acousticeye g3 - user manual_v6.pdf

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AcousticEye G3 Tube Inspection System User Manual

Doc#: UTM00006 Rev: 6 Date: 6 June 2012

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AcousticEye Dolphin G3

Tube Inspection System

USERMANUAL

This manual applies to a complete testing system comprised of a Main Controland Analysis unit (AEMUN-30000) and an Acoustic Probe (AEPRB-30000)

CE Authorised Representative:

Acoustic Eye International

Attn: Gijs Cremer Eindhoven

Mail address: PO Box 205 3830 AE Leusden, The Netherlands

Visit address: Arnhemseweg 87 Leusden, The Netherlands

Telephone: +31 33 4453114


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Revisions Record

Rev. Description of Change Revision Date Revised By

1 Initial release 24-03-11 Roy Shtainman

2 Add calibration tube 12-05-11 Roy Shtainman

3 Change CE authorized rep. 10-08-11 Roy Shtainman

4 Version 3.3 Release 05-12-11 Roy Shtainman5 Minor changes 21-02-12 Roy Shtainman

6 Version 3.4 Release 6-06-12 Roy Shtainman

Created By: RoyShtainman

Tech SupportManager

15-Mar-11

Reviewed By: Willy Grunfeld Quality Manager 24-March-11


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Table of Contents

1 INTRODUCTION .................................................................................................................... - 1.1 SCOPE ....................................................................................................................................... -4-1.2 INTENDED USE........................................................................................................................... -4-1.3 ENCLOSURE................................................................................................................................ -4-

2 TEST SYSTEM COMPONENTS. ........................................................................................... - 2.1 MAINMEASUREMENT AND TESTUNIT.......................................................................................... -5-2.2 OPERATOR INTERFACE................................................................................................................ -5-

3 POWER CONSUMPTION ....................................................................................................... - 1.3 OVERVOLTAGE CONDITIONS........................................................................................................ -6-

4 PHYSICAL AND ENVIRONMENTAL CHARACTERISTICS ............................................ -4.1 DIMENSIONS AND WEIGHT........................................................................................................... -6-4.2 EQUIPMENTSPECIFICATIONS...................................................................................................... -7-

5 QUICK START GUIDE ........................................................................................................... - 5.1 REMOVING EQUIPMENT FROM THE CARRYING CASE, SET-UP......................................................... -9-5.2 ATTACHING A TUBE ADAPTER TIP TO THE PROBE......................................................................... -11-5.3 CONNECTING TO A POWER OUTLET............................................................................................ -17-5.4 TURNING THE SYSTEM ON.......................................................................................................... -18-

6 OPERATION INSTRUCTIONS ............................................................................................ - 26.1 PROBELEDS............................................................................................................................ -20-6.2 PRELIMINARYTESTS.................................................................................................................. -22-6.3 SETUPPRE MEASUREMENT..................................................................................................... -32-6.4 MEASUREMENT......................................................................................................................... -60-6.5 REPORTPOST MEASUREMENT................................................................................................. -64-

APPENDIX IPACKAGING INSTRUCTIONS, CABLE ARRANGEMENT ........................ - 7

APPENDIX IIINSTRUCTIONS FOR ASSEMBLING EXTERNAL SEALING

SPONGE ON ADAPTORS. ............................................................................................................. - 8

APPENDIX III

MISCELLANEUOS ........................................................................................... - 8

APPENDIX IVPC HW BUTTONS ............................................................................................ . - 8

APPENDIX VPROBE SCREEN NOTOFICATIONS .............................................................. - 8

APPENDIX VISPECIFICATIONS AND STANDARDS ......................................................... - 8


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1 Introduction

1.1 Scope

This manual provides the specifications and instructions for the safe andeffective operation of Acousticeyes Dolphin G3 Tube Inspection System, aNDT testing and evaluation solution for tubular systems usingAcousticeyesproprietary Acoustic Pulse Reflectometry (APR) technology .

The system consists of a main measurement and control unit referred toas the MCU, a hand-held measurement probe referred to as Dolphin Probeand a calibration tube.

While it covers basic instructions for performing tests and generating abasic test report, it is intended to be used primarily as an installation andoperation instructions manual, not a substitute for the operators training courseoffered by Acousticeye. This training offered by Acousticeye provides the skilland know-how necessary for analyzing and interpreting the data obtained frommeasurements and for obtaining the best possible assessment of the condition ofthe target tubing system.

Note:

Screen shots provided in this manual are based on version 3.0 of the applicationsoftware (PTS) and may differ slightly from the actual screen shots in yourparticular version.

1.2 Intended Use

The system is designed for on-site inspection and evaluation of faults suchas holes, pits, erosion, partial blockages etc. in tubular systems (materialindependent), in process industries such as power plants, refineries and the like,by means of the injection of acoustic pulses through one open end of the tubeunder test, and analysis of the reflected waves.

