TESTEX

TX-4400

STANDARD EDDY CURRENT TESTER (ECT)

MANUAL

SOFTWARE INSTRUCTIONS
REV 0.94

8-10-2013
 TABLE OF CONTENTS

TABLE OF CONTENTS .........................................................................….. i

INTRODUCTION .....................................................................................…... 1

THEORY OF OPERATION ............................................................................. 1

EQUIPMENT SETUP .......................................................................................... 1

Packing List Essentials ............................................................................. 1
Computer and Power Requirements ........................................................... 2
Software Description and Installation ........................................................ 2
Equipment Description and Setup .............................................................. 3
Equipment and Software Testing ............................................................... 4

USING THE SOFTWARE ........................................................................…........ 5

Data Collection Software ........................................................................... 6
Keyboard Controls .......................................................................... 7
File Storage Controls .............................................................. 7
Equipment Setup Controls .............................................................. 12
Pusher Puller Controls .............................................................. 15
Program View Controls .............................................................. 20
Calibrating the System - A Brief Overview ......................................... 27
Auto-Analysis Setup ............................................................................. 30
Data Analysis Software .....................................................................…................ 31
Display Window Keystrokes .................................................... 32
Flaw sizing keystrokes ............................................................... 34
Mixing Keystrokes .......................................................................... 35
Flaw Logging Dialog ................................................................................ 37

@ Copyright 2007, TesTex Inc. Pittsburgh, Pennsylvania 15239 USA

INTRODUCTION

The DSP based 4/8-channel TesTex regular eddy current examination systems (TX-4400) is used
for detecting wall thickness changes in austenitic tubing. This inspection method works by forming a
high frequency (1-1200 KHz) magnetic field in the tube in order to measure the change in the field as the
coil moves past a flaw in the metal. By using 2 coils in the probe (differential mode) it is possible to
detect relatively small flaws in relation to the coil size.

An IBM-PC computer is also connected to the instrument through a USB cable. The computer is
used to control the instrument and for storing and analyzing the data using the TesTex supplied WinECT
software. The data is stored at 500-6000 samples/second/channel (on the TX-4400) with permitted pull
rates of up to 5.5 feet per second.

THEORY OF OPERATION

Wall losses and pitting can be detected by injecting a high frequency magnetic field (1-1280KHz)
into a tube and measuring the distortions in the resulting magnetic field that occur in a flawed region.
This injection is done by using an internal circumferential coil. Flaws are detected by measuring the
magnetic field directly under the flaw area with the coil. A flaw or defect causes the magnetic flux lines
in that area to be distorted or different than expected. This distortion can be measured as a change in the
horizontal and vertical components of the signal. With suitable calibration tables, flaws can be analyzed
and a determination of the flaw depth can be made.

High frequencies (>1 KHz.) are used in non-magnetic metal tubes because the low magnetic
permeability of these materials presents little resistance to the penetration of the metal. By using high
frequencies, the magnetic field produced has a very good signal to noise ratio while still penetrating the
metal.

EQUIPMENT SETUP

The following sections describe the steps necessary to operate the TX-4400 system. Included are
the Packing List, Computer Requirements, Equipment Connections and Software Installation details.
This section also describes how the equipment can be tested by the user to see if it is working properly.

Packing List Essentials (See invoice for complete packing list )

TX-4400 instrument (electronics)
Probe
USB cable
IBM-PC Computer
Software CD
Power cords
ECT Manual
Misc 1
Misc 2
Misc 3

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Computer and Power Requirements
IBM-PC compatible computer with clock speed at least 1 GHz. (2.5GHz + Recommended).
USB capability (works with 1.1, compatible with 2.0 ).
10 megabytes or greater of free Hard Drive space (not including data storage).
CD-Rom/DVD-Rom drive for software installation.
Graphics capability of 800x600 pixel at 256 colors minimum.
OS - RAM
Windows 2000 or Windows XP 32-bit 1 GB Ram
Windows 7 32-bit 2 GB Ram
Windows 7 64-bit 4 GB Ram
The voltage requirements of the TX-4000 series are: 85 to 265 VAC @ 50/60 hertz.
( Instrument power supplies adjust themselves automatically )

Software Description and Installation

The TX-4000 series comes with an installation CD. This disk contains the ECT software/driver
installer.

To load the ECT program onto the IBM-PC hard drive:

(1) Insert the ECT program disk into your CD/DVD drive.
(2) If the Setup program does not automatically start, run X:\SETUP.exe where X is the drive letter
of the CD/DVD drive.
(3) If running Windows 7, Windows 7 security features will not allow the security key software to
install from inside the main installation program. If running Windows 7,, right mouse button click
on X:\HASPUSERSETUPP.EXE and select Run as Administrator.
(4) Attach the TX-4000 series to a USB port and turn on the electronics.
(5) When the new hardware found message comes up, select to Install from a Specific Location. For
the location: select the C:\Program Files\TesTex, Inc\WinEct Rxx.x\ usbdriver2.06 folder and
allow the driver to load. Please note: if your OS is not on C:\ drive, substitute the correct drive
letter. Also, Rxx.x will vary depending on the version of the software you are installing. The
browse button, when selecting the specific location, will allow you to pick the correct folder. The
usbdriver is subject to change as newer versions of the driver become available. As of this writing,
the current version would be WinEct Rxx.x\ usbdriver2.06.
(6) Windows tends not to share the driver automatically between different USB ports. Therfore, it is
recommemded to move the USB cable to each of the ports on the IBM-PC and load the driver to
each of the ports.

