Acfm Inspection Procedure

ACFM Inspection Procedure
for U31 and QFMu
Dr. Michael C. Smith
TSC Inspection Systems

6 Mill Square, Featherstone Road,
Wolverton Mill, Milton Keynes, MK12 5RB
UNITED KINGDOM
Document: TSC/MCS/1523
Date: 04 March 2003
Issue: 1.1 (2)
Revision: 1
© 2003. Technical Software Consultants Ltd.

Document Revision Approval Sheet
6 Mill Square, Featherstone Road, Wolverton Mill,

Milton Keynes, MK12 5RB
KEYWORDS:
Controlled Copy: Yes No

TITLE:
ACFM Inspection Procedure

for U31 ACFM Instrument and
QFMu
Document: TSC/MCS/1523
update for 3.2b -

1.1 (2) MCS MCL MCL new probe 04 March 2003
change procedure
1.0 (1) MCS MCL MCL 26 April 2002
Issue(Rev) Initiated by Checked by Approved by Date

Issued Document Revisions
Contents
Introduction 1
Overview...................................................................................................................1
Introduction to ACFM..............................................................................................1
Description of Hardware 3
The ACFM Probes....................................................................................................3
Topside Unit..............................................................................................................3
Sub-Sea Unit.............................................................................................................4
Routine Maintenance and Handling..........................................................................5
Connectors..................................................................................................5
Subsea Unit and Umbilical.........................................................................6
Handling of unit..........................................................................................6
Annual Maintenance...................................................................................6
Manufacturers Contacts..............................................................................6
Inspection Requirements 7
Introduction...............................................................................................................7
Personnel Required...................................................................................................7
Equipment Requirements...........................................................................................8
Inspection Considerations 9
Probe Deployment Considerations............................................................................9
Cleaning......................................................................................................9
General Considerations - All Welds...........................................................9
Circumferential Welds - No Ground Out Regions..................................10
Inspecting Ground Out Areas...................................................................10
Inspection During Grinding......................................................................10
Inspecting Flat Plate Welded Supports/Stiffeners......................................11
Rat-holes and plate ends...........................................................................11
Transverse Cracks....................................................................................14
Material Features.....................................................................................................15
Coating Thickness....................................................................................15
Magnetic State..........................................................................................15
Surface Grinding or Work Hardening......................................................16
Seam Welds..............................................................................................16
Inspecting materials other than ferritic steel............................................16
Inspection Reporting 17
Reporting Requirements.........................................................................................17
QFMu ACFM Report Form....................................................................................19
Probe Operator Briefing: Check off list..................................................................20
Interpretation of ACFM Signals 21

General Method.......................................................................................................21
Crack Sizing............................................................................................................24
Using MPI With ACFM.........................................................................................24
Length Sizing With ACFM......................................................................24
MPI Indications........................................................................................25
1523.DOC, Issue 1.1 Contents Page i

Use of MPI Lengths In ACFM Calculations.............................................26
Operational Procedure 28
System Setup...........................................................................................................28
Connections..............................................................................................28
Function Check.......................................................................................................30
Inspection Procedure...............................................................................................31
End Of Session Function Check And Backup Procedure.......................................33
Post-Session Function Check..................................................................33
Backup Procedure.....................................................................................33
Exit QFMu and check backup..................................................................33
Appendix A 34
Probe Specifications................................................................................................34
Underwater Weld Probe............................................................................34
U31 Underwater Mini-Pencil Probe.........................................................34
Underwater Pencil Probe..........................................................................35
Other Probe Types....................................................................................36
Purpose of Probe Files............................................................................................36
1523.DOC, Issue 1.1 Contents Page ii

TSC Inspection ACFM Inspection Procedure- QFMu and
Introduction
Overview
This document describes the inspection procedure to be used with the U31 Underwater ACFM instrument for
manual inspection with standard probes. These probes are designed to be deployed by diver, with data
collected and sent to a controlling PC. An example system is shown below.
This procedure has been written for use with version 3.x of the QFMu inspection software on a PC running
Windows 9x / ME / 2000 / XP or NT. To check the version of software in use, select the "About..." option in
the "Help" pull-down menu in QFMu.
Figure 1. U31 instrument with Topside Unit, Weld Probe and laptop PC
Introduction to ACFM
The A.C. field measurement (ACFM) technique was developed from the A.C. potential drop (ACPD)
technique which has been used for crack sizing and crack growth monitoring. ACPD has been used
underwater even though electrical contact has to be maintained between the probe and the component being
inspected. The ACFM technique is simpler in operation as it depends on the measurement of the near-surface
magnetic fields rather than the surface electric fields, thus requiring no electrical contact. Theoretical work
carried out at the Wolfson NDE Centre in the Mechanical Engineering Department of University College
London determined the relationship linking these two fields. Thus existing models of electric fields around
cracks can be used to size cracks using magnetic field measurements. This non-contacting sizing capability
relies on the use of unidirectional input current in the region under inspection, similar to that required for the
1523.DOC, Issue Introduction Page

ACPD technique. For the ACFM technique, the input current is induced into the specimen thus making the
system fully non-contacting.
In single probe ACFM operation the Crack Microgauge passes two signals to the ACFM crack detection and
sizing software (QFMu). The first is the magnetic field strength measured in the direction parallel to the
crack edge (Bx) and the second is the magnetic field strength measured in a plane perpendicular to the
surface of the metal (Bz). The software (QFMu) then displays these signals in three forms; the Bx and Bz
traces separately against a timebase, a dual digital meter display, and a polar plot display in which one
component is plotted against the other. This latter form is known as a butterfly plot because of the
characteristic trace produced by a defect.
For more information, refer to TSC's introductory literature.
The ability to size surface breaking cracks without cleaning the weld region down to bare metal offers
significant potential benefits over existing techniques such as magnetic particle inspection, ACPD and eddy
currents. As well as allowing crack depth estimates to be made (for ferritic materials), the use of a
unidirectional input current provides further practical benefits. Firstly, the decay in strength of the input field
with probe height is relatively small so that variations in signal with probe lift-off are reduced. Secondly, the
current flow is arranged normal to a weld toe or other material discontinuity so that there is no perturbation in
current direction and hence no signal from the interface due to a change in material property. A final benefit
is that the technique requires no calibration for sizing. Techniques requiring calibration rely on the
measurement of signal strength on a standard notched sample. For weld inspection the standard block is
invariably of different material to that at the crack location leading to errors in interpretation.
1523.DOC, Issue Introduction Page

Description of Hardware
The ACFM Probes

Each probe contains a sensor coil pair consisting of a Bx coil and a Bz coil wound concentrically. A field
induction solenoid is housed in the top of the probe body.
Standard weld probes (type 293) should be used for all inspections where access and local geometry allows.
If the chord-to-brace angle is too small to allow access of the standard probe, a tight access weld probe
should be used (type 312). It is important that a tight access probe is not used in geometries with a chord-
brace angle of more than 90o because this results in a lower detection sensitivity compared to a standard
probe. The tight access probe relies on the proximity of both chord and brace to induce a strong uniform field
across the weld. A pencil probe (type 303) should only be used for inspecting ground out regions or other
geometries where a weld probe cannot gain access.
Miniature pencil probes are also available for very restrictive geometries (type 291 with right angle cable
entry, type 292 with straight cable entry). These probes are inevitably more prone to probe rock and lift-off
than other types of probe, and should only be used when absolutely necessary.
Note that the type number for a particular probe is included on the label. If there is any doubt about a
particular probe, refer to T.S.C.
Other special probes, including probes for detecting and sizing small defects, can be made to order if required
by TSC.
Topside Unit
The Topside Unit acts as the interface between the software running on the controlling computer and the
subsea unit. It contains a microprocessor that handles the conversion in serial communications between
RS232 from the computer and RS485 to the subsea unit. It also supplies power to the subsea unit and
provides a 110V output to power the computer.
mstances must the Topside Unit be connected to any device (e.g. computer) which is powered from another source, unless that source also ha
1523.DOC, Issue Description of Hardware Page

