An inspection tool apparatus includes a core having an axial length. The axial length is determined based on a desired depth of inspection radially from the core. A plurality of arms are coupled to and extend radially from the core. The core and the plurality of arms comprise a high permeability magnetic material. The core or at least one of the plurality of arms is wound by a respective coil that is positioned to receive magnetic flux that is passing through the core or at least one of the plurality of arms.

An inspection tool apparatus includes a core having an axial length. The axial length is determined based on a desired depth of inspection radially from the core. A plurality of arms are coupled to and extend radially from the core. The core and the plurality of arms comprise a high permeability magnetic material. The core or at least one of the plurality of arms is wound by a respective coil that is positioned to receive magnetic flux that is passing through the core or at least one of the plurality of arms.

A probe 100 includes exciter units 102 arranged in an array and detector units 104 and 106, also arranged in arrays, with the arrays positioned proximal to and in the shape of the exterior circumference of an individual boiler tube 108. The detector units 104 are “absolute” coil detectors which are used to detect and quantify general wall loss, for example, resulting from steam impingement erosion. The detectors 106 are differential, axial pairs which are used for detecting pits in the boiler tubers. The exciter units and detector units are mounted in a stainless steel housing 110 of the probe. The housing 110 is shaped to closely match the contour of the boiler tube 108. The probe can be moved along the boiler tubes by hand to inspect the flame side of boiler tubes, one at a time. Wheels 112 are provided to roll the probe along the boiler tubes.

A probe 100 includes exciter units 102 arranged in an array and detector units 104 and 106, also arranged in arrays, with the arrays positioned proximal to and in the shape of the exterior circumference of an individual boiler tube 108. The detector units 104 are “absolute” coil detectors which are used to detect and quantify general wall loss, for example, resulting from steam impingement erosion. The detectors 106 are differential, axial pairs which are used for detecting pits in the boiler tubers. The exciter units and detector units are mounted in a stainless steel housing 110 of the probe. The housing 110 is shaped to closely match the contour of the boiler tube 108. The probe can be moved along the boiler tubes by hand to inspect the flame side of boiler tubes, one at a time. Wheels 112 are provided to roll the probe along the boiler tubes.

A system for magnetically inspecting a metallic component uses a manipulator configured to manipulate a relative position between a part fixture that holds the metallic component and a probe fixture that holds a magnetic probe, thereby causing the probe tip to trace an inspection route along the surface of the metallic component so that the probe tip contacts the metallic component such that an angular difference between the probe axis and a vector normal to the surface is less than a predetermined angle delta. The magnetic probe has a probe tip that measures magnetic permeability of the metallic component along the inspection route, which the controller receives. A method of performing the magnetic inspection is also disclosed.

A system for magnetically inspecting a metallic component uses a manipulator configured to manipulate a relative position between a part fixture that holds the metallic component and a probe fixture that holds a magnetic probe, thereby causing the probe tip to trace an inspection route along the surface of the metallic component so that the probe tip contacts the metallic component such that an angular difference between the probe axis and a vector normal to the surface is less than a predetermined angle delta. The magnetic probe has a probe tip that measures magnetic permeability of the metallic component along the inspection route, which the controller receives. A method of performing the magnetic inspection is also disclosed.

Circumferential and axial magnetizers for a magnetic flux leakage pig. A magnet bar may comprise at least one magnet and may be configured to collapse radially inward to the shaft. Magnetizers may include a cushion disposed about the shaft and biasing the magnet bar against a pipe wall. A sensor head disposed between circuit poles at each polar end of the magnet monitors magnetic flux. The central shaft of a circumferential magnetizer or axial magnetizer may comprise a joint linking an additional smart pig module. A novel magnetizer cushion is described, as are smart pigs containing one or more circumferential or axial magnetizers.

A probe 100 includes exciter units 102 arranged in an array and detector units 104 and 106, also arranged in arrays, with the arrays positioned proximal to and in the shape of the exterior circumference of an individual boiler tube 108. The detector units 104 are “absolute” coil detectors which are used to detect and quantify general wall loss, for example, resulting from steam impingement erosion. The detectors 106 are differential, axial pairs which are used for detecting pits in the boiler tubers. The exciter units and detector units are mounted in a stainless steel housing 110 of the probe. The housing 110 is shaped to closely match the contour of the boiler tube 108. The probe can be moved along the boiler tubes by hand to inspect the flame side of boiler tubes, one at a time. Wheels 112 are provided to roll the probe along the boiler tubes.

A probe 100 includes exciter units 102 arranged in an array and detector units 104 and 106, also arranged in arrays, with the arrays positioned proximal to and in the shape of the exterior circumference of an individual boiler tube 108. The detector units 104 are “absolute” coil detectors which are used to detect and quantify general wall loss, for example, resulting from steam impingement erosion. The detectors 106 are differential, axial pairs which are used for detecting pits in the boiler tubers. The exciter units and detector units are mounted in a stainless steel housing 110 of the probe. The housing 110 is shaped to closely match the contour of the boiler tube 108. The probe can be moved along the boiler tubes by hand to inspect the flame side of boiler tubes, one at a time. Wheels 112 are provided to roll the probe along the boiler tubes.

Apparatus and methods for detecting flaws in objects comprised of ferromagnetic materials are disclosed. A wireless energizing unit is disclosed that includes an array of permanent magnets is used to induce a magnetic field into the objects and transducers are configured to detect a magnetic flux property in the presence of a flaw in the object. Embodiments that are configured to be clamped over the object are also disclosed. In addition, methods for retrofitting EMI detection systems with a wireless energizing unit are disclosed.