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Equipment Description and Setup
The TX-4400 system consists of the probe, TX-4400 electronics box, USB cable, the IBM-PC
compatible computer, an ASME calibration standard, and a probe. An optional pusher puller may also be
added to the system. Equipment connections follow the diagram in Figure 1.

Figure 1- Equipment Connections

A – Power Cord connection and On/Off switch

B – USB Cable connection
C – Data Cable eight (8) pin connection. (¼ turn locking)
D – Probe Cable four (4) pin connection. (Threaded)
Connections should be made in this order:

(A) Turn off the TX-4400 instrument box.

(B) Turn on the IBM-PC computer (to give it time to boot up).
(C) Connect USB cable between the TX-4400 box and the computer.
(D) Turn on the TX-4400 instrument box.
(E) Run ECT acquisition software by double-clicking the "EctAcq R94" icon.
(F) Attach probe

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Equipment and Software Testing
To determine if the equipment is correctly connected, insert the probe into the standard and do the
following:
(1) Set the GAIN to 127 using the ^G key.
(2) Set frequency (^F key) to the correct frequency for your standard.
(3) Sweep time (^T) to 20 seconds on left sweep.
(4) Observe the vertical bar on the left side of the screen. This bar represents the overload indicator
for all channels.
(5) Move the probe past the flaws in the tube but stop in an unflawed (full wall) region
(6) Balance the probe (CTRL-Z).
(7) Adjust the gain settings (^G key) and observe a flaw in the tube. If the flaw doesn't change size
with the gain change then the electronics is not accepting commands. Try restarting the
acquisition software. If this doesn't work, try powering down the electronics. If the system still
isn't changing then check your frequency and balance settings.

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USING THE SOFTWARE
To run the ECT software double-click EctAcq R94. This will place the user on the main
collection screen. This screen is shown below (Fig 2).

Select the mode to use. The mode will either be 4200,4400, TS2000 or Magwave depending on the
system attached.

Figure 2: - Mode 4400 Selection Option

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 Data Collection Software

At this point, the settings used the last time the unit was in use will be restored. Most of the
settings are visible at the bottom of the screen. The settings include the current file name, frequencies
used, Driver Level, Gains, and rotations (See Fig 4).
This system uses a ± 5V Analog to Digital converter(A/D) and all readings are displayed in scaled
Voltages allowing a ± 20V range.
Above each of the plots the channel number and component to display (H for Horizontal, V for
Vertical) are listed.

Figure 3- Default Collection Screen When Program is Run

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Collection Program Keyboard Controls:

File Storage Controls:

“F2” or “Alt-F F” SELECT DRIVE\Folder Select the location where the data is to be stored.
Default is drive C, folder temp (C:\PLANT NAME\UNIT NAME\BOX ID\A\SECTION I).

Figure 5 - Select Drive/Folder Dialog Box

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“F3” or “Alt-F O” or “CTRL-O” SELECT FILE NAME Enter the name of the file that the
collected data will be stored in. This name is a series of numbers in ROW-COL-RUN format.
These numbers are used as part of the filename with the following maximum values 9999,999, and
999 respectively. When the enter key is pressed the program will start displaying the incoming data
(data collection screen). It is not recommended to store more than 100 file names in a single
directory as this may slow drive access and can make selecting a specific file difficult.

Figure 6- Enter File Name

“Alt-F T” STEPPER This control allows the user to select how the file name is stepped. Just
enter the number to step by into the appropriate field and the number will be incremented
automatically whenever the file is stored.

Figure 7 – Select Stepper Figure 8 - File Stepper

“Alt-F E” ALTERNATE STEPPER This control allows the user to select how the file name is
stepped when the stepping keystroke (Alt-C) is pressed. If the assign value on check box is
checked, then when the step occurs that field is assigned the value. Otherwise, the field is stepped
by the value. So, suppose you are testing a unit and the first 2 tubes are a different material. So
when testing you want to start every row on tube 3. The settings in the dialog box to the left will
step the row up by 1 every time and set the tube number to 3 and run number to 1. Please note:
negative values are permitted for step by but should not be entered for assigning values.

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“Alt-F A” SAVE SETTINGS This option allows the user to store the current setup to a file for
later retrieval. For instance, the user can calibrate the system for a given tube, store the settings,
and then calibrate for the next kind of tube. When it comes time to test the units, the calibration
can be loaded and the system set up more quickly.

Figure 9 – Save Settings

“Alt-F L” LOAD SETTINGS This option allows the user to retrieve previously stored settings.
This is of particular use when setting up an inspection of various exchangers, etc. For instance, the
user can calibrate the system for a given tube, store the settings, and then 'calibrate' for the next
kind of tube. When it comes time to test the units, the calibration can be loaded and the system set
up more quickly

Figure 10 – Load Settings

“Alt-F S A” ASSISTED SINGLE FILE This mode allows the program to assist the user during data
acquisition. See “SPACE BAR” for more information.

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“Alt-F P” PLANT INFO This control allows the user to set the basic information about the
data being acquired. Please note: this control is now used to set the folder for data storage (see F2)
This information is used by the auto-analysis module (see PUSHER PULLER AUTO-ANALYSIS
SETUP) in the display/analysis program. Please enter this information prior to starting data
acquisition.

