APRIS Product Manual

Acoustic Pulse Reflectometry Inspection
System (APRIS)
Operation and Maintenance Manual
Draft_2.0
Doc. No: APRIS_UTM001 Rev:00
Proprietary Notice
The information disclosed in this document, including all designs and related materials, is the valuable
property of Talcyon Pte Ltd in Singapore. Talcyon reserve all copyright and other proprietary rights to this
document, including all design, manufacturing, reproduction, use, and sales rights thereto, except to the
extent said rights are expressly granted to others.
Talcyon product(s) discussed in this document are warranted in accordance with the terms of the Warranty
Statement accompanying each product. However, the actual performance of each such product is dependent
upon factors such as system configuration, customer data, and operator control. Since implementation by
customers of each product may vary, the suitability of specific product configurations and applications must
be determined by the customer and is not warranted by Talcyon.
To allow for design and specification improvements, the information in this document is subject to change at
any time, without notice. Reproduction, modification, dissemination of this document or portions thereof
without the prior written approval of Talcyon is prohibited.
APRIS and other upcoming products of Talcyon are registered trademarks of Talcyon Pte Ltd.
All other products, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective trademark owners.
2 APRIS User Manual

APRIS User Manual
PRODUCT CONTENTS
8
2
7
# Item # Item
1 Tube adapters 6 Sound Gun to POE Box cable
2 100-240VAC POE Box 7 Tube adapter locking nut
3 Sound Gun 8 APR carrying strap
4 POE Box to PC cable 9 Operation and Maintenance Manual
(Not shown)
5 24VDC POE Box 10 (Optional) Ethernet cable (Not shown)
APRIS User Manual 1

APRIS User Manual
LIST OF REVISIONS
REV REVISION DATE DESCRIPTION OF CHANGE

CR Initial
ABBREVIATIONS
ALC APR LCD Controller

APR Acoustic Pulse Reflectometry
APRIS Acoustic Pulse Reflectometry Inspection System
AWG American Wire Gauge
GUI Graphic User Interface
HW Hardware
LCD Liquid Crystal Display
LED Light Emissive Diode
PC Personal Computer
POD Probability of Detection
POE Power Over Ethernet
PTS Pulse Test Software
QC Quality Control
RMA Return Merchandise Authorization
SNR Signal to Noise Ratio
SW Software
TBD To Be Defined
TSP Tube Support Plate
TWH Through Wall Hole
UUT Unit Under Test
2 APRIS User Manual

