Magnetic Flux Leakage (MFL) Inspection Limitations

API 2006 Storage Tank Conference

Presentation

Morris Kline
General Manager of Domestic Sales
HMT Inc.

All Limitations

Technology
Human (Training and experience)
Physical

Don
t Discard the Technology and go backwards

MFL is the
Best
method to
evaluate a
tank bottom
condition
quickly and
cost effectively

Information on Technology Limitations

A lot of information has been available and presented on

technology limitations. Some of the information is not
common to all brands and types of scanners, so it is not
without some controversy.
API has been trying to quantify these technology limitations
through a task group performing the re-write of nonmandatory Appendix G in API Standard 653 which call for
operator qualification testing and certification. This effort is
on-going but will not happen soon.
This presentation will identify most of the physical limitations
and offer solutions to overcome those physical limitations

Let
s Talk about the Physical Limitations

Tank Bottom inspection preparation

Bottom Plate Lap Welds seams
Bottom Plate Shapes and Sizes (sketch plates)
Shell (corner weld) radius
Patch Plates
Tank Bottom Obstructions (columns / re-pads, internal
piping, etc.)
Edge Settlement
Uneven Bottom Plates peaks and valleys
Thick Reinforced Coating
Thick Annular Plates

Edge effectof Magnetic field extends the non-scanned

areas
Magnet and Sensor location

Typical Full Sized MFL Scanner

Front to base
sensor = 10

Bridge Width = 12
Overall scanner width = 14

Overall
Length = 36

Bottom Plate Lap Weld Seams

Limitation Zone

Sketch Plate Example

Another Sketch Plate Example

Typical Patch Plate

Patch Plate near lap seam - hole

Typical Column with repad

Floating Roof Leg Striker Pad

Tank Bottom Obstructions

Potential Multiple Patch Plates

Corner Weld No Scan Zone

Manual/Mini Scanner Solution

Overall Scanner
length = 9
Front to back of
sensor bar = 6
Hand scanner width = 6

Scanner width = 6

Manual/Mini Scanner for Near Corner Weld

Solutions/Options

Following an informed
risk assessmentwhat are your
best options:
Do Nothing!!
Extensive Visual Exam (should already be standard)
Vacuum Box Testing (leak detection only)
ACFM Crack Detection / Magnet Particle Examination
(surface breaking crack-like indications only)
Helium Testing (leak detection only)
Manual Ultrasonic Scrubs (corrosion locator)
Hand/ Mini MFL Scanner (corrosion locator)

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Vacuum Box Testing

ACFM Crack Detection Equipment

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Helium Testing - Equipment

Helium Testing Weld Seam Scanning

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In Summary

Be aware of Limitations
Make an informed risk assessment
Revise or develop a work scope for your inspection vendor
that addresses either:
All tanks
or
Specific to particular tanks based upon tank
characteristics, risk analysis or tank condition

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