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Table of Contents
Introduction…………………………………...……………………5
Welcome…………………………….………..……………….6
Scope………………………………...………………………..6
Principle of Operation…………………...……………………6
Specifications…………………………………………...………….7
Table of Contents
Maintenance………..…………………...…………………...……37
Filling the Wheel……………………………………………...41
Troubleshooting…..……..………………………...……………...43
Contact Information……………………………………………....69
Introduction
(Fig 1-1)
Scope: the purpose of this setup procedure is to provide the TechSonic EZ III™ operator with a basic
understanding of the equipment and its capabilities. The information contained in this manual is only a
guide to performing inspection. The example procedures contained in this manual are NOT intended to be
followed verbatim or to be construed as the correct way an inspection operation is to be performed. As
with any inspection operation, it is the responsibility of the inspection company to develop, and implement
seervice and eqipment operating procedures (including safety procedures), and to establish acceptance
criteria for the product being inspected.
Capacity:
Standard API Drill Pipe up to 6 5/8in (168.275mm)
Detected Defects:
1) 3-Dimensional transverse flaws
2) Wall thickness variations (optional)
Electronics Console:
Dimensions: 22in. H x 20in. W x 20in L (56cm. H x 51cm. W x 51cm. L)
Weight: 90 lbs. / 41KG
Power: 110 volts ac 60 hz, 1 phase (Step-Down transformers are available)
Scanning Head:
Dimensions : 11in. H x 6in. W x 24 in. L(28 cm. H x 15 cm. W x 61 cm. L)
Est. weigh: 24 lbs. (11 kg.)
Rotator Modules:
Dimensions (each): 16 in. H x 16 in. W x 22 in L (41 cm. H x 41 cm. W x 56 cm. L)
Fits std. pipe rack size: 3 1/2 in to 6 5/8 in. (89 mm. to 168 mm.)
Weight (each): 130 lbs. (58 kg.)
Rotate Speed: up to 150 rpm
CAUTION!
110V AC ONLY
Safety Instructions:
CAUTION!
Please read the following Safety Instructions BEFORE Starting Up Operating Equipment
Inspection equipment is designed to inspect Oil Country Tubular Goods (OCTG). Accomplishment
of this function requires a combination of high electrical and mechanical power inputs, high speeds,
heavy and numerous moving components including the OCTG itself. Failure to observe certain
basic safety rules or incorrect usage of the equipment may result in a injury to the operator or by-
standers.
Although every effort has been made to design and construct safe, dependable equipment, it is im-
possible to foresee all circumstances under which the equipment may be utilized or to anticipate all
possible combinations of factors which may trigger an accident. It is therefore imperative that the
equipment operator, as well as all others engaged in any phase of set-up or maintenance of the unit
consider Safety-First an important part of the job.
The following general safety considerations are offered as an aid to users of this inspection equip-
ment to assist them in becoming safety oriented:
1) READ all operations / maintenance manuals before attempting to lift, move, operate or perform
maintenance on any piece of equipment! Become intimately familiar with all equipment controls, their
locations, their operation, and their effect on equipment functions. Keep the operator’s instruction
book in a clean location immediately adjacent to the equipment for quick reference. Educate all em-
ployees to the correct operation and possible safety hazards associated with this type of equipment.
Have all employees read all manuals.
2) BEFORE ATTEMPTING TO START THE EQUIPMENT, inspect all areas around and adja-
cent to movable parts for possible obstructions: tools, rags, crating remnants, etc!
3) PRACTICE GOOD HOUSEKEEPING: Maintain the area adjacent to-NOT ON-the equipment
for tool and or accessory storage. Remove all oil spills and potential trip points from the operating
areas around the equipment to prevent slipping or falling into the working zone.
4) AVOID WEARING LOOSE CLOTHING, LONG HAIR, NECKTIES, Etc. when operating
equipment as these can easily become entangled in moving parts. It is highly recommended that
safety glasses be worn at all times. Safety shoes are recommended.
