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PALM Flat Operating Instructions

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PALM Flat Operating Instructions

PALM Flat Operating Instructions

page ii © 2014 ALSTOM Inspection Robotics Ltd

Legal Note This document may not be copied, redistributed or republished for any reason whatsoever, without the written permission of ALSTOM Inspection Robotics Ltd.

PALM Flat Operating Instructions

page iii © 2014 ALSTOM Inspection Robotics Ltd

Document Information

File name P1119_Manual PALM_V1.1 - GE Version 1.2 Date 2015-01-05

Manufacturer

ALSTOM Inspection Robotics Ltd Technoparkstrasse 1 8005 Zürich Switzerland

phone +41 44 275 25 75 fax +41 44 275 25 70

[email protected] www.inspection-robotics.com

Change History

Date Edition Authors Modifications Pages 17.09.2014 V1.0 DRU Create all 05.01.2015 V1.1 WZE Updated to new scanner version all 30.04.2015 V1.2 VKL Implement encoder exchange description all

PALM Flat Operating Instructions

page 1 © 2014 ALSTOM Inspection Robotics Ltd

Contents

1 Safety ....................................................................................................................................... 2

2 General ................................................................................................................................ 3

3 Technical Data ...................................................................................................................... 4 3.1 Data .................................................................................................................................. 4

4 Scope of supply .................................................................................................................... 6 4.1 Transport and Packing ........................................................................................................ 6 4.2 Scope of delivery ................................................................................................................ 7

5 System Description ............................................................................................................... 8 5.1 Intended Use ...................................................................................................................... 8 5.2 System Features................................................................................................................. 8 5.3 System Components ........................................................................................................... 8

6 Operation ........................................................................................................................... 10 6.1 Overview ......................................................................................................................... 10 6.2 Preparing the Test Specimen ............................................................................................ 10 6.3 Preparing the Scanner ...................................................................................................... 10 6.4 Preparing wedge and probe .............................................................................................. 10 6.5 Mounting and AligningProbe and Wedge .......................................................................... 11 6.7 Using the Brake ................................................................................................................ 13 6.8 System Connection ........................................................................................................... 11 6.9 Functional Test ................................................................................................................ 11 6.10 Placement of the PALM Flat and Scanning ....................................................................... 11 6.11 Removal from Specimen and Packaing ............................................................................. 11

7 Maintenance ...................................................................................................................... 12 7.1 Cleaning .......................................................................................................................... 12 7.2 Batteries .......................................................................................................................... 12 7.3 Inspection Interval ........................................................................................................... 12 7.4 Exchanging the Encoder .................................................................................................. 12

8 Disposal ............................................................................................................................. 14

9 Technical Support ............................................................................................................... 15 9.1 Customer Support Centers ............................................................................................... 15 9.2 Fault Rectification ............................................................................................................ 16 9.3 Replacement Part ............................................................................................................ 16

PALM Flat Operating Instructions

page 2 © 2014 ALSTOM Inspection Robotics Ltd

1 Safety

The design of the PALM Flat is intrinsically safe. Its characteristic features are as follows:

1) The PALM Flat does not contain any actors or other force generating elements that could harm the operator

2) The PALM Flat is operated with voltages smaller than 48V. For the probes please refer to the corresponding instructions.

3) In the event of faults the PALM Flat can be removed from the support by hand.

These operating instructions are intended for operators of the PALM Flat. Certain items are not described in detail in these operating instructions. It is assumed that the operators of the PALM Flat are qualified professionals possessing well-founded technical knowledge and experience.

These instructions cover the operation of the PALM Flat. Items such as UT probes, UT device and couplant supply are not covered by these operating instructions. Refer to the specific instruction for those elements.

Risk of Injury: The PALM Flat (w/ optional alignment laser) contains a class 2 laser Never look directly into the laser! Switch off the laser when not in use

PALM Flat Operating Instructions

page 3 © 2014 ALSTOM Inspection Robotics Ltd

2 General

The main task of the PALM Flat is the scanning of tubes, vessels, plates. It is specifically suited to inspect tube to tube welds (TTW) or tube to header welds (THW) of OD 90mm or larger. For this task the PALM Flat carries a phased array (PA) ultrasonic (UT) probe and guides it around the tube on a circumferential path. The scanning process is performed manually.