1.3 Enclosure

The test set is enclosed in one carrying case which provides protection for thecontained system components during air and ground transportation, storage andhandling.

For operation the system components are removed from their carrying case

(Refer to section5 )


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2 Test System components.

2.1 Main Measurement , Test Unit andCalibration Tube

The main unit is contained within a metal enclosure with a removable top paneland contains the following main components:

iEi Panel PC industrial computer

iEi Lithium Battery Pack (BAT-LI-4S2P3800A)

- Rating: 14,8V DC, 3800 mAh,

- Maximum Charging Voltage/Current 16.8Vdc/2000mA

Amplifier Maya sound card

Dolphin Probe

A formed plastic housing containing:

Microphone

Speaker

LCD screen

Calibration tube:

A 1.5 meter in length, faultless and plugged aluminum tube.

2.2 Operator interface

The operator interfaces with the tester primarily through the computer andspecifically its GUI (Graphic User Interface), an integral part of the operationsoftware.

Hardware interfaces consist of a push button switch and 4 indicator LEDs locatedon the probe handle.

The push button switch initiates the test by generating the acoustic wave andcapturing of the reflected signals.

The LED functions are as follows:


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Blue: Ready for taking a measurement (or step to the nextmeasurement)

Yellow: Measurement in process

Red: Last measurement was not taken properly probably due to asealing problem. If applicable please repeat the measurement. Thereis also an indication on the SW interface.

Green: Last measurement was taken properly.

3 Power consumption

Installation category II, IEC 60364-4-443

Power Input: Dual voltage system (110V/220V).

3.1 Overvoltage conditionsOvervoltage Category II type of supply for connection of equipment

4 Physical and Environmental characteristics

4.1 Dimensions and weight

4.1.1 Weight:

Gross (In carryingcase/trolley)

Net (Removed fromcarrying case)

MCU18 kg (39.7 lbs)

8kg

Probe: 1kg

4.1.2 Dimensions

Trolley: 56 x 45.5 x 26.5 cm

The trolley incorporates built in wheels and 2 handles, one for lifting and anotherfor pulling, to enhance portability and handling.

4.1.3 Accessory stowage

The carrying case (trolley) has provisions for the stowage of all the accessories.


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These are designed to prevent damage to the accessories and probe duringtransit.

4.2 Equipment Specifications

# Specification Spec Limits Tested to Comments

1. Overall size (L xW x H)

33 x 28 x 14 cm(MCU)

Size of carryingcase

25 x 14 x 12 cm

(probe)

56 x 45.5 x 26.5 cm

Weight : 8kg (MCU)

1 kg (probe)

18 kg (Inside

carrying case)

2. Temperature,Operating

-100C to +500 MIL-PRF-8822,

Procedure: 4.5.5.1.1for Class 2

Temperature,Storage

-200C to +700

3. Humidity RH: up to 95% MIL-PRF-8822,Procedure4.5.5.1.1.2

4. AltitudeOperating:

Altitude non-operating:

0 to 4000m (0-3123feet)0 to 10000m (0-32800feet)

MIL-PRF-8822,Procedure 4.5.5.2

5. Ingress IPX0 IEC 60529


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# Specification Spec Limits Tested to Comments

Protection

Enclosed incarrying case

IP67 (1 meter)submersion for 30minutes)

6. SinusoidalVibration/Transportability

Class 2 :15-55 Hz. 15min./axis cycling+10min. dwell@resonance frequency(or 33 Hz if noresonance found) for

each of the 3 axis

MIL-PRF-8822 ,4.5.5.3.2 for Class2

In carrying case

7. Transit drop test Drop height of 30 cmson each of the 6 facesand 4 corners for atotal of 10 drops.

MIL-PRF-8822,4.5.5.4.2 for Class2,

In carrying case

8. ExplosiveAtmosphere

N/A MIL-PRF-8822,Procedure 4.5.6.3

9. EMC Detailed in Test Report EN 61326-1

CISPR 11, CLASS 1IEC 6100-3-2 , 3-3,-4-2 , -4-3,-4-4, -4-5,-4-6 & -4-11

FCC Part 15, Sub-part B, CLASS A

0. SAFETY Detailed in Test Report EN 61010-1:01IEC 61010

UL 61010-1

CSA C22.2 61010-1-04+GI1

Safety evaluated t

+40 0 C max.ambient


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5 Quick Start Guide

5.1 Removing equipment from the carrying case, set-up

Open the carrying case and remove the main unit.

Fig. 1


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Fig. 2

Fig. 3

Place the main unit on a suitable workbench or table top. In case no suitabletable is available, place the main unit on the carrying case.


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5.2 Attaching a tube adapter tip to the probe

The probe mechanically interfaces with the inspected tube by means of anadapter and a rubber sponge seal.

According to the tubes to be inspected, select an adapter that matches the tubesdiameter.