Figure 11 - Plant Information Dialog Box

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“SPACE BAR” COLLECT DATA (Single File Mode) Pressing the space bar once will
activate the collection mode (see Fig. 12) and cause the incoming data to be stored in the computer.
Pressing the space bar again will stop the collection and the program will ask you if you want to save the
data (see Fig. 13). Pressing Y will cause the data to be stored on the disk. Pressing N will cause the
program to start displaying the incoming data again without storing the data to disk. Pressing T will store
the data and switch to the display (like F10 was pressed).
(Assisted Single File Mode) Pressing the space bar once will tell the program to start storing data
as soon as the probe enters the tube. This is determined by a threshold value set on the F1 absolute signal.
This means that the F1 absolute must be set up (calibrated) prior to using this feature. Also, the program
will automatically stop collecting data and ask if you want to store data whenever the probe exits the tube.
(Continuous) Not intended for field use. This feature is used in the office for equipment checks.
It simply stores the data until the maximum file size is reached, automatically saves the data (without
asking the operator), steps to the next file name and starts storing data again. This starts and stops with
the pressing of the space bar.

Figure 12- Collecting Data Figure 13- Data Collected, option to store file

Whether or not data is stored, the file number will step at this point. Also, at this time the program will
re-transmit the settings to the electronics. This means that each time a file is stored the electronics is reset
to the current settings. This is to prevent data acquisition from occurring on the wrong settings.

What happens if the power fails momentarily?

Under this condition a notebook computer with a built in battery will still not loose power. The
PC will be running the acquisition software and will have all of the appropriate settings. However, the
electronics does not have a battery backup. This means that the electronics will loose power. When the
power comes back on the electronics will go to a default set of settings which will not be the settings on
the computer. The software will correct for this when the electronics comes back by re-sending settings.
This can take up to 10 seconds and the zero (Ctrl-Z) may need to be restored prior to continuing the
inspection.

“Alt-N” and “Alt-P” NEXT TUBE and REPULL TUBE These keystrokes cause the program to either
step to the next file name or step backwards to the previous file name respectively. On a repull, the
program will increment the run number by 10 until an unused file name is acquired.

“F10” SWITCH TO DISPLAY PROGRAM As stated, this keystroke switches to the display
program and causes the display program to load the last file stored by the acquisition.

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Equipment Setup Controls

“Ctrl-F” or “Alt-I F” FREQUENCY ADJUST Pressing CTRL-F activates the input box
that is used to adjust the testing frequencies (see Fig 14). After opening the Test Frequency Selection Box
window, click on the Estimate F90 Freq button. From the list, select the appropriate material and enter
the correct wall thickness (see Fig 14B). Press the Calculate F90 to approximate the starting F90
frequency. Click OK to go back to the Test Frequency Selection Box to enter frequencies 2, 3 and 4. You
can manually enter these frequencies or use the drop down menu to select the correct even multiple of the
F1 (F90). The allowable frequency range is from 1 KHz to 1.28 Mhz (Megahertz). Please Note: Even
harmonics usually produce the cleanest signals. It is therefore recommended that even harmonics be used
whenever possible to test the tubing. An example would be as follows.
Using the Edit Material button, materials can be added to the list using their respective resistivity values.

Testing: 1” O.D. 0 083” wall SS 304

F1 (F90) = 50.06 KHz
F2 (F1*2) = 100.12 KHz
F3 (F1*4) = 200.24 KHz
F4 (F1/2) = 25.03

Figure 14 – 4400 Frequency Selection Box Figure 14B – 4400 Estimate F90 Frequency

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“Ctrl-G” or “Alt-I G” GAIN Pressing the Ctrl-G key activates the Gain input box (see Fig.
15). This box sets the gains of the amplifiers in the instrument in order to control the amplification
of the return signal from the probe. This option should not be confused with the Driver Level Gain
function which controls the gain on the output signal sent to the probe (see Ctrl-D).
Set this gain so that the amplitude of the signal on a flaw is acceptable. Warning: setting the gain
too large can cause the A/D converter to overload and the signal to be distorted. To reduce this
problem place the probe in a clean stretch of tube and use either the CTRL-Z or CTRL-X balancing
function.
To detect saturation, the left hand side of the screen has a saturation alarm indicator on it. If the
indicator changes color (any color but gray indicates a saturation condition) then the A/D converter
has overloaded. If this occurs in the standard then you should turn down the gain on the appropriate
channel until an acceptable level is reached. Please note: the differential signals will overload when
the probe passes into the gradual wall losses. If this occurs it is an acceptable condition.

Figure 15 – 4400 Gain Control Box

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“CTRL-D” or “Alt-I L” DRIVER LEVEL This dialog box allows the user to select the power
level to excite the probe at for each frequency. The value can be set anywhere from 1-600, however,
the system works best at 300-500 and values should be kept in this range whenever possible. (see
Fig 16).

Figure 16 - 4400 Driver Level

“Alt-I S” SAMPLE RATE This control is used to adjust the sample rate of the system. The
sample rate should not exceed ½ of the lowest test frequency. So if a low frequency material such
as copper is being tested at 3 Khz, keep the sample rate at 1500 or less. Also, there can be
problems with sample rate frequencies interfering with test frequencies. If a given frequency
seems very noisy, try adjusting the sample rate up or down by 500 samples per second and see if
the problem decreases. Please note: when using a 4400 it is not recommended to use 6000
samples/second with an air assist or pusher puller unit as the electronics may not be able to keep
up with the pusher puller operations. When using a 4400 with air assist or pusher puller system
please keep the sample rate between 1500 and 5500 for best performance.