The PALM Flat is configured for use in work-shops as well as on site in facilities such as power plants, or refineries. It is characterized by the following features:

1) The PALM Flat can be transported, connected, operated and removed by one person.

2) The PALM Flat is designed to leave behind no damage to the object under test, providing it is correctly operated.

3) The PALM Flat is designed to inspect minimum from OD of 90mm to flat surfaces. For pipes and tubes with an OD below 90mm please use the PALM Circ Scanner family.

PALM Flat Operating Instructions

page 4 © 2014 ALSTOM Inspection Robotics Ltd

3 Technical Data

3.1 Data

General

Dimensions (L x W x H) 98 x 85 x 29 mm3 (w/o laser)

Weight 680g (w/o laser and probe)

Protection rating IP67

Storage Temperature -20 … +70°C

Operation Temperature -5 … 50°C (couplant!) Performance

position feedback A/B encoder signal, 4.07 cts/mm

handling magnetic wheels manual brake adjustable probe position

diameter range (sample)

90mm OD … flat … 50mm ID

laser guidance line projection on sample

<1mW, red adjustable position and orientation battery driven w/ switch

NDT

wedges size max 40 x 70mm footprint width23 … 40mm further width upon request

interface 2 gimbal pins D = 2mm, length 3mm

PALM Flat Operating Instructions

page 5 © 2014 ALSTOM Inspection Robotics Ltd

3.2 Principle Dimensions

PALM Flat Operating Instructions

page 6 © 2014 ALSTOM Inspection Robotics Ltd

3.3 Encoder pin assignment

Encoder resolution: 1024 counts per turn pin assignment for I/O Connector (LEMO ECG.2B.314.CLV)

4 Scope of supply

4.1 Transport and Packing

Dimensions

− External 360 x 304 x 194 mm − Internal 330 x 234 x 102 mm

Weight

− empty 2.51 kg

− full 3.45 kg

PALM Flat Operating Instructions

page 7 © 2014 ALSTOM Inspection Robotics Ltd

4.2 Scope of delivery

The complete scope of supply comprises the following objects:

Item. Designation Quantity 1 PALM Flat 1 2 Probe fork 23 to 30mm 1 *) 3 Probe fork 40mm 1 *) 4 Alignment laser (w/ batteries) 1 **) 5 Tool set 1 6 Spare part set: screws, gimbal pins 1

*) second probe fork optional, depends on order

**) optional

PALM Flat Operating Instructions

page 8 © 2014 ALSTOM Inspection Robotics Ltd

5 System Description

5.1 Intended Use

The PALM Flat is a manually operated scanner intended to perform UT (ultrasound) inspection in magnetic specimen.

Other sensors – such as eddy current probes – can be mounted as well.

5.2 System Features

Arbitrary sensor/probes up to a footprint size of W = 40mm x L = 70mm can be mounted in the different probe forks The sensors can adjust to the surface to be inspected by integrated spring loading and 2-axis gimballing joints

The scanner attaches itself to the specimen surface by magnetic wheels. In case of non-magnetic surfaces the PALM Flat has to be pressed to the surface by the operator. An integrated manual brake stops the PALM Flat automatically at its current position as soon as the brake is released.

The integrated encoder provides positions feedback the NDT device (UT, EC, …) in order to allow for position triggered inspection (B-scan, C-scan)

5.3 System Components

Probe with wedge (dummy, NOT scope of delivery)

probe fork

chassis

Alignment laser (optional)

PALM Flat Operating Instructions

page 9 © 2014 ALSTOM Inspection Robotics Ltd

Brake lever

Cable holder / Guidance

Braking wheel (magnetic)

Encoder unit w/ encoder wheel

Alignment laser (optional)

Non-magnetic Wheel

Passive wheel (magnetic)

The low profile palm scanner has 4 wheels, 3 of them magnetic. The wheel opposite to the encoder wheel is non-magnetic by design in order to guarantee continuous contact of the encoder wheel on uneven surface or in case of special placements, i.e. when not all 4 wheels can touch the sample surface due to the geometrical constraints (bumpy surface, weld crossing, scan direction not aligned w/ curvature).