6) THE OPERATOR MUST REMAIN ALERT for pinch points created by moving parts and must
be prepared to stop the equipment at any time in the event of unsafe conditions arise.
7) WHEN CHANGING SET-UP or performing maintenance work, cleaning equipment, etc., it is
recommended that main power supply or supplies (electrical, air, hydraulic, etc. ) be shut off to
avoid accidental operation and possible resultant injury. This is particularly important in the event
more than one person is involved in such duties.
NOTICE
Machines manufactured by New Tech Systems, Inc. over the years have continuously been upgraded and
refined. This process may affect the accuracy of New Tech Systems’ Parts Catalogues and/or Service /
Operator Manuals furnished with your equipment or procured later.
All New Tech Systems Parts Catalogues and Service/Operator Manuals should be treated as “generic” doc-
uments. They may, or may not match your unit exactly. While every effort has been made to provide you
with the most current and accurate information possible, omission or incorrect information about your unit
may be present in the Technical Publications supplied with your unit. This is particularly true with Plant
Units as most are custom-built units. Some group, i.e.: Conveyor Systems, vary so greatly between differ-
ent units that the customer may have to order replacement parts by description. Photographs supplied with
your order can help prevent unnecessary delays.
When ordering parts, please give the unit serial number and date of manufacture. This information is locat-
ed on a Serial Number Plate. This will make it easier to get the correct parts for your unit.
If you require additional information regarding your unit or its supporting documents, contact the NEW
TECH SYSTEMS’ Customer Service Department.
(Fig 2-1)
(Fig 2-2)
UT Scanning Head( both version shown with cable)
The UT scanning head contains the ultra sonic transducer, UTEA
wheel (filled with water to provide a path for the soundwaves to travle)
and the connections necessary to connect the scanning head to the
electronic console.
(Fig 2-3)
Calibration Standard
The calibration standard is used to setup your flaw scope. The OD notch
standard has an OD notch and ID notch cut about 3" from the end. These
notches are use to set your OD and ID indications on your scope.
ID notch
(Fig 2-5)
(Fig 2-4)
Zero Standard
The zero standard is used to set the course setting for incident angle
of your transducer in the wheel. The standard has a through hole so you can
use it to setup the incident angle on for the ID and OD indication to get the
highest reading on the scope. Once you have this set then move to your
calibration standard and use it to fine tune your incident angle.
Through Hole
(Fig 2-7)
(Fig 2-6)
(Fig 2-9)
Tighten nut
(Fig 2-12)
Place ramps on rotators and rack making sure that the ramp is securely resting on both.
(Fig 2-13)
(Fig 2-14)
Use the angle adjustment knob to make any fine adjustments needed for the incident angle to
achieve the best ID and OD indication
FLAW SCOPE
Connect all cables
Turn on the unit and the Flaw Scope
use appropriate standard to setup flaw scope
set the Velocity for the material that you are testing.
Adjustment knob
Adjust
Velocity display
(Fig 2-15)
Range display
Range button
(Fig 2-16)
Setup
Set the Delay (press 2nd F then Range buttons)
Run Standard and adjust the Gain
Gain display
Gain button
(Fig 2-17)
Set Gates
Gate display
Gate button
(Fig 2-18)
The Flaw Scope provides navigation arrows, [CHECK] and [ESCAPE] keys, and an adjustment
knob. They are general purpose keys, regardless of instrument mode or function. The [CHECK] and
[ESCAPE] keys are available on both left and right side of the front panel.
(Fig 2-19)
(Fig 2-20)
The [CHECK] key has three primary functions:
1. When a submenu is highlighted, [CHECK] enters this submenu and brings the highlighted focus
to the first parameter within the submenu.
2. When an adjustable parameter is highlighted, [CHECK] toggles the parameter adjustment be-
tween a coarse and fine adjustment.
- Coarse adjustment is active when the parameter title is underlined.
- Fine adjustment is active when the parameter title is not underlined.
3. When a function parameter button is highlighted, [CHECK] activates that functions (example
CAL Zero).