Figure 17 - Select Set Sample Rate Figure 18 - Set Sample Rate

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“Alt-I P” PUSHER PULLER CONTROL This control is used to adjust the parameters for the
TesTex pusher puller. See Pusher Puller/Assist Setup instructions for more details.

Figure 19 - Pusher Puller Control

ENABLE PUSHER PULLER/AIR ASSIST

This is the control that enables this panel. If this box is not checked, none of the parameters below take
affect. To turn off the Pusher Puller or the Air Assist so data can be collected manual with the spacebar,
simply uncheck this box.
Pusher Puller
If this mode is selected, the Pusher Puller is running in full auto mode. On a straight tube, the gunner will
only have to press the trigger button once at the beginning of the fire cycle and when the probe reaches the
other end of the tube, the system will automatically turn off the air, start recording and retract the probe
back to the gunner and once the probe comes out of the near end of the tube, the system will shut down the
Pusher Puller, save the tube, and advance to the next tube in the inspection Pattern.
Air Boost
When this mode is selected, all controls on this panel are grayed out except for the Tube Length and Open
Air Threshold because these are the only controls that are used in this mode. If this mode is selected while
running the Pusher Puller, the unit will run just like an Air Assist Box. This mode disables both motors
and encoders on the Pusher Puller and only works the electronic air valve. Air Boost mode is there for a
backup for the Pusher Puller in case of a mechanical breakdown. The cable is pulled out of the Pusher
Puller but still left connected to the drum, then this unit is still capable of the auto save but is a manual
retract on the probe.
Air Boost Box Connected
This box is checked when the system is run in Air Boost mode with an Air Boost Box Instead of a Pusher
Puller. This option exists because of the differences of the electronic boards in the Air Boost Box and the
Pusher Puller. The Air Boost Box will still run if this is not checked but there may be communication
errors while the system is running causing the whole system to malfunction.

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 FEED WATER HEATER MODE
This mode is for inspecting tubes where the probe will not be coming out of the far end, so it will not see
Open Air at that end. This is mainly done on Feed Water Heaters (FWH) where only the straight part of
the tube is inspected to the beginning of the U-bend. This can also be used when there is some type of
obstruction in the far end of the tube where the probe cannot pass the full length of the tube, such if there
are sleeves or epoxy in the Inlet of the tubes. In this mode, a predetermined tube length is set (this will be
discussed under Tube Length) and once the Pusher Puller reaches this length it will shut off the motors and
apply the brake while leaving the air valve open until the gunner presses the trigger for a second time.
Once the length is reached and the gunner presses the trigger for the second time, the air valve is closed
and the probe is retracted and data is recorded is the same as normal operation. Please note: nothing will
happen if the gunner presses the trigger for the second time unless the preset length is reached. This mode
can also be used in the Air Boost mode where tape on the cable is used to set the length.
Saturation Mode
This mode is for using a modified Air Boost Box with Magwave. This has not been released for staff to
use yet but Rich Brown has put this function in the software for future use.
2nd Encoder Enable (STALL MODE)
This option enables the system to read the back encoder, which is located on the level wind shaft on the
side of the Pusher Puller. This should always be enabled unless the encoder is damaged or malfunctioning.
In this mode the back encoder compares reading with the front encoder during the fire cycle and if the back
encoder is reading a longer distance than the front encoder the system will turn off the back motor and tap
the brake, leaving all other components functioning normal, until the two encoders read the same distance.
Once they read the same distance, the fire cycle will continue normally. This mode was created to prevent
tangles on the drum (Bird’s Nests) when the cable is wet or muddy and the front pulleys slip while a tube
has an internal obstruction
.

Encoder Control
Green Cable
This mode should be selected if green or black cable is being used.
Blue Cable
This mode is selected when using the small diameter blue cable which is used on small diameter probes
such as 0.390, 0.400, etc. To use the blue cable with the Pusher Puller a smaller diameter pulley must be
installed in place of the standard pulley on the front motor on the Pusher Puller. When this mode is
selected, it disables the cable out micro switch located under the front motor and encoder pulleys because
with the smaller diameter blue cable pulley the switch is always tripped even if the cable is in the pulley.
Currently these switches are being removed from the Pusher Pullers because the 2nd encoder mode can
perform the same function as these switches. In future software, the Encoder Control panel will be
removed.

Tube Length/Braking Info

Tube Length
This setting is for the full length of the tube that is to be inspected. This measurement is in feet and can be
set from 0 -100. In Feed Water Heater mode, set this to the length of the portion of the tube that is to be
inspected.
Distance to Motor Rampdown
This is one of two settings that are designed to slow the probe down before it comes out of the far end of
the tube. This measurement again is in feet. Once the encoder reads the distance that is set in this field,
the system reduces the power to the drum motor, but this motor does not hold the drum back, it simply
allows the drum to free wheel. This action is similar to driving an automatic car down a steep hill in
overdrive and letting off the gas, the forces on the car will keep it moving at a consistent speed.

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 Distance to Brake at
This is the second setting for slowing the probe down before it comes out of the far end of the tube. This
measurement again is in feet. Once the encoder reads the distance that is set in this field, the system will
apply the brake for a set amount of time (set in the Brake Level field) and then release the brake. This
action is similar to applying the brake in a car at high speeds to slow the car down.
Brake Level
This setting is for how long the brake will stay on when the encoder reads the distance that is set in the
Distance to Brake at field. This is a function of time; the higher the number the longer the brake stays on
and can be set from 0-15. Again this action is similar to applying the brake in a car at high speeds; the
longer the brake is held on the more the car slows down.
Stop Retract Length
This setting is for turning off the motors on the retract, so the probe coasts out of the near end of the tube.
This measurement is in feet. Once the encoder reads the distance that is set in this field, on the retract of
the probe, the system will turn of power to the motor allowing the drum to coast down to a stop. The
probe should come out of the tube and gently tap the gun while keeping the probe cable tight between the
Pusher Puller and the Gun. If this setting is too high, the probe will not come completely out of the tube or
once the probe comes out there will excessive slack in the cable between the Pusher Puller and the Gun. If
this setting is too low, the probe will come out of the tube too fast slamming into the Gun and can cause
damage to the probe or probe cable.