Please use the get recommended adaptor wizard on the SW after insertingthe inspected tube OD and wall thickness the application recommends the mostfitted adaptor to be used can be identified by code:

-RDP (Regular Diameter Probe):

- Type AXX - cylindrical adaptors.

- Type BXX - conical adaptors with perforated tips.

-LDP (Large Diameter Probe): Type LDP_XXX

Note:

It is important to use only adapters and seals supplied by AcousticEye.

See instructions for attaching the rubber sponge to the adapter in Appendix II.

In order to choose the right adaptermake sure that the adapters OD is a bitsmaller then the measured tube ID.


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Attaching an adaptor to a RDP Probe:

Fig. 4

Fig. 5


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Fig. 6

Fig. 7

Fig. 8


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Attaching an adaptor to a LDP Probe:

Fig. 7a

Fig. 8a


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Fig. 9a

Fig. 7a


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Connect the probe to the main unit panel.

Connect the probe cable to the probe. Pay attention to the connector orientation.

Fig. 9

Connect the other end of the cable to the main unit.

Fig. 10


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5.3 Connecting to a power outlet

Connect the power cord to the top panel of the main unit (next to the ON/OFF

switch) See Fig. 11.

Fig. 11

Connect the power cord to the mains (Its important to ensure proper grounding!)

Fig. 12


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5.4 Turning the system onSwitch on the main unit power switch located on the upper panel

Fig. 13


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Launching the software

Double click on the PTS icon located on the desktop using the supplied stylus.

Fig. 14

Make sure that the status line indicates that the software is ready (Fig 12A)

Fig 14A


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6 Operation Instructions

6.1.1 Probe LEDs

During system initialization, all the 4 LEDs at the back of the probe are turned on.

A blue LED light on the gauge indicates that the initialization is over and thesystem is ready to take measurements.

Fig. 15

Notes about functions of the probe controls and indicators:

The lower button initiates a measurement

The upper button skips a tube (can be used in case of a plugged tube forexample)and it increases the measurement counter by 1, all 4 LEDsflicker once when applied.


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LED colors and their meaning:

o BLUE: software is ready, press button at will

o YELLOW: measurement in course, dont move

o RED: Last measurement was not taken properly probably due to asealing problem. If applicable please repeat the measurement (afterdeleting last measurement and reducing the counter). There is also anindication on the SW interface.

o GREEN: Last measurement was taken properly.

6.1.2 Initial Templates

Upon initialization or when a new session is created, the user is prompted tochoose a session template.The available templates are:

Regular Diameter Probe - Standard MeasurementTube dimensions: 5/16 to 1.5Tube length: Over 6 meters.

Regular Diameter Probe - Short MeasurementTube dimensions: 5/16 to 1.5Tube length: Up to 6 meters.

Large Diameter Probe - Standard MeasurementTube dimensions: 1.5 to 4

Tube length: No limitation


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6.2 Preliminary Tests

6.2.1 Perform Hardware Test

In order to verify the system functionality, perform one test measurement in theair by clicking in the upper menu: Advanced -> Perform Hardware test.

Verify that you can hear the sound wave and that the test result was positive.

In case the HW test failed

Try restarting the system. If the problem persists -

Dont use the system and contact AcousticEye Support promptly.


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6.2.2 Perform Calibration Verification

The second part of the inspection preliminary tests is verifying the probecalibration.

This test should be performed following a successful Hardware test.

The test is performed using the supplied calibration tube a 1.5 meter in length,

Faultless and plugged from one side, aluminum tube.

The non-plugged side has an interface to the system probe.

This test verifies the probe calibration and if needed recalibrates it.

This procedure must be performed on site before conducting anyinspection session.

Its recommended to climate the probe to the site environmental conditions1 hour before performing the calibration (due to temperature changesbetween storing to operating locations).

Connecting the calibration tube RDP:

Open the probe bolt.

Fig. 16


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Fig. 17

Take off the probe membrane

Fig. 18


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Fig. 19

Attach the calibration tube to the probe (note the tube end orientation).

Fig. 20


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Connecting the calibration tube LDP:

Take off the probe membrane

Fig. 16a

Fig. 17a


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Attach the calibration tube to the probe (note the tube end orientation).

Fig. 18a


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Back on the PTS application; go to Advanced->Probe->Probe Calibration

A note will be displayed

The procedure status is displayed at the bottom left status bar


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When done a completion note will be displayed

In case the probe calibration fails:

a. Verify that the calibration tube is attached properly to the probe.

b. Quiet any external noise or vibration sources.

c. Repeat the calibration process.

d. If fails again, Restart the main unit.

e. Place the probe and the calibration tube tip on a soft (shock observing) ground

f. Repeat the calibration process.


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Disconnect the calibration tube from the probe.

Dont forget to reinstall the probe membrane.


