Wall Crawler

Posted on Mar 5, 2012 in Systems | Comments Off

Wall Crawler

Automatic crawler systems for continuous ultrasonic thickness measurement on storage tank walls, with data presentation on a PC screen, recording and automatic evaluation according to API 653. Very fast, with outstanding strength and manoeuvrability, the systems allow a safe operation on up to 23m high tank walls either welded or riveted.

CETA-1:

A crawler for automatic and continuous ultrasonic (local immersion) wall thickness measurement through coatings. The system works, on ferromagnetic surfaces, with the capability to crawl safely on vertical surfaces, crossing over those typical weld seams on storage tanks, etc. Remotely controlled, it can be easily driven in all directions (very small turning radius) and with variable speeds.
The data acquisition system allows speeds up to 200 mm/s taking measurements every 1 mm with accurate control of position (measurement accuracy is better than 0.1 mm). Acquired data is recorded and presented on the system PC with automatic evaluation according to different criteria including those in specification API-653.
Specifically, the series of thickness values are shown in a two axis graphic format (distance to the reference position versus thickness or thickness loss), allowing image scrolling, zoom… referenced to the input nominal value and 20%, 40% and 60% remaining thickness. The dedicated software of the system also allows signal filtering and data processing to erase false or deviated measurements (user defines thresholds), calculation of average values within a user defined range and, as per API-653 for the inspection of oil storage tanks, the calculation of actual minimum acceptable thickness and maximum allowable tank capacity.
System applications include thickness measurement on conventional oil storage tanks (walls and roofs), spheres, ship hulls, etc.
System components:
Probe holder carriage
Magnetic wheels
Two DC motors
Position encoder
Local immersion cup
Ultrasonic probe (5 MHz)
Weight: 10 kg
Length: 400 mm
Width: 280 mm
Height: 140 mm
Umbilical cable (up to 25 m)
Probe holder carriage control signals
Water line for coupling
Ultrasonic signal cable
Transport and control trolley

Electronic control desk
Water reservoir (5 ltr) and pump
Ultrasonic equipment and PC attachment
Battery pack
Industrial PC with digitizer card
Ultrasonic equipment
DFD Sonatest Masterscan 350
Optional: USPC3100 PC board
Software
Data acquisition
Data analysis
Data report wizard

Other standard system components

Battery charger
Tool box
CETA-2:
A crawler for automatic and continuous ultrasonic (local immersion) wall thickness measurement through coatings. Like the CETA 1 system, it works, on ferromagnetic surfaces, with the capability to crawl safely on vertical surfaces, not only crossing over typical weld seams on storage tanks and but also over riveted joints. Remotely controlled, it can be easily driven in all directions (even smaller turning radius than CETA-1) and with variable speeds.
The CETA-2 carriage is more robust and it is articulated allowing the inspection on curved surfaces (pipes). With an optional kit, the system can perform thickness measurements in inverted position (from below pipes, tank roofs, etc). The rest of the system features are those described for the CETA-1 system.

CETA-8
A crawler for automatic and continuous (precision) ultrasonic wall thickness measurement through coatings. Derived from the outstanding and well proven CETA-1 system, the CETA 8 uses dry coupling ultrasonic measurement with up to eight probes for a band scanning of up to 70 mm.
The system works, on ferromagnetic surfaces with the capability to crawl safely on vertical surfaces, crossing over typical weld seams on storage tanks, etc. Remotely controlled, it can be easily driven in all directions (very small turning radius) and with variable speeds. System applications include thickness measurement on conventional oil storage tanks (walls and roofs), spheres, ship hulls, etc.
Ultrasonic probes are placed into a wheel with a specific, resistant, rubber tyre allowing coupling with just a little water to provide positive coupling, thus avoiding water irrigation. The system includes an industrial laptop with an expansion box for a multiplexed 8 channel ultrasonic board, performing high performance and accurate ultrasonic thickness measurements with a pulse repetition frequency of up to 20kHz. For system setup, the software allows adjustment of all ultrasonic parameters.
Other outstanding features are memory capacity for configuration data files, Ethernet connection, off-line or remote data evaluation and reporting, etc.
With seven channels, the data acquisition system allows speeds up to 100 mm/s measuring every 1 mm with accurate control of position (measurement accuracy is better than 0.1 mm). Acquired data is recorded and presented (every channel independent and all active together) on the system laptop screen with automatic evaluation according to different criteria including those in specification API-653.
Specifically, the series of thickness values is shown in a two axis graphic format (distance to the reference position versus thickness or thickness loss) for each and every channel, allowing image scrolling, zoom… referenced to the input nominal value and 20%, 40% and 60% remaining thickness. The dedicated software of the system also allows signal filtering and data processing to erase false or deviated measurements (user defines thresholds), calculation of average values within a user defined range and, as per API-653 for the inspection of oil storage tanks, the calculation of actual minimum acceptable thickness and maximum allowable tank capacity.
System components:
Probe holder carriage
Magnetic wheels with suspension.
Two DC motors.
Position encoder.
Weight: 16 kg.
Length: 572 mm
Width: 390 mm
Height: 186 mm
Ultrasonic wheel probe
Wheel tyre and probe holder with mechanics
Set of up to eight seven ultrasonic probes (6.3 mm crystal, 5 MHz)
Umbilical cable (up to 30 m)
Probe holder carriage control signals
Water line for coupling
Ultrasonic signal cable
Transport and control trolley
Electronic control desk
Ultrasonic equipment and PC attachment
Battery pack
Industrial PC with digitizer card
Ultrasonic equipment
PCMUX3108 BC/HC
Expansion box with PCMCIA and cable connectors
Software
Data acquisition.
Data analysis.
Data report wizard
Other standard system components
Battery charger
Tool box

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