INTRON PLUS LTD.

Wire ropes deteriorate during operation and need inspection throughout their service life for safety of personnel and operations, economic and safe extension of rope life, and satisfying regulatory agency requirements.
Wire rope tester INTROS is designed for accurate inspection of ropes made from ferrous wires, and comprises basic unit and magnetic head (US Pat. RE 40,166E)

Basic Unit

The basic unit is important part of wire rope tester INTROS. It supplies the whole instrument with electricity, controls the instrument, shows measuring data on-line and stores them for further downloading. The basic unit is compatible with each magnetic head. Connection with magnetic head is provided with connecting cable 5 or 8 m length. Connecting cable delivered with magnetic head.

Magnetic Heads

Magnetic heads for inspection of ropes up to 64 mm diameter have one-piece construction. They contain 2 flaps on hinge, and can be attached on to the rope under test and latched by the inspector manually. Rope is centered for better results with plastic liners installed into the magnetic head. In case with bigger ropes which are tested with magnetic heads MH 60-85, MH 80-120, and MH 100-150 magnetic attraction to the rope is much bigger. Installation technology for these magnetic heads is different. Their flaps are installed on to the rope one by one and connected thereafter with the cable. The MH 80-120 and MH 100-150 are also equipped with special roller frame for the installation, alignment on the rope, and moving along the rope.

*Type of Magnetic Head
Appropriate rope size
MH 6-24 - Diameter 6-24 mm
MH 6-24F - Diameter 6-24 mm
MB 8-24 - Diameter 8-24 mm
MH 20-40 - Diameter 20-40 mm
MH 24-64 - Diameter 24-64 mm
MH 24-64M3 - Diameter 24-64 mm
MH 40-64 - Diameter 40-64 mm
MH 60-85 - Diameter 60-85 mm
MH 80-120 - Diameter 80-120 mm
MH 100-150 - Diameter 100-150 mm
MH 124 - Flat 20 x 124 mm
MH 124R - Rubber flat 30 x 124 mm
MH 233 - Flat 38 x 233 mm
MH 233R - Rubber flat 35 x 233 mm
MH 450R - Rubber flat 24 x 450 mm

WINTROS® Software Package for rope tester INTROS

During inspection of the rope basic unit INTROS stores data for further downloading, analysis, and printing inspection report. This function is possible using the software WINTROS®. Besides, it is possible to show test data in form of LMA and LF traces on-line on the computer screen. For this purpose software WINTROS-RTV is used.
WINTROS® allows;
• Downloading data from basic unit;
• View the rope inspection traces;
• Detailed analysis of the rope traces;
• Zoom-in/Zoom-out
• Compare traces from different data files;
• Process traces: filtering, cutting-off, etc;
• Changing calibration and distance of the traces;
• Merging different traces into one;
• Set up and view the rejections threshold;
• Print the traces;
• Add comments to the traces;
• Create test results report;
• Modify the instruments setting.
• Export data to Word or Excel format

INTROS-AUTO is a successor of widely used wire rope tester INTROS.

INTROS-AUTO designed for non-destructive inspection of wire ropes with automatic data interpretation. Automatic interpretation is based on “traffic light” conception. Green light allows continuing rope operation; yellow light means defects reached 70% of discard riteria, and red light alerts that rope may no longer be used. Following criteria are used to discard rope – number of broken wires along lay length and loss of metallic cross section area in percentage. INTROS-AUTO stores detailed data, which can be downloaded and interpreted in regular manner.

The instrument consists of magnetic head and control and display unit connected with cable up to 80 m length. Magnetic head has strong permanent magnets, and measuring systems is equipped with Hall Effect sensors and coils. Optionally odometer can be fixed on the magnetic head. Control and display unit is powered with DC 12V, and has wireless connection with PC. INTROS-AUTO can be used for rope monitoring and implemented into hoisting controlling system. It has been proven as effective mean to inspect ropes at onshore drilling rigs.