(Fig 2-21)
(Fig 2-22)
(Fig 2-23)
(Fig 2-24)
(Fig 2-25)
(Fig 2-26)
(Fig 2-27)
(Fig 2-28)
This section describes how to calibrate the flaw scope in conventional ultrasound mode.
Calibration is the process of adjusting the unit so that it measures accurately on a partic-
ular material, using a particular transducer at a particular temperature.
You must adjust the zero offset and velocity parameters of the flaw scope during the calibration. Ze-
ro offset (sometimes referred to as probe delay) compensates for the dead time between the firing of
the main bang and the entry of the sound into the test piece. The unit must be programmed with the
correct velocity setting so that it matches the material velocity of the test piece.
1. Press [GAIN] to select an initial gain value that is appropriate for the calibration. If the appro-
priate gain level is unknown, set the initial gain at 20 dB and adjust it as necessary during cali-
bration to obtain the desired height.
2. Choose 1/5>Basic>Velocity, and then enter the velocity for the test material.
3. Choose 1/5> Basic> Zero, and then adjust the zero offset of the instrument to 0.000µs.
4. Choose 1/5> Basic> Range, and set the range so that you can see the second O.D. indication
on the right side of the screen.
Use more range than necessary to ensure all calibration echoes appear on the
screen and to allow for the internal upset.
5. Choose 1/5> Basic> Delay, and then set the screen delay so the interface indication is on the
left side of the screen.
Adjust interface indication to left side of screen Interface indication to left side of screen
(Fig 3-3)
ZOOM
Use to zoom the display on the width of the gate.
START
Used to adjust the gate start position.
WIDTH
Used to adjust the gate width.
LEVEL
Used to adjust the vertical position of the gate.
ALARM
Used to select a gate alarm condition.
7. Use the [Right] or [Left] arrow keys to scroll between gate start, width, and level of the selected
gate.
8. Edit the value of the selected gate parameter.
9. Choose 2/5>Gate2> Status= On to activate gate 2.
(Fig 3-4)
You can now set one gate for an ID indication and the other gate for an OD indication
10. Interface Gate-This interface gate is principally used in immersion application where the water
path distance between the front surface of the test material and the transducer face is continuous-
ly changing. The interface gate is also commonly used in captive water application (UTEA Scan-
ning Wheel). The interface gate option tracks the position of the reflection from the interface of
the water path and the test piece and compensates for the variance in this reflector’s position.
(Fig 3-5)
Edge
Acquires measurements readings on the position of the first crossing point of a gated signal.
The indication must break the threshold of the gate for a measurement to be made.
Peak
Acquires measurement reading based on the position of the highest peak within the gated
screen range. The indication does not have to break the gate threshold for a measurement to be ac-
quired.
1st Peak
Acquires measurement reading based on the position of the first peak to break
threshold of the gate within the gated region.
When a measurement is being made using one of the measurement gates, a small
triangle appears on the gate to indicate from which echo/point the measurement is
Being acquired.
(Fig 3-7)
Gate RF Setup
In unrectified (RF) mode, used to choose the polarity of the gate. Options include:
Dual Gate
The gate appears in the positive and negative side of the X-axis.
Position and width are identical, and the gate level mirror across the
X-axis (example 25% and -25%).
Positive
The gate appears only on the positive side of the x-axis.
Negative
The gate appears only on the negative side of the-axis.
Highest Peak
Acquires the amplitude measurement of the gated indication from the highest
Peak within the gated region.
1stPeak
Acquires the amplitude measurement of the gated indication from the first peak
within the gated region. The peak must break the threshold of the gate to be measured.
NOTE
The wall scope does not acquire measurement readings unless the indication of
Interest is within a gated region of the screen. You should be careful to adjust the
Start, Width, and Level of a measurement gate so only the indication of interest
Falls within the gated region, per the measurement definition above.
