Scanner components and maintenance

Improving Inspection Through Technology

Scanner components and maintenance
 Aim
 To familiarise technicians on scanner health and safety, identify
the components of the scanner and correct maintenance of the
system.
 Learning Outcomes
 Establish the operational hazards of the scanner.
 Demonstrate correct manual handling of the scanner.
 Demonstrate correct placement of the scanner onto a plate.
 Locate and describe the components of the scanner.
 Identify maintenance required during and after an inspection.
 Examine key areas of the scanner to check for any damage.
 Establish how to correctly store the scanner when not in use.

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 Scanner Health and Safety
 The scanner is fitted with powerful permanent magnets
and a continuous magnetic field flows around the bridge.
 Keep all body parts clear of magnetic bridge when
moving scanner around the tank.
 Correct safety footwear must be worn when operating
the scanner.

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 Scanner Health and Safety
 Magnetic field can destroy magnetic media such as hotel
room keys, ATM / credit cards, watches, cell phones,
computers etc.
 Any person fitted with a pacemakers must not come
within 3 meters [10 feet] of the scanner. This must be
written into the method statement.
 The scanner is not ATEX intrinsically safe.
 Risk of explosion if a spark occurs.
 Hot Work Permit is required.

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 Transportation and Manual Handling
 The scanner is supplied in a purpose build transit case.
 Scanner is held securely via handles.
 Meets IATA regulations allowing it to be flown by airfreight.
 Storage shelves for systems accessories.
 Keep plate controlling magnetic field.

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 Transportation and Manual Handling
 Handling the Scanner.
 Scanners weight is 60kg (130lbs).
 Be aware of the magnetic field at all times.
 Carry the scanner using the correct carry handles.
 Two handles either side of the chassis:
 Right handle: Drive handle.
 Left handle: Removable handle.
 One handle in front of the battery cover.

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 Transportation and Manual Handling
 Important to use the correct technique for placing and
removing the scanner from a plate.
 Magnetic attractive force increases as scanner approaches plate.
 Do not twist the motor handle ON and allow the drive wheels to
rotate when placing the scanner onto the plate.
 Incorrect technique will cause damage to the scanner.

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 System and Component Overview
 Component Location
Removable Handle
Sitemaster Computer
Drive Handle

Computer Power & Data

Connectors

Battery
Damper

Magnet Bridge Drive Motor

Encoder

STARS Sensor Head MFL Sensor Head

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 System and Component Overview
 Magnetic Bridge
 300mm [12inch] wide mounted on a roller carriage.
 64 sensor channels.
 Neodymium Iron Boron Permanent Magnets.
 No loss of magnetic force.
 Generate a ton pressure on a 6mm [1/4inch] plate.
 Thicker the plate, stronger the magnetic pull.

Front Rollers

Front Magnet

Rear Magnet
Rear Rollers

64 Channels
300mm [12inch]
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 System and Component Overview
 MFL Sensor head
 Located in the centre of the magnetic bridge.
 Detachable MFL sensor head cable.
 Sealed unit but not fully waterproof.
 Spring mounted to minimise damage.
 Sensor height must be correctly set.
 Periodically checked during inspection.
 Sensor head removal required for cleaning.
 Removal after completing every inspection.
 Recalibration required if MFL sensor head.
 Has been removed for cleaning.
 Height has been altered during inspection.
MFL Sensor head

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 System
Scanner Setupand Component Overview
 MFL Sensor head
Old method New method
Adjustable height sensor head Fixed height sensor head
4 brass thumbnuts Red and silver bushes

 Fixed height MFL sensor head reduces any setup errors by the
operator.
 During the systems annual calibration the adjustable height
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MFL sensor head are changed to the Fixed height sensor head.
 System and Component Overview
 STARS Sensor head
 Located underneath rear magnetic pole.
 Integrated STARS sensor head cable.
 Sealed unit but not fully waterproof.
 Sensor head is bolted in place
 Sensor height must be correctly set.
 Periodically checked during inspection.
 Recalibration required if STARS sensor head.
 Position has been altered during inspection.

STARS Sensor head

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 System and Component Overview
 Battery
 12 Volt, 25 Amp hour sealed lead acid gel filled battery.
 Powers the system electronics, motor and Sitemaster.
 13.5 Volts (approx.) – Fully charged battery.
 11.5 Volts (idle) – Battery requires charging.
 Disconnect battery from scanner when not in use.
 System is supplied with 4 batteries,
cycle batteries during use.
 Keep batteries out of direct sunlight.

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 System and Component Overview
 Battery Charger
 Mains input: 100 to 240 AC Volts 50/60Hz.
 Only use the battery charger supplied with the system.
 Charging time of up to 6 hours.
 3 chargers supplied with the system.
 Power switch at rear of charger.
 Red LED – Charger Power
 Orange / Green LED – Charging Status
 Fuse protecting charging circuit (6A 12V)

BLOWN FUSE!
IF the Green LED is lit after connecting a flat
battery check the fuse.
Replace with same rating fuse.

