Scorpion B-Scan

Remote Access Ultrasonic Crawler

Operating Manual

Silverwing UK Ltd Clos Llyn Cwm, Swansea Enterprise Park, Swansea, SA6 8QY Wales, UK

t: +44 (0) 1792 798711 f: +44 (0) 1792 793481 e: support@silverwingndt.com w: www.silverwingndt.com
MANUFACTURER:
Silverwing (UK) Ltd.
Clos Llyn Cwm,
Swansea Enterprise Park,
Swansea,
SA6 8QY
Wales, UK
Phone: +44 (0) 1792 798711
Fax: +44 (0) 1792 793481
Email: sales@silverwingndt.com
Web: www.silverwingndt.com

DISTRIBUTOR:

Scorpion B-Scan Operating Manual

Manual Version 7.3

Copyright© 2016 by Silverwing (UK) Ltd

The text, figures and programs have been worked out with the utmost care. However, we
cannot accept either legal responsibility or any liability for any incorrect statements which
may remain, and their consequences. The following documentation is protected by
copyright. All rights reserved. No part of this manual may be reproduced or transmitted in
any form or by any means, electronic or mechanical, including photocopying and recording
for any purpose without the express written permission of Silverwing (UK) Ltd. The rights of
reproduction through lectures, radio and television are also reserved. The software and
hardware descriptions referred to in this manual are in many cases registered trademarks
and as such are subject to legal requirements.

Silverwing (UK) Ltd reserves the right to continue developing the system and software
without documenting each individual case. Silverwing (UK) Ltd are happy to determine
whether this manual is up-to-date. Silverwing (UK) Ltd holds no responsibility for any
damage or destruction caused when following instructions within this manual.
General Introduction

Purpose of this Operating Manual

This manual has been designed so that a person with a good knowledge of the basics of Ultrasonic
non-destructive Testing (UT) may understand the operation and use of the features offered by the
Scorpion B-Scan system.

Keep this manual safe and handle with care:

 It must be readily available throughout the use of the system.
 It must be provided to any individuals who assume responsibility for operating the system at a
later date.
 It must include any supplementary material provided by the manufacturer.

Improper use of this instrument or failure to follow these instructions may cause injury or equipment
damage. All individuals responsible for operating this instrument must therefore be properly trained
and aware of the hazards, and must carefully follow these operating instructions and the safety
precautions detailed within. Contact Silverwing (UK) Ltd if you have any questions on any part of
this operating manual.

Basic Safety Directions

 Do not operate the Scorpion B-Scan system without reading, understanding and following this
operating manual, otherwise injury or damage may result.
 Observe all warnings, notes and instructions as marked on the packaging, on the equipment,
and detailed in the operating manual.
 The customer takes responsibility for the compliance to all appropriate safety measures.
 Reliable and trained staff should only be authorised to work with the equipment.
 All users of the equipment must have undergone training by the manufacturer to operate and
control the system.
 The equipment must not be used for purposes other than those intended. Silverwing (UK) Ltd
assumes no responsibility for any damage resulting from such improper usage.
 The equipment must not be modified. In case of modifications the customer takes all
responsibility for any incidents due to such modifications.
 Ensure the equipment is always in safe operation condition. Qualified staff shall perform
functional tests and checks for damage at regular intervals. Authorised staff shall only do
disassembly, and according to operation instructions only.
 Maintenance of electrical components of the equipment must be performed by a professional
electrician, or under supervision of a professional electrician.
 Ensure, by regular checks, that working site, equipment and environments are kept in a clean
and clearly arranged state.
  Rules and regulations regarding the prevention of accidents that apply to the working site
should be observed.
 If the system does not operate normally, please contact Silverwing (UK) Ltd for assistance.

Safety Warnings & Precautions

During operation of the Scorpion B-Scan system adhere to the following safety warnings and
precautions.

DANGER!
The Scorpion B-Scan system is designed for a specific use. Using the
Scorpion B-Scan system outside of its intended use is dangerous.
Severe injury or death could result. Read and understand this operating
manual before use.

CAUTION!
MAGNETIC MATERIAL. Due to magnetic material, consult IATA
documentation before air shipping.

WARNING!
MAGNETIC MATERIAL. The wheels of the Scorpion B-Scan contain
strong magnets that produce an extremely strong magnetic field which
may cause failure or permanent damage to items such as watches,
memory devices, CRT monitors, and medical or other electronics
devices.

WARNING!
PERSONEL SAFETY. Tools, magnets, and metal objects can cut,
pinch, or entrap hands and fingers. HANDLE WITH CARE. People with
pacemakers or ICD’s must stay at least 2m (79’’) away.

DANGER!
FALLING OBJECT HAZARD. Keep the area below an operating
Scorpion clear at all times. A NO ENTRY ZONE must be clearly
marked and cordoned off directly below the Scorpion. The NO ENTRY
ZONE must be a minimum of 6m (20ft) in all directions from the point
below the Scorpion.

WARNING!
Damage to the Scorpion and/or cables during or prior to use may cause
explosion or fire.
 DANGER!
A suitable safety line must be attached to the attachment points of the
Scorpion at all times during operation. Attach the safety line BEFORE
placing the Scorpion onto the inspection surface.

CAUTION!
FINGER CRUSH. The wheels of the Scorpion contain
strong magnets that produce an extremely strong magnetic
field which could cause entrapment of hands and fingers.
HANDLE WITH CARE.