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The Set-up, Measuring and Report Workflow

The PTS application is operated by means of the three main tabs and applicable

sub-tabs described below.

Main Tabs

a) Setup for the pre-measurement steps.

b) Measurement for taking measurements.

c) Report for the post measurement analysisand report generation

The basic workflow is to go through the tabs from left to right start with the maintab on the left (setup), go over all its sub tabs from left to right. When finished,move to the next main tabMeasurement.


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6.3 Setup Pre measurement

6.3.1 Tube sheet map creation

In the PTS application there are several methods of creating a tube sheet mapand choosing the tube ordering. Here is a description of the most commonmethod using a digital photo:

Take a digital photo of the measured equipment and place it on the systemscomputer.

Open the Map buildersub application

Go to file->New

TIPS FOR TAKING PICTURES OF TUBE SHEETS

Use a good quality camera, having at least 5 mega pixels resolution with

optical zoom capabilities Use flash photography under all circumstances, even at full sunlight,

unless there are safety limitations.

Position the camera in front of the tube sheet, holding the cameracentered (in line with the tube sheet center)

The distance between the camera and the tube sheet should be at least 4-5 times the diameter of the tube sheet. Make sure that most of the pictureframe is occupied by the tube sheet. Come closer to the tube sheet or useoptical zoom if necessary to achieve that goal.


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Double click on the path at the Picture File Name field to open a browse window.

Navigate to the image taken, open it, and then double click on the C reate Map

button.

The equipments photos will be shown on screen.


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There are 2 ways of performing the tubes detection on the digital image manually or automatically.

6.3.1.1 Manual tube detection on the MapBuilder

Check the addbutton at the bottom left corner. Then start clicking on the tubes,according to the tube ordering you want to use.

Note:

The circle size can be adjusted by changing the value of the Radius field, right tothe Mode field.

To delete or select a certain tube use the Delete/Add/Selectmenu at the Modefield.

To zoom in or out, use the keyboard +/- keys or the mouse scroll wheel.

To move the picture, use the arrow keys.

After the tube map is ready, choose file->save to custom, then choose a mapname.


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Close the Map builderapplication.

The tube map is set.


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6.3.1.2 Automatic tube detection on the MapBuilder

While preparing a map in Map Builder, it is possible to automatically detect the

tubes holes in the map, without clicking on them one by one:

Load the equipment map

Choose the Path selection mode:

On the top menu, click Tube detection -> Custom


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Click on the map to create a region of interest for the searching process.


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Click on the Set button in Region of interest

Zoom in onto the map, and select 2 points on the diameter of some tube.


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Click on the Set button in Diameter

Click Search


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Note: if a message that there is not enough memory for the operation isdisplayed, try selecting smaller portions of the map at a time, until the map is

completed

The Search further button can be clicked to perform a deeper search.

Remaining tubes may be filled in manually by changing the Mode at the left-bottom part of the screen to Add, and changing the selection mode toRectangle by right clicking on the map, and choosing Selection type - >Rectangle

Note: The tube radius may be changed to see if the tubes are obscuringsome suspicious area.

Note: Using the Tube detection mechanism obliges the use of Tube

Ordering (Row-Column-Zone ordering) before saving the map.


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6.3.2 Row Column Zone Annotation

6.3.2.1 Row Column Zone Support - Map Builder

After building the tubes map, the tubes can be ordered by rows, columns andzones.

There are 2 methods to set Row Column Zone info for a given picture:

A) Automatic

B) Manual

Automatic6.3.2.1.1

In the top menu, click Tube ordering -> Custom

For regular maps as the above one, using the Automatic tube ordering should beenough. By looking at the above map, the user can see that it is best to divide it

by Columns (vertical), so the Advance at angle by parameter should be set tocolumnsas well as the colorized by parameter.


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Mark the first tube (the tube you want to define as (0,0)) and press set.

The first tube ID box should be filled in with a number.


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Select two adjacent tubes (select the second one by pressing and holding the ctrlbutton). Then press the set button.

A number representing an angle should appear in the angle box.


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Press the apply button.

The presented coloring help verify that the ordering was done properly.

Zoom in the better verify it.

Once done, go to file->save to custom, and specify a name for the map.


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Note: If the tube set in First tube ID is not located in one of the maps corners,the program will display a message and select on the map the tubes that can beset as the first tube.


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Manual26.3.2.1.

If the Automatic method didnt provide the desired results, the Row Column

Zone properties can be set using the Manual method.

For example, in the following map, select the first column, then in the bottomOrientation panel set the C field to 1, select the desired starting point (Top atthe above example) and click Apply.

To determine the coloring orientation, on the top menu, click Tube ordering ->

Custom and set the Colorize by parameter.By leaving the R field empty, the user indicates to the software to automaticallyfill in the R values into the selected tubes.

After setting the first column, select the second column, set the C field to 2 andclick Apply.