Motor Controls
Takeout (Fire) Delay Time
This is a time setting for a delay between opening the air valve and turning on the motors. This setting is
in seconds. This setting was created to clear standing water from the tube prior to shooting the probe
down. This time setting is measured from when the gunner presses the trigger. Once the gunner presses
the trigger, the air valve immediately opens, the system waits the time that is set in this field and then
begins the normal fire cycle. This setting can be at 0 if this delay is not needed.
Takeout (Fire) Motor Speed
This setting is for the speed for probe insertion or probe firing down the tube. This setting is not a direct
variable of time, feet, or voltage. Simply put, the higher the number the faster the Pusher Puller runs. The
top end setting of this variable changes depending on the Tube Length setting. The longer the tube, the
higher the setting can go. This will change because of the acceleration curve of the drum motor; at shorter
length tubes the drum cannot accelerate to the top speed so the top end setting automatically lowers. After
the initial system set up, this is usually set to the upper limit.
Probe Test Motor Speed
This setting is for the speed of the probe in the retract mode while the data is being collected. Again, this
setting is not a direct variable of time, feet, or voltage. Simply put, the higher the number the faster the
Pusher Puller runs. The top end setting of this variable changes depending on the Tube Length setting.
The longer the tube, the higher the setting can go. Normally a setting of 1000 will give a test speed of 5
ft/sec and a setting of 1750 will give a test speed of 10 ft/sec. After each tube, the inspection speed is
show in the lower left hand corner of the screen in the third line down. This number is in ft/sec.
Motor Start Delay Time
This setting is for the delay time from when the probe comes out the far end of the tube till the system
starts recording and retracting the probe. This setting is in seconds. Most of the time this setting should be
set to 0.01 and never changed.
Misfire Motor Run Time
Currently this setting is not functional and may be removed in future software versions.
Open Air Threshold
This is the threshold the system uses to know whether the probe is in or out of the tube. F1, F2, F3, or F4
Absolute Channel can be used for this threshold. If this setting is too high, the system always thinks the
probe is in the tube and if this setting is too low, the system never thinks the probe is in the tube.

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Figure 20 - Pusher Puller Controls

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“Ctrl-Z” BALANCE This keystroke activates the absolute balancing function. This function
adjusts the rotation and power level of the reference signal that is subtracted from the probe signal
to produce the absolute signal. When running, the LED's on the front of the box will turn off as a
given reference signal is being generated. Please note: before pressing the balance key (Ctrl-Z)
place the probe into a baseline region of the tube (no flaws present). Once the electronics has
determined a balance the signal will start back up on the screen.

“Ctrl-X” CENTER This keystroke is used to adjust the hardware zero function. The purpose
behind a hardware zero is to gain A/D resolution. For example, suppose a differential signal in the
baseline of the tube is at 2.5Volts horizontal and 3.5 Volts vertical. If the flaw causes the signal to
change by 3.0V horizontal and 3.0V vertical then the resulting voltages would be 2.5+3.0 = 5.5V
horizontal and 3.5+3.0=6.5V vertical. The problem is that the A/D converter has a fixed range of
±5V. This means that as the signal passes 5V on the horizontal or vertical, all responses are
clipped to the 5V response. To prevent this, the CENTER function will cause the hardware to read
the 2.5 volt signal and it will set the hardware to add -2.5V to the horizontal and -3.5V to the
vertical signal. This will result in the hardware signal being 0V on both the horizontal and vertical
at the baseline material in the tube. This translates to being able to use a stronger signal without
saturation as the 3.0V horizontal and vertical signals will come out as 3.0 and 3.0 and nothing will
be clipped.

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Program View Controls:

“Alt-P P” or “F4” PLOT SELECT The plot select dialog box (see Fig. 22) is used to control the
following:
1. How many plots will be displayed on the screen
2. What type of plotting will be done for each plot (Impedance plane or Strip Chart)
3. Which channel of data will be plotted in the plot.
4. What voltage span will be used.

Figure 22 - Plot Select

Please note: The default button will set all differential and mix channels to 1.0V and all absolute
channels to 10.0V.

“C” CLEAR SCREEN Pressing C will cause the program to clear all of the plots and restart the
strip charts at the top of the screen.

“X” UNZERO Pressing X will cause the digital offsets to go to zero. This means that no digital
signal subtraction is occurring. It effectively undoes the ZERO operation (see “Z” ZERO below).

“Z” ZERO Pressing Z will cause all of the waveforms to be offset to zero. This function only
performs a digital offset inside the PC and should not be confused with the Ctrl-X function which
causes the hardware to set up an analog signal offset. The analog offset will allow better dynamic
range off of the A/D converter but doesn't necessarily achieve a signal as close to zero as the
operator desires. Therefore, the additional capability of the Z function is available.