Operator Training
We advise that all users of the Scorpion B-Scan system receive adequate training before using the
system. They must be trained to understand the operation, application and limitations of the Scorpion
system. Users must understand:
 Ultrasonic Testing;
 Scanner components;
 Scanner setup and calibration;
 Scanner maintenance;
 UT Lite operation;
 Silverwing’s software operation.

More specific information about user training, qualification, certification and test specifications can be
obtained from technical societies, industry groups and government agencies.

Ultrasonic Testing Limitations

During ultrasonic testing the only information obtained is from within the confines of the sound beam
as it travels through the inspection material. The user must be cautious and prudent when assessing
the condition of the inspection material outside of the sound beam limits properties, since the material
condition could vary significantly causing unpredictable results.

Service and Maintenance

 The specified calibration and maintenance work should be performed promptly according to the
maintenance schedule.
 After completion of maintenance work test all functions and all safety devices.
 Refer to Section 10 – Scorpion Care & Maintenance for a detailed guide.
After Sales and Technical Support
Silverwing (UK) Ltd provides after sales and technical support and is available from Monday through
Friday from 9:00 AM to 5:00 PM GMT (excluding UK public holidays). Contact us either by:
Phone: +44 (0) 1792 798711
Fax: +44 (0) 1792 793481
Email: support@silverwingndt.com

Please provide the following information when contacting:

 Your name and your company name.
 The technical point of contact (name, phone number, email).
 System serial number, equipment type and any software versions.
 A detailed description of the issue.

Return Policy
If the Scorpion B-Scan system has been diagnosed as being faulty, or if it is in need of repair, it can
be returned to Silverwing (UK) Ltd. A Return Material Authorisation (RMA) number must be obtained
from Silverwing (UK) Ltd before it can be returned. To return the system:
1. Pack the system safely in the original transit case and ensure the product is shipped fully
insured.
2. Include the following:
a. The RMA number supplied by Silverwing (UK) Ltd. Clearly mark this on the outside of the
box.
b. A return address where the system can be shipped.
c. A contact telephone number / email address to be reached during work hours.
d. A detailed description of the problem.
3. Ship the unit prepaid to the address specified by Silverwing (UK) Ltd.
Legislative requirements
The Scorpion B-Scan system is designed to meet the safety requirements in accordance with
electrical safety and electromagnetic compatibility. It has been tested and has left the factory
in a condition in which it is safe to operate. The equipment is in conformity with the statutory
requirements of the EC directive and complies with the following provisions of Low Voltage
Directive 2006/95/EC and the Electromagnetic Compatibility Directive 2004/108/EC.

The Waste Electrical and Electronic Equipment Directive (WEEE Directive) aims to minimise
the impact of electrical and electronic goods on the environment by increasing re-use and
recycling and by reducing the amount of WEEE going to landfill. It seeks to achieve this by
making producers responsible for financing the collection, treatment, and recovery of waste
electrical equipment, and by obliging distributors to allow consumers to return their waste
equipment free of charge.

Silverwing (UK) Ltd offers its customers the possibility of returning unused and obsolete
equipment for correct disposal and recycling. The Dustbin Symbol indicates that when the last
user wishes to discard this product, it must be sent to appropriate facilities for recovery and
recycling. By not discarding this product along with other household-type waste, the volume of
waste sent to incinerators or landfills will be reduced and natural resources will be conserved.

The European Union’s RoHS (“Restriction of the use of certain Hazardous Substances”)
Directive (2002/95/EC) came into effect on July 1, 2006. All of the systems manufactured by
Silverwing (UK) Ltd fall under Category 9, Measurement and Control Equipment. Currently
this category is exempt from RoHS compliance until at least 2018, when it and other
exemptions will be reviewed. Regardless of this, all products manufactured by Silverwing
(UK) Ltd are compliant with the RoHS Directive.
Transportation and Storage

Receiving and Inspection

For transport purposes the Scorpion B-Scan system is supplied within a transit case. Any transport
work may only be carried out by appropriately trained personnel.
On receipt of the system, carefully check it for any damage that may have occurred during shipping.
The transport company is responsible for damage that occurs during transport. If there appears to be
damage, carefully inspect the system components for any further damage and check that all
components correspond to the packing list. In the event of damage, notify the transport company
immediately and keep the packaging as evidence. A full report describing the damage in detail must
be submitted to the Transport Company and serves as the basis for the damage claim.
Damage or loss of goods delivered must be reported immediately to Silverwing (UK) Ltd and
confirmed by a copy of the above-mentioned report. If the operating manual is removed, do not lose
or misplace.

Unpacking
Care should be taken when unpacking the Scorpion B-Scan system, any markings or warnings shown
on the packaging should be observed prior to opening. The following steps should then be taken:
 Unpack the Scorpion B-Scan system in a dry area.
 If a knife is used to remove packaging care should be taken not to damage the Scorpion B-
Scan system or cables.
 Check the contents of the Scorpion B-Scan system against the packing list supplied and any
missing items are to be reported immediately.
 The package and contents of the Scorpion B-Scan system should be checked for signs of
damage during transport and any problems reported immediately.
 Silverwing (UK) Ltd accepts no responsibility for damage or injury caused during the unpacking
of the system supplied.

