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Ferrologica LLC is  the world leader in the field of scientific development of instruments of non destructive testing based on MMA (magnetic mechanical  anisotropy of ferromagnetic metals) method. 

 

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STRESSVISION  is a novel non destructive testing system that detects and classifies the level of mechanical stress in metallic structures and pressure equipment. Mechanical stress may be present due to poor design, incorrect manufacturing techniques or the presence of manufacturing or in-service produced flaws.

The unique character of Stress Vision is not only in detecting serious flaws that are present in test components but also in its ability to predict locations where these types of flaws may initiate in the future. 

STRESSVISION
 also gives a severity classification for these stress areas according to the concentration and gradients of these stresses. This allows fitness for purpose judgments to be made on components containing known flaws.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Typical applications include:

Determination of heat treatment effectiveness

Detection and classification of welding flaws 

Classification of known flaws for fitness for purpose

Detection and classification of in-service related material degradation such as hydrogen embrittlement 

 

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Applications

 

Stressvision

The STRESSVISION is used for detection of areas with local mechanical stress concentrators (MSC) and quantitative assessment of the danger of such areas (on the basis of MSC maps), areas with a dangerous level of maximum gradient of principal mechanical stress difference – PMSD (the 3D strength criterion, or Tresk criterion), boundaries of areas with residual plastic strains and dangerous welding (thermal) stresses on the basis of PMSD distribution maps in engineering structures of low-alloyed or low-carbon steel. For measurements, no surface cleaning from paint, protective coatings (up to 3 mm thick) or dirt is required.

Oil and Gas (pipelines, structures)

•   Residual stresses, PMSD, local mechanical stress concentrators resulting from fabrication processes such as welding and cutting.

      
Gas Distribution (pipelines)

•   Mapping of residual and applied stresses - external measurements as illustrated and also internal measurements; 
•    Mapping of local mechanical stress concentrators; 
•    PMSD.      


Power Generation

•    Stresses caused by in-service damage and degradation; 
•    The efficacy of stress relieving; 
•    Service stresses in power plant components; 
•    MSC;
•    PMSD.

        
Chemical/Petrochemical

•    Efficacy of stress relieving for prevention of stress corrosion cracking; 
•    MSC;
•    PMSD.

  Other "STRESSVISION" applications include:

•     Steel Product Manufacturing (plate, sheet, tube, rail) measurement of stresses due to manufacturing processes such as rolling and forging; 
•      Steel and Metal Products Industries
  Stress monitoring during fabrication and manufacturing. 
•      A Range of Capital Intensive Industries
Plant condition evaluation to prevent unscheduled shutdowns and unnecessary component replacements.

 

 

 

 

Operating Principle

 

STRESSVISION belongs to a radically new class of flaw detectors.
It is known that "necessary and sufficient" conditions of defect development are:

а) for blowholes – the presence of MSC without prevalent direction of a high PMSD gradient;
b) for slip lines (ductile failure lines) – a high PMSD gradient without a distinct MSC;
c) for cracks – the presence of MSC with adjacent high PMSD gradient in one of directions.


All traditional flaw detector types are designed to detect such defects of metal structures as lack of metal continuity and foreign inclusions. A decision about classification of hazard of detected defects is made on the basis of defects’ size and spatial position.

 

However, a significant portion of such defects is not dangerous for the structure since they either do not create MSC or do not lead to significant growth of PMSD gradient.

 

On the other side, many micro defects cannot be detected by the known flaw detection methods, though they actually create the above-mentioned "necessary and sufficient" conditions.

 

Therefore, the known types of flaw detectors are characterized by the rates of passing dangerous areas unnoticed and false alarms unacceptable for the engineering practice.

 

In scanners of "STRESSVISION" series, such situations are fundamentally impossible.

Electromagnetic (magnetoanisotropic) scanner-defectoscopes "STRESSVISION"use the effect of magnetic anisotropy of ferromagnetic materials exposed to mechanical stress.

 

Due to forming a test magnetic field of a special configuration, account of optimum information contained in a magnetic hysteresis loop and a new algorithm for processing the information received, the accuracy and validity of PMSD assessment results and MSC distribution parameters have increased significantly.