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 System and Component Overview
 Top Panel
 Power Switch
 Switch illuminated BLUE when ON.
 Battery Voltage
 DO NOT operate the scanner below 11.5 Volts idle.

Battery Voltage
Power Switch Indicator

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 System and Component Overview
 Drive Motor
 Speed of 500mm/sec [19.7inch/sec].
 Motor is activated via drive handle.
 If the scanner becomes stuck never
turn the motor on.
 Correctly place the scanner onto
the plate otherwise damage can
occur to the drive motor.
 Always fit the battery and motor
cover during inspection to avoid
damage to drive motor and battery.

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 System and Component Overview
 Sitemaster
 Ruggedized touch-screen computer.
 Microsoft Windows Operating System.
 Data acquisition software.
 Powered by Floormap3Di battery.
 UPS battery allows up to 15 minutes of power after battery disconnected.
 Communication to scanner by USB.
 Data transfer by high speed USB drive.
 Desktop power supply included.

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 System and Component Overview
 Encoder
 Measures distance travelled during a scan.
 Encoder pickup via brass gear attached to the front roller axle.

Encoder

Encoder pickup
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 System and Component Overview
 Damper Strut
 Located at the rear of the scanner.
 Helps overcome the scanners magnetic pull from the floor.
 Allows the drive wheels to be raised and push the scanner.
 Never lift or carry the scanner by it.
 Never put your foot against it.
 Do not damage when passing through the manway of a tank.

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 Maintenance during an Inspection
 Conduct periodic cleaning around the magnetic bridge
during inspection.
 Remove magnetic dust, debris and foreign objects that
are attached to the magnetic bridge.

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 Maintenance during an Inspection
 Remove any magnetic debris around rollers as this can
prevent the scanner from moving.
 Remove any foreign object that become embedded
within the rollers.

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 Post Inspection Cleaning
 After each inspection remove the MFL sensor head in
order to clean any magnetic debris from behind it.

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 Check for scanner damage
 Damage caused to the Motor / Gearbox.
 Loose fixing or a broken gearbox mounting.
 Leaking gearbox
 Cracked motor cap.
 Loose or sticky drive handle.

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 Check for scanner damage
 Damage caused to the Encoder assembly.
 Encoder assembly rubbing front axle.
 Loose grub screw on the encoder gear causing movement.

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 Check for scanner damage
 Damage cause to either the MFL and STARS sensor head.
 Scraping across the bottom of the sensor head.
 Broken sensor head connectors.

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 Check for scanner damage
 Results of a damaged MFL and STARS sensor head.
 In the RAW view the a faulty sensor creates a line on the track.
 During the inspection check the raw views, MFL, MFLi and
STARS, because it is clear to see if any damage has occurred.
 Replace the sensor head immediately as the captured data is
unreliable and the inspection results are compromised.

A dent in the STARS sensor After damage has occurred a faint As the fault becomes worse during
head affects the scanned data grey line appear on each track the inspection the line get white
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 Check for scanner damage
 Damaged caused to the damper strut.
 Leaking or bent strut.
 Snapped damper strut.

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 Check for scanner damage
 Damage caused to the scanners chassis
 Chassis pivot bolts and bushes.
 Any loose, missing or snapped bolts.
 Broken motor or front covers.

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 Check for scanner damage
 Scanner Rollers
 Corrosive product attaching wheels.

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 Recommended Spares
 Motor
 Damper strut
 MFL Sensor head
 STARS Sensor head
 Wired Encoder

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 Packing and storage of the scanner
 Store the scanner in the transit case when not being
used.
 Before storage of the system ensure:
 The system is cleaned and free from debris.
 All the batteries are fully charged.
 Correct storage of the scanner.
 Scanner and components are packed correctly into transit case.
 In a clean, dry and secure location.
 Away from water and harsh environment conditions.
 Store in such a way to avoid damage to the system.
 Within temperature limits of -35⁰C to 75⁰C (-31⁰F to 167⁰F).

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 Packing and storage of the scanner
 Examples of incorrectly packed systems.
 Arrived strapped and taped onto a pallet, no transit case!
 Scanner the wrong way around in the transit case.

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 Practical Session
 Practical Exercises
 Removing the scanner from the transit case.
 Correct manual handling of the scanner.
 Correct technique for placing and removing the scanner from a
plate.
 Battery Charging.
 Removal of the MFL sensor head.
 Packing the scanner back into transit case.

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 Practical Session
 Review of Learning Outcomes
 Establish the operational hazards of the scanner.
 Demonstrate correct manual handling of the scanner.
 Demonstrate correct placement of the scanner onto a plate.
 Locate and describe the components of the scanner.
 Identify maintenance required during and after an inspection.
 Examine key areas of the scanner to check for any damage.
 Establish how to correctly store the scanner when not in use.

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