Storage
If storage of the Scorpion B-Scan system is required then all components must be packed correctly.
The Scorpion B-Scan should be stored;
 In a clean, dry and secure location.
 Away from water and harsh environment conditions.
 In such a way as to avoid damage to the system.
 Table of Contents
1. Introduction ................................................................................................................................... 1
2. General Description ...................................................................................................................... 2
2.1. Scorpion Crawler ................................................................................................................... 2
2.2. Sitemaster30 Battery Box ...................................................................................................... 3
2.3. Control Module ...................................................................................................................... 3
2.4. Steering Control Pad ............................................................................................................. 3
3. Scorpion Pre-Inspection Setup.................................................................................................... 4
3.1. Preparation of the Inspection Equipment .............................................................................. 4
3.2. Charging the Sitemaster30 Battery Box ................................................................................ 4
3.3. Preparation of the Inspection Surface ................................................................................... 4
3.4. Scorpion B-Scan Inspection Area .......................................................................................... 5
4. Scorpion B-Scan Hardware Setup and Operation ..................................................................... 5
4.1. Short RG174U leads .............................................................................................................. 5
4.2. Connecting the Scorpion ....................................................................................................... 5
4.3. Connecting the UT Module .................................................................................................... 6
4.4. Connecting the Control Module ............................................................................................. 6
4.5. Sitemaster30 Battery Box Operation ..................................................................................... 7
4.6. Scorpion Steering Control Pad .............................................................................................. 7
5. UT Lite Software - Inspection Setup ........................................................................................... 8
5.1. Loading the UT Lite Software ................................................................................................ 8
5.2. Inspection Setup in UT Lite Software .................................................................................... 8
5.2.1 Encoder Calibration ............................................................................................................... 9
5.3. Handling the Scorpion ......................................................................................................... 10
5.4. Placing the Scorpion onto the Test Surface ........................................................................ 10
5.5. Attaching the Safety Line ..................................................................................................... 11
5.6. Removing the Scorpion from the Test Surface.................................................................... 11
5.7. Wheel Probe Normalisation ................................................................................................. 11
5.8. Wheel Probe Height ............................................................................................................. 13
6. Scorpion A-Scan Calibration ..................................................................................................... 14
6.1. Automatic A-Scan Calibration .............................................................................................. 14
6.2. Manual A-Scan Calibration .................................................................................................. 15
7. Scorpion B-Scan Setup .............................................................................................................. 16
7.1. Scorpion Resolution ............................................................................................................. 16
8. Scorpion B-Scan Operation ....................................................................................................... 17
8.1. Scorpion Scan Path ............................................................................................................. 17
8.2. Ready for Operation Checklist ............................................................................................. 17
8.3. Encoder................................................................................................................................ 18
8.4. Scanning Head Wheel Magnets .......................................................................................... 19
8.5. Scanning Operation & Missing B-Scan Data ....................................................................... 19
9. Viewing / Analysing B-Scans ..................................................................................................... 20
10. Scorpion Care & Maintenance ................................................................................................... 21
10.1. Scanning Head Component Identification & Location ......................................................... 21
10.2. Wheel Probe / Transducer ................................................................................................... 22
10.2.1 Wheel Probe Removal ........................................................................................................ 23
10.2.2 Wheel Probe Servicing ........................................................................................................ 23
10.2.3 Wheel Probe Replacing ...................................................................................................... 24
10.3. Cleaning Pad ....................................................................................................................... 25
10.4. Scorpion Drive Wheels ........................................................................................................ 25
10.5. Encoder................................................................................................................................ 25
Scorpion B-Scan Operating Manual Rev 7.2

1. Introduction
The Scorpion system is a B-Scan imaging system that is used with Silverwing’s UT Lite system. The
Scorpion has been developed to perform ultrasonic thickness measurements on ferrous material. The
Scorpion can be used on vertical ferrous surfaces such as oil storage tank shells, towers and stacks.
It can also be used on circumferential ferrous surfaces including horizontal pressure vessels and
spheres as well as above and below horizontal surfaces.

The minimum outside diameter the Scorpion can inspect both circumferentially and axially is 1.5m
(59”). The minimum internal diameter the Scorpion can inspect is 1.5m (59”) axially and 3m (118”)
circumferentially. The maximum surface temperature the Scorpion can continuously operate on is
o o
80 C (176 F).

The Scorpion system comprises of:

 Scorpion fitted with a 5MHz dry coupled wheel probe.
 Sitemaster30 battery box.
 Control module.
 Steering control pad.
 Scorpion maintenance kit.
 50 meter umbilical cable.

Note: We advise that users read the UT Lite Operating Manual before continuing with the
Scorpion B-Scan Operating Manual. Alternatively ensure the UT Lite Operating Manual is
readily available as some sections of this manual refer to sections of the UT Lite Operating
Manual.

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2. General Description

2.1. Scorpion Crawler

The Scorpion contains four DC motor units, which are used to drive the four 70mm (2.8”) diameter
drive wheels. These motors can be driven synchronously in forward or reverse, or independently in
pairs of left or right hand side for steering. Centred between the wheels, in the belly of the Scorpion is
a large magnet assembly ensuring the Scorpion adheres to the scanning surface.

Mounted within the rear wheels are ring magnets which assist with traction while inverted. The
combined clamping pressure of the magnets is approximately 22.7kgs (50lbs) when used on flat
plate. The Scorpion is fitted with a single axis encoder, which provides positional information of the
Scorpion to the UT Lite system along with the UT data.