Technical specification:

• Principle of operation - Magnetic Flux Leakage
• Embedded sensors - Hall effect sensors, coils
• Diameter of rope - From 25 to 36 mm
• Inspection speed - From 0.2 to 5 m/s
• Ambient temperature - From -40 to +50°C
• Power supply - DC 12 V
• Weight of magnetic head - 15.5 kg
• Weight of control and display unit - 3 kg
• Dimensions of magnetic head - 400 х 182 х 185 mm
• Dimensions of control and display unit - 311 х 147 х 114 mm
• Explosion proof version - Yes
• Ingress protection - IP66 (magnetic head) IP65 (control and display unit)

Intron Plus is now approaching similar conception to develop continuous wire rope monitoring systems (CWRMS) for high value subsea construction ropes. CWRMS can be installed on the rope in operation to collect data on request, it will have interface to PLC. CWRMS enables to extend rope life according to current technical condition, or to discard dangerous ropes to avoid losses.

INTROCON is designed to non-destructively inspect steel cords in conveyor belts for breakage, corrosion, check splicing areas that may not be revealed visually. Results obtained from inspection help making decision about technical condition of the belts, and so, prevent accidents and provide savings. The instrument can be used for inspection of conveyor belts during its manufacture or on-site, it requires no termination of production run.  Typical industries where INTROCON can be used are mining, steel plants, power stations, seaports, etc., INTROCON can be used for continuous monitoring technical condition of steel cord conveyor belts. INTROCON utilizes eddy-current method of operation and comprises battery powered data logger, scanner, and software WINTROCON. The scanner is recommended to install with a frame 10-20 mm above the belt surface nearby the drum. To avoid damage of the scanner by bulky material running with the belt, the scanner is fixed with spring system. Data logger is connected to the scanner with the cable and shows inspection data on 2 LED displays, simultaneously storing data for further downloading.

The INTROCOR M-150 is a magnetic flux leakage scanner capable of non-destructive inspecting of ferrous steel plates used as tank floor, wall, roof, as well as steel plates of general applications. The scanner design, coupled with the latest magnetic and measuring technology, have resulted in an easy to operate, accurate, reliable, highly productive inspection tool.
INTROCOR M-150 is designed to reveal general and pitting corrosion of steel plates with only one-side access. It provides assessment of detected defects such as cracks, grooves, etc. located on inside and outside surface, document inspection report, and mapping. Inspection is carried even through protective coating, the instruments also measures the thickness of the coating. The implemented eddy-current systems make the instrument possible to recognize location of the defects and increase measurement accuracy.
The INTROCOR M-150 comprises the scanner, the data logger, and the software WINTROCOR for imaging and processing inspection data. The scanner includes latest generation sintered neodymium iron boron magnetic material and sensors. Data logger is batteries powered and is conveniently located on the main frame.

The battery powered hand-held gauge ITM-525 is the enhanced successor to the INTROMET ITM-52 sold in quantity worldwide. The gauge is designed for fast, precise, non-destructive measurement of copper thickness in plated through-holes (TH) of printed-circuit boards (PCB) and measurement of copper on laminate. This gauge can be used for in-process control to maintain high-quality PCB production.

Principle of operation;
The gauge utilizes eddy-current principle for measurement copper thickness in the holes and four-point electrical resistance principle to measure copper thickness on laminate.

Features:

• measures in smaller holes than others
• measures copper thickness on laminate
• applicable for single, double and multilayer PCB
• measures copper thickness under SnPb coating
• measures on wet PCB
• only one-side access to the board required
• boards of unlimited size measured
• calibrated with NIST traceable standards
• can be calibrated by the customer
• automatic zeroing
• fast and accurate reading

The ITM-525 consists of a basic unit offering a variety of probe sizes.

