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Overview of CIA's Remote Robotic Crack Detection Service
Field Test: ACFM Crawler in Drum.	CIA Inspection (CIAI) started the development of its internal coke drum crack detection concept in 2005. Alternating Current Field Measurement (ACFM) was our technology of choice because it requires no surface preparation and allows surface-breaking flaws to be detected and sized through coke and other contaminents. A custom ACFM probe was built, tested and tuned by TSC, the original developers of ACFM technology, specifically for coke drum metallurgy. Simultaneously, CIAI worked to develop a system for deploying the probe to the coke drum wall. Requirement included being able to fit through a 30 inch manway and deploy a crawler containing the probe to circ welds in drums up to 32 feet in diameter in a potentially explosive environment. Five years of research and development has yielded a system where the robotic crawler is launched from an pneumatically articulated and telescoping boom mechanism that hangs below the existing laser scanner and video capture system. Using remote camera views, the crawler is robotically positioned and magnetically coupled to the drum wall. Once deployed, the crawler moves horizontally along the designated circumferential weld inspecting the complete cross-section including the inconel weld cap and the HAZ on both sides of the weld. All controls and probe data are managed in CIAI's building located up to 600 feet from the drum. As is the case with our existing equipment, the robotic crack detection system is designed to meet or exceed the requirements for operating on line, so the inspection can be conducted in a live vessel without the need to blind or scaffold. In September, 2009 the prototype system was a deployed during a successful field trial at Flint Hills Refinery. In preparation for the launch of this service, extensive training and testing was conducted in March 2010, under the supervision of Dr. Martin Lugg, of TSC. The results were a resounding success. Using a purpose built, 12-foot section of clad coke drum material, manufactured by CB&I (Chicago Bridge and Iron), with EDM cuts of known length and depth acting as simulated cracks, the system was able to identify and size these flaws with an accuracy of better than +/- 15%, maintained even through coke cover. As a result of this session, CIAI now has a fully vetted system ready to offer for commercial service and six technicians qualified to run and interpret its results in the field. We are pleased to announce the service is commercially available and we are currently scheduling inspections from July 2010 forward.
Coke cover on simulated crack.
CIAI Crawler on test plate.
Coke Drum Section / Test Plate in CIAI Shop	CIAI's ACFM Certified Technicians	Contour Report on CIAI Test Plate (Click for PDF Version)

Overview of CIA's Remote Robotic Crack Detection Service

ACFM System in a Coke Drum

Field Test: ACFM Crawler in Drum.

CIA Inspection (CIAI) started the development of its internal coke drum crack detection concept in 2005. Alternating Current Field Measurement (ACFM) was our technology of choice because it requires no surface preparation and allows surface-breaking flaws to be detected and sized through coke and other contaminents. A custom ACFM probe was built, tested and tuned by TSC, the original developers of ACFM technology, specifically for coke drum metallurgy.

Simultaneously, CIAI worked to develop a system for deploying the probe to the coke drum wall. Requirement included being able to fit through a 30 inch manway and deploy a crawler containing the probe to circ welds in drums up to 32 feet in diameter in a potentially explosive environment. Five years of research and development has yielded a system where the robotic crawler is launched from an pneumatically articulated and telescoping boom mechanism that hangs below the existing laser scanner and video capture system. Using remote camera views, the crawler is robotically positioned and magnetically coupled to the drum wall. Once deployed, the crawler moves horizontally along the designated circumferential weld inspecting the complete cross-section including the inconel weld cap and the HAZ on both sides of the weld. All controls and probe data are managed in CIAI's building located up to 600 feet from the drum.

As is the case with our existing equipment, the robotic crack detection system is designed to meet or exceed the requirements for operating on line, so the inspection can be conducted in a live vessel without the need to blind or scaffold.

In September, 2009 the prototype system was a deployed during a successful field trial at Flint Hills Refinery. In preparation for the launch of this service, extensive training and testing was conducted in March 2010, under the supervision of Dr. Martin Lugg, of TSC. The results were a resounding success. Using a purpose built, 12-foot section of clad coke drum material, manufactured by CB&I (Chicago Bridge and Iron), with EDM cuts of known length and depth acting as simulated cracks, the system was able to identify and size these flaws with an accuracy of better than +/- 15%, maintained even through coke cover. As a result of this session, CIAI now has a fully vetted system ready to offer for commercial service and six technicians qualified to run and interpret its results in the field.

We are pleased to announce the service is commercially available and we are currently scheduling inspections from July 2010 forward.

Coke Covered Weld - Look for the crack!