Magnetic Analysis Corp. has recently supplied a new Echomac® WLD ultrasonic weld line test system for an Ohio tube mill. Featuring new operating conveniences for inspecting tube weld zones on-line during continuous production, the system is designed to test for longitudinally oriented defects that are typical of the ERW welding process. These systems are typically four channels, using both CW and CCW sound modes for detection of ID and OD longitudinal defects between 5% and 10% of wall thickness. Additional channels can be added, depending on the application.

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Magnetic Analysis Corp. Ultrasonic Weldline Tester with the Test Head conducting  production testing of a tube. A separate calibrate tube is shown in the off-line position in the foreground.

The WLD system includes MAC’s well regarded Echomac® instrumentation, and a test head incorporating transducer assemblies with irrigated shoes for constant coupling with the tube being tested.  A key issue in weld line inspection is keeping the transducers focused on the weld zone, despite changes in the weld location during production. Maintaining optimal positioning of the transducer assemblies with respect to the weld zone in the Echomac WLD is quick and easy with a new “joystick” that allows the operator to rotate the entire test head by means of a high resolution stepper motor. At any time, the operator can verify that the transducers are correctly positioned by observing a monitor which shows a laser beam that must bisect the weld center. With this convenient control, the transducer assemblies can be rotated to follow the weld to achieve continuous optimal testing over a weld position of 10:00 to 2:00 o’clock.  Individual adjustment of each transducer to easily achieve optimal position for CW and CCW direction is available. In addition a coupling alarm alerts the operator to any loss of coupling between any transducer and the tube, because of loss of water or improper alignment.

Another convenience during operation is that individual irrigated transducer shoes can be easily exchanged to accommodate tube size changes in 5 seconds using MAC’s new quick disconnect mechanisms.

The test head is supported by a strong gantry that allows for operating on the weld line for mill testing, or off line for easy calibration for a new tube size. A precision roller assembly is located in the off-line position to allow for easy calibration of the transducers. Once the calibration is achieved, the test head is simply moved back to the on-line position for production line testing. A large, oversize stainless steel catch pan is used to help control splash water and keep the operator area relatively dry.

The premium Allen Bradley system controls are designed for simple operation, but have flexible features accessible in the flat panel control display. Siemens Controls are also available, if requested. The remote operator station contains essential controls including the video monitor. The instrument system is programmed with the transducer locations and a spray marker located downstream is automatically instructed to spray paint onto the actual defect location to enable sorting of the cut tubes. Separate colors can be selected for OD and ID condition. Chart recordings are also generated that represent the tube condition of each cut tube. These are stored in digital format and are archived for future retrieval.

Published inProcessing

Eddy current and ultrasonic test systems, including the new Minimac® eddy current tester and Echomac® ultrasonic test system will be featured by Magnetic Analysis Corporation (MAC) at Booth #N-1005 at the Fabtech Show in Chicago, IL.

The new Minimac® 55 offers high performance eddy current testing for a broad range of production applications, all at an affordable price. This CE compatible, single channel instrument is the first eddy current tester to offer the robust capabilities of Magnetic Analysis Corp.’s top of the line Multimac®, in a powerful, compact design.

MAC MINIMAC w screen 9591 00000002

Especially well-suited for continuous production line testing where ease of setup, without the need for constant operator adjustment is needed, the Minimac 55 has software controls for all functions including phasing, filtering and sensitivity, all while operating at speeds over 4000 f.p.m. Test results in full-color polar and linear mode show real time, true wave form signals for easy review on an on-site monitor or remote locations.

Minimac 55 can detect short surface and some subsurface defects including laps, slivers and cracks in tube, bar, wire and parts, and weld line faults, including short ID or OD defects. Using the MID model, magnetic inclusions such as iron filings in copper material can also be detected.

MAC’s broad range of encircling and sector test coils is available for use with the Minimac which can also be configured for flaw or absolute mode, depending on the application. Coil Platforms, including those with DC saturation for testing magnetic material are offered.

Information on the Echomac® ultrasonic test systems, now capable of handling 500mm diameter pipe, and other MAC test systems and instruments will also be available at the booth.

MAC test systems are installed in major tube manufacturers world-wide and sales and service is provided in most areas by MAC’s Field Engineers and experienced Representatives.