PALM Flat Operating Instructions

page 10 © 2014 ALSTOM Inspection Robotics Ltd

6 Operation

6.1 Overview

The main task of the PALM Flat is the scanning of tubes, vessels, plates. It is specifically suited to inspect tube to tube welds (TTW) or tube to header welds (THW) of OD 90mm or larger. For this task the PALM Flat carries a phased array (PA) ultrasonic (UT) probe and guides it around the tube on a circumferential path. The scanning process is performed manually.

The PALM Flat is configured for use in work-shops as well as on site in facilities such as power plants, or refineries. It is characterized by the following features:

4) The PALM Flat can be transported, connected, operated and removed by one person.

5) The PALM Flat is designed to leave behind no damage to the object under test, providing it is correctly operated.

The procedure below describes UT inspection. However, for other sensors/technologies, similar procedure applies.

6.2 Preparing the Test Specimen

It is highly recommended to clean scan path prior the inspection. Furthermore a visual check for damages should be performed.

6.3 Preparing the Scanner

1) Unpack scanner from the safety case and unroll the cable

2) Check the scanner and cables for damage, do not use when damaged.

3) Check the wheels (4) for easy rotation and that the rolling surfaces are clean (magnetic particles !)

4) Check the correct function of the brake

5) Check the function of thee laser

6.4 Preparing wedge and probe

Select the correct probe and wedge for your application (contact curvature, beam angel, probe type, frequency). Refer to the probe instruction on how to mount the probe on the wedge.

As an interface to the probe fork, the wedge needs to have 2 gimbal pin holes as shown in the drawing below

Risk of damage: Unroll the cable WITHOUT twisting it.

PALM Flat Operating Instructions

page 11 © 2014 ALSTOM Inspection Robotics Ltd

6.5 Mounting and AligningProbe and Wedge

1) Select the correct probe fork for your wedge (3 different widths available)

− wedge width 40mm:

− wedge width 30mm:

− wedge width 30mm mount spacer parts

2) insert wedge between probe fork lever

Fix Probe with Screw. Apply equal force on both sides. There should be a small gap between the wedge and probe fork lever on both sides to allow for free movement of the probe.

probe & wedge

probe fork lever

PALM Flat Operating Instructions

page 12 © 2014 ALSTOM Inspection Robotics Ltd

3) fix probe cable and couplant tube and mount the cable clamp

4) Adjust the probe position

− untighten fixation screws

− move probe fork to desired position and align probe frame according to the inspection procedure, refer to the ruler engraved on the chassis

− tighten both fixation screws

Important: In order to align the probe fork well with the chassis, i.e. with the scanning direction, press probe frame to one side while tightening the screws (red arrows)

6.6 Mounting the Alignment Laser (if applicable)

1) insert alignment laser into slot in chassis

2) Adjust position according to your inspection needs, refer to ruler engraved in chassis

3) fix attachment screws firmly

4) switch on and off the laser at the button at the back of the laser to check the correct function and alignment

PALM Flat Operating Instructions

page 13 © 2014 ALSTOM Inspection Robotics Ltd

5) if needed, rotate to laser in its holder to position the laser line at the optimum orientation.

Therefor the fixation screw has to be released slightly Retighten the fixation screw after orienting the laser

6.7 Using the Brake

The brake is engaged in default condition. It block one wheel

The brake is released be pressing the break lever

Do NOT move the scanner (on magnetic surfaces) when the brake is NOT released

Risk of damage: Never open the screws that fix the mirror to the laser

PALM Flat Operating Instructions

page 11 © 2014 ALSTOM Inspection Robotics Ltd

6.8 System Connection

1) connect the probe to the UT controller

2) connect the tubes to the couplant supply unit

3) Connect the PALM Flat to the UT controller (encoder connection) and switch on controller

6.9 Functional Test

On completion of the connection the complete system should undergo a function test.

1) Check the direction of motion and compare the distance travelled with the distance displayed.

2) Switch on couplant supply and check if couplant escapes from the contact surface of the wedge

3) Calibrate probe & controller according to separate calibration procedure.