Figure 2. Layout of front of topside unit
The topside unit is housed in a case that is IP54 rated and the unit can withstand rain from above when stored
or in use providing that all connectors or blanking plugs are used. The front panel has the following features:
 On/Off button which turns power on to the internal electronics and microprocessor. When
switched on, mains power is also routed to the Mains Out socket and DC power is sent to the
Umbilical connector. Thus, if the subsea unit is connected via the umbilical, this is powered up at
the same time.
 Mains in - 4-way panel-mounted plug for connection to 110V AC supply. Connection to
mains power must be through the in-line RCD supplied with the system.
 Mains Out - 4-way panel-mounted socket for output of 110V AC supply to computer. The
computer should be connected to this socket rather than to a separate mains connection to maintain
protection from the RCD.
 Umbilical socket - 12-way Amphenol socket used to connect an umbilical cable to the subsea
unit. The umbilical takes DC power to the subsea unit and carries RS485 communication lines
between the topside unit and the subsea unit.
 RS232 socket - 6-way Lemo socket used to connect the RS232 serial communications cable to
the associated computer running the QFMu software. The other end of this cable is a 9-way 'D'
connector which plugs into the serial port (Com1:) on the computer.
 TX - Green led which flashes when the topside unit sends data to the subsea unit.
 RX - Red led which flashes when the topside unit receives data from the subsea unit.
Sub-Sea Unit
The subsea unit houses the electronic instrumentation which generates the field signals for the probes and
samples and digitises the raw ACFM signals detected by the probes.
The subsea unit has just two connectors. One, labelled Umbilical, is an 8-way Wet-Con plug for connection
of the umbilical cable from the topside unit; the other is a 16-way socket for connection of a probe. Both
connections should made prior to the subsea unit being put underwater. The probe can be disconnected

underwater to allow a different one to be used, but the probe socket power must be turned off, using a
button in the software, while the change is made.
All connectors must be cleaned with fresh water at the end of a shift and should be lubricated using silicon
spray.
Figure 3. U31 Subsea bottle
Routine Maintenance and Handling

Before carrying out any of the following maintenance, Switch off Mains Power at Topside Unit
Connectors
1. Clean subsea unit with fresh water after each dive while probe and umbilical are still connected.
2. Always keep connectors covered when not in use to avoid contamination - do not allow to 'dry
out' by long exposure to heat and sunshine!
3. Lightly lubricate the connector pins with silicon spray on the rubber part only.
4. Check cleanliness of contacts.
5. Use warm soapy water with cotton buds to clean female Wetcon connectors.
6. Before each dive, visually check the connectors, particularly with regard to splits or
mechanical damage.

Subsea Unit and Umbilical

1. There are no user serviceable parts in the subsea bottle. Opening the bottle will invalidate
the warranty. Always use 110V AC supply to topside unit.
2. The system must never be used without RCD protection.
3. The umbilical is a special cable and must not be substituted or shortened.
Handling of unit
1. Never use the umbilical to lift the subsea unit. A separate lift line should be used and attached to
the lifting eye on the top of the unit.
2. Never put strain on the probe or connectors. Always use "tie wraps" to provide strain release in
case of accidental tension being applied to the cables.
3. Avoid bending the connectors where they are attached to the bottle.
4. If the umbilical is damaged, refrain from using the unit.
** IF IN DOUBT, REFER TO MANUFACTURER **
Annual Maintenance
It is recommended that the unit is returned to the manufacturer annually for a routine check and issue of new
Certificate of Conformance. It is also recommended that the connectors are replaced at this time if they show
signs of degradation.
Manufacturers Contacts
TSC Inspection Systems
6 Mill Square, Featherstone Road
Wolverton Mill South
Milton Keynes, MK12 5RB
UNITED KINGDOM
Tel: + 44 01908 317444
Fax: + 44 01908 220959
Email: [email protected]

Inspection Requirements
Introduction
This procedure has been developed to enable underwater ACFM inspection to be carried out. Although it has
been developed primarily for the inspection of uncoated tubular welded connections, additional procedures
have been included for other situations including coated structures, ground-out regions, and structures
containing plate to plate welds or stiffeners. For inspection using special-purpose probes or of any geometries
not covered in this document, please refer to TSC.
This procedure should only be used once the operator/supervisor is fully familiar with the following
documents:
1. QFMu Software User Manual Level 1.
2. U31 User Manual (TSC Doc. No. 1522).
3. An Introduction to Underwater ACFM. Document MCL/0581 Revision 1.008, 10 April 1992.
Note: QFMu User Manual Level 1 is intended for use by Level 1 (Inspectors) in order to collect, store and
analyse data. The QFMu User Manual Level 2 is intended for use by Level 2 (Supervisors) allowing them to
change the parameters of the probe set-up and instrument control and to overwrite data files.
Personnel Required
ACFM Operator Experienced operator holding a CSWIP ACFM Level1 certificate or a Lloyds ACFM
certificate. Access to a CSWIP Level 2 is required if complex welds or interpretation
difficulties are encountered. If there is no Level 2 on site then reference may be made to
ACFM supervisory staff within TSC (see "Manufacturers Contacts" on page 6).
Probe Operator For subsea operation, a diver qualified to CSWIP 3.1U who has received training on
probe handling and scanning procedures and for whom the TSC Probe Operators check
list has been completed.
Whenever remote probe operators are used, continuous audio communication is required to enable the
ACFM operator to lead the inspection and for the probe operator to be able to report back on any local factors
influencing the inspection.
In addition, if an inspection is carried out with divers then a diver helmet-mounted camera system must be
used to enable the ACFM operator to supervise the subsea inspection site.
Operators holding certification from other recognised Qualification / Certification schemes than the above
may be considered suitably qualified, however they should contact the qualification body responsible for the
inspection site for official approval.
1523.DOC, Issue Inspection Requirements Page

Equipment Requirements
The following equipment list is not an exhaustive list of equipment that may be needed for a particular job but
does highlight essential and recommended equipment that will be needed as a minimum.
 U31 Crack Microgauge including Subsea Bottle, Topside Unit
 Test Umbilical
 Main Umbilical (150m), 1 or 2 off depending on requirements
 240V to 110V transformer (optional depending on local supply)
 Topside Unit power cable
 RS232 Serial Communications cable
 ACFM Probes – Weld probe (type 293) plus other types selected according to geometry and use
 Transit Case
 Marker Pencils / chalk (Box) or magnetic arrows
 Ruler / Measuring Tape
 Function Check Block of the same material type as that to be inspected.
 Laptop portable PC with 3.5" Floppy Disk Drive (A:) and RS232 comms port on 9-pin 'D'
connector, running Windows (9x, ME, 2000, XP or NT) and QFMu Software v3.x installed on hard
disk.
 Spare Computer Battery and Charger
 Probe File Disk for all ACFM Probes*
 Box of Formatted Floppy Disks or other storage media appropriate to the computer
 U31 User Manual
 QFMu Vn3.x Software Manuals Level 1 and 2
 TSC ACFM Report Sheets
*N.B. The TSC issued probe files delivered with the probes are set up for use on ferritic steels. If they are to
be used on another material they may need to be modified to ensure that the signal levels obtained are
correctly displayed on the screen. The procedure for doing this is described in the Level 2 Software User
Manual.
1523.DOC, Issue Inspection Requirements Page

