Magnetic Flux Leakage (MFL) Inspection Limitations

API 2009 Storage Tank Conference

Presentation

Aaron Lund
Regional Sales Manager of Gulf Coast
HMT Inc.

Dont Discard the Technology and go backwards

MFL is the Best

method to
evaluate a
tank bottom
condition
quickly and
cost effectively

All Limitations

Technology
Human (Training and experience)
Physical

Information on Technology Limitations

A lot of information has been available and presented on in

regards to technology limitations. However, the information
is not common to all brands and types of scanners, so it is
not without some controversy.

API has been trying to quantify these technology limitations

through a task group performing the re-write of nonmandatory Appendix G in API Standard 653 which call for
operator qualification testing and certification. This effort is
on-going but still has not happened thus far.

This presentation will identify most of the physical limitations

and offer some solutions to overcome those physical
limitations

Lets Talk about the Physical Limitations

Tank Bottom inspection preparation

Bottom Plate Lap Welds seams
Bottom Plate Shapes and Sizes (sketch plates)
Shell (corner weld) radius
Patch Plates
Tank Bottom Obstructions (columns / re-pads, internal
piping, etc.)
Edge Settlement
Uneven Bottom Plates peaks and valleys
Thick Reinforced Coating
Thick Annular Plates
Magnet and Sensor location

Bottom Plate Lap Weld Seams

Typical Full Sized MFL Scanner

Front to base
sensor = 10

Overall
Length = 36

Bridge Width = 12
Overall scanner width = 14

Limitation Zone

Corner Weld No Scan Zone

Sketch Plate Example

Typical Patch Plate

Typical Column with repad

Floating Roof Leg Striker Pad

Tank Bottom Obstructions

Solutions/Options

Following an informed risk assessment on limitations what

are your best options:
Do Nothing!!
Extensive Visual Exam (should already be standard in
any scope of work)
Vacuum Box Testing (leak detection only)
Helium Testing (leak detection only)
Manual Ultrasonic Scrubs (corrosion locator)
Hand/ Mini MFL Scanner (corrosion locator)
ACFM Crack Detection / Magnet Particle Examination
(surface breaking crack-like indications on welds only)

Patch Plate near lap seam hole/extensive visual exam

Vacuum Box Testing

Helium Testing - Equipment

Helium Testing Weld Seam Scanning

Manual/Mini Scanner Solution

Overall Scanner
length = 9
Front to back of
sensor bar = 6
Hand scanner width = 6

Scanner width = 6

Manual/Mini Scanner for Near Corner Weld

ACFM Crack Detection Equipment

HISTORY

This Technology was introduced in 1991.

The method was initially developed for offshore structures

Since then it has been applied to:

Theme Park Rides

Bridges
Ships
Petrochemical/Refinery Equipment
Tanks

APPLICATIONS

Weld inspection
Detection of Crack-like indications
Depth Sizing
Monitoring Dimensional Propagation

SURFACE PREPARATION

With the Magnetic Particle (MT) and Dye Penetrant Testing

(PT) Methods, the quality of the surface preparation is
critical to the ability of the method to detect
discontinuities.

This level of preparation is not required for electromagnetic

techniques as the method of detection is not based on the
migration of inspection media to the site of discontinuities.

SURFACE PREPARATION-Contd

Reduced surface preparation does not imply no preparation

The presence of ferromagnetic scale will impair the ability

of the method to identify discontinuities

However, the presence of surface rust will not significantly

impair the sensitivity of the test

Coatings-less than .200 does not need to be removed

ADVANTAGES

No set up Calibration required

Single direction deployment unlike MT

Inspection time is reduced

Data can be recorded for later comparison, review, or audit

CONCLUSION

ACFM has proven effective for:

Coated Components

Internal/External Shell-to-Bottom Welds

Internal Lap Welds

Sump Welds

After tank bottom replacement

When Stress Corrosion Cracking is suspected

This techniques provides consistent results - at a lower cost

In Summary

Be aware of real world Limitations that exist everyday

Make an informed risk assessment
Revise or develop a work scope for your inspection vendor
that addresses either:
All tanks
or
Specific to particular tanks based upon tank
characteristics, risk analysis or tank condition
Be informed of the technology/tools that can help

QUESTIONS?