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Repeat the procedure for the entire map.

If the map is at a certain angle, the tubes for each row or column can be chosenby the Path selection mode.


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Then click several times to bound the desired Row or column:


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Then right click again and choose Select from path


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Once the user has selected the desired column, he can click Apply and repeatthe action for the remaining columns.

Note: To set different zones to the map, select the tubes at the needed zone,clear the R, C fields, set the Z value, and click Apply

Once done, go to file->save to custom, and specify a name for the map.


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6.3.2.2 Row Column Zone Support PTS

PTS supports Row Column Zone tube identifiers.

If a user wishes to work without Row-Col-Zone, he can only use the R (row ) values, by right clicking on the ,measurements list and choosingMeasurement name format


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The N value at the 2D map tube drawings represents the order by which thetubes need to be measured. This order will change if the user changes the

Advance by field at Measurements name control panel. The Advance by field at Measurements name control panel will also

determine the way that the defect tables and measurement list are sorted.

As always, there is a backward compatibility which means PTS can load oldersessions.

The user can also use the D field (Description) to type free text at certainmeasurements.

By selecting tubes in the 2D map, the corresponding tubes in themeasurement list will be selected. If tubes selected in the 2D map dont exist

in the measurement list, they will be immediately unselected. By clicking on a single tube in the 2D map, the tube Zone-Row-Column

information will be set at the Measurement name control panel.

An existing measurement can be renamed by right clicking on it and selectingRename. The Zone-Row-Column-Description info in the Measurementname control will be setin the measurements name.

After the map is finalized, use file->save to custom in order to save the map tothe main application. Close the map builder.


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Back on the main application, the first step is to open a new session and to nameit.

Go to file->newand then file->save as; choose a unique name and location forthis session.

Note:

The measurements are saved automatically to the hard-drive as they aretaken (no data is lost due to a crash/outage problem).

By default all measurements are saved to a temporary directory on disk asthey are made Path\TempDir_XX

In order to avoid overwriting this temporary directory use the Rename orthe Save As options.

The Save As button canbe used to make a copy of the measurements,but will entail copying large amounts of data to the new directory,cluttering the disk and taking some time to execute.


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6.3.3 Setting the tube map

Go to Setup tab, then Map sub tab.

UnderFacilities drop down menu, choose custom. Then at the System Type dropdownmenu, choose the map you have created. Click theApplybottom.

Note: To Zoom in/out or move the map use the relevant keyboard keys.

Other mapping options will be introduced in the hands-on training part of thecourse.


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6.3.4 Setting up tube parameters

Go to the Parameters sub tab. Insert the temperature, tube length, outer

diameter, wall thickness and probe adaptor code in the corresponding fields.

Note:

- Pay close attention to the units in each parameter.

- The unit type (metric/US) can be changed using thepreferences->units in themenu bar.

- When moving to the measurementtab for the first time, the system will ask youto fill in the 5 parameters mentioned above.

Filling in these parameters correctly is crucial for proper system performance.These parameters affect the final analysis (report generation). However, theydont affect the raw data acquisition meaning that in order to perform ameasurement you can insert dummy values, but before generating a report youmust insert the parameters accurately.

The tube length should be taken from the measurements signals afterfinishing the job, go to report->signals, right click ->select allmeasurements. The average tube length is the one you should use.

When inspecting U-Tubes set the U-Tubes parameter to yes.

- Checking theshow advanced

box, opens a list of all the advanced parameters.Dont change those values without consulting with AcousticEye supportfirst!

- Restoring the parameters list (both basic and advanced) to its default values,can be done by choosing Advanced-> Database -> Restore default values,in the upper menu.


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6.3.4.1 Choosing the proper adaptor

The application has a wizard that assist the user in choosing the proper adaptor.

After inserting the tube OD and Wall Thickness, choose the Get recommendedadaptor button.

The system will suggest the proper adaptor code to be picked from the systemset.


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6.3.4.2 Measuring the inspection temperature

Since the speed of sound is affected by the air temperature inside the tube, it isimportant to measure and update it on the software.

Measuring the temperature inside the tube can be performed simply bymeasuring the temperature of the tube wall with a surface thermometer (underthe assumption that on steady state conditions both should be equal).

The requirements from the thermometer are:

- Accuracy: Up to 5 degrees Celsius variation (2.5 Celsius).- Surface thermometer: the measurement is done on the tube wall.

- Time to a steady reading: 1 minute.

Note:

- The temperature update affects only the location reporting accuracy andnot the system sensitivity.

- The thermometer is not supplied with the system.


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After taking the trouble to enter all setup parameters, you might like toexport them to a file of their own

Next time you start a session you can save time by importing previoussettings

Heres how to do it:

o Export: Import:

Note: these parameters are saved with all the measurements of aparticular session

6.3.5 Inspection details

Fill in the relevant fields to appear in the final report.