Inspection Considerations
Probe Deployment Considerations
Cleaning
The surface must be cleaned sufficiently to allow smooth probe travel and to allow features such as grinds or
seam welds to be seen. This requires removal of marine fouling and flaking paint or corrosion for which use of
a wire brush, hand scraper or water jet is normally sufficient. It should be noted that cleaning to bright metal is
not required.
However in some locations, particularly in warmer waters, marine growth can be hard and thick. In such cases
it will be necessary to use grit blast cleaning.
The system operator shall confirm that the surface condition is acceptable prior to carrying out the inspection,
using information supplied by the diver and the divers video camera.
General Considerations - All Welds

The following notes on probe deployment describe how to inspect welded components for fatigue cracks where
it is assumed that defects will closely follow the weld line. The technique relies on recognition of the signal
from a probe scan along the length of a defect, so an ACFM probe is always scanned along a line parallel to the
weld. For this reason, defects that lie at an angle of more than about 25 to the weld may not be detected. If
inspection for transverse defects is required, refer to the procedure in section "Transverse Cracks" on page 14.
Standard weld probes should be used for all welds where access allows. A pencil probe should only be used for
inspecting ground out regions or other geometries where a weld probe cannot gain access.
The recommended scanning speed is about 10mm per second. The standard probe scans a width of
approximately 20mm. Scans should always be made along both weld toes and, if wider than 20mm, the weld
cap should also be covered by making a number of passes sufficient to cover the weld cap width taking into
account the coverage of the probe.
Finding the Plane of a Crack

If a defect indication is found during a weld toe scan, repeat the scan 10mm away from the toe in the relevant
plate and in the first interbead root on the weld cap to confirm the crack identification and to identify whether
the crack indication is due to interbead cracking. If the indication in the parent plate is of similar amplitude to
that of the weld toe, it is likely to be due to Seam Welds, Surface Grinding or Work Hardening. Note that a
seam weld may have been ground off and so not visible. Conduct another scan 20mm from the weld toe to
confirm this observation. If the indication during the bead scan is larger than that observed during the weld toe
scan, the defect must be in a weld cap. Repeat in the adjacent roots until the defect indication is greatest. The
root giving the greatest signal is the root containing the defect. Note that interbead cracking often jumps
between beads, which will result in a sudden drop in the signal from one bead coinciding with a sudden rise in
the adjacent bead.
Cracking into Parent Plate

In some geometries, especially tubular intersections, long defects that start growing along a weld toe can
deviate into the parent plate. This will show itself as a sudden drop in Bx with no corresponding Bz peak or
trough. In this case, scans should be made on the parent plate, along the expected defect line, to find the
defect's end.
1523.DOC, Issue Inspection Considerations Page 9

Through Cracking
Where the crack depth calculated is greater than the plate thickness this indicates that cracking may be
completely through the weld and so the diver should be asked to look for further evidence of this. Such
evidence may be visual crack opening or, if the back face is accessible (e.g. on flat plates), crack-like
indications there.
Circumferential Welds - No Ground Out Regions

Where the length of weld to be inspected is greater than 400mm the weld should be marked up into smaller
lengths which overlap. (Longer scans tend to be more difficult for the diver to perform, therefore increasing
the chance of probe lift off etc.). The measurements from a datum to the four cardinal clock positions should
be recorded. The location of any features that affect probe movement or probe signal should be reported (e.g.
the position of a seam weld that joins the weld under inspection, or the presence of weld spatter).
When a crack is located it should be re-scanned in more detail by scanning the defect area plus 30mm before
and after each end at a slower scan rate. The crack tips should be located and marked and surface breaking
crack length reported to the ACFM operator. The circumferential distance from a datum (e.g. 12 o'clock
position) to one end of the crack should also be noted.
If the weld is to be ground out to remove the defect the estimated depth using ACFM should be the depth to
which the first grind is made. Before grinding takes place the defect plus 30mm either side should be scanned
with a Pencil probe for later comparison. After grinding the grind should be re-inspected with the same Pencil
probe to ensure the defect has been removed (the pencil probe type selected for the pre-grind scan should
therefore be chosen to fit into the subsequent ground area).
Inspecting Ground Out Areas

Welds that have been ground to remove defects require the use of a Pencil probe. A pencil probe is necessarily
easier to tilt or rock than a weld probe and so extra care must be taken during a scan to ensure that this does not
happen. The first scan with the probe should be with the probe axis perpendicular to the root of the grind. The
weld should be scanned such that at least 30mm either end of the ground out region is scanned. If a defect
signal is found two further scans should be performed to determine whereabouts around the grind the defect is
located:
a) Probe axis at +30o angle from the normal to the root of the grind.
b) Probe axis at -30o angle from the normal to the root of the grind.
The maximum signal perturbation should be used to determine crack depth and should also indicate the
location of the defect in the ground out channel.
The ground out region of the weld should be marked at suitable intervals (e.g. 20mm) which should be called
to the ACFM operator as the probe scan passes each mark. A measurement of length from a suitable datum
(e.g. 12 o'clock position) to the weld grind marks should be made and also reported to the ACFM operator.
Where the geometry of the grind start or finish is sharp this may obscure small defects. The ACFM operator
will advise whether further grinding is required to smooth off the edges of the grind to give good probe
movement and signals at the grind start.
Inspection During Grinding

If a detected defect is to be removed by grinding, a scan of the defect using a pencil probe must be made prior
to any grinding. This provides a baseline for comparison, removing the effects of variations in sensitivity
between different probes. The whole of the grinding process should be monitored with the same probe.
Between grinding passes, the defect should be rescanned. Particular note should be made of the position of the
defect in the grind profile, to ensure that the grind follows the defect even if the defect curves away from the
expected direction.
1523.DOC, Issue Inspection Considerations Page

The ACFM operator should note changes in the ACFM signal between grinding passes, such as changes in
length, or splitting into two or more separate cracks. An apparent increase in length or depth may indicate a
sub-surface or branching crack.
If MPI is being used in addition to ACFM, care must be taken when comparing the results for sizing purposes.
Refer to the section "Length Sizing With ACFM" on page 24 for the procedure to be followed in this case.
Inspecting Flat Plate Welded Supports/Stiffeners

Full geometry detail is required by the ACFM operator before scanning can commence. As with tubular
components, the standard weld probe should always be used where geometry allows and other probe types only
used where necessary.
The use of a uniform input field, which allows defect sizing, means that the standard weld probe picks up
strong signals from sharp geometry changes such as plate edges, corners and rat-holes. This edge effect occurs
when a probe is used within a certain distance of the edge, the distance being roughly equal to the width of the
main part of the probe body. Thus a standard weld probe will pick-up edge signals when the mid-point of the
probe is within about 50mm of the edge. A pencil probe also experiences edge effects, but to a much lesser
degree. Mini/micro pencil probes can be used up to about 10mm from an edge.
The presence of an edge does not preclude the use of standard probes but signal interpretation is not so easy.
The effect of an edge is to superimpose a general slope in probe readings that will increase in gradient as the
plate edge is approached. For detection, this has the effect of separating the signal from either end of a defect
on the butterfly plot so that the loop formed is not closed. Where cracks are located within 50mm of a plate
edge the depth of the defect should be calculated using an estimate of what the background Bx would have
been at the centre of the defect, as shown below.
Bx background
Bx minimum
Figure 4. Bx background and minimum values to be used near a plate edge.
If there is not too much curvature in the signal, this background Bx is best estimated as an average of the Bx
values either side of the defect.
Instead of clock position marking, the weld to be inspected needs to be marked off in suitable linear intervals
(maximum 100mm).
Rat-holes and plate ends

On rat-hole specimens with full welds (as shown in Figure 5), the mini pencil probe should be used if the weld
lengths involved are all short.

