Magnetic Flux Leakage Reliability Experiment

Summary:

Basic principle of Magnetic Flux Leakage (MFL) is that a powerful magnet is used to magnetize
the steel. At areas where there is corrosion or missing metal, the magnetic field "leaks" from the
steel. Analysts interpret the chart recording of the leakage field to identify damaged areas and to
estimate the depth of metal loss.
1. Advantage:

1) Can be used on all ferromagnetic materials;

2) Good sensitivity to pitting;

3) Effectively inspection;

4) The output from the detector can be amplified, filtered, digitized, etc and stored to produce

automated inspection systems.

It is a very suitable tool for detecting bad spots in the plates. The fast MFL inspection is done only
the “suspicious” areas of the surface will be quantified by the slower but more accurate UT
technique.
2. Disadvantage:

No absolute values but relative volumetrically changes are detected.

The“suspicious” areas of the surface has to be quantified by more accurate UT technique.
3. HandScanHS100 Official Technical Description:

3.1 Applicable Scope：

Ferromagnetism Material: Diameter≥1500mm; Thickness≤19mm.

3.2 Thickness Range：

Ferrous material with wall thicknesses from 6 mm to 15 mm;

Maximum: At reduced sensitivity wall thicknesses up to 20 mm can be inspected.

Prepared by: Wang Qingmin; Reviewed by: Feng Qiang

3.3 Max sensitivity：

10% Wall Loss in 0.25”(6.4mm) Wall

40% Wall Loss in 0.5”(12.7mm) Wall
50% Wall Loss in 0.75”(19mm) Wall
4. Actual Sensitivity from Experiment(HandScanHS100):

Calibration by sample plates: 10mm and 12mm, test results please see below table 1 and 2：

Table 1 10mm sample plate Test results

Defects No. 1# 2# 3# 4#
Defects Depth 2mm/20% 4mm/40% 6mm/60% 8mm/80%
Results ╳ ● ● ●
Note：●Can be detected，╳Can’t be detected。
Table 2 12mm sample plate Test results

Defects No. 1# 2# 3# 4#
Defects Depth 3mm/25% 5mm/42% 7mm/58% 10mm/83%
Results ╳ ● ● ●
Note：●Can be detected，╳Can’t be detected。

It can’t detect the lowest holes at two different thickness sample plates.
(If increase sensitivity, the lowest hole can be detected, but the error alarm rate increases, so it is
not reliable)

Prepared by: Wang Qingmin; Reviewed by: Feng Qiang

At the same time, sensitivity is declining when increasing thickness.
Recommend 40% scan sensitivity on the plate that thickness higher than 10mm

5. Experiment at site:

Water- Water Heat Exchanger E11930B at AnDong workshop

Internal pit corrosion UTG Confirm

6. Conclusion：

6.1 Normal wall thickness: 12mm; Detected defect depth: 6mm; Wall thickness loss: 50%.
Experiments show that MFL HandScan is valid for natural defect detection, suitable for large

Prepared by: Wang Qingmin; Reviewed by: Feng Qiang

 area preliminary scanning. Followed by accurate UT technique at the“suspicious” areas for
accurate qualify.

6.2 During the experiment, it was found that the Ferro internals of equipment may cause the alarm
when the thickness was increased (such as internal sacrificial anode, support, etc.).

6.3 The heat exchanger diameter is less than 1500mm, probe is difficult to maintain balance when
scanning, have to keep the probe balance manually.
The effectively advantage of MFL is not distinct at this experiment, so it is not suitable for the
device that diameter less than 1500mm.

Prepared by: Wang Qingmin; Reviewed by: Feng Qiang