Figure 1 - Scorpion B-Scan Scanner

On top of the main chassis is the umbilical cable connector box. In front of this box are two SMC
bulkhead connectors, which the two short transducer leads connect to the dual elements of the wheel
probe. At the rear of the box there is one LEMO connector to which the umbilical cable is connected
and two colour coded BNC connectors to which the umbilical UT cables are connected. At the rear of
the chassis is a cable restraint pillar that is used to anchor the Umbilical cable restraint clip on the
umbilical cable. The cable restraint must always be used to prevent premature damage to the
Umbilical cable or connectors.
The Scorpion B-Scan utilises the Silverwing UK Ltd TWP12 dry-coupled wheel probe. The wheel
transducer assembly is attached to the main chassis by a parallelogram hinge system to keep the
transducer normal to the surface. The wheel transducer itself can be normalised using the adjusting
nuts on the top arm of the parallelogram. The two small nylon wheels mounted towards the front of
the transducer assist in lifting the wheel probe clear of welds. The two larger nylon wheels mounted
each side of the wheel probe transducer are designed to minimise compression of the wheel probe
tyres over uneven surfaces. Compression of the wheel probe tyres may result in irregular B-Scan
traces.

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2.2. Sitemaster30 Battery Box

The Sitemaster30 12v battery box provides power to the Scorpion and the control module. It has an
integral charger and is fitted with an audible low voltage alarm to help prevent the Scorpion becoming
trapped in inaccessible areas due to loss of power. The Sitemaster30 provides around 8 hours
continuous operation from a full charge.

Figure 2 – Sitemaster30 Battery Box

2.3. Control Module

The lightweight control module provides an interface between the Scorpion crawler, the UT module,
the steering control pad and the Sitemaster30. It also houses the Scorpion motor control circuitry.

Figure 3 – Control Module

2.4. Steering Control Pad

The Steering control pad provides forward, reverse, left and right steering control for the Scorpion as
well as a stop button to halt its movement.

Figure 4 – Steering Control Pad

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Scorpion B-Scan Operating Manual Rev 7.2

3. Scorpion Pre-Inspection Setup

3.1. Preparation of the Inspection Equipment

Before use, ensure the following checks have been performed:
 The Toughpad and UT module of the UT Lite system are fully charged (refer to the UT Lite
Operating Manual).
 The Sitemaster30 battery box is fully charged.
 The latest UT Lite software is installed on the UT Lite system.
 The Scorpion system and associated umbilical cables are in good condition.
 All equipment is packaged safely within the provided transit case during transport.

3.2. Charging the Sitemaster30 Battery Box

Before charging the Sitemaster30 battery box, the module must be switched off so as to allow for a
battery cool down period of at least 15 minutes. Disconnect the output power supply cable from the
side of the box. After at least 15 minutes have elapsed, charging can begin. To charge:
1. Connect the charging cable to the ‘INPUT 95-277v AC’ connector inside the lid of the
Sitemaster30 (Figure 5).

Figure 5 – Sitemaster30 Charging Panel

2. Connect the battery charger cable to a suitable mains power supply.

3. Switch the power switch to the ‘CHARGE’ position. During charge the Red ‘Charging’ LED
light stays on.
4. The Sitemaster30 is fully charged when the Green ‘Charged’ LED light stays on. A full charge
takes approximately 5-7 hours.

3.3. Preparation of the Inspection Surface

Preparation of the inspection surface is critical to the quality of the results obtained from the scanner.
If possible all surfaces to be scanned should be cleaned and free from any scale and debris.

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3.4. Scorpion B-Scan Inspection Area

The maximum inspection length the Scorpion can inspect during a single scan is 10m.

4. Scorpion B-Scan Hardware Setup and Operation

Before the Scorpion can be used for inspection, ensure the system is properly connected by reading
this section of the Scorpion B-Scan Operating Manual.

4.1. Short RG174U leads

The two short RG174U leads connect the wheel probe to the lid of the Scorpion at each end (see
Figure 6 below). One end connects to the SMC bulkhead socket at the end of the wheel transducer
axle and the other end connects to the SMC connector in front of the connector box. These
connectors should only be “hand” tightened and on no account should any tools be used to
tighten them. Either side of the transducer can be used as a transmitter or receiver.

SMC Connector
RG174U Leads

Figure 6 – RG174U Leads

4.2. Connecting the Scorpion

To connect the umbilical cable to the Scorpion crawler, follow the steps below:
1. Secure the umbilical cable restraint clip to the restraining post at the rear of the crawler.
2. Connect the umbilical cable to the umbilical connection box, ensuring the red dot on the cable
connector lines up with the red dot on the bulkhead socket.
3. Connect the two umbilical UT connectors to the BNC connectors on the umbilical connection
box ensuring that the colour codes on the connectors are observed.

Umbilical Connections

Restraint Clip

Figure 7 - Scorpion B-Scan Crawler

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4.3. Connecting the UT Module

The front panel of the UT module can be found on the left hand side of the UT Lite bag underneath a
Velcro flap. Connect the 25-way connector to the socket marked I/O on the front of the UT module
and tighten the screws on the parallel connector.
Note: Do not over tighten the securing posts of the connector.
The two BNC connectors on the umbilical cable are required for the UT signal. One connector for TX
(Transmit) and the other for RX (Receive). These connectors are colour coded to ensure they are
connected correctly. The red colour connector must be connected to the BNC connector marked TX,
as shown in Figure 8.
BNC Extension Cable
The UT module BNC connectors can alternatively be connected to the female BNC connectors of the
BNC extension cable. The male BNC connectors of the BNC extension cable can be connected into
the female BNC connectors located on the UT module (Figure 8).
Note: Failure to observe the Red / Black colour codes when connecting the umbilical cable to
the UT module prevents any back-wall echoes being displayed.