Top view
Side view
Figure 5. Views of rat-hole with complete welds (welds shown hatched)
The probe should be first used to detect longitudinal defects in a series of 6 scans as indicated in Figure 6. The
scan directions are such that the probe is always moving in the 'C' direction so that a defect will be indicated by
a clockwise going loop in the butterfly plot. Note that when the probe leaves or approaches a weld, a change in
the Bx level is seen. There is no significant associated change in Bz however, so the signal should not be
confused with a defect signal.
3 4
6
5
1 2
I.D.
Figure 6. Detection scans 1 to 6 for rat-hole specimen with complete welds
With any scan, a defect lying wholly along the scan path will give a complete loop. However a defect leaving
the scan path will give a lop-sided loop because one or both of the defect ends may not be covered. A defect
leaving the scan path will show a sudden return in Bx to the background level but no accompanying Bz peak or
trough.
Scan 1, for instance, starts on the parent plate about 25mm from the corner of the weld. A defect running into
the parent plate from the weld toe (marked as A in Figure 7) will thus give a complete loop as shown, while a
defect that follows the weld toe round the corner (marked as B) will give a lop-sided loop.
Traces for scan along path a

Defect A Defect B
Bx
B
Bz
A
a
Butterfly
Figure 7. Comparison of signals from a defect that follows weld to one that leaves weld

Similarly, the end of scan 1 in Figure 6 follows the weld toe round to the mid-point of the rat hole, so a defect
following the weld toe will give a complete loop, while a defect continuing into the parent plate will give a lop
sided loop. In either case, a later scan should be taken along the suspected line of the defect to confirm the
defect and to size it.
Scan 5 (or 6) will give a complete loop for a defect running into the parent plate. For a defect running around
both corners, only a dip in Bx will be seen coinciding with the extent of the weld. In this case, the defect ends
will be seen in scans 1 and 3 (or 2 and 4). Again a scan around the weld corner must be made later to confirm
the defect. When no defect is present, scans 5 and 6 show a low peak in Bx. This produces a dent in the trough
produced by a defect as shown in Figure 8.
Traces from defect shown
Bx
Butterfly
Figure 8. Signal from a short defect at a free plate end
Finally, scans should be made as shown below in Figure 9 to detect defects growing into the parent plate from
the rat-hole welds. On specimens with large rat-holes, the scans can be combined into two scans (i.e. join 7 and
8 together, and 9 and 10). For smaller rat-holes, the right-angled mini pencil probe should be used. The scans
should be continued into the parent plate until the traces become flat - i.e. about 25mm if no defect is present.
Four scans will be necessary for specimens with very small rat-holes where there is insufficient room for the
probe to pass through, but scans 7 and 8 (and 9 and 10) should be combined on one page by pausing the scan
between lifting the probe from the surface at the end of scan 7, and putting the probe down at the start of scan
8.
8 9
7 10
I.D.
Figure 9. Detection scans 7 to 10 for rat-hole specimen with complete welds
Having completed all the detection scans, positions and lengths should be measured with the same probe, and
then defects should be sized with the standard weld probe if possible. Defects inside the rat-hole can be sized
with the mini pencil probe. The procedure to be followed is therefore:
1. Use the standard weld probe or mini pencil probe to do 10 scans as described above.
2. If defects suspected to run away from scan line, carry out additional detection scans as
described above.
3. Measure the position and length of all defects found in steps 1 and 2.

4. Change to the standard probe, if necessary, and scan over all defects found and measure their depths.
For rat-holes and plate ends with incomplete welds, a similar procedure should be followed, but no scans
should be made where no weld exists (e.g. scans 5 - 10 above).
Transverse Cracks
If the geometry or conditions are such that it is suspected that the weld may contain transverse defects, the
following probe deployment procedure should be carried out for detection. In order to obtain a signal from a
transverse defect, the input field must run perpendicular to the defect, so to detect a transverse defect the
ACFM probe must be turned around by 90 o as shown in Figure 10. The standard weld probe should be used
for flat or cylindrical butt welds; for T-butt welds where deployment of this probe is not possible, a pencil
probe should be used.
The normal probe scan path to produce a butterfly plot loop would then be across the weld cap, however for
detection this would have to be repeated every 10mm or so along the weld resulting in a slow detection
process. Instead of this the probe should be scanned along the centre of the weld cap as shown in Figure 10.
butt weld T butt
Figure 10 . Probe orientations and scan directions for initial detection of transverse defects across
weld caps
Since the scans are not along the expected line of a defect, a transverse defect will not produce a loop in the
butterfly plot. Instead, the possible presence of a defect is indicated by a dip in the Bx signal. The Bz signal
may show a peak or a dip if the scan passes nearer to one end of the defect than the other, but will show
nothing if the scan passes over the middle of the defect. The dip in Bx will be about 20mm across - this width
is determined mainly by the probe input field geometry rather than the defect size. The depth of the dip is
determined by the defect depth.
Since probe rock and lift-off changes will inevitably be more severe when the probe is scanned along the weld
cap, the presence of a dip in Bx is not enough on its own to indicate the presence of a defect. In order to
confirm a defect-like indication, a scan should be made across the weld cap along the line through the dip
found in Bx (i.e. along the line of the suspected defect) as shown in Figure 11.

Figure 11. Probe orientation and scan direction for confirming detection of transverse defects across
weld caps
The probe should still be oriented as before, and the scan should start and finish at least 25mm from the weld
toes to ensure that both defect ends will be covered. In this way, a defect will produce a loop on the butterfly
plot as for conventional weld toe defects. Note, however, that since any material property change associated
with the weld now runs across the scan direction, signals may be seen in both Bx and Bz due to the weld (this
is similar to scanning across a seam weld in conventional deployment). Since these weld signals may produce
confusing loops in the butterfly plot, a scan must also be made across the weld cap away from the suspected
defect for comparison.
Material Features
Coating Thickness
With the ACFM technique, it is possible to detect defects through 5mm or more of non-conducting coating.
The signal strength obtained is obviously smaller than for an inspection with no coating but sizing estimates
can still be obtained by entering an estimate of the coating thickness in the QFMu sizing procedure using the
box labelled "Extra lift off". The look up tables presently implemented do not support extra lift-offs greater
than 3 to 5mm (dependent on probe type) - refer to TSC for sizing through thicker coatings. Note that, because
of the use of a unidirectional input field, the ACFM signals are relatively insensitive to lift-off and so the
thickness need only be estimated to the nearest millimetre. For the same reason, the ACFM technique is
relatively insensitive to changes in coating thickness (or changes in lift off) and in any case, only the Bx signal
is affected so no confusion with a possible defect signal can occur. It should be borne in mind that the
reduction in Bx and especially Bz amplitudes due to coatings will result in smaller butterfly loops than
otherwise expected for a given defect size. To compensate for this, a new probe file should be made through a
non-conducting layer of the same thickness on a standard function check sample.
Magnetic State
It must be ensured that the surface being inspected is in an unmagnetised state. Therefore the procedure
followed with any previous magnetic technique deployed (particularly MPI inspection) must include
demagnetisation of the surface. This is because areas of remnant magnetisation, particularly where the leg of
an MPI yoke was sited, can produce loops in the butterfly plot which may be confused with a defect signal.
If magnetisation of the structure is unavoidable (e.g. d.c. magnets used to attach an ROV), the magnetised area
must be at least 500 mm away from the weld to be inspected.