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“Ctrl-T” or “Alt-P T” SWEEP TIME Use up/down arrows to select sweep time in 1 second
increments up to the maximum permitted number of seconds. This is the time it takes for one
complete sweep on the selected plot type. (Note: The tab key is used to select plot type to adjust.)
At the end of this time the plot will clear and the sweep will start over.

Figure 23- Sweep Time Control Panel

Plot Setup -> Plot Scrolling This menu option allows the user to toggle the display between a
sweeptime which clears the screen and starts over at the specified time (non-plot scrolling) or keeps
the data on the screen for the specified time (plot scrolling).

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“Ctrl-V” or “Alt-P V” VOLTAGE SPAN This control is used to adjust scaling of the signal on
the screen. Normally, the system will be calibrated using a 1V span for the differential signals.
This control does not adjust the gain or driver level on the system, it simply allows the user to
adjust the scale of the plots. For instance, if you set the span of the Lissajous to 1 volt and the signal
is 0.5 volt peak to peak, the signal will cover half of the plot. Use the tab key to select the plot to
adjust and either type in a voltage span or use the UP ARROW or DOWN ARROW keys to modify
the existing voltage span.

Figure 24- Plot Span Control Panel

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“Ctrl-R” or “Alt-P R” ROTATION CONTROL This control allows the user to select a phase
angle in degrees to rotate the incoming signal by. The value can be selected from a range of 0 to
359 degrees. The live plots in the figure show the channel 1 and the selected channel. Additional
controls are available to adjust the voltage span, zero the waveforms, etc.

Figure 25- Rotation Control Panel

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“Ctrl-K” SCREEN CONTROL The screen control function is used to modify the color
palette of the screen. This alternate palette is useful for running the acquisition in bright
environments such as direct sunlight.

Figure 26 - Normal Screen View

Figure 27- Alternate Color Views

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“CTRL-P” POPUP MENU The popup menu just allows you to access the menu without going
to the top of the screen. All functions are accessible thru the menu bar at the top of the screen. This
is simply a conveyance.“Alt-F4” EXIT PROGRAM This key exits the program. Settings
are stored when the program exits.

“Alt-H A” ABOUT This key brings up the dialog box that tells the user what version of the
software and firmware are currently running. Please note: there must be a USB data signal or the
software has no means to get the firmware and fpga revision numbers.

Figure 28 – HELP ABOUT BOX

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“Alt-X Enter” MIX CANCELLATION This control allows the user to cancel out a given
signal. First, select mix cancellation from the menu. Next, using the space bar to start and stop acquiring
data, acquire data on just the signal that you want to capture. When the space bar is pressed the second
time, the program will open the cancellation panel instead of asking if you want to store the data. From
the panel, select the Auto-Balance button in order to cancel out the signal.

Figure 29- Mix Cancellation Figure 30 - After auto cancellation

Please note: The MIX CANCELLATION mode cannot be mixed with either the PP mode or the assisted
single file mode. These modes must be off during mix cancellation mode.

“Alt-X G” MIX GAIN This control allows the user to select the multiplier in order to adjust the
mix signal strength. The mix will usually run at 50% to 75% so the value will be 0.5 to 0.75 in
most cases. This value does not take affect until the OK button is pressed so don't adjust the value
and look at the screen plot behind the panel as it will not be changed. Instead, change the value,
push ok and look at the results.

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CALIBRATING THE SYSTEM - A BRIEF OVERVIEW:

First, start the collection program and select the frequency that you want to use for a given tube.
Usually a frequency of about (X*100)/T2 is used to ensure a good penetration of the magnetic field
through the tube wall. X is the resistance of the tube material and T is the wall thickness of the tube. So
for Stainless 316 with a resistance X of 7.496 ohm-m and a wall thickness T of 0.083” the frequency F
is:
F = (X*100)/T2
F = (7.496*100)/0.0832
F = (749.6)/0.006889
F = 108811.1482 = 108.8 KHz

This frequency is the F180 frequency (the frequency at which a 10% OD and a 10% ID groove
will produce signals which are approximately 180 degrees apart from each other on the differential
signals). Typically we use an F90 which has 90 degrees of separation between the 10% grooves. To get
the F90, divide the F180 by 2 (or multiply by 50 instead of 100 when calculating). This gives the F90 .
F/2 = 108.8 KHz/2 = 54.4 KHz.

Once the F90 has been approximated, the actual F90 frequency is determined using the calibration
standard. First, the approximate F90 frequency is entered (CTRL-F ). Next, the F2 thru F4 frequencies
are set.
Having selected the frequencies, it is now time to select the driver level (Ctrl-D). This is the
power level at which the coils are excited in order to create the magnetic field. The F90,F180 will usually
be run at 300-400 and the F1*4 at 400-500. The F1/2 at 250 to 3501. These values are guidelines only. If
necessary, it is possible to push the levels higher or lower, but the recommended starting settings are F90
325, F180 375, F90/2 300, F90*4 450. The requirement is that the signal to noise ratio is sufficient to
detect the flaws at a level of at least 3:1 as a bare minimum. If, after running the rest of the calibration, it
appears that the Signal to Noise ratio is inadequate, then adjust the power levels and repeat the following
steps at the new power level1.
Once the frequencies and driver levels have been selected for F1-F4, input gains are selected for
F1-F4 Diff and ABS (starting at 50 for all channels) CTRL-G.
Next the probe is pulled through the 10%OD and ID rings. The frequency is then adjusted until a
90º separation is achieved between the OD and ID flaw responses on F12. Now that the F90 frequency
has been selected, make certain that the remaining frequencies are set to even multiples of F1 and each
other. For example: F2 is set to F1*2, F3 = F1*4, F4 = F1/2.
Please note: if the signals are not close to zero after a balancing operation (Ctrl-Z, then it is
possible to get signal distortion on the system. Turn down the driver levels until all of the frequencies
center on balance. It is possible that lowering the driver level on an adjacent frequency might help. So if
the F90*4 is distorted when the signal to noise ratio is poor, try lowering the driver level on the F90/2
frequency (assuming a good signal level is present).