APRIS User Manual
TABLE OF CONTENTS
PRODUCT CONTENTS 1
LIST OF REVISIONS 2
ABBREVIATIONS 2
TABLE OF CONTENTS 3
LIST OF FIGURES 6
1 GENERAL 1
1.1 SCOPE 1
1.2 INTENDED AUDIENCE 1
1.3 HOW TO USE THIS MANUAL 1
2 SAFETY AND OPERATIONAL WARNINGS 3
2.1 GENERAL 3
2.1.1 LEGEND 3
2.1.2 GENERAL WARNINGS 3
2.2 ELECTRICAL SAFETY 4
2.3 OPERATIONAL SAFETY 4
2.4 STORAGE SAFETY 4
3 APRIS TECHNOLOGY INTRODUCTION 6
3.1.1 OVERVIEW 6
3.1.2 ACOUSTIC PULSE REFLECTOMETRY SIGNATURES 6
3.1.3 UNIQUENESS OF APRIS 7
3.1.4 limitations OF APR TECHNOLOGY 7
3.1.5 INTERNATIONAL STANDARDS 7
4 SYSTEM DESCRIPTION 8
4.1 HARDWARE 9
4.1.1 SOUND GUN 9
4.1.2 TUBE ADAPTER 12
4.1.3 POE BOX, 110-240VAC POWER INPUT 13
4.1.4 (OPTIONAL) POE BOX, 24VDC POWER INPUT 15
4.1.5 REFERENCE TUBE BUNDLE 16
4.1.6 CARRYING CASE 18
4.1.7 PHYSICAL CHARACTERISTICS 18
4.2 SYSTEM SOFTWARE 19
4.2.1 HW REQUIREMENTS 19
4.2.2 SW INSTALLATION PREREQUISITES 19
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APRIS User Manual
4.2.3 SW INSTALLATION 19
4.2.4 SW REGISTRATION PROCEDURE 19
5 STANDARD OPERATING PROCEDURE (SOP) 20
5.1 GATHER FIELD INFORMATION 20
5.2 TUBES MAPPING/NUMBERING 21
5.2.1 CREATING A NEW INSPECTION SESSION 21
5.3 CLICKS PURCHASE 22
5.4 FIELD INSPECTION 23
5.4.1 SYSTEM ASSEMBY AND SET-UP 23
5.4.2 MEASUREMENT PROCEDURE 28
5.4.3 START TUBES INSPECTION 32
5.5 REVIEW AND EXPORT 33
5.6 SYSTEM TEARDOWN 34
6 SW OPERATION 36
6.1 SW MAIN MENU BAR 36
6.1.1 FILE 36
6.1.2 PREFERENCES 37
6.1.3 ADVANCED 37
6.1.4 HELP 39
6.1.5 LANGUAGE 39
6.2 SETUP TAB 40
6.2.1 MAP TAB 40
6.2.2 PARAMETERS TAB 59
6.2.3 INSPECTION DETAILS TAB 61
6.3 MEASUREMENT TAB 62
6.3.1 MEASUREMENT INSPECTION 62
6.3.2 SIGNAL TAB 69
6.4 ANALYSIS TAB 70
6.4.1 VIEW TAB 71
6.4.2 PRE-ANALYSIS TAB 78
6.4.3 DEFECTS TABLE TAB 81
6.4.4 VERIFICATION TAB 84
6.4.5 REVIEW TAB 89
6.4.6 FINAL REPORT TAB 90
7 MAINTENANCE 93
7.1 PERSONNEL REQUIREMENTS 93
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APRIS User Manual
7.2 VISUAL INSPECTION 93

7.3 CLEANING 93
7.4 SOUND GUN CALIBRATION PROCEDURE 94
7.5 SPARE PARTS 96
7.6 REPLACEMENT PROCEDURES 97
7.6.1 TUBE ADAPTER FOAM REPLACEMENT 97
7.6.2 ETHERNET CABLE REPLACEMENT 97
7.6.3 SW LICENSE UPDATE 97
7.7 HW TROUBLESHOOTING 97
8 QUALIFICATIONS AND CONFORMITY 98
APPENDIX I. EXAMPLES OF TUBE SIGNALS 99
APPENDIX II. CONFIGURE IP ADDRESS ON PC NIC 106
APPENDIX III. REFERENCED DIRECTIVES, SPECIFICATIONS AND STANDARDS 112
APPENDIX IV. RJF 544 ETHERNET CONNECTION SYSTEM 113
APPENDIX V. ARTIFICIAL TUBE MAPPING 117
APRIS User Manual 5