Surface Grinding or Work Hardening

It has been noted in a number of instances, especially on Duplex, that areas of surface grinding or work
hardening etc. which produce localised changes in material properties can result in strong signals in both Bx
and Bz which may be confused with a defect signal. Areas of grinding should be reported by the probe
operator at the time of scanning and recorded by the ACFM operator.
If a defect signal is suspected in a region of grinding or possible work hardening, further scans should be taken
parallel to but away from the weld toe. The signal from a defect (especially Bz) will drop off quickly away
from the defect, so that a scan away from the weld toe will be much flatter. The rate at which the signal drops
off will depend on the length and depth of the crack, but a significant difference in amplitude should be seen
20mm away if the signal is due to a defect. If there is no significant change in signal amplitude 20mm away
from the weld toe, the signal is likely to be due to the effects of the grinding. A further scan 40mm away
should be made to confirm the trend. To assist later signal interpretation, marker lines should be added on the
display at the start and end of the ground area.
If an edge effect probe is available, and geometry allows its deployment, a scan with this probe will produce a
much flatter signal from grinding marks than from a defect.
Seam Welds
Seam welds running across the line of scanning also produce strong signals in Bx and Bz which can sometimes
be confused with a defect signal. As for grinding marks above, if a defect is suspected at or near a seam weld,
further scans should be made away from but parallel to the suspected defect line to confirm the defect. The
signal from the seam weld will persist at roughly the same amplitude, whereas a defect signal will exhibit a
much reduced amplitude. Again, an edge effect probe, if available, can be used to emphasise any defect signal.
Inspecting materials other than ferritic steel

The probe file associated with a given probe contains information used to produce accurate sizing estimates,
and scaling information to match the screen display limits to the signal levels produced by the probe on a
reasonable size defect. By default, these scales are set so that a 50mm long by 5mm deep notch in ferritic steel
produces a loop on the butterfly plot that is roughly centred on the screen, fills about 50% of the height of the
plot (i.e. Bx amplitude) and more than fills the width (Bz amplitude).
If a probe is to be used on other materials, such as Duplex, aluminium, stainless steel, etc. the scaling may not
be correct so that the display may be more or less sensitive resulting in the possibility of getting more spurious
indications or missing small defects respectively. Also, the depth sizing will not be accurate. In order to avoid
this a new probe file must be used for the material in question. In the first instance contact TSC to see if a
relevant probe file is available. If not, refer to the QFMu v3.x Level 2 Software Manual.
Duplex
Duplex is known to be more susceptible than other materials to spurious signals caused by material differences
arising from grinding, heat treatment etc. In some cases it is possible for these signals to produce butterfly plot
loops similar to those produced by a defect. For this reason defect signals should be confirmed by taking extra
probe scans adjacent and parallel to the suspected defect as described in “Surface Grinding or Work
Hardening” on page 16.

Inspection Reporting
Reporting Requirements
ACFM results are backed up onto floppy disks, or other media, which contain the raw inspection data. These
will only be useful to the client if backed up with data sheets filled in correctly. This section deals with the
information required and production of these data sheets.
The data report sheets generated by ACFM inspections will be specifically designed with the ACFM system
and current inspection requirements in mind. The essential information contained on an ACFM data sheet will
include:
General Information
Date
Operators Name
Probe Operator
Component number/name
File Number
Scanning Data
Filename
Page Number
Position on Weld (i.e. Chord toe, Brace toe, Weld cap)
Probe Number
Probe Direction
Clock or Tape Positions
Inspection Summary
Detailed Record of Indications/Anomalies

Filename
Page Number
Position on Weld
Start of Defect (Tape reference)
End of Defect (Tape reference)
Length of Defect (in millimetres)
Depth of Defect (in millimetres)
Remarks
Diagram/Drawing of component under inspection.
1523.DOC, Issue Inspection Reporting Page

The overall inspection will most certainly be supplemented with video tapes and photography. However, the
final report that ends up on the clients desk is the only visible outcome of an inspection campaign that will have
cost many thousands of pounds. It is therefore impossible to over emphasise the importance of this document
and the necessary care with which it needs to be completed.
A poorly filled in report sheet reflects badly on the operator, and the equipment, and will render off-line
interpretation difficult if not impossible.

QFMu ACFM Report Form
Date: Location: Sketch of geometry:
Time:
Operator: Diver:
Component ID:
Summary of indications:
Filename:
Probe number/configuration: Probe file:
Location: Direction of Circumf.

Page Inspection report / comments
C/B/W travel A/C Position

Probe Operator Briefing: Check off list
Operators name
Date
Probe operators name
Tick boxes accordingly

Probe YES NO
1)
1) Shown
Shownvarious
variousprobe
probeselections
selectionsand
andreasons
reasonsfor use
2) Shown probe connections/connectors to instrument
3) Shown probe identification markings and sensor centre-line
4) Instructed on leading edge of probe direction ie A or C
5) Shown how to hold the probe
Scanning techniques YES NO

6) Instructed on marking up component under inspection
1) Advised
7) Shown various
on scanprobe selections
starting and reasons
procedure
8) Advised on scanning rate and indicating circumf. posn.
9) Instructed on overlapping procedure
Visual Inspection YES NO

10) Made aware of visual defects that might influence scans
11) Probe fit for tight geometries
1) Shown various probe selections and reasons
Marking and Sizing Defects YES NO

12) Instructed on how to size defects for length
1) Shown various probe selections and reasons

Interpretation of ACFM Signals
General Method
In general, a defect will product a characteristic signal on Bx and Bz signals and these combine to give the
"butterfly". The rule adopted is that the signal represents a defect when
1) Bz responds by a peak and trough, and
2) Bx responds by a "dip" from the mean value.
In the majority of situations for, isolated and relatively short cracks, this will give a butterfly plot which
moves to right or left (according to probe direction), then downward then returns to the original position to
close the loop. Figure 12 The figure below shows the relationship between Bx, Bz and the butterfly trace
where "A" represents the first Bz peak, "B" represents the deepest point in Bx, and "C" represents the Bz
trough.
Chart recorder plots

Bx
B
Time
A
Bz
Bx
C
A
B
Bz
Butterfly plot
Figure 12.Schematic showing relationship between butterfly and chart recorder plots
Lift off, permeability changes, probe rocking etc. can cause responses from Bx and/or Bz. Lift-off, for
example, causes the Bx signal to dip or peak (depending on material type) with little response from the Bz
signal. This would produce a closed loop confined to the vertical axis rather than the open loop produced by
1523.DOC, Issue Interpretation of ACFM Signals Page

a crack. A seam weld, on the other hand, usually causes a peak in Bx combined with Bz signals that result in
an open loop moving upwards from the starting point. Hence, for the signal to represent a crack, the butterfly
loop must move downwards. This rule is intended to eliminate false calls due to momentary lift off, perhaps
as the probe runs over local weld imperfections. It therefore is intended for small signals.
There are exceptions to the general rules and these mainly apply to long defects (> 50mm).
For long cracks the Bz peak and trough may be some way apart. This means that at the centre of the crack
there is no Bz signal and we rely on Bx (i.e. the dip in Bx) to make the butterfly go down. If there is a general
drift on the Bx signal, i.e. if the top signal is not perfectly level, this may confuse the butterfly by acting
against the crack signal. This conflicting Bx signal means the butterfly rules no longer can be relied on and it
is necessary to use the Bx and Bz plots to look for tell-tale signals where there is a response from Bz followed
by a downward deviation, from the trend, on Bx. This is particularly important for tight angles where the Bx
signal trend rises toward the tight angle due to global geometry effects.
In theory it is possible for a weld to be cracked around the full circumference, thus resulting in no crack ends.
If the crack has a uniform depth, the Bx signals would be lower than expected, but in all other aspects the
signals could be similar to an uncracked connection. In this situation the presence of a signal centred much
lower on the butterfly plot than for other connections should be an indication that a full circumference defect
is present. This can be further investigated by comparing the Bx signals as the probe is moved from parent
plate to the weld toe area and then repeating the exercise on the other weld toe.
In practice, cracks do not tend to grow this way in tubular connections. Experience has shown that full
circumferential cracking is normally associated with significant variations in crack depth around the
connection combined with crack branching. In this situation the crack branching provides Bz signals resulting
in butterfly loops in the normal way. Thus in practice detection of full circumferential cracks on node
connections is similar to normal cracks in that butterfly loops will normally be present together with
significant depth variation represented by dips in Bx and downward movement of the butterfly trace.
Crack depth measurement is more complicated if full circumferential cracking is suspected because the
"length" and background Bx readings will not be easily established. Refer to TSC if assistance is needed.