The ITM-525 basic unit is adjustable for thickness of PCB, electrical conductivity, measuring units (metric or imperial), high and low limits, local time and alarm. It stores up to 15,000 readings and has USB downloading capabilities. Built-in functions include number of readings taken, min/max reading, mean value, standard deviation, range, Cp, Cpk, histogram. It is battery powered and equipped with an internal charger.

Probes and cartridges

Eddy-current probes for through holes are detachable, consisting of a probe holder with replaceable EP-25 and EP-30 plug-in cartridges. The EP-20 probe is not detachable. Probe sensing tips (US Pat. 5,600,240) are inserted into through-holes to take readings. Due to special construction of probe tips, cracks in the copper may be detected. Probe tips are protected with special material to provide measurements in wet holes. Measurements are possible on etched or un-etched PCBs. The cartridge during measurement copper thickness in the hole. The stainless tip with coils inside is inserted into the hole firmly.

ITM-525 set

ITM-525 set may include the following items:

• ITM-525 basic unit
• EP-20 probe
• EP-25 cartridge
• EP-30 cartridge
• EP-25S shortened probe
• EP-30S shortened probe
• Cartridge holder
• Reference standard RS-52-1 for the EP-30/EP-30S
• Reference standard RS-52-2 for the EP-25/EP-25S
• Calibration unit for EP-25/EP-30/EP-25S/EP-30S
• Reference standard/calibration unit RS-52-3 for the EP-20
• Hand-held probe guide
• Copper surface probe (CSP) probe
• CSP calibration foils
• AC adapter
• USB cable
• Operating Manual
• Plastic storage case

ITM 525 specification:

• PCB thickness range - 0,5 - 6 mm
• Hole diameter range - 0,45 - 2 mm
• Measuring range in the hole - 5 - 60 µm
• Measuring range on copper laminate - 15 - 80 µm
• Minimum continuous operation - 10 hours
• Weight - 280 g
• Size - 155 x 80 x 30 mm
• Stored readings - 15,000

Conveyors  with   steel-cord   conveyor  belts   operate  when  carrying bulky  materials  is necessary for a long distance. Such belts are usually stronger than rubber-fabric belts, and may be employed primarily to transport  coal, bauxite, iron ore and  other mineral ores, as well as for conveying  people in mines. Failure  of these  belts is  extremely  costly. In   many cases   failure  is  caused   by  cord  corrosion   or  broken  cords. Steel-cord  conveyor  belt inspection  instrument  INTROCON is  able  to electromagnetically  inspect   steel  cords for brakes, corrosion, and condition of splicing areas during production run at belt speed up to 7 m/s.  Trained  personnel  of  our  company  may  visit  your  site and perform  full  longitudinal scan  of the  belt  providing nondestructive inspection  of the  belt  and its  splices. Detailed inspection report  will be  issued  and sent to  the  client including our recommendations on residual breaking strength of the belt. We have inspected number of belts in Russia, Estonia, Chile, other countries.

Our equipment is produced according to strict standards and norms accepted at Intron Plus. Each procedure of manufacturing and testing is documented and records are stored in the data base for the whole period of equipment life. To prove specification valid during operation of the equipment we recommend annual calibration of the equipment. This calibration can be done at our laboratory, and calibration certificate for 12 month period is issued. If the equipment has been damaged and requires repair and maintenance, we will do it at reasonable price. We kindly request our customers to clean their equipment before shipping the equipment for calibration and maintenance.

Each kind of equipment is delivered with detailed manual, so the customer may learn it by himself. However we recommend training course for effective study of the equipment. During training we focus not only on the equipment itself, but also on the corresponding norms, standards, interpretation of test results, share our experience with the customers. Normally training lasts 3 working days and is carried out at our laboratory or at customer’ site whichever is more convenient for the customer. To teach customers not only theory but also practice of operation and to ensure high level of training, we do not recommend more than 4 persons in the group. Training is available in Russian, English, Spanish, Polish, Portuguese languages.