6.10 Placement of the PALM Flat and Scanning

1) Place the PALM Flat carefully at the surface to inspected (strong magnets !)

2) Ensure that the encoder wheel is always in contact with the surface by pressing it down at placement. Otherwise the encoder might not measure the position correctly

3) Align the PALM Flat with the scan direction and position

4) Perform your scan according the procedur. Do NOT forget to release the brake.

6.11 Removal from Specimen and Packaing

1) Switch of the alignment laser when the PALM Flat is still on the specimen

2) Remove the scanner manually the specimen (strong magnets !)

3) unmount wedge/probe

4) After operation clean the PALM Flat according to section 6.1. Coil up the cable carefully and store the scanner in the safety case

Danger of damage: Do NOT twist the cables when coiling up.

PALM Flat Operating Instructions

page 12 © 2014 ALSTOM Inspection Robotics Ltd

7 Maintenance

7.1 Cleaning

The PALM Flat should be cleaned after each operation with couplant.

7.2 Batteries

The laser is equipped w/ a battery (type 357). To exchange the battery, unmount the laser from its holder and open it by unscrewing the 2 parts of its housing.

7.3 Inspection Interval

It is recommended for the PALM Flat to be inspected by the manufacturer after 200 hours of operation or 12 months, whichever is the sooner.

7.4 Exchanging the Encoder

The PALM Flat Encoder cable consists of 2 parts. One part is fixed to the housing, this does not need maintenance. The second part is the cable; it is available as spare part and can be exchanged by the operator. Please follow these steps:

Risk of destruction: The cleaning should be done with smoothly running water and a soft brush only. Do NOT clean not with direct compressed air – or water pressure acting on to the encoder unit or any bearing.

PALM Flat Operating Instructions

page 13 © 2014 ALSTOM Inspection Robotics Ltd

1) Unmount the screws that hold the encoder

bracket on the bottom of the PALM Flat.

2) Remove the encoder

3) Remove the encoder cable by loosening the

screw. Replace with spare encoder cable and refix the screw.

4) Place the encoder back into its tray and fix the bracket.

PALM Flat Operating Instructions

page 14 © 2014 ALSTOM Inspection Robotics Ltd

8 Disposal The PALM Flat contains metal, electronic, cables, plastic, oils and other materiel. Dispose it according to local law and procedures.

The batteries of the laser have to be removed and disposed separately

The PALM Flat can be returned to the manufacturer. For the exact procedure, contact our support service, E-Mail: [email protected].

PALM Flat Operating Instructions

page 15 © 2014 ALSTOM Inspection Robotics Ltd

9 Technical Support

9.1 Customer Support Centers

GE Sensing & Inspection Technologies GmbH Service-Center Robert-Bosch-Strasse 3 50354 Hürth Germany or: Postfach 1363 50330 Hürth Germany T +49 (0) 22 33 601 111 F +4910) 22 33 601 402 France GE Measurement & Control France SAS 68 Chemindes Ormeoux 69578 Limonest Cedex Fronce T +33 (0) 472 179 220 F +33 10) 472 179 237 Great Britain GE Inspection Technologies ltd. Building 4 Leicester Road Rugby, CV211BD T +44 OJ 845 6015771 USA GE Inspection Technologies.LP Industrial Pork Road Lewistown, PA 17044 USA T +1717 242 03 27 F +1717 242 26 06 E-mail: [email protected]

PALM Flat Operating Instructions

page 16 © 2014 ALSTOM Inspection Robotics Ltd

9.2 Fault Rectification

For fault rectification or technical support, contact the manufacturer’s support service:

[email protected]

ALSTOM Inspection Robotics Ltd

Technoparkstrasse 1

8005 Zürich, Switzerland

www.inspection–robotics.com

9.3 Replacement Part

If replacement parts are required, these can be ordered directly from the manufacturer, using the article numbers listed in the annex.

To provide a speedy service we require the following information:

1) Contact person and access data (telephone. E-Mail etc.)

2) Delivery address

3) Invoicing address

4) Exact designation of the replacement part (see drawings/parts list)

5) Article number (see drawings/parts list)

6) Quantity

You can E-Mail your order to [email protected].