影像顯示
資料儲存 結束
Conclusions
Laboratory and preliminary field trials proved
the method satisfactory in detecting real
cracks down to 10mm in length and 1mm in
depth in both regions. However, minor
improvement on the scanner manipulation is
required before practical application.