Free text summary can also be edited.

The name of the company performing the inspection and its logo can be applied

both will appear in the header on top of each report page.


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6.3.6 License update

In order to operate, the program requires a valid license that needs tobe updated every 90 days.

There are two ways to update the license:

When internet connection is available, clicking the Updatebutton will cause the program to connect to the AcousticEyeserver and retrieve a 90 days license and a software update ifavailable. 21 days before the license expiration date a propermessage will be displayed to the user. If the license expires, theprogram will cease to work until the license is updated.

When internet connection is not available, clicking the Importlicense button will prompt the user for a license file. Such .licfile can be sent to the user by email.

6.3.7 Export Click DB

When Internet connection is not available, and the user wants to sendan activity report to AcousticEye, an activity file can be exported to belater sent by mail.


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6.4 Measurement

You should keep 3 goals in mind as you make measurements:

You probably want to go through measurements of as many tubes aspossible in a given time

You definitely want to synchronize the measurement label in thesoftware with the actual tube that has been measured

Finally you should use the built in safeguards to make sure that themeasurements are good (this will be explained below in detail)

6.4.1 Conducting a reference measurement

Move to the Measurementtab. Insert the probe tube adaptor into the tubemarked as 1 in the tube map, verifying a good seal. When ready press the

lower button on the probe or use the software button.

The reference measurement is much longer then all the others (about 45seconds), and during it the system performs a volume optimization to theexcitation signal. Once done the volume parameter will be updated by thechosen value.

After getting the blue LED indication (meaning that the reference is done), pressthe push button again or use the software Measure button to take anothermeasurement of the first tube (marked with red circle).


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6.4.2 Taking the tubes measurements

Go over all the tubes you wish to measure using the probe push button or the

software Measure button. Wait for the blue LED indication before moving on tothe next tube.

The system gives an indication whether the measurement was taken properly(sealing considerations). 2 indications are given in parallel:

1. Probe indication Green indication stands for a good measurement; redindication together with a "bad sealing" error message stands for a badmeasurement.

2. GUI indication at the measurements window on the right, under the QCcolumn.

Stands for a measurement taken properly. Stands for a badmeasurement.

In case of a bad measurement a warning message appears:


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In case of a bad measurement indication, if applicable improve the sealing andrepeat the measurement.

Example (Bad Sealing):

During work it is recommended to use the 2D sub-tab in order to validate yourposition on the tube map. To view the acoustic signal, just switch to the Signalssub-tab.


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6.4.2.1 Deleting a measurement

To delete a measurement, mark it with the cursor then right click->delete

selected.

The counter value will be decreased automatically.

Note on labeling:

Measurements can be are labeled as follows:

[R] = Row

[C] = Column

[Z] = Zone

[N] = Tube number (a continuous counter following the measuringsequence)

If a user wishes to work without Row-Col-Zone, he can only use the R (row ) values, by right clicking on the ,measurements list and choosing

Measurement name format


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6.5 Report post measurement

In the reportmain tab you will see the following sub-tabs:

Options:Analyzing all the measurements or only selected tubes

Signals: On this screen signals can be Displayed and analyzed using severalimportant features Noise margins, Thresholds (per defect type), Subtract ofcalibration.

Defects table: All detected defects are listedin separated tabs based on theirtype. Filtering can be done as well.

Final report: Printing a report and 3 dimensional representations.

6.5.1 Before report generation

Before generating an inspection report, you need to verify that the following stepswere completed:

1. Parameters

All the tube and adaptor parameters were inserted correctly.

If needed, the relevant advanced parameters (primarily detectionthresholds), were adjusted.

2. Optimal visual reference was selected

Before running a final analysis we need to choose an optimal visual reference.

If a good reference tube is available we can just use it as a reference.

In order to do so just measure it as was explained in section 6.4.1.

Or just click on the tube measurement, then right click ->change reference to->the selected measurement.


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Since in most cases a reference tube will not be available, we need to choose adifferent reference method averaging.

To do so, in the measurementtab, click on one of the tubes ->right click->selectall measurements, then clear off the bad measurements from the group (badsealing, plugged tubes). Once done: right click->change reference to->the

average of selected measurements.Since the measurement quality status depends on the reference tube, the systemwill ask whether to recalculate the tubes QC status.

Note:

Indications of the measurements that participated in the creation of theReference and Noise can be seen in the R N columns.


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6.5.2 Generating a report

6.5.2.1 System interpretation

Go to Report -> options

Choose the measurements that you want to analyze (All/selected only).

Choose whether the inspected tubes are U-Tubes

When the U-Tubes analysis mode is selected, the automatic analysissplits the tubes into length based groups (marked "GXX"):

Choose whether to impose reference tubes on small statistics sessions,creating a reference tube by averaging is meaningless. The visualreference is imposed to be used in the automatic analysis as well.

