Visitor No.  5225

*DinSearch is a trade mark of Dinsley Devices Limited 

The DinSearch 500 system measures the thickness of Inconel cladding in the bore of steel tubes.  It combines Dinsley Devices Ltd systems and electromagnetic experience, with Inspection Software's data-acquisition and analysis capability to create a powerful new inspection tool.

Equipment

Fig1.DS500 Pusher-Puller and Control Console

The DINSEARCH 5-00 was developed for use in pipe mills to measure the thickness of Inconel cladding in the bore of pipe.  The photograph to the left shows the pusher-puller and the control consol.  The pipe under test can just be seen at the lower left of pusher-puller cabinet.

• An automated pusher-puller conducts the transducers through 
  14 metre tubes at up to 500mm/sec, with l mm spatial resolution. 

• Dedicated sensors deliver a linear output corresponding to 
  0mm to 10mm of cladding thickness, with precision of 0.1mm. 

•  Results are analysed automatically by the integral computer.

The equipment can be operated in automatic or manual modes.  In automatic mode the computer monitors the status of the machine, then automatically acquires and processes the data.   In manual mode the computer shows a continuous display of the clad thickness under the sensors.

Sensor Carriage

The carriage can be fitted with several sensors.  Typically four sensors are employed to measure the thickness of the cladding in pipes up to 300mm diameter.  For larger pipes up to eight sensors can be can be employed. 

The electromagnetic sensors are configured to optimise their accuracy and stability.   However to guarantee the highest reproducibility, all four sensors are calibrated at the end of every test.

Fig2. Carriage with four sensors.

Inspection

The pipe to be inspected is aligned with a reference pipe which incorporates machined calibration steps.   The carriage is normally parked in this reference pipe between tests.

During tests the sensors are driven to the remote end of the test pipe, then re-wound into the reference pipe.  Data is collected during the rewind phase, including measurements of the calibrations steps.  The system is automatically calibrated at the end of every test. 

Fig3. Inspection Set-up

The photograph above shows a pipe-mill set-up. The sketch below (Fig.4) helps to visualise the arrangement.

The macrograph in Fig 5 below shows the cross-section of an extruded pipe. The outer part of the wall is carbon steel, the inner part is Inconel.

The pipe has been extruded from a steel billet which had been first bored through its centre, then lined with Inconel using a continuous welding technique.

 The Inconel was metallurgically bonded to the billet during welding, and remains bonded after extrusion.

Fig 5. Internal Inconel Cladding

Fig4. Test Pipe and Reference Pipe alignment

Analysis

The DS500 computer continually monitors the status of the machine and reacts accordingly.  

In Manual mode the computer acquires data from the four sensors and displays real-time active bar-charts of the local cladding thickness. 

In Automatic mode, the machine first pushes the carriage to the remote end of the test pipe, then re-winds it back into the reference pipe.  The computer continually monitors the status of the machine, and acquires data during the entire re-wind phase, including measurements of the calibration steps in the reference pipe.

Within moments of completion the computer processes the data and draws the charts.  QA logs of the processes are also created. 

Fig6. DS500 screen - note the similarity to Fig 4 above

Specifications
This is a guide to features and capabilities of the DS500 system, which may change without notice.
Dinsley Devices Ltd. would be pleased to discuss variations or other applications for this product.

0 to 10mm. 
Inconel on Steel, or similar materials

 0.1mm

±0.1mm  
Depending on the condition of the bore of the pipe, particularly loose debris)

125mm to 300mm bore

Up to 14 metres

0.5 metres per second

Typically 10 pipes per hour with manual pipe handling.
Actual inspection rate depends on the clients material handling facilities.

A.C. mains, 50/60Hz, 500VA, 110V and 240V, single phase.  
Other voltages by arrangement.

Main cabinet:- 2.5m x 0.7m x 1.5m high

Computer cabinet:- 0.7 x 0.7 x 1.2m high

Main cabinet and computer:- 250kg

Dinsley Devices Limited,
Ivy House, Streatlam Park,
County Durham, DL12 8TZ, UK.
Phone/Fax:  +44 (0)1833 637971
email: dinsearch@hotmail.com

Inspection Software Limited

3 Brynau Drive, Mayals, 
Swansea, SA3 5EE, UK
Phone +44 (0) 1792 404235
email: doug.breeze@inspection.co.uk