APRIS User Manual
LIST OF FIGURES
FIGURE 1 HEARING HAZARD WARNING LABEL......................................................................................... 4
FIGURE 2 ACOUSTIC PULSE REFLECTOMETRY ......................................................................................... 6
FIGURE 3 MAIN SYSTEM COMPONENTS GENERAL VIEW........................................................................... 8
FIGURE 4 SOUND GUN BACK SIDE VIEW ................................................................................................. 9
FIGURE 5 SOUND GUN FRONT SIDE VIEW ............................................................................................... 9
FIGURE 6 SOUND GUN ASSEMBLY ..........................................................................................................10
FIGURE 7 SOUND GUN DIMENSIONS ......................................................................................................11
FIGURE 8 TUBE ADAPTER EXAMPLE (SPONGE REMOVED) .......................................................................12
FIGURE 9 POE BOX P/N ARG01004 GENERAL VIEW .................................................................................13
FIGURE 10 POE BOX P/N ARG01004 INDICATION LED ............................................................................13
FIGURE 11 POE BOX P/N ARG01004 DIMENSIONS ..................................................................................14
FIGURE 12 POE INJECTOR P/N TP-DCDC-2USB-24 GENERAL VIEW ..........................................................15
FIGURE 13 REFERENCE TUBE BUNDLE ...................................................................................................16
FIGURE 14 CARRYING CASE GENERAL VIEW ...........................................................................................18
FIGURE 15 MENU “FILE” ........................................................................................................................21
FIGURE 16 110/220VAC POE CONNECTION DIAGRAM .............................................................................23
FIGURE 17 48VDC POE CONNECTION DIAGRAM .....................................................................................23
FIGURE 18 SYSTEM INITIALIZATION ......................................................................................................28
FIGURE 19 SYSTEM INITIALIZATION ......................................................................................................28
FIGURE 20 INITIALIZATION FAILURE MESSAGE ......................................................................................29
FIGURE 21 RETRY SYSTEM INITIALIZATION ...........................................................................................29
FIGURE 22 “MEASURE” ..........................................................................................................................30
FIGURE 23 FUNCTIONAL TEST FINISHED ...............................................................................................31
FIGURE 24 FUNCTIONAL TEST FINISH MESSAGE ....................................................................................31
FIGURE 25 SW MAIN MENU ...................................................................................................................36
FIGURE 26 "FILE" MENU OPTION ...........................................................................................................36
FIGURE 27 PREFERENCES MENU OPTION ...............................................................................................37
FIGURE 28 ADVANCED MENU OPTION ....................................................................................................37
FIGURE 29 LICENSE MANAGEMENT WINDOW .........................................................................................38
FIGURE 30 CLICKS STATUS WINDOW .....................................................................................................38
FIGURE 31 HELP MENU OPTION .............................................................................................................39
FIGURE 32 LANGUAGE MENU OPTION ....................................................................................................39
FIGURE 33 SW OPERATION WORKFLOW ................................................................................................40
FIGURE 34 MAP CREATION - TUBE DETECTION ......................................................................................40
FIGURE 35 CREATE A NEW MAP .............................................................................................................41
FIGURE 36 CREATE A NEW MAP FROM PHOTO .......................................................................................41
FIGURE 37 SELECT PICTURE FOR MAP ...................................................................................................42
FIGURE 38 PICTURE FOR MAP EXAMPLE .................................................................................................42
FIGURE 39 ROW X BASED MAP ..............................................................................................................43
FIGURE 40 ROW BASED MAP EXAMPLE ...................................................................................................44
FIGURE 41 TUBE DETECTION AREA BUTTON ......................................................................................44
FIGURE 42 BORDER THE TUBES AREA ....................................................................................................45
FIGURE 43 TUBE DIAMENER MEASUREMENT ..........................................................................................45
FIGURE 44 “SEARCH TUBES” BUTTON ....................................................................................................46
FIGURE 45 DEECTED TUBES MARKS .......................................................................................................46
FIGURE 46 TUBE RADIUS FIELD .............................................................................................................46
FIGURE 47 ALL TUBES ARE PROPERLY DETECTED ..................................................................................47
FIGURE 48 MANUAL EDITING .................................................................................................................48
FIGURE 49 ADDITIONAL RIGHT CLICK OPTIONS.....................................................................................49
FIGURE 50 MEASUREMENT NAME EXAMPLE ............................................................................................49
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APRIS User Manual
FIGURE 51 DEFINE THE 1ST TUBE ......................................................................................................... 50