Published inProduction

The new Minimac® 55 brings high performance eddy current testing to a broad range of tube production applications, at an affordable price. This is the first eddy current tester to offer the robust capabilities of Magnetic Analysis Corp.’s top of the line Multimac®, in a powerful, compact design.

The instrument is especially well suited for dedicated, continuous production line testing where simple setup, without the need for constant operator adjustment, is desirable. Once the optimum settings have been established, a lockout mode feature can be set to prevent unauthorized changes.

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With MAC’s proprietary Multimac performance, the single channel Minimac 55 instrument features software controls for all functions, including phasing, filtering and sensitivity, all while operating at speeds over 4000 f.p.m. The test results are displayed in full-color polar and linear mode showing real time, true wave form signals for easy review on a separate on-site monitor or at remote locations. The Track screen depicts the test product’s length, with data on line speed, end suppression, flaw tracking, piece count and alarm routing.

Linear strip charts and complete test data, as well as an unlimited number of settings can be stored, annotated and recalled from a library on the internal storage device or network. When networked, multiple instruments can share the same library to ensure correct settings in multiple test lines. Setup and monitoring can be handled through a computer network, and reports with customer, product information, defect location, time, amplitude and phase, can be stored locally or on a network server for quick follow up and quality assurance.

Defects and conditions that can be readily detected by the Minimac 55 include finding short surface and some subsurface defects such as laps, slivers and cracks in tube, and locating weld line faults, including short ID or OD defects. The Minimac, using the MID model, can also detect magnetic inclusions such as iron filings in non-ferrous material.

MAC’s broad range of encircling and sector test coils is available for use with the Minimac which can also be configured for flaw or absolute mode, depending on the application. Coil Platforms, including those with DC saturation for testing magnetic material are offered.

To the Editor:
For more information:
Jean R Gould, Marketing Manager
Magnetic Analysis Corp.
103 Fairview Park Drive, Elmsford, New York 10523-1544
Tel: +1-914-530-2000   Fax: +1-914-703-3790
www.mac-ndt.com email: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published inProcessing

The new Minimac® 55 brings high performance eddy current testing to a broad range of tube production applications, at an affordable price. This is the first eddy current tester to offer the robust capabilities of Magnetic Analysis Corp.’s top of the line Multimac®, in a powerful, compact design.

MINIMAC-55

The instrument is especially well suited for dedicated, continuous production line testing where simple setup, without the need for constant operator adjustment, is desirable. Once the optimum settings have been established, a lockout mode feature can be set to prevent unauthorized changes.

With MAC’s proprietary Multimac performance, the single channel Minimac 55 instrument features software controls for all functions, including phasing, filtering and sensitivity, all while operating at speeds over 4000 f.p.m. The test results are displayed in full-color polar and linear mode showing real time, true wave form signals for easy review on a separate on-site monitor or at remote locations. The Track screen depicts the test product’s length, with data on line speed, end suppression, flaw tracking, piece count and alarm routing.

Linear strip charts and complete test data, as well as an unlimited number of settings can be stored, annotated and recalled from a library on the internal storage device or network. When networked, multiple instruments can share the same library to ensure correct settings in multiple test lines. Setup and monitoring can be handled through a computer network, and reports with customer, product information, defect location, time, amplitude and phase, can be stored locally or on a network server for quick follow up and quality assurance.

Defects and conditions that can be readily detected by the Minimac 55 include finding short surface and some subsurface defects such as laps, slivers and cracks in tube, and locating weld line faults, including short ID or OD defects. The Minimac, using the MID model, can also detect magnetic inclusions such as iron filings in non-ferrous material.

MAC’s broad range of encircling and sector test coils is available for use with the Minimac which can also be configured for flaw or absolute mode, depending on the application. Coil Platforms, including those with DC saturation for testing magnetic material are offered.

Meeting one of its biggest challenges to date, Magnetic Analysis Corporation (MAC) recently completed and successfully passed pre-acceptance for a new 500mm (19.6”) Transverse/Longitudinal Flux Leakage Rotoflux® test system that is destined for a new tube mill at a major OCTG producer in Russia.