Press the

To stop the report analysis, click theAbortbutton.

When finished a completion message will appear.


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In the defects table tab you can see all the detected defects, separated into tabsbased on their type. Filtering based on the column attribute can be done as well.

In the Signals tab, measurements can be displayed and analyzed manually usingseveral features Thresholds, noise, subtract calibration, Filter view.


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6.5.2.2 User interpretation

Now comes the final part of the analysis the user reviews the system reportand verifies the findings.

Go to the signals tab, choose the measurement you want to analyze, its signalwill appear on the screen.

All the defects that were detected in this tube will be listed below the signal onseparated tabs, based on their type.

Clicking on an indication will zoom in on its location on the signal.


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Now, the user can decide whether to approve or decline the system classificationand add its graph to the final report

And simply continue to the next indication by using the dedicated arrow key

The tube condition can be classified as well if needed.

Free text can be inserted in the comments column.

Notes:

Assigned keyboard buttons to improve usability during the analysis.

The list is shown when clicking on the button.


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Load last saved in Defects Table screen:

o Clicking this button will load the last saved defect table.

o The defect table is saved automatically every few minutes or whenthe Apply button is clicked, or when the session is closed.

At any defects table scheme, right clicking on an indication will enable the

following options:o Approve/Decline Selected indications can be applied simultaneity

using the Ctrlkey.o Delete to delete the indicationso Add newinsert a new defect to the marked tube, based on the

user manual analysis.o Move toMove the current classification to any of the other

options.o Approve/Decline allAll the indications in the same tube/class

(depends on your viewing scheme) will be approved/declined.o Add/Remove graph from allo

Approve without adjacent fault filtering- approve very close faults.o PropertiesDefect ID, tube ID and the defect location and

amplitude attributes are displayed


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Filters views:

In order to increase defect delectability while using the automatic analysis,

the system applies 5 types of filters Low/Low_BP/High/High_BP/None.

In order to let the user verify the defect using the same filter that was usedby the system the filter at which this defect was detected is listed at thedetection filter column and the user can toggle between the filters tooptimize the defect verification.

The same defect will look totally different under different filters:

A hole:

LPF:

HPF:

BPF:


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In order to know how a certain defect type looks under a certain view filter,the user can apply the theoretical defect signatures at the right click

options menu:


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Signals screen options:

o Displaying multiple signals can be done using the Ctrlkey (one by

one), or the shiftkey (selecting a group of signals).

o Zooming can be done using the + - keys; panning can be doneusing the arrowkeys.

o Right click on a line (signal or a threshold) will color it orangemomentarily and display its text

o Other right click options:

View all will zoom out to the entire signal length

Undo zoom will return to the last zoom step

Save as image save the current screen capture

Show holes/Pitting/Erosions/Blockages signaturesShowsthetheoretical defect type signatures under the selectedview filter with various sizes.

Hide defect signaturesHides the selected signatures.

Deselect from measurement listunselect the tube from thehighlighted measurements list.


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6.5.2.3 Printing the report

After the user has finished going over all the reports and verifying the systemclassification, its time to print the report.

Under report->Final report->Issue report, the user can:

Choose some report printing options

Add pictures to the report to appear after the 2D colored map (Usuallythis option is useful for displaying some zoomed in zones of a big heatexchanger.

In order to print the report, all you need to do is press the Issue reportbutton.


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A report (at the chosen format) will be displayed; the chosen signal graphs willappear in the report as well.


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Pie charts summarizing the malfunctions can be viewed at the final reporttab.

The pie chart is also added to the HTML/PDF report.


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APPENDIX I PACKAGING INSTRUCTIONS, CABLE

ARRANGEMENTThere are two cables: the external power cord and a second cable for theconnection of the main control unit (computer) to the probe.

The cables are packaged in the carrying case, inside a cell located under themain control unit.

In order to re-pack the cables follow the instructions below.

STEP 1: open (lift) the cell plastic cover.

STEP 2: probe-main unit arrangement.

components: cable, plastic cable drum (Fig. 2.1).

Fig. 2.1

A. Place the connector in its place using the cable locator bracket(Fig.2.2)


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Fig. 2.2

B. Start rolling tightly the cable on the internal drum tube (Fig. 2.3)

Fig. 2.3

C. Final configuration of the rolling cable should be as shown (Fig.2.4)

Fig. 2.4


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STEP 3: place the cable in its place as shown (Fig. 3)

Fig. 3


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STEP 4: Internal Suitcase arrangement

Is displayed at the image below (Fig. 4.1)

Fig. 4.1


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APPENDIX II INSTRUCTIONS FOR ASSEMBLING EXTERNALSEALING SPONGE ON ADAPTORS.

STEP 1: clean the adaptor tip & tip base (sealing sponge bonding surface) withethanol as shown in Fig. 1.