START Yes
Downward Butterfly ? CRACK
No
Crack Unlikely No Yes

Any Significant Possible Crack
Loops ?
Any Dips in Bx
No Below the Trend ?
Yes
No
NO CRACK Any Associated If it is possible that the probe was not
peaks and troughs following the weld, rescan.
Yes Otherwise, NO CRACK
Probably a long CRACK.

Figure 13.
ScanDecision Tree
a large section andfor
lookIdentification
for crack-like of a crack
trends, especially on Bx, to confirm.
At all times look at the Bx and Bz traces. If Bx has a dip then suspect a crack. If the butterfly makes any
significant loops, look at a broad area either side of the signal. This is particularly important if the butterfly is
moving up or down the screen. A butterfly moving up or down the screen with any sort of looping is likely to
be a long crack.

Crack Sizing
Crack sizing can be carried out either on-line (immediately after the necessary data has been collected) or off-
line (by recalling stored data). During the detection stage, scans of Bx and Bz are recorded for all defects
found. A first estimate of length is also obtained from a manual measurement of the extent of the Bz signal.
This data is then used to obtain sizing estimates using the QFMu program as outlined below. For more
details, refer to the Level 1 Software User Manual.
1. Select a section of the Bx timebase plot to one side of the defect signal that is representative of the
background level. This should simultaneously be near the centre of the area filled by the general
off- crack background noise in the butterfly plot. This value is chosen as the Bx Background Level.
N.B. If the background level is significantly different either side of the defect, the average of the two
values should be used. This is normally necessary for defects in regions of changing geometry or
near to a plate edge (see Inspecting Flat Plate Welded Supports/Stiffeners).
2. Select the minimum of the Bx timebase trace from the centre of the defect signal (or the bottom
of the butterfly loop). This value is chosen as the Bx Minimum Level.
3. To calculate defect length and depth, the QFMu software requires three parameters - the two Bx
values selected above, and the length estimate obtained during the detection stage (the length in
mm between the Bz peak and trough indications at the inspection site).
Where the crack depth calculated is greater than the plate thickness this indicates that cracking may be
completely through the plate and so the probe operator should be asked to look for further evidence of this.
Such evidence may be visual crack opening or, if the back face is accessible (e.g. on flat plates), crack-like
indications on a scan made there. Alternatively, because the currents follow the crack faces exactly in ferritic
steel, depths apparently greater than the wall thickness can arise from crack branching into the parent plate, or
from a highly curved crack path.
Using MPI With ACFM

When defects are being removed by grinding, it is often the case that MPI is used in conjunction with ACFM
to monitor defect removal. In these cases it is tempting to save inspection time by using MPI lengths instead
of Bz lengths when sizing defects. This will lead to errors and is not a recommended practice. This section
considers the implication and suggests how, under certain conditions, data from MPI inspection can be used
in the absence of any additional information.
When conducting MPI inspections an approved MPI inspection procedure should be
used. De-magnetise the area following MPI inspection (see "Magnetic State" on page 15).
Length Sizing With ACFM

The method of length sizing involves determining the location of the Bz peak and trough signals on the
component. The distance between peak and trough is referred to as the Bz Length. The ACFM modeling
shows that the Bz peak/trough actually occur just inside the physical ends of the crack. This is confirmed in
practice when the crack ends are marked and compared visually. Thus the Bz lengths are always less than the
actual crack length. This is taken into account in the sizing algorithms so that the ACFM calculated length is
greater than the Bz length.
Because ACFM also considers the depth of the crack, ACFM will "concentrate" on those parts of a crack
with significant depth.
If two cracks are joined at the surface by a shallow surface crack, ACFM will focus on the two deep parts,
not the whole, and ACFM sizing procedures take this into account.

MPI Indications
MPI will simply indicate the length of a surface flaw and give no indication on depth. MPI lengths should not
be used as a substitute for Bz lengths because:
1. For any crack MPI length > Bz Length. (Figure 14)
2. The crack may be made up of more than one deep section. MPI will treat it as one crack
and therefore misrepresent the length. (Figure 15)
3. The crack may have long "tails", again misrepresenting the length of the significant crack.
(Figure 16)
Bz Length
MPI Length
Figure 14. Comparison of Bz peak/trough with actual crack

ends

Bz 1 Bz 2
MPI Length
Figure 15. ACFM Bz signal compared to MPI indication for two adjacent
cracks
Bz
MPI Length
Figure 16. ACFM Bz signal compared to MPI indication for crack with shallow ends.
Use of MPI Lengths In ACFM Calculations

One example where it may be preferable to use MPI lengths instead of Bz lengths is a situation where ACFM
is being used during a grinding process and it is found that there is a start/stop Bz signal at the grind profile

ends which are close to the defect ends. Hence there may be some doubt as to whether the crack Bz locations
are being masked by the grind profile end signals. As an alternative, MPI lengths may be used in the crack
depth sizing. As described earlier, the use of MPI length as a substitute for Bz length is incorrect. However
there is a work around if, and only if, certain criteria are met. The answer will still be approximate but may
be acceptable. The criteria are:
1. Before grinding, carry out an ACFM inspection and use Bz to calculate the crack
length. If:
i) The calculated length agrees with the MPI length, and
ii) The Bx signal indicates a simple crack
continue to step 2. If either of these conditions are not satisfied, do not attempt to use MPI
information with ACFM.
2. Estimate by how much the Bz length is less than MPI. You should find that the Bz length is
between 80% and 90% of MPI length.
3. Carry out the grinding.
4. Re-inspect with ACFM. If the crack remains a single crack (i.e. no additional features appear on
Bx) take the MPI length after grinding and apply the factor in (2) above. Then compare the
estimated ACFM length with the factored MPI length. If they agree, the factored MPI length should
give a reasonable depth estimate when used in the ACFM sizing procedure. If the two estimates do
not agree, it is possible that a situation such as shown in Figure 12 has arisen and the MPI length
should not be used to depth size the defect.
5. The above process can be repeated providing the crack remains as a single defect. Should it
split into two, the process will not work and any depth calculation will be in error.