1 The sum of all of the driver levels should be kept at an approximate value of 1000-1600. This will help to prevent signal
distortion between the frequencies.
2 Whenever the frequency or driver level is changed it is necessary to 'balance' the absolute signals in order to prevent them
from interfering with the differential signals. To accomplish this use the CTRL-Z function. If the signal still doesn’t
approximate zero, decrease the power level CTRL-D.

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 Please remember that this is a simultaneous injection system and frequencies can interact with
each other if the electronics become overloaded. To prevent this, keep the driver levels such that the
system can go to zero during a balance operation and the signals won't interfere with each other.
Check the driver levels by plotting the ABS signals (F4) and running the probe thru the wall loss
region of the calibration tube. The 60% deep flaw should produce a signal that reaches the bottom right
corner of the plot when using a 10V scale (F4). Adjust rotation (CTRL-R) and gains (CTRL-G) to achieve
this. In the event that the gain is at maximum and the signal still won't reach the corner of the plot,
increase the driver level. This is most likely to happen at the highest test frequency.
When raising the driver level be sure to balance the signal in a baseline region of the tube (Ctrl-Z).
If the signal will not return to zero (even if the overload color bar does not change color for an A/D
overload) then it is possible to get signal bleed between the channels. To prevent this, lower the overall
driver level. This can be done by lowering the driver level on other frequencies if they are using a low
enough gain level to allow the signal to achieve the 10V plot.
Repeat this process across all of the absolute plots until either the 10V level has been achieved or
it is determined that the 10V level cannot be achieved for a given frequency. If the 10V level cannot be
achieved for a given frequency then set a 5V level for that frequency. And repeat the process to determine
if the 5V signal can be achieved on just that frequency. If not, pick the levels that make the other
frequencies look the cleanest and gives the highest response on the problem channel.
Now that the Frequency and driver level have been established, it is necessary to set the gain (Ctrl-
G) for the F90. The differential should be rotated (Ctrl-R) so that the 10% ID ring is on the horizontal
axis (0º ). Prior to attempting to set the gain it is necessary to set the voltage span to 1 V (Ctrl-V). The
acquisition will be done on a 1 V span for differential signals. To adjust the gain, run the probe past the
thru hole flaw in the standard. The hole should be facing up and the voltage span on the screen should
have a response of 0.600 V – 0.750 V. If you can not see the correct channel, use the plot select option
(F4) in order to select the channel the F90 is on.
For the remaining frequencies, adjust the rotation (Ctrl-R) and gain (Ctrl-G) until the thru hole
signal matches the F90 thru hole response.
(Please refer to Calibration Steps Manual for a more detailed explanation)

Figure 30- Calibration Pull.

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 Once the system is set up and calibrated, it is time to configure a mix.

For example: to mix out a support plate signal.

First, start with an otherwise calibrated system. From the MIX SETUP on the menu, select
Mix Cancellation (Alt-X Enter). Find a support plate in the unit and use the SPACEBAR to
acquire data on just that plate. When the space bar is pushed the second time, instead of
being asked to save the file, the mix cancellation dialog box will automatically appear.
Select the higher frequency channel (F90) as the first of 2 channels and the lower frequency
channel (F90/2) as the second (going from top to bottom in the panel). Use the AUTO
BALANCE button to have the system determine the balance settings for the mix.
Once the cancellation settings have been determined, push the ok button to exit the
panel. This will cause the system to begin calculating a signal that cancels out the support
plate signal, however, it is still necessary to adjust the signal in order to be able to analyze
it properly.
Now that the mix cancellation has been created, adjust the gain using the mix gain control
(Alt-X G) and the rotation using Ctrl-R to make the hole signal match the F90 hole signal.
Finally, store a pull of the calibration tube with the mix added and you are ready to
begin testing tubes.

LOAD TUBE SHEET MAP

With the ect acquisition software, the user is able to import a pre-drawn map into the
software. This allows the software to follow the row and tube count of the entire map.

The user can select the entire map or a partial test pattern that have been made for the
inspection. The user is prompted to select the correct file extension for their inspection.

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 PUSHER PULLER AUTO-ANALYSIS – ACQUISITION MUSTS:
The pusher puller can be used in conjunction with the auto-analysis functionality found in the
analysis software. However, the auto-analysis software has requirements over and above an ordinary eddy
current inspection. To this end, the following steps must be observed in the acquisition program to use
the auto analysis functions.

Step 1: The first file stored in each folder must be a calibration pull2.
Step 2: All calibration pulls must be numbered 9999-xxx-yyy
Step 3: If possible, mixing the support plates should occur in the acquisition.
Step 4: Create Calibration curves and name the files to match the pulls. (9999-xxx-yyy)3
Step 5: See the auto-analysis set up procedure

3 Each group must have a calibration as the first file. This is because analysis can optionally be run on only 1 group at a time
so each group must start with a calibration pull. This does not mean that a pull must be done for each group, however, a
copy of the calibration in effect at the start of testing the group must be copied into the group folder prior to starting the
analysis. Don't forget to also copy the corresponding calibration curve file. The calibration curve files should be located in
the same folder as the calibration pulls with corresponding names so the analysis software can locate them.