Figure 8 – UT Module Connections

4.4. Connecting the Control Module

To connect the control module correctly follow the steps below:
1. Connect the encoder bulkhead connector (other end of the 25-way parallel connector) to the
socket labelled ‘ENC.’ on the front of the control module.
2. Connect the Sitemaster30 power cable to the socket marked ‘12v DC’ at the back of the control
module.
3. Connect the steering control pad to the socket at the left side of the control module (labelled
‘DIR’).
4. Connect the umbilical bulkhead connector to the bulkhead connector to the socket labelled
‘UMB.’ On the front of the control module.

Figure 9 - Scorpion Control Module Front Connectors

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4.5. Sitemaster30 Battery Box Operation

The Sitemaster30 battery box is used to power the Scorpion and the control module. To switch the
Sitemaster30 on, press the power switch to the ‘12V OUT’ position. After use, ensure that the power
switch is switched back to the ‘OFF’ position.

Figure 10 - Sitemaster30 Power Switch

During operation if a buzzer alarm sounds it indicates that the battery pack has limited power
remaining.
After the Sitemaster30 buzzer alarm sounds drive the Scorpion back to ground level immediately.
With a fully charged battery the Sitemaster30 can operate continuously for up to 8 hours.
Do not allow the Sitemaster30 battery to completely discharge as this will shorten its service life
considerably.
Note: Extended use during the alarm period can damage the battery pack.

4.6. Scorpion Steering Control Pad

The steering control pad is used to control the movement of the Scorpion. The forward and reverse
buttons are latching whereas the steering buttons only operate while pressed. To disengage the two
latching buttons and stop the Scorpion, press the stop button.

Stop
Forward Drive
Steer Left Steer Right
Reverse Drive

Figure 11 - Steering Keypad Controls

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5. UT Lite Software - Inspection Setup

5.1. Loading the UT Lite Software

Load the UT Lite software by ‘double clicking’ on the UT Lite desktop icon. With a pre-configured
system the software can also be accessed from the start menu.

5.2. Inspection Setup in UT Lite Software

Refer to Section 5 – Inspection Setup of the UT Lite Operating Manual to ensure the software is
correctly setup for an inspection. Below are the steps to generate a new inspection:

Start

Enter the Main Menu

Window

Select B-Scan Mode

Enter inspection details

Select measurement units

Select colour options

No
Has an encoder calibration been
performed recently?

Perform new encoder

calibration
Yes

Save encoder calibration

Load encoder calibration

End

Figure 12 – Inspection Setup Flowchart

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5.2.1 Encoder Calibration

The Scorpion encoder provides accurate one-directional measurement data, which is illustrated in the
B-Scan window of the UT Lite software. The encoder must be calibrated to ensure correct distance
measurements are recorded. Figure 13 shows the steps taken to perform an encoder calibration.

Start

Under the Utilities option,

select the Units button to
select the preferred units of
measurement

Select New Encoder

Calibration

Position the Scorpion on a

smooth, ferrous surface and
mark a reference point on
the surface in relation to a
fixed point on the
equipment

Select Start

Move the equipment

forward a minimum
distance of 300mm and
mark a 2nd reference point
on the surface in relation to
the same fixed point on the
equipment

Select Stop and measure the

distance moved between
the two reference points

Enter the distance into the

box in Step 2 and press the
enter key

The encoder calibration is

No
Is the calibration factor incorrect due to an incorrect
between 13-18? entered distance
measurement

Yes

The encoder calibration is

correct

Do you want to save the Yes

encoder calibration for future Select Save and Finish
use?

Enter a suitable filename

No and select Save
Select Finish

End
Figure 13 – Scorpion Encoder Calibration Flowchart
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Scorpion B-Scan Operating Manual Rev 7.2

The mobility of the Scorpion is affected by one or more of the following variables:
 Condition of the Scorpion drive wheels (e.g. quality of maintenance, wear and any ferrous
materials attracted to the magnetic wheels).
 Condition of the inspection surface (e.g. wet, dirt, rust and loose ferrous materials).
To load an encoder calibration, select the Load Encoder Calibration button then open the required
encoder calibration file.

Figure 14 – Load Encoder Calibration File

5.3. Handling the Scorpion

The Scorpion crawler weighs approximately 6kgs (13.2lbs) Extreme care must be taken when
handling the Scorpion due to the magnetic pull from the wheels, crawler body and scanning head
assembly. Before handling, ensure the power to the Scorpion is switched off.

WARNING!
Care MUST be taken whilst positioning the Scorpion on the test surface
to avoid jarring the carriage or transducer.
Never attempt to hold, touch or reposition the Scorpion during use.
The Scorpion has an extremely powerful attractive force towards any
ferromagnetic object. Serious injury can result if limbs or tissue become
trapped between such objects and the Scorpion.

5.4. Placing the Scorpion onto the Test Surface

Pick up the crawler at the front and rear, and then use a finger from the front hand to lift the wheel
transducer assembly to the maximum distance away from the test surface allowed by the
parallelogram hinge.

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Place the rear wheels of the crawler on the test surface first then gently lower the front wheels to the
surface. Finally allow the wheel transducer to lower onto the surface.

5.5. Attaching the Safety Line

Connect a suitable safety line to the safety line attachment point on the lid of the Scorpion, as shown
in Figure 15.

Safety line attachment

point

Figure 15 – Scorpion Safety Line Attachment

DANGER!
FALLING OBJECT HAZARD. Keep the area below an operating
crawler clear at all times. A NO ENTRY ZONE must be clearly
marked and cordoned off directly below the crawler. The NO
ENTRY ZONE must be a minimum of 6m (20 ft) in all directions
from the point below the crawler.