The gate tracking feature of the scope allows you to make echo-to-echo measurements whenever this
feature is required by an application. Echo-to-echo measurement can be made between: Gate 2 - Gate
1, Gate 2– IF Gate, and Gate 1-IF Gate.
Gate tracking maintains a constant separation between the two gates involved in an echo-to-echo
measurement. This prevents fluctuation from the first gated indication to cause an incorrect or lost
measurement due to improper positioning of the second measurement gate.
When gate tracking is active, the start position value of the tracking gate (the second gate involved in
the measurement) defines the separation between the gates, not a fixed start position
.
Gates 1 & 2 sample setup:
Gate * measurement mode Edge
Gate * RF setup Positive
Gate * % Amp measurement Highest Pea
Gate * Floating ON
1. Position the standard so the wall loss is in a position where you can slide the scanner across it.
2. Wet the standard and place the scanner firmly on the standard. Make sure the scanner is not
placed on the wall loss at this point.
3. Choose 1/5>Basic>Velocity, and then enter the velocity for the test material
4. Choose 1/5> Basic> Zero, and then adjust the zero offset .
5. Choose 1/5> Basic> Range, and set the range so that you can see the second O.D. indication on
the right side of the screen.
6. Choose 1/5> Basic> Delay, and then set the screen delay so the interface indication is on the
left side of the screen.
7. Make sure 1/5 Receiver(F3)>Filter Group(P1)= AxleInspFR
8. Select 2/5> Gate1> Status= On, to active gate 1.
9. Use the [Right] or [Left] arrow keys to scroll between gate start, width, and level of the select-
ed gate.
10. Choose 2/5>Gate2> Status= On to activate gate 2.
11. Select 2/5> IF Gate> status= ON, to activate the IF Gate. The Wall Scope gate 1 and gate 2
provide measurements of a gated indication based on one of three possible measurements mode.
You can define the measurement mode of each gate in the Gates setup page.
12. Select 2/5 >Gate Setup(F4)> Setup (P1).
(Fig 3-6)
Used to adjust
the speed of the
rotators
Displays the
signal from the
scanner
Used to control
the direction of
the rotators
When a signal breaks
the gate it is recorded
on this chart Used to turn on
and off the
printer
Used to adjust
the speed of the
printer
(Fig 3-8)
Interface connection
for the optional wall
thickness monitor
Main breaker
push button Main power
Switches from
scanning unit switch
Computer
interface controls to main
Signal input for scan- unit controls
ner 1 and 2
(Fig 3-9)
Signal cable
Remote cable
(Fig 3-10)
(Fig 3-11)
To set the angle of the wheel, loosen the knobs on top of the frame.
Turn the wheel frame to desired angle ( the smaller the angle the slower the travel and the more
coverage, the grater the angle the faster the travel and the less coverage) and tighten the knobs
(Fig 3-14)
It is recommended that the “helical advancement” be adjusted so that the reference notch is
detected on at least 2 consecutive revolutions.
Maintenance
1. Assure that the transducer (#2 Fig 4-4 page 40) is firmly mounted and the cable connector is sealed
with a non-electrical conductive-type silicone sealer (waterproof). Run the cable through the wheel
shaft (#8 Fig 4-4 page 40) and fill the hole in the shaft with silicone. Metal cased transducers must
be isolated from the mounting bracket.
2. Assure that the angle adjustment mechanism moves freely (#9 Fig 4-4 page 40).
3. Wash the entire wheel (#1 Fig 4-4 page 40) assembly (including the internal components and inside
the tire) with distilled water. Rinse thoroughly with clean water. Assure that all hardware is
Secure
.
4. Carefully slide the tire into position on the flanges (# 4 and 5 Fig 4-4 page 40) and tighten
down one retaining flange (#3 Fig 4-4 page 40) . Rotate around the flange, tightening each screw a
little at a time until the screws are tight. Turn the wheel assembly over and repeat on the other flange
(make sure the cable does not get pinched or trapped).