FIGURE 52 DEFINE THE 1ST DIRECTION ................................................................................................ 50
FIGURE 53 DEFINED ORDER .................................................................................................................. 51
FIGURE 54 ORDER MARKS DETAILS ....................................................................................................... 51
FIGURE 55 WRONG TUBES ORDERING EXAMPLE .................................................................................... 52
FIGURE 56 MANUAL TUBE ORDERING MENU .......................................................................................... 52
FIGURE 57 MANUAL TUBE ORDERING EXAMPLE – 1ST COLUMN ............................................................... 53
FIGURE 58 MANUAL TUBE ORDERING EXAMPLE – 2ND COLUMN .............................................................. 54
FIGURE 59 “PATH” SELECTION .............................................................................................................. 54
FIGURE 60 DEFINING BORDER .............................................................................................................. 55
FIGURE 61 "SELECT FROM PATH" EXAMPLE ........................................................................................... 55
FIGURE 62 “SELECT FROM PATH” RESULTS ............................................................................................ 56
FIGURE 63 DEFINING ZONE MUMBER .................................................................................................... 56
FIGURE 64 TUBE NAMING ..................................................................................................................... 56
FIGURE 65 IMAGE RIGHT CLICK OPTIONS ............................................................................................. 58
FIGURE 66 STRUCTURAL ELEMENTS DEFINITION ................................................................................... 59
FIGURE 67 TUBE PARAMETERS EXAMPLE ............................................................................................... 59
FIGURE 68 TERMOMETER ...................................................................................................................... 61
FIGURE 69 INSPECTION DETAILS .......................................................................................................... 61
FIGURE 70 MEASUREMENT .................................................................................................................... 62
FIGURE 71 COLOR CODED 2D MAP ........................................................................................................ 62
FIGURE 72 LIST OF PERFORMED MEASUREMENTS ................................................................................. 63
FIGURE 73 TUBE ROW-COLUMN-ZONE ATTRIBUTES............................................................................... 64
FIGURE 74 BOTTOM MENU .................................................................................................................... 64
FIGURE 75 MEASUREMENT LIST RIGHT CLICK OPTIONS ........................................................................ 65
FIGURE 76 CHANGE TUBE ATTRIBUTES ................................................................................................. 65
FIGURE 77 “MEASUREMENT NAME FORMAT” DEFINITION ...................................................................... 66
FIGURE 78 “MEASUREMENT NAME FORMAT” EXAMPLE ........................................................................... 66
FIGURE 79 1ST TUBE MARK .................................................................................................................... 66
FIGURE 80 SYNCHRONIZATION REPRESENTATION EXAMPLE .................................................................. 66
FIGURE 81 FAILED TEST INDICATION EXAMPLE ..................................................................................... 68
FIGURE 82 APR ..................................................................................................................................... 68
FIGURE 83 SIGNAL TAB ......................................................................................................................... 69
FIGURE 84 ANALYSIS SUBTABS ............................................................................................................. 70
FIGURE 85 SIGNALS OVERLAPING ......................................................................................................... 71
FIGURE 86 FILTERS .............................................................................................................................. 72
FIGURE 87 GRAPG RIGHT CLICK MEU .................................................................................................... 73
FIGURE 88 ARP FILTERS ..................................................................................................................... 74
FIGURE 89 NO FILTER ........................................................................................................................... 74
FIGURE 90 APR_LOW_BP ...................................................................................................................... 75
FIGURE 91 APR_HIGH_BP...................................................................................................................... 75
FIGURE 92 APR_LOW_N FILTER ............................................................................................................ 75
FIGURE 93 APR_WIDE_BAND FILTER ..................................................................................................... 76
FIGURE 94 APR_BASIC .......................................................................................................................... 76
FIGURE 95 RIGHT CLICK MENU ............................................................................................................. 77
FIGURE 96 PRE-ANALYSIS FINISHED ..................................................................................................... 78
FIGURE 97 LANDMARK TABLE - STRUCTURAL ELEMENTS ....................................................................... 78
FIGURE 98 REPORT FINISHED MESSAGE ........................................................................................... 79
FIGURE 99 PRE-ANALYSIS TAB SCREEN ................................................................................................. 79
FIGURE 100 STRUCTURAL ELEMENTS (LANDMARKS) MANAGEMENT ............................................... 80
FIGURE 101 DEFECTS TABLE .............................................................................................................. 81
FIGURE 102 RIGHT CLICK MENU ........................................................................................................... 82
FIