MAGNETIC FLUX LEAKAGE

Before Knowing about Magnetic Flux Leakage,

at first we have to know what is

MAGNETISM
Magnetism:
It is the ability of matter to attract other matter to itself.

Using the magnetism property we inspect Ferromagnetic

materials by a technique Magnetic particle inspection(MPI)

MPI uses magnetic fields and small magnetic particles

(i.e. Iron filings) to detect flaws in components.

MPI is a relatively simple concept. It can be considered

as a combination of two non-destructive testing methods
Magnetic flux leakage testing and Visual testing.
Magnetic Flux Leakage:

MFL is an NDT technique used to detect pitting,

circumferential cracks, and wall losses in ferromagnetic tubes
such carbon steel, nickel, and ferrous stainless steel.

 The MFL method uses an array of sensors such that each

sensing field overlaps with its neighbour.
 The probability of detection of any flux leakage signal depends
on the amplitude of that leakage field in relation to any noise
signals.
 In other words, the signal to noise ratio is the primary factor
governing detection.
 The probability of detection of any flux leakage signal depends
on the amplitude of that leakage field in relation to any noise
signals.
Basic Principle:
The principle of operation is based on
magnetization.
 Two permanent magnets coupled to a steel core are used to
magnetize the tube wall until complete saturation is reach. To
that, three coils are added each one being sensitive to specific
defects.

 An absolute coil is winded around the core to measure the

magnetic field variation caused by general wall losses
 When a small flaw is located between the two magnets, the
magnetic field in the tube wall is disturbed and a small
amount of flux leak in to the inner tube.

 This flux leakage is detected by differential coil located

between magnets.
 For Wall Loss Detection:
 Wall losses are detected with the absolute coil winded on the
core of the magnetic circuit
 This coil measures the length on the magnetic field produced
by the magnet
 When there is general thinning like an erosion, there is no flux
leakage in the tube but the strength of the magnetic field
reduces.
 This variation is detected by absolute coil.
 For OD Defect Detection:

 Lead coil can detect this flux leakage because it is located

between the magnet, right in the middle of the magnetic
circuit.
 Trail coil which is outside the magnetic circuit, cannot see the
defect because there is no flux leakage inside the tube.
 For ID Defect Detection:

 Lead coil can detect the flux leakage.

 After the magnetic circuit passes the defect some residual
magnetism remains on the defect.
 Trail coil will detect the residual magnetism and produces a
signal output to the system.
 Limitation:
 The defect sizing capacity of MFL has some limitations the
signal amplitude is affected by pulling speed variations and
the signal has no phase component.
 This makes MFL more a detection method than a sizing
one.
 Inspection is quite fast the pulling speed can go up to 1 m/s.
 Applications:

This technique is typically used for the inspection of

 Feed water heaters

 Air coolers

 Carbon steel heat exchangers

 Tank Floor Mapping

Thank you