5.6. Removing the Scorpion from the Test Surface

To remove the Scorpion from the test surface, first lift the wheel transducer assembly away from the
test surface, and then remove the front wheels followed by the rear wheels from the test surface.

Note: Always remember there are very strong magnets located on the underneath of the
Scorpion and inside the rear wheels, which will attract and be attracted to any ferrous material.

5.7. Wheel Probe Normalisation

This adjustment is only required if:
1. A new wheel transducer is fitted,
2. A component in the parallelogram hinge has been replaced,
3. The curvature of the test surface has changed.

To carry out normalising adjustments, the system needs to be mounted on a steel plate, connected
and powered on. The software must be initialised with the A-Scan back-wall echoes displayed on

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screen as described in Section 7 – A-Scan Setup of the UT Lite Operating Manual. With the system
set up as above:

1. Obtain at least two back wall echoes, and adjust the system gain so that the first back wall
echo is about 60% full screen height.

2. Slacken the rear-adjusting nut four or five turns then slowly tighten the front adjusting nut
whilst observing the ultrasonic signals.

Front Adjusting Nuts

Rear Adjusting Nuts

Figure 16 - Scorpion Probe Normalisation Adjusting Nuts

3. If the first back-wall echo immediately begins to fall – stop tightening the front nut.
Immediately re-tighten the rear nut and then slacken the front nut four or five turns.

4. Then slowly tighten the rear nut and observe the ultrasonic signals, which should be rising.

5. When the first back-wall echo reaches a maximum and starts to fall, Stop adjusting the rear
nut and lock up the front nut.

The transducer is now normalised and the wheel probe height should now be checked.

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5.8. Wheel Probe Height

The wheel probe height should be adjusted so that the large diameter nylon wheels each side of the
wheel probe just make contact with the test surface. To do this:
1. Loosen the wheel probe clamp screws.

Wheel Probe Clamp

Screws

Figure 17 - Scorpion Wheel Probe Clamp Screws

2. Turn the wheel probe height adjustment screws until the correct height has been achieved.
Both height adjustment screws must be turned equal amounts to ensure the wheel probe
does not point to one side.
 If the wheel probe is set too high, there will be insufficient pressure between the wheel
probe and the test surface resulting in low amplitude back wall echoes.
 If the wheel probe is set too low, the nylon guide wheels will not make contact with the
test surface which may cause irregular B-scan images due to changes in wheel probe
tyre compression.
3. To complete the adjustment, re-tighten the wheel probe clamp screws.

Wheel Probe Height

Adjustment Screws

Figure 18 - Scorpion Wheel Probe Height Adjustment Screws

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6. Scorpion A-Scan Calibration

Ensure the wheel probe normalisation and height tasks have been completed in Sections 5.7 & 5.8
of the Scorpion B-Scan Operating Manual.
Read Section 7 - A-Scan Setup in the UT Lite Operating Manual and decide whether an Automatic
A-Scan Calibration or a Manual A-Scan Calibration is preferred.

6.1. Automatic A-Scan Calibration

To perform an Automatic A-Scan Calibration, follow the steps below:

Start

Select A-Scan Setup

Select Scorpion under Load

Default Settings

Move the Scorpion to the

area of thickness 1

Enter the value of thickness

1 into the Thickness 1 box

Press Set below the

Thickness 1 box

Move the Scorpion to the

area of thickness 2

Enter the value of thickness

2 into the Thickness 2 box

Press Set below the

Thickness 2 box

Press Calculate

End
Figure 19 – Automatic A-Scan Calibration Flowchart

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After completing the Automatic A-Scan Calibration, perform calibration checks on some known
thicknesses to ensure the B-Scan is reporting the correct thickness measurements. If the
measurements are incorrect, manually adjust the UT flaw detector settings and gates until the correct
measurements are displayed.

6.2. Manual A-Scan Calibration

To perform a Manual A-Scan Calibration, follow the steps below:

Start

Select the A-Scan button

under Setup

Select the Scorpion button

under Load Default Setup

Select Velocity and set the

correct velocity of sound for
inspection material

Adjust Gain, Delay and

Range

Adjust Filter, Smooth level

and Reject

Yes
Are two thickness Setup Gate 1 over the first
measurements required? A-Scan signal

No

No
Setup Gate 1 and Gate 2 Is the reported thickness of Gate 1
over the first and second A- the same as the known inspection
Scan signals respectively surface thickness?

Yes

No
Is the reported thickness of Gate 1
Adjust the velocity so Gate 2
and Gate 2 the same as the known
reads the correct thickness
inspection surface thickness?

Re-adjust Delay so Gate 1

Yes
reading is the same correct
thickness as Gate 2

The System is ready to

capture B-Scan data

End

Figure 20 – Manual A-Scan Calibration Flowchart

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7. Scorpion B-Scan Setup

In order to capture a B-Scan, ensure:
 The scan resolution is set to the required amount between 1-10mm. Refer to Section 7.1 –
Scorpion Resolution.
 The B-Scan Window is showing the correct viewing mode.
Refer to Section 8 - B-Scan Setup in the UT Lite Operating Manual for more information.
Follow the steps below in order to setup the desired B-Scan:

Start

Select the B-Scan button

under Setup

Adjust the Resolution

Set B-Scan viewing mode

End
Figure 21 – B-Scan Setup Flowchart

Note: The colour scheme displaying data within the B-Scan Window can be changed under the
Utilities tab in the Main Menu Window.

7.1. Scorpion Resolution

The scan resolution is the distance travelled by the Scorpion between each data capture point. The
optimum resolution for the Scorpion is 4mm, due to the constant travel speed of the crawler.
However, the resolution can be set between a 1mm to 10mm step if required.

Note: In some rare circumstances the Scorpion B-Scan can miss data due to surface
conditions. These blocks of missing data are shown by vertical white lines within the B-Scan.
If this occurs the Scorpion B-Scan can be moved backward and forward to fill in the missing
data.

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8. Scorpion B-Scan Operation

8.1. Scorpion Scan Path

When selecting a scan line, check to see that there are no obvious obstructions. Check that all four of
the driving wheel tyres have not become polished. If necessary roughen the rubber by a gentle rub
with 120 grit emery cloth.

On painted vertical surfaces, check the surface condition as it is common for the paint to bloom with
age creating a powdery deposit on the surface. Rain tends to wash this deposit to the lower courses
and the thicker layers of powder can be quite slippery, especially when wet. If the surface is slippery it
may be wise to set the Scorpion on a diagonal course then straightening up as the top courses are
reached.

Note: Before climbing, ensure the safety line has been attached to the front of the Scorpion
and ensure the wheel probe has been lowered onto the surface and that UT signals are being
received by the UT Lite software.

8.2. Ready for Operation Checklist

Check the Scorpion system is setup and ready to perform an inspection by the completing the
following processes:
 The Scorpion and associated modules are connected correctly and the UT module is displaying
live A-Scan data from the Scorpion (Start A-Scan enabled).
 The inspection surface is correctly prepared for Scorpion operation (clean and free of excess
ferrous material) and the Scorpion wheel probe is normalised for the inspection surface.
 The ‘Inspection Setup’ process has been performed.
 The ‘Scorpion A-Scan Calibration’ processes have been completed.
 The ‘Scorpion B-Scan Setup’ processes have been completed.
If the above checklist has been performed correctly, the Scorpion and UT Lite software is calibrated
and ready for inspection.

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Refer to Section 10 – Capturing, Saving and Loading Data in the UT Lite Operating Manual before
capturing a B-Scan. Follow the steps below in order to capture B-Scan data:

Start
Place the Scorpion at the
start of the required
inspection path

Select the Start B-Scan

button from the Main
Screen

Select Yes to the Start New

Scan message prompt

Yes
Is a scanning offset Enter the scan offset value
required? into the Enter Offset field

No

Select OK

Scan inspection surface

No
Continue scanning
Is the scan completed?
inspection surface

Yes
Select the End B-Scan
button

End
Figure 22 – Capturing B-Scan Data Flowchart

8.3. Encoder
The Scorpion B-Scan is fitted with a single axis bi-directional encoder, which is gear driven by the
front wheels. Ensure no debris becomes stuck between the meshing of the gear teeth as this could
cause damage to the teeth and report incorrect distance measurements.
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8.4. Scanning Head Wheel Magnets

The Scorpion B-Scan is fitted with front and rear magnet wheels. During use these components can
and often do attract dust, debris and paint from the surface which can cause movement and accuracy
problems. To avoid any potential problems it is recommended that the wheel magnets are periodically
cleaned during inspection.

8.5. Scanning Operation & Missing B-Scan Data

Any of the three B-Scan images (amplitude, profile and line profile) can be generated from the A-Scan
data as the Scorpion is moved in a forward or backward direction. To use the Scorpion in a
backwards scan:
1. Place or position the Scorpion in the starting position for the scan.
2. Press the Start B-Scan button.
3. When prompted to enter the offset distance, enter a value which matches or exceeds the
desired scan length. E.G. If a backwards scan of 6M is required then enter 6,000 (mm) as the
offset value and select OK.
4. The B-Scan capture is now active and the Scorpion can be moved in a backwards motion (or
forward to re-profile any areas) up-to the distance entered as the offset field. E.G If 6,000
(mm) was entered as the offset value, and then the B-Scan Window only shows data
captured up-to that distance and not exceeding the distance.
The Scorpion moves forward over the inspection surface at one constant and steady speed to fill in
the B-Scan image.
During operation there can be areas of data missed on the B-Scan amplitude, which are represented
by vertical white lines of varying thickness. These areas can be re-scanned by driving the Scorpion
back over the areas that are missing data to fill in the vertical white lines with B-Scan data. Once the
scan is completed press the End B-Scan button before removing the Scorpion from the inspection
surface.

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9. Viewing / Analysing B-Scans

The UT Lite software is equipped with analysis tools to help analyse the B-Scan data. Refer to
Section 11 – B-Scan: Viewing / Analysing Data of the UT Lite Operating Manual for further
information on these analysis tools. The following steps in the Analysing B-Scan Data Flowchart
can be used as a basic outline for analysing B-Scan data (not all processes are required to be
performed, but it is advised):

Start

Capture B-Scan

Set Marker Lines

View Statistics

Yes
Adjust B-Scan View?

Change B-Scan View

No

Highlight area of interest &

press ‘Zoom’ button

Yes
Save area as bitmap?

Save image file

No

Export data

Yes
Save entire B-Scan?

Save file
No

End

Figure 23 – Analysing B-Scan Data Flowchart

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10. Scorpion Care & Maintenance

During an inspection it is recommended that the Scorpion B-Scan Crawler is kept as clean as
possible. After every inspection the scanner head must be thoroughly cleaned ensuring all dust and
debris is removed especially around the critical components such as the wheel probe, both magnetic
wheels and the encoder. The wheel probe / transducer can be removed for further cleaning.