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500mm Rotoflux® Transverse and Longitudinal Flux Leakage System,
shown in Östersund, Sweden following final checkout for shipment to
a Russian OCTG tube mill. The Rotoflux Transverse tester, shown at center,
is temporarily moved out for ready access during maintenance operations.

The vertical element hanging in front of the face of the Transverse unit is
an add-on crane that's used to move the heavy pole pieces, when adjusting
for changes in tube dimensions.

The 500mm size rotary is the largest diameter MAC has developed and it required new mechanical designs to provide for the greater magnetization and detection capabilities, along with substantially new software. Initial assembly of the two flux leakage units was handled in MAC’s plant in Elmsford, NY, US, with final assembly, adjustments, and check out of the entire system taking place in MAC’s subsidiary Magnetic Analysis Nordic’s Östersund, Sweden plant. Additionally, a new Demagnetizer design was implemented to meet the customer’s requirements.

This 500mm system also features MAC’s latest wireless transmission of test signals between the test probes and the rotating head, a major improvement over traditional transmission by brushes and rings. The result is superior performance, lower maintenance costs and downtime, and less noise.

Flux leakage technology is well suited for inspecting high-permeability ferromagnetic metals such as heavy wall carbon steel pipe used in the oil and gas industry. MAC’s Rotoflux® can detect seams, laps, pits, scabs, rolling skins, cracks, weld line defects, and transverse and longitudinal defects as small as 5% of the wall on the OD and ID, allowing pipe producers to meet critical API 5CT, 5L, and ASTM E570 requirements.   As the oil and gas industry has expanded in recent years with the development of new fields and extraction techniques, the demand for high quality tube and pipe that meets industry standards has grown dramatically.

During the test, the pipe first passes through the multiplexed 48 channel Rotoflux® TRFX Transverse flux leakage rotary where it receives a high level of magnetic saturation which creates intense magnetic flux flow within the material. Some of this flux extends or “leaks” beyond the tube surface when interrupted by a surface or internal defect. This “leakage flux” generates test signals which are detected by the test probes rotating around the pipe. The signals are wirelessly channeled to the Rotoflux® test electronics for analyzing, processing, and data management, followed by display in real time vivid color on screen. The pipe then passes through the multiplexed 24 channel Rotoflux LRFX longitudinal rotary to detect signals from longitudinally oriented seam type defects , followed by a Demagnetizer to remove any residual magnetization.  A fully automated flaw tracking system with end suppression is used to control output sorting, alarm and marker functions.

This 500mm system is designed to handle tube and pipe ranging in size from 125mm to 500mm (5” – 19.6”) with wall thickness of 6mm – 40mm (.23” – 1.57”) at speeds that can range up to 60m/m (200 fpm), depending on the wall thickness of the test pipe. Straight or upset ends can be successfully tested. The testers are mounted on constant center automated triple drive roll benches that adjust to align the testers and drives with the level of the incoming test material, an important requirement for accurate tests. MAC also has 190mm and 360mm model Rotoflux rotaries for smaller diameter tube.

Published inProduction

Magnetic Analysis Corp. is receiving strong interest in its newest ultrasonic system for full body inspection of spinning tube.

mailAt the heart of MAC’s new ultrasonic inspection system is the unique APC (Adaptive Pitch Control) transducer carrier which adjusts to the actual helical pitch as the tube is rotated during the test. With a built in simple immersion water container the transducer carrier follows even un-straight tube and reliably maintains constant coupling. This allows testing of a large range of pipe sizes, 50mm – 355mm (2” – 14”) diameters, without having to adjust or change the transducers and lose significant setup time during size changeovers. An air cylinder provides a flexible holding structure for the carrier which allows it to follow material that is not straight. A convenient knob with a diameter scale further adjusts the roll separation, if needed. The sound entry point and incident angles stay constant for any tube size and multiple UT element arrays and/or discrete elements can be used, depending on test specifications. Defect detection down to 5% of the wall thickness is reliably achievable – meeting API 5CT and 5L specifications.

The system installs easily, whether it is on a new test line, or an upgrade of an older unit. A recent installation to test DOM (drawn over mandrel) carbon steel tube for OD, ID defects and wall thickness, replaced an EMAT system that no longer met the customer’s needs. 100% coverage is provided with 12 longitudinal and 6 transverse elements in each transducer head, covering both clockwise and counter-clockwise directions.