For example: Calibration pull 9999-121-333 will have a calibration curve file of 9999-121-333. In windows
explorer the files will be named as follows:
4400 curve file
9999-121-333.tx4 9999-121-333.ecl

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 Data Analysis Software
To run the ECT software double-click ECTView r94. This will place the user on the main
collection screen. This screen is shown below (Fig D.1).

File Selection Keystrokes:

"Alt-F O" or “Ctrl-O” SELECT FILE A list of the files stored in the currently selected folder will
be displayed. From here it is possible to select the drive, folder and filename to be loaded.

Figure D.1- File Selection Screen

“ALT-N” NEXT TUBE This function causes the program to load the next tube and display it on the
screen.

“ALT-P” This function causes the program to load the previous tube

“F10” SWITCH TO ACQUISITON This keystroke cause the acquisition program to be

restored as the active application.

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Display Window Keystrokes:

“Ctrl-A” AUTOSCALE This keystroke cause the Lissajous plots to be scaled to match the
data to be displayed in the plot. The strip charts below the Lissajous in 1 channel mode will also
rescale to match the data.

“Ctrl-V” SET FIXED SCALE This keystroke allows the plots to be set to a specific scale.
That, in turn, permits the operator the capacity to judge the relative signal strengths of the flaw
responses.

Figure D.2 - Set fixed Scale

“F4” or “Alt-L S” SELECT PLOT TO VIEW This feature is designed to allow the user to select
what will appear on the screen. The options include how many channels to display, what data
channels will be displayed, what type of display will be used to plot the data channels and what
voltage span to use. If the user does not check the Save Layout box, the plots will revert back to
the original selected plots.

Figure D.3- Select data to plot options

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“Ctrl-T” or “Alt-L C” CURSOR SIZE This option allows the user to control how large an
area will be zoomed up in the Lissajous window. This can also be accomplished by using the 3rd
mouse button and dragging the area larger or smaller.

Figure D.4 - Adjust cursor size

“Alt-L L” AUTO-SCROLL RATE This option allows the user to adjust the speed at which the
data window will scroll down the screen. As the zoom area will shift to whatever position the
mouse is clicked on and can be dragged, this function is less important than it used to be. Still, the
signal will auto-scroll whenever the space bar is pushed and until the space bar is pushed again.
This control is currently counter-intuitive. It actually adjusts the amount of delay added to the
scroll, so lower numbers sweep faster and higher numbers sweep slower.

Figure D.5 - Adjust Scroll Rate

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Flaw Sizing Keystrokes

“Alt-C E” CALIBRATION PANEL This panel allows the user to Load, Input, Save, and View
calibration data for the probe. To input a new curve the user would simply use the TAB key to
highlight the 'tabs' and select the tab for the channel to be entered. Next, use the arrow keys to
select the field to change. Then press the space bar and input the percent loss and the
corresponding phase angles. Once entered the curve can be seen by selecting generate button.

Figure D.6- Enter Calibration Data Figure D.7- Enter Calibration Loss Data

Figure D.9 - Store Calibration Curve

Figure D.10 - Load Calibration

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ANALYSIS MIX CANCELLATION

“Alt-X R” MIX ROTATION To perform the final rotation and scaling functions select “Alt-X R”
and use the rotation and scale controls to match the waveforms.

Figure D.14 - Rotation Control Figure D.16 - Rotate to Value

Figure D.17 - Rotated and Scaled Value

Figure D.18 - Mix Result

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“Alt-O S” SAVE This option allows the user to save the screen setup so that it will become the
default the next time the program is loaded. The settings stored include:
• Current Folder to retrieve data from
• Background Color settings
• How many channels to display
• What channel (F1 Diff, F1 Abs, F2 Diff, etc.) is displayed in a given plot
• What voltage span is used in each plot

“Alt-O F” FILTER This option turns on a high pass filter on the differential signals. This type
of filter is good for removing signal drift due to volumetric flaws which are measured on the the
absolute. It will also compensate for a bend or bowed tube. It should be noted that this feature
works best when the pull rate is maintained at at least 2-3 feet per second.

“Alt-O A” AUTO ZERO This option tells the software to attempt to automatically determine the
baseline (full wall) position of the data and shift that position to zero. This is accomplished by
determining where the signal resides the majority of the time. This feature can therefore make a
wrong determination if, for instance, the operator does not stop recording data after the probe
leaves the tube. If the 'open air' signal is longer than the in tube signal, the AUTO ZERO will
think that the 'open air' reading is the in tube baseline read and center the open air signal. To
prevent this, the ASSISTED SINGLE FILE option was added to the acquisition program. It would
be advisable to use this feature. This is particularly important when using the solution/auto-
analysis features.

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 LOGGING DIALOG CONTROLS

The logging dialog controls are used to create a spreadsheet file with results from an inspection.
Simply go to Options – DataBase – Logging Dialog on the main menu and the logging dialog box will
open.

Simply select the flaw depth and location and click the Next button to add an entry to the file. The
file created will be located in the 'Box' folder and will be named groupid.csv. So in the case of the tube
above the file will be located in the C:\PLANT NAME\UNIT NAME\SECTION I\BOX ID folder. The
file will be called A.CSV.
So the file containing the logged data is:
C:\PLANT NAME\UNIT NAME\SECTION I\BOX ID\A.CSV

The CSV file is a comma-delimited file that will import into any commonly available spreadsheet.

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