Fig. 1


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STEP 2: find the right sealing sponge on the sealing sponge plate and remove itfrom the plate.

As shown in Fig. 2.1 & 2.2

Fig. 2.1


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Fig. 2.2

STEP 3: remove the internal part of the sealing sponge ring. As shown in Fig. 3

Fig. 3

STEP 4: remove the adhesive protective wrapping. As shown in Fig. 4


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Fig. 4


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STEP 5: place the sponge ring on the adaptor tip. As shown in Fig. 5

Fig. 5


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STEP 6: turn the ring clockwise till the bonding surface touches the tip base.As shown in Fig. 6

Notice:

You must turn the sponge ring on the adaptor tip in order to make thesponge come closer to the adaptor bonding surface.

Fig. 6


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APPENDIX III MISCELLANEUOS

1. Report -> Signals screen

Check here to see a graphical representationof the various defect types thresholds

Check here to see a subtraction of the

calibration from the measured signalCheck here to see a graphicalrepresentation of the noise

Check here to order to get the exactestimation for a specific fault


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2. File menu

New Open a new session file (under Path\TempDir_0), need to be renamed in

order not to be over written by a later session.Load Load an existing session file

Save As File is copied and saved to a chosen name.

Compress to zipis used for reducing raw data size before sending on the net.Use default setting (without checking any box) unless asked otherwise.

Rename renaming current session name.

Import/Export setup parametersIs used to import/Export an existing parameter

file from/to an external folder for future use. Note that the parameters file must benamedArgumentsDB.xml


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APPENDIX IV PC HW Buttons

From right to left:

- Screen on/off

- Increase brightness

- Decrease brightness

- Increase volume (not in use)

- Decrease volume (not in use)

- Auto screen brightness

- Mute power alert buzzer


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APPENDIX V Probe screen notifications

In order improve the system usability by decreasing the use of the main unitduring the measurement acquisition phase Most of the measurementcontrol process was mirrored to the probe screen.

Almost all the user notifications appear on the probe screen and the user canoperate the system using the probe only.

Here are the complete scenarios and the handling from the probe:

Legend: Low = lower probe buttonUp = Upper probe button-> = Pressing a probe button

HW TEST During hardware test - on the probe: performinghardware test.

At the end: Hardware test succeeded / hardware test failed.

CALIBRATION During calibration: calibrating probe.

At the end: Ready.

REFERENCE During Reference: measuring

If a Reference exists: Ref exists. Low=OK ->

Perform new Ref? Low=OK UP=NO

Regular measurementMeasuring: R[ ]C[]

At the end: SNR:___. Next: R[ ]C[ ].

Repeating an existing Measurement - meas exists. Low = OK->

Remeasure ? Low=yes UP=NO

Problematic measurement - problematic meas. Low=OK ->

UP=Continue. Low=Repeat


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Bad sealing - Bad sealing. Low=OK - >

UP=Continue. Low=Repeat

Bad measurement - After 3 attempts: Meas failed. Low=Ok ->

Next: R[ ]C[ ] ->

Measuring

Example (Bad Sealing):


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APPENDIX VI - REFERENCED EC DIRECTIVES,SPECIFICATIONS AND STANDARDS

The following documents referenced in this manual are pertinent only in thequoted context and to the extent specified.

UNIVERSAL SERIAL BUS REVISION 2.0SPECIFICATION

IEC 61010-1EDITION 2.0 2001-

02

SAFETY REQUIREMENTS FOR

ELECTRICAL EQUIPMENT FORMEASUREMENT, CONTROL ANDLABORATORY USEPART 1: GENERALREQUIREMENTS

IEC 61326-1EDITION 1.0 2005-12

ELECTRICAL EQUIPMENT FORMEASUREMENT, CONTROL ANDLABORATORY USEEMCREQUIREMENTS PART 1: GENERALREQUIREMENTS

UL 1950 SAFETY INFORMATION TECHNOLOGYEQUIPMENT, INCLUDING ELECTRICALBUSINESS EQUIPMENT

MIL-PRF-28800F GENERAL SPECIFICATION FOR TESTEQUIPMENT FOR USE WITHELECTRICAL AND ELECTRONICEQUIPMENT

MIL-STD-810F Department of Defense Test MethodStandard for Environmental EngineeringConsiderations and Laboratory Tests
http://www.usb.org/developers/docs/usb_20_122208.ziphttp://www.usb.org/developers/docs/usb_20_122208.ziphttp://www.usb.org/developers/docs/usb_20_122208.ziphttp://www.usb.org/developers/docs/usb_20_122208.zip


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EU DIRECTIVE 2006/95/EC Low Voltage Directive

EU DIRECTIVE 2004/108/EC EMC

EU DIRECTIVE 2002/95/EC RESTRICTION ON HAZARDUOUSSUBSTANCES - ROHS

acousticeye g3 - user manual_v6.pdf

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