This transducer system can also be used for testing tube ends. As an end tester, the system includes a tube end tracking device consisting of a cone which is inserted in the tube end. The tube is spun, and the tracking cone adjusts to the variations in the straightness of the spinning tube, keeping the couplant out of the tube interior to prevent interference with the test signals. The tube end is inspected by the ultrasonic transducers contained in the APC transducer carrier as it traverses the tube.

Published inProcessing
Wednesday, 28 May 2014 00:54

MAC to Hold Private Seminars

CHOOSING THE RIGHT NDT TECHNIQUES
SE ASIA SEMINARS BY
MAGNETIC ANALYSIS CORPORATION:

Jakarta, Indonesia — August 21, 2014
Shanghai, China — September 23, 2014

With 85+ years of experience in designing and manufacturing nondestructive test instruments and systems for the metals industry, Magnetic Analysis Corp. will be hosting its own set of seminars this year is South-East Asia.

mac semiBuilding on the outstanding success of MAC’s Echomac® Rotary ultrasonic testers, the company will be featuring a new Spinning Tube ultrasonic test system at both seminars. This system features a unique APC (Automatic Pitch Control) transducer carrier which contains the water couplant and follows and adjusts to the pitch of the tube as it rotates through the tester. This allows testing of a large range of pipe sizes, including large diameters, with minimal transducer adjustments, if any, during size changeovers. Further, because the transducers are under the pipe, no tight fitting glands or shoes are needed, resulting in lower water circulation requirements, fewer wear components and virtually no changes required to the basic water tank on size changeover. This Spinning Tube transducer system can also be used for testing tube ends as well as for a retrofit or upgrade of existing installations.

MAC will also have a Rotomac® eddy current rotary and coil platform on display.

Information will be presented on test systems using a combination of more than one type of test technology, a requirement to meet many of today’s stringent test standards such as API and ASTM as well as information on inspection of specific products such as heat exchanger tube, wire, and so on.

MAC’s knowledgeable field staff will provide information in multiple languages on all of Mac’s products.  In Indonesia, our Guest will be Vice President Dudley Boden, our Representative; Mr. Zulfikri Testindo, and David Terry; Business Development Manager for SE-Asia.  In China, Our Guest will be Mr. Klaus Dickmann; Technical Manager for Europe and Jerry Zhu; Business Development Manager for China.

Monday, 05 May 2014 11:07

MAC to Hold Private Seminars

  CHOOSING THE RIGHT NDT TECHNIQUES

SE ASIA SEMINARS BY
MAGNETIC ANALYSIS CORPORATION:

 Jakarta, Indonesia — August 21, 2014

Shanghai, China — September 23, 2014

With 85+ years of experience in designing and manufacturing nondestructive test instruments and systems for the metals industry, Magnetic Analysis Corp. will be hosting its own set of seminars this year is South-East Asia.

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Building on the outstanding success of MAC’s Echomac® Rotary ultrasonic testers, the company will be featuring a new Spinning Tube ultrasonic test system at both seminars. This system features a unique APC (Automatic Pitch Control) transducer carrier which contains the water couplant and follows and adjusts to the pitch of the tube as it rotates through the tester. This allows testing of a large range of pipe sizes, including large diameters, with minimal transducer adjustments, if any, during size changeovers. Further, because the transducers are under the pipe, no tight fitting glands or shoes are needed, resulting in lower water circulation requirements, fewer wear components and virtually no changes required to the basic water tank on size changeover. This Spinning Tube transducer system can also be used for testing tube ends as well as for a retrofit or upgrade of existing installations.

MAC will also have a Rotomac® eddy current rotary and coil platform on display.

Information will be presented on test systems using a combination of more than one type of test technology, a requirement to meet many of today’s stringent test standards such as API and ASTM as well as information on inspection of specific products such as heat exchanger tube, wire, and so on. 

MAC’s knowledgeable field staff will provide information in multiple languages on all of Mac’s products. In Indonesia, our Guest will be Vice President Dudley Boden,Casey Powers, Systems Engineer, our Representative; Mr. Zulfikri Testindo, and David Terry; Business Development Manager for SE-Asia. In China, Our Guest will be Casey Powers, Systems Engineer and Jerry Zhu; Business Development Manager for China.