FLOORMAP3Di

 

Building on the success of the Floormap3D with STARS top and bottom defect discrimination, continuous research and development has resulted in the most advanced Magnetic Flux Leakage MFL tank bottom inspection scanner theFloormap3Di. The new system introduces:

• MFLi (intensity) – advanced search and verification tool
• Dynamic cursor – advanced defect sizing and classification tool

Together these innovative features achieve significant advances in tank inspection corrosion measurement, with the potential to reduce inspection times and significantly enhance the quality of a tank inspection. This enables tank engineers to determine the optimum repair strategy and improve the outcome of Fitness For Service (FFS) assessments, Remaining Life Assessment (RLA), and Risk Based Inspection (RBI) programs.

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High Productivity And High Accuracy Tank Inspection
The Floormap3Di has a wider scan width than previous models capable of scanning up to 1440 m2 per day, this is irrespective of the number of indications found.

The software guided mapping process encourages the most efficient plate coverage, and helps ensure the maximum area is scanned reducing the chance of missed corrosion. The high resolution MFL sensor head coupled with advanced signal processing, and new defect classification tools significantly improves corrosion detection and sizing capability over previous generation systems.

Floormap3Di-M
The Floormap3DiM model adds free scan and a stop on defect mode, which bring together the advanced defect detection capability of our Floormap systems with simple to use operation of the MFLi3000.

The Floormap3DiM has a unique Real Time Scan view that displays the MFL signal response whilst scanning, and the latest MFLi defect analysis view for evaluation at the end of each scan. An innovative reverse drive mode allows the technician to retrace the scan, easily locating areas of interest and significantly reducing prove up time. For more information on the M features please the MFLi3000 page by clicking here.

Key Benefits:
• Auditable inspection data
• Full tank floor mapping
• Full data recording
• High probability of detection
• Inspection confidence
• Field proven durability & reliability
• 20 years MFL development in over 60 global locations

Key Features:
• High Resolution 64 channel sensor arrays to maximise detection capability
• 256 individual sensors for 4.6 x 2 mm scanning resolution
• Advanced signal processing and defect classification tools
• Through coating inspection up to 6 mm including FRP, GRP and SS
• USB based, simplified data transfer
• Digital calibration for different plate thicknesses
• Battery powered, no external cables required
• Touch screen computer providing immediate plate view for defect assessment
• Motor driven, 0.5 m/s constant scanning speed
On board software functions:
• Immediate display of plate inspection data
• Pan and zoom in on defects
• C-scan / MFL and STARS views
• Advanced MFL signal processing for improved defect accuracy
• Plate scan guidance
• Tank statistics shows progress and un scanned percentage
• Individual calibrations per plate to handle different plate thickness ( main area, annulars )
• Touch screen display works with gloves

Calibration Routine
The Floormap system incorporates a novel calibration routine that creates separate calibration curves for top side and bottom side corrosion. During the inspection, the software first identifies if a signal is generated from the top side or bottom side, and then automatically applies the most relevant calibration curve for more accurate defect depth estimates.

These calibration curves are linked to the inspection data and reproduced in the report along with the scanner serial number to provide an auditable inspection data archive which increase inspection confidence for both inspection companies and asset owners.

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Corroded Plate Sample
Extensive top side corrosion pitting.

STARS Raw Data View
View of STARS sensor output
Accurate representation of top surface profile.

MFLi View
‘Intensity’ view of MFL data. Used to classify and evaluate defects.

Calibrated MFL View
View of processed and filtered MFL data, colour coded to represent estimated percentage loss.

Calibrated MFL View
New signal processing algorithms developed for the Floormap3Di introduce greater accuracy for defect area presentation, and automatically separate and filter ‘noise’ indications from the displayed plate view.

The enhanced area representation and noise reduction filters further improve accuracy for top / bottom discrimination using STARS, whilst simultaneously reducing the requirement for ‘prove up’ and increasing inspection efficiency.