Operational Procedure
System Setup
Connections
Test Umbilical
PC
Printer
Topside Unit Comms
110v
110v
150m
Main Umbilical
ACFM
Probe
Subsea
Bottle
U31 Underwater ACFM Crack Microgauge
Figure 17. Overall System Connections
U31 Subsea Bottle

The U31 subsea bottle is designed to be deployed underwater with the diver. An ACFM probe is attached to
the bottle via the 16 way Wetcon Connector. This connector may be broken subsea, to change probes for
instance, but the bottle should be powered down first to prevent accelerated corrosion of the pins. Note that
there is no shock hazard to the diver. An umbilical is connected to the 8 way Wetcon connector which carries
power and communications to the bottle. The main umbilical is 150m long as standard but two may be joined
together to give a 300m total length. Note that no more than two main umbilicals can be connected
together. The main
1523.DOC, Issue Operational Procedure Page

umbilical is deployed from the surface and attaches to the test umbilical which in turn is connected to the
Topside Unit.
U31 Topside Unit

The topside unit provides power and communications to the subsea bottle. The test umbilical is connected to
the 12 way Amphenol connector on the front panel. This umbilical can then be plugged directly into the subsea
bottle for testing purposes or routed to a convenient location and attached to the main umbilical.
110V power is supplied to the unit via the 4 way Amphenol connector on the front panel. If the local supply is
240V then a suitable transformer will be required. Note that unlike previous underwater ACFM instruments the
U31 does not require a centre tapped isolation transformer.
The power cable is supplied with an integral inline RCD protection device. Never operate the instrument wi
A 110V output connector is supplied on the front panel to power the computer.
The topside unit is connected to the computer via a communications cable which is attached to the 6 way Lemo
connector on the front panel.
Computer
The computer operates on its own internal battery or on 110/240V AC (50/60Hz) through a mains pack /
battery charger. Refer to the computer user manual for details on how to connect the mains pack. The mains
pack should be connected to the 110V output socket on the topside unit rather than to a separate mains
connection to maintain protection from the RCD. A cable is supplied for this purpose but if the connector on
the battery pack is of a different type than on the supplied cable, the 110V connector can be removed from the
supplied cable and mounted onto the mains cable supplied with the computer.
The computer communicates to the U31 via the RS 232 cable supplied. The RS232 port is usually a 9-way D-
plug on the rear of the computer. Refer to the computer user manual for more details.
Connection Procedure
1. Ensure all mains switches are OFF
2. Connect the topside unit to the mains supply using the RCD protected lead. If the local supply is
240V then a suitable transformer will be required.
3. Connect the computer to the topside unit using the RS232 cable (8-way Lemo to 9-way 'D'-type).
4. If the computer needs to be powered from the mains supply, instead of running from the internal
battery, connect the mains lead to the 110V output connector on the topside unit. Note that when the
topside unit power switch is turned off, the power to the output connector is cut. If there is no
internal battery in the computer then the computer will shut down automatically in this event.
5. Connect the test umbilical to the topside unit and connect the main umbilical to the other end of
the test umbilical.
6. Connect the main umbilical to the subsea bottle.
7. Test RCD by turning ON the mains supply to the lead (with the topside unit still switched OFF). Press
the Reset button and verify that the red indicator is showing. Press the Test button and confirm that
the red indicator is removed. Press the Reset button again and check that the red indicator reappears
and remains.
IF THIS DOES NOT FUNCTION SUSPEND ALL OPERATIONS, TURN OFF MAINS SUPPLY AND SE

8. Press the power switch on the topside unit panel to turn on the power to the system.
IF DURING OPERATION THE RCD TRIPS SUSPEND ALL OPERATIONS, TURN OFF MAINS SUPPL
Function Check
At the start and end of an inspection session a function check must be performed using the equipment. This is
to ensure that the equipment is functioning correctly and to familiarise the operator with the relative levels of
noise and defect signal. The following procedure assumes familiarisation with the QFMu software. For details,
refer to the appropriate Software User Manuals.
1. Select Probes for next series of scans to be carried out (see “Probe Deployment Considerations”
on page 9). If not already done, connect instrument as described in System Setup - Connection
Procedure.
2. Create a directory to store the data for the new inspection session.
3. Start the QFMuv3 software, and check that U31 is initialised correctly.
4. Connect the first probe to the instrument and select the appropriate configuration from those
available for that probe.
5. Create a new data file for the function check data.
 The format for the file name should
be FNpppnn.WDF where
FN stands for Function-check
pppp is the probe serial number (e.g. 1734)
nn is the number of the function check of that day, i.e. first function check in the day would
have n = 01.
6. Place probe on the test block and start data collection.
7. Scan along the test block slot at approximately 25mm/sec. After passing the slot stop the scan.
Signals such as that shown below in Figure 18 should be displayed. Note that small differences in
material or gain used between creating the probe file and doing the function check may mean that the
display is just off screen, in which case the signal should be centred on the screen.

Figure 18.Typical plots for function check on a single defect
If the display is well off the screen, check that the correct configuration was chosen for the material of
the function check plate, and that the serial number of the probe displayed by the software matches
that marked on the probe. If no configuration matching the probe and/or the function check plate
material is available, a new configuration file must be set up, as described in the Software Level 2
User Manual.
If a display similar to this Figure 18 cannot be produced, SEEK SPECIALIST ADVICE before proceeding.
8. Save the data file.

9. Check all probes to be used in the session (Repeat steps 4-8)
Inspection Procedure
1. Mark up the inspection area. For flat plate and T-butt geometries, mark positions at 100mm
intervals from left hand plate edge using paint stick or chalk. For cylindrical geometries, mark clock
positions or 100mm markers as appropriate.
2. ACFM operator to inform diver of scan required and which probe to use.
The probe can be disconnected underwater to allow a different one to be used, but the ACFM operator mus
The ACFM operator should press the Probe Off button and confirm that the following message is
displayed:

The operator should then instruct the diver that the probe can be changed. The diver should connect
the new probe, ensuring that the connection is fully mated, and confirm the probe serial number.
3. When the diver has completed connecting the new probe, press the Select Probe button and select
the required probe configuration. This will restore the power to the probe socket.
4. Create a new file for the inspection data.
 Choose a filename in the form "XXXXXXXa"
where: XXXXXXX = Identifying code for location to be inspected (up to 7 characters).
a = Inspection number/letter for that location (e.g. a for first inspection, b for second inspection etc.).
When choosing a data filename, make sure the file is uniquely identifiable and contains a reference
to the component under test.
Note: The individual scans within the inspection are described by pages within the file, in
numerical order. A separate recording sheet or log-book must record the scan made on each page
(i.e. the weld toe/bead inspected and the direction of the probe 'C' or 'A').
5. Set the range of the numbered marker lines (or clock-points) to be covered in the scan (start, end
and direction)
While recording data, reference markers can be entered which are called CLOCK POINTS. These are
lines labelled with a number between 1 and 99. The numbers wrap around at the end point so that
they can be used to mark positions when scanning around a tubular geometry. The default end point
is 12, appropriate for conventional clock positions around a circle, however the markers can just as
easily be used to scale mark a linear geometry. e.g. each marker may represent 100mm increments.
6. The diver should place the probe at beginning of scan, and confirm intended probe direction
(Probe marker A or C leading) to the ACFM operator. When A is leading, the loop produced by a
defect in the butterfly plot should be traced in an anti-clockwise direction, when C is leading it
should be clockwise.
7. The ACFM operator should start the scan and instruct the diver to begin moving the probe. The
scan speed should be approx. 25mm/sec, but if this needs to be reduced or increased for operational
reasons, the data sampling rate should be set accordingly. Note that if scan rates are set too high
that there is an increased chance of the diver not scanning the probe carefully along the weld line.
8. The diver should report when the centre of the probe passes a marker. The ACFM operator logs his
position. The diver should report visual indications such as seam welds, weld run overlap, weld
spatter or grinding marks when these are encountered. The ACFM operator may add an un-numbered
marker to log these.
9. When the desired section is scanned or the end of the data page is reached or the diver
cannot comfortably continue, then the ACFM operator should stop the scan.
10. When the scan has stopped the diver may be remove the probe from the component.
11. Study the data, looking for any defect indications.
For defect detection refer to “Interpretation of ACFM Signals” on page 21.
Any defect signal is to be noted in the report sheets by the operator and the area marked by the
probe operator.