10.1. Scanning Head Component Identification & Location

2
1
3

Figure 24 - Scorpion B-Scan Crawler Diagram

Scorpion B-Scan scanning head components:

1. Probe pressure magnet
2. Cleaning pad holder
3. TWP12 Wheel probe
4. Probe normalising adjustment
5. Front Drive wheels
6. Belly magnet assembly
7. Umbilical cable connector box
8. Rear Magnetic Drive wheels

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10.2. Wheel Probe / Transducer

The dry coupled rubber of the Wheel Probe is most effective when the contact surface is slightly
tacky. As the Wheel Probe picks up dust and debris from the surface it becomes less effective. The
cleaning pad removes any dust and debris from the Wheel probe and applies a thin film of oil to help
improve coupling. A Silicone Oil, such as silicone brake fluid, should be manually applied to the
cleaning pad to ensure that it remains moist.

Discolouration of the Wheel Probe tyres suggests they be cleaned using a cloth moistened with
Acetone. This will help restore the tyre to their original ‘tacky’ condition. The frequency of cleaning
will depend upon the condition in which the unit is being used, for example where the paint surface is
particularly dusty (or coated with a thick 'bloom'), it may be necessary to clean the tyres after each
scan.

Figure 25 - Details of Recommended Silicone Oil

IMPORTANT!
ONLY USE SILICONE OIL TO MOISTEN THE CLEANING PAD. ANY
OTHER FORM OF MINERAL OIL MAY DAMAGE THE WHEEL PROBE
TYRES.
THE USE OF ANY “OIL” OTHER THAN THAT SPECIFIED BY THE
MANUFACTURER INVALIDATES THE WARRANTY ON THE WHEEL
PROBE TYRES.

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10.2.1 Wheel Probe Removal

For comprehensive cleaning and servicing the Wheel Probe must be removed. To remove the wheel
probe:
1. Disconnect the two SMC connectors on the short leads which connect the wheel probe to the
lid of the crawler.
2. Slacken both wheel probe clamp screws so that the wheel probe can be removed from the
carriage from the bottom.
o
3. Disconnect the two 90 SMC connectors at either of the wheel probe axle.

Wheel Probe Clamp

Screws

Figure 26 - Scorpion Wheel Probe Clamp Screws

10.2.2 Wheel Probe Servicing

To dismantle the wheel probe:
1. Unscrew the brass nuts and remove.
2. Carefully easing off both side plates complete with bearings.
3. Slide off both parts of the tyre
4. Remove the cork washer (if a twin-crystal wheel probe)

Figure 27 - Wheel Probe

Inspect the tyres for any signs of splitting, cracking, excessive abrasion or any evidence of swelling
due to contact with mineral oil. Check the condition of the cork insulating washer and ensure that it
sits snugly and turns freely in the groove. Check that the ball bearings in the side plates turn freely.

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Use acetone to clean all components and surfaces. Take extra care that all traces of film and dirt are
removed, especially around the outer circumference and Perspex plug over the crystal and the inner
face of the wheel probe tyres.

If new tyres are to be fitted, it is very important they are first cleaned with acetone to remove
protective film.

To re-assemble the wheel probe:

1. Apply silicon brake fluid to axle assembly, cork washer and tyres.
Note: Only use Silicone DOT 5 brake fluid. Any other oil can cause irreparable damage and
void warranty.
2. Gently ease the cork washer over the shoulder of the axle and ensure that it rotates freely in
its groove.
3. Fit tyres then the side plates before screwing the brass nuts onto the axle.
DO NOT use a spanner to tighten the brass nuts, they must be figure tight only.

Once reassembled, check that there is only slight resistance when rolling the wheel probe. Do this by
holding the wheel probe ends between finger and thumb of each hand.

10.2.3 Wheel Probe Replacing

To replace the wheel probe into the crawler:
1. Reconnect the SMC connectors to either end of the wheel probe axle.
2. Slide the wheel probe back into the carriage. Ensure the marks (dots) on the wheel probe
axle are facing towards the inspection surface.
3. Push the wheel probe fully into the carriage and tighten the wheel probe clamp bolts.
4. Reconnect the SMC connectors to the lid of the crawler.

Once replaced check the system to ensure UT signals are being received.

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10.3. Cleaning Pad

The cleaning pad is located in front of the wheel probe. Before inspection fill the reservoir located in
front cleaning pad with silicone oil.
To fill the reservoir:
1. Remove the screw located at the front.
2. Using a syringe fill the reservoir with the recommended silicon oil.
3. Soak the cleaning pad with the recommended silicon oil.

Cleaning Pad

Reservoir Screws

Figure 28 - Cleaning Pad and Reservoir

10.4. Scorpion Drive Wheels

The Scorpion B-Scan crawler is fitted with four drive wheels. During use these on wet or dusty
surfaces, the wheels can spin and become polished, which can lead to more spinning and slippage.
Clean the wheels after each use and if they become polished, lightly roughen the surface with 120 grit
emery cloth.

10.5. Encoder
The Scorpion B-Scan is fitted with a single axis bi-directional encoder on the side of the crawler.
 Ensure no debris becomes stuck between the meshing of the gear teeth as this could cause
damage to the teeth.
 Ensure the optical encoder does not get damaged during use as it could cause distance
measurement inaccuracies.

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Notes:
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