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MFLi View
The Floormap3Di introduces a new high contrast plate view based on the intensity of MFL signal response. The MFLi defect map uses multiple colour palettes to highlight areas of corrosion, reduce the effect of spurious indications, and most importantly to help classify defect type.

This powerful detection and classification tool can reveal the presence of small diameter pitting, SRB attack, erosion patterns and other features that require further verification. MFLi has been made possible by the industry’s highest resolution sensor array and advanced signal processing capabilities of the Floormap3Di.

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Surface Profile With STARS Technology
The innovative STARS technology adds an additional 64 channel sensor array to detect variations in magnetic field strength caused by top side defects. STARS and MFL signals are combined and processed within software to distinguish top side defects from bottom side defects.

STARS works effectively through up to 6 mm (1/4”) of coating, enabling efficient defect surface discrimination without coating removal.

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MFL RAW View
The Floormap3Di has been made possible by the industry’s highest resolution sensor array and advanced signal processing capabilities. These high resolution sensors are essential to providing the detailed MFL raw view.

The MFL raw view is an unfiltered depiction of all the data, both top side and bottom side. The MFL raw view allows the operator to analyse and verify and inspection data, this process will increase inspection efficiency and confidence and reduce the likelihood of MFL inspection errors.

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Dynamic Cursor
The unique Dynamic Cursor (DC) sizing and verification tool assists in identifying difficult to size defects such as deep pits, bacterial attack and through holes.

Dynamic Cursor is based on the expected volume loss and diameter of ‘known depth’ reference defects. The screen cursor forms a ring when moved over an indication which dynamically changes to show the expected diameter of the defect.

By using the DC, prove-up inspections such as pit gauging and ultrasonic measurements can be targeted towards the most relevant defects, reducing overall inspection time and improving inspection accuracy.

At a glance, the operator is able to determine which indications are likely to have been sized within expected accuracy levels, and which defects may have been oversized or undersized due to volumes being significantly different to the reference defects.

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Corrosion Defect Presentation

New signal processing algorithms developed for the Floormap3Di introduce greater accuracy for defect area presentation, and automatically separate and filter ‘noise’ indications from the displayed plate view.

The enhanced area representation and noise reduction filters further improve accuracy for top / bottom discrimination using STARS, whilst simultaneously reducing the requirement for ‘prove up’ and increasing inspection efficiency.

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SIMS Reporting Software

Silverwing Inspection Mapping Software (SIMS) reporting suite provides the most powerful and efficient means to create high quality reports on tank condition, and archiving of inspection results for traceability.

SIMS imports data from the Floormap and automatically positions each of the separate plate files together to produce a CAD drawing of the entire tank floor showing the location and severity of all corrosion over 20% loss or specified value with 10% colour banding.

Corrosion can be displayed as individual coloured pixels to provide precise information on the condition of specific areas of the tank floor. Alternatively the plates can be coloured according to the maximum corrosion detected on each track to provide an overview of the general condition of the tank.

A unique feature of SIMS is the ability to add results from other inspections carried out on the tank floor. Results from visual, ultrasonic, Handscan, MFL and even weld inspections can be added to the SIMS report to produce a complete ‘fingerprint’ of the tank floor condition.

SIMS Key Features:

  • Displays complete tank floor inspection data
  • Automatic CAD layout when used with Floormap systems
  • CAD layout tool for manual recording
  • Measurement tools for sizing areas of corrosion
  • Patch plate design tool (includes API standardised plates)
  • Incorporate Manual MFL, Vacuum box, MT, UT test results as well as visual observations
  • Top/Bottom defect views
  • Comparison of historic inspections
  • UT prove up lists and data recording
  • Free viewer for report distribution
Casp System Dofinansowanie
Introduction of B2B class system that automates business processes taking place between CASP system and its business Partners. The project is co-financed by European Union with funds of European Regional Development Fund.
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