12. Continue scanning with a minimum of one clock position, or 100mm overlap on each scan (e.g.
clock positions 11-3, 2-6, 5-9, 8-12).
Repeat steps 5 to 11 until scan area is covered.
When defects are detected, additional scans are necessary in order to facilitate sizing. These are:
i) a slow scan to cover all defects within a region.
ii) a scan or series of scans to locate the ACFM crack ends. In these scans the ACFM operator
will ask the diver to move the probe so that it coincides with the peaks and troughs of the
Bz signals (usually easiest to observe on the butterfly plot). When the ACFM operator is
satisfied that the probe is in the correct place, the diver should place a mark or magnetic
arrow to mark the location. The marking will normally be aligned directly with the probe
centre. Alternatively, if the access does not allow this, the trailing edge of the probe can be
marked first with the position of the centre of the probe marked later.
13. Save the collected data in the file selected at the beginning of this session.
14. The diver should place a ruler or tape on the specimen and read off crack end positions to the AC
FM operator. The ACFM operator must record this “Bz crack length” and the distance to a datum
on the data sheet.
15. Repeat steps 1 to 14 for all inspection areas on the specimen.
16. Crack depth sizing can be carried out immediately, or at a later date, in accordance with the
procedure described in "Crack Sizing" on page 24.
End Of Session Function Check And Backup

Procedure
Post-Session Function Check

To ensure that the system was functioning correctly during the session, the function check should be repeated
on the appropriate sample at the end of the shift using the procedure outlined in "Function Check" on page 30,
steps 3 to 9.
Backup Procedure
1. Mark back-up medium (e.g. floppy disc, magneto-optical disc, CD-R) with files to be copied.
2. Put back-up medium in appropriate drive
3. Back-Up all files created in the inspection shift.
Exit QFMu and check backup

1. Exit QFMu:
2. Check files are stored on the backup medium using (e.g.) Windows Explorer
3. Remove the backup medium from drive and write-protect (if applicable).
4. Switch off all power.

Appendix A
Probe Specifications
Underwater Weld Probe

The Underwater Weld Probe is designed for subsea inspection of welds, plate and tubulars. The bottom face is
fitted with two feet which, together with the wear-resistant probe nose housing the sensors, give a stable tripod
arrangement for ease of scanning. The probe is sealed and fitted with a 50m cable. The probe electronics are
encapsulated in a bulge in the cable about 30cm from the probe body.
If the probe is to be used in an environment where sharp marine growth could easily damage the probe cable, it
is recommended that the cable be protected using additional sheathing.
54.0
58.0
50.0
The underwater ACFM weld probe
U31 Underwater Mini-Pencil Probe

Sub-Types Straight Entry Cable
Right Angle Entry Cable, parallel nose
Right Angle Entry Cable, transverse nose
1523.DOC, Issue Appendix A Page

The Mini Pencil Probe maintains the sensitivity of the normal Weld Probes. They have the advantage of being
able to access restricted areas and areas of weld associated with rat holes in structures. They are less prone to
signal variations near plate edges, but are less accurate for depth sizing deep defects (>5mm). The parallel nose
type is ideal for inspecting through rat-holes, or for longitudinal cracks inside pipes. The transverse nose is
ideal for circumferential cracks inside pipes.
STRAIGHT CABLE ENTRY RIGHT ANGLE CABLE ENTRY (PARALLEL NOSE)
RIGHT ANGLE CABLE ENTRY (TRANSVERSE NOSE)
Underwater Pencil Probe

The Underwater Pencil Probes are designed to fit into grind repairs. They are built to be factory serviceable but
should not be disassembled on site.

The underwater pencil probe
Other Probe Types

Other probe types may be introduced as part of TSC's continuing policy of product development. If a suitable
probe for a particular application is not shown here, contact TSC.
Purpose of Probe Files

The aims of a probe file are:
a) To maintain a consistent detection sensitivity between inspections, and between probes.
b) To maintain sizing accuracy
The first aim is satisfied by the probe file containing graph scalings to give a standard size butterfly loop from
a given defect.
The second aim is satisfied by the probe file containing calculated values for inherent coil lift-off and
sensitivity.
If, after checking instrument settings etc., it is found that the issued probe file is unsuitable for a particular
application (for example the inspection is not on ferritic steel or the readings are saturating), refer to TSC. If
approval is given to create a new probe file on site, TSC will issue the appropriate procedure. It should be
noted that to produce a new probe file, an function check plate in the same material as that under inspection
will be needed, containing a slot (preferably 50mm long by 5mm deep).

Acfm Inspection Procedure

Uploaded by

Copyright:

Available Formats

Acfm Inspection Procedure

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Acfm Inspection Procedure

Uploaded by

Copyright:

Available Formats

ACFM Inspection Procedure

for U31 and QFMu

Dr. Michael C. Smith

TSC Inspection Systems

© 2003. Technical Software Consultants Ltd.

6 Mill Square, Featherstone Road, Wolverton Mill,

Controlled Copy: Yes No

ACFM Inspection Procedure

update for 3.2b -

1.0 (1) MCS MCL MCL 26 April 2002

Issue(Rev) Initiated by Checked by Approved by Date

Interpretation of ACFM Signals 21

1523.DOC, Issue 1.1 Contents Page i

1523.DOC, Issue 1.1 Contents Page ii

1523.DOC, Issue Introduction Page

1523.DOC, Issue Introduction Page

The ACFM Probes

1523.DOC, Issue Description of Hardware Page

Figure 2. Layout of front of topside unit

1523.DOC, Issue Description of Hardware Page

Figure 3. U31 Subsea bottle

Routine Maintenance and Handling

1523.DOC, Issue Description of Hardware Page

Subsea Unit and Umbilical

** IF IN DOUBT, REFER TO MANUFACTURER **

1523.DOC, Issue Description of Hardware Page

1523.DOC, Issue Inspection Requirements Page

1523.DOC, Issue Inspection Requirements Page

Probe Deployment Considerations

General Considerations - All Welds

Finding the Plane of a Crack

Cracking into Parent Plate

1523.DOC, Issue Inspection Considerations Page 9

Circumferential Welds - No Ground Out Regions

Inspecting Ground Out Areas

Inspection During Grinding

1523.DOC, Issue Inspection Considerations Page

Inspecting Flat Plate Welded Supports/Stiffeners

Figure 4. Bx background and minimum values to be used near a plate edge.

Rat-holes and plate ends

1523.DOC, Issue Inspection Considerations Page

Figure 5. Views of rat-hole with complete welds (welds shown hatched)

Figure 6. Detection scans 1 to 6 for rat-hole specimen with complete welds

Traces for scan along path a

1523.DOC, Issue Inspection Considerations Page

Traces from defect shown

Figure 8. Signal from a short defect at a free plate end

Figure 9. Detection scans 7 to 10 for rat-hole specimen with complete welds

1523.DOC, Issue Inspection Considerations Page

butt weld T butt

1523.DOC, Issue Inspection Considerations Page

1523.DOC, Issue Inspection Considerations Page

Surface Grinding or Work Hardening

Inspecting materials other than ferritic steel

1523.DOC, Issue Inspection Considerations Page

Detailed Record of Indications/Anomalies

1523.DOC, Issue Inspection Reporting Page

1523.DOC, Issue Inspection Reporting Page

QFMu ACFM Report Form

Date: Location: Sketch of geometry:

IF IN DOUBT, REFER TO MANUFACTURER