5. Turn the end with the cable down and secure the wheel assembly.
6. Fill the tire with couplant solution via the valves located on the angle adjustment side
of the tire. Locate the valve (#7 Fig 4-4 page 40) that does not have a secondary outlet through the
end of the flange (visible through the tire membrane) and fill with solution. Bleed air through the
other valve. (#6 Fig 4-4 page 40)
COUPLANT: Ethylene glycol (cold climates only) and /or distilled water.
mix 1 part glycol to 6 parts water in a container. Pour mixture through a filter (coffee
filter works well) into a clean container before introducing solution into the wheel assembly.
7. Fill the wheel ( see instructions page 41) with couplant until the tire is firm and free of air bubbles
(approximately 5 to 15 psi - .34 to 1.03 bar).
8. Place the wheel into the frame and snug the yoke clamps (do not tighten yoke clamps at this time
just snug enough to keep the wheel from moving freely ) ( Fig 4-3 page 40)
9. Connect the cables to the UT Scanning Head and turn on the electronic console. (Do not connect
or disconnect the UT scanning head while the electronics are “ON "as damage to the electronic
logic circuitry could result)
8. Place scanner on the ZERO standard, and apply couplant to the standard. With the leading
edge of the wheel approximately flush with the end of the standard. Rotate the wheel shaft
until the edge of the standard is detected on the scope (reduce UT gain to obtain the highest
peak signal). Slide the scanner backwards until the drill hole (Fig 4-2) is detected on the scope.
Rotate the shaft to obtain the highest peak signal on the scope. Tighten the yoke clamps
(Fig 4-1)
(Fig 4-2)
Tire
Yoke Clamp
Yoke Clamp
Transducer
Retaining Flange
ADJUST PERPENDICULAR TO
Flange LONGITUDINAL AXIS OF THE
STANDARD
“X”
ZERO STANDARD (REST STANDARD ON FIRM SURFACE)
(Fig 4-3)
(Fig 4-4)
Stand the scanner up on it’s end with the angle adjustment knob
up.
To fill the wheel with couplant solution, take the air valve exten-
sion and attach to the air valve that does not have a secondary out-
let through the end of the flange (visible through the wheel mem-
brane) (see Fig 4-4 #7 page 40)
(Fig 4-5)
Attach the chuck from the fluid hand pump to the air valve
extension. Place the open end of the pump into your couplant
Solution.
(Fig 4-6)
Squeeze the bulb on the pump to fill the wheel. Continue pump-
ing until the wheel is firm and free of air bubbles (approximately
5 to 15 psi - .34 to 1.03 bar). Air is removed by tilting the wheel
in a way that the air bubbles are at the flange edge beside the
bleed valve, and depressing the valve stem slightly until the air is
out of the wheel.
(Fig 4-7)
TROUBLESHOOTING TABLE
Problem Problem Cause Remedy
A. Unit will not 1. Supply voltage 1. Check power outlet
turn on 2. Power cord 2. Check Power cord for damage ohm out cord
3. Circuit breaker 3. Check the circuit breaker replace if needed
4. Power Switch 4. Check or replace Power switch
5. Fuses 5. Check fuses inside electronic console
B. No Signal 1. Damaged signal cable 1. Ohm out signal cable repair or replace cable
displayed 2. Scope 2. Ensure scope is powered up
3. Transducer 3. Repair or replace transducer
Parts List/Drawings
WALL UNIT
2
1
3
4
1
4
3
2
4 3
,
PART NUMBER DESCRIPTION QTY
1. 10635 KNOB 2
2. 10939 KNOB, 10 TURN 2
3. 54237 PANEL, EZ III FRONT FIN 1
4. 54228 SCOPE, Flaw 1
9
14
10
6
11
13 7
12
5 2
1
1 3
13 2
4
12
6
10
11 7
5
9
8
5 4
10
2 3 4
9
8
7
6 5
PART NUMBER DESCRIPTION QTY
7 6
8 8
3 2 10 5
4
9
BUGGY CABLE ASSY
31888 60FT BUGGY/SIGNAL
PART NUMBER DESCRIPTION QTY
Contact Information