 

Further, it has been possible not only to eliminate negative influence but also to use such phenomena as magnetomechanical and magnetoelastic hysteresis, etc., which have a disastrous effect on results of inspection by traditional magnetic methods of flaw detection (coercimetric, by flux-gate meter or using eddy currents) and by slip line indication methods (known as MMM – "metal magnetic memory method").

 

The method allows detection of mechanical stress anomalies not only in surface layers but also in deep metal layers (patented). 

 

Knowledge of MSC and PMSD, as follows from the classic theory of strength of materials, enables one to assess the hazard degree of the examined area at once, without any additional calculations.

 

 

 

 

Features and Advantages

 

The method registers the totality of MSC including MSC caused by defects that can be detected by ultrasonic, X-ray, magnetic-particle, eddy-current and other inspection methods, as well as dangerous places (MSC and high PMSD levels) that are fundamentally undetectable by the known methods. It enables one not only to establish the fact of an emergency situation or the fact of existence of a defect but also to carry out preventive actions in order to eliminate the danger in good time.

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A specific feature of the defectoscope is that it displays the result of inspection of the whole area on the PC (notebook) screen in the form of a map similar to a geographic one. The map shows not only the position of a dangerous defect but indicates quantitatively the mechanical stress concentration coefficient, i.e., the degree of the defect danger. From the character of distribution of PMSD isostress concentrations (by the gradient), one can, without any calculations, identify the type of actual stress-strained state (bend, torsion, etc.), predict the place of defect generation and the direction of crack development. 

Inspection results are documented by PC, archived and can be displayed for further analysis or printed out at any time.

 

 

 

 

Benefits

 

1. The method registers the totality of MSC including those caused by defects detectable by main types of flaw detection (ultrasonic, X-ray, magnetic-particle, eddy-current, etc.) and dangerous places undetectable by the known techniques.

2. The instrument is the first in the world to show both positions of dangerous defects and the degree of their danger, i.e., mechanical stress concentration – MSC.

3. Inspection results are documented by PC, archived and can be displayed for further analysis or printed out at any time.

4. The memory volume of the instrument is more than 43,000 measurement points (1 week of operation). Duration of storing data in the instrument is more than 6 years (non-volatile memory).

5. It is not required to remove insulation (up to 3 mm thick) from the base metal of the item to be tested.

6. Function-value effectiveness of "StressVision-2" is significantly higherthan that of the best instruments used for this purpose.

7. Operator's qualification requirements are considerably lower than the requirements imposed on operators of magnetic-particle flaw detectors.

8. The instrument is controlled by one operator

9. Time of testing, for example, a whole weld and heat-affected zone, 250 mm on either side (from the beginning of measurements to dumping MSC and PMSD maps to the PC screen or to printing) for a pipe 1020 mm in diameter (1410 points) is 2.5 hours.  

10. Maps of stress distribution of the inspected area of construction can be made in reliance on measurements taken at a depth of 0-3 mm and 0-7 mm (Two layers) with an included standard probe.

 

 

 

 

Specifications

 

MAIN TECHNICAL PARAMETERS

Parameter

Unit of measure

Value

1.       

Minimum square of scanning

mm*mm

90х90

2.       

Minimum number of sites of scanning

lines*points

5х5=25

3.       

Number of measurements (points of object's check) stored in MD of device's controller, not less

line*point

14433

4.       

Maximum number of zones of scanning in a regime №3

 

577

5.       

Time of measurement in one point at AMF=5

s

1

6.       

Voltage of the accumulator unit to provide power supply 

V

+ 6.0 ± 0.6

7.       

Consumption current, not more than

А

0,25

8.       

Time of continuous work with fully charged accumulator at temperature +20 оС, not less than

h

8

9.       

Time of readiness for operation,  not more than

min

0,5

10.   

Duration of storage of data recorded in MD at switched off power supply, not less than

years

6

 

Overall dimensions and weight of blocks

Name of block

Length, mm

Width, mm

Height, mm

Weight, kg

Measuring block

Transducer МА40.02

Transducer МА20.02

224

Ψ 40

Ψ 20

227

-

-

147

70

70

2.8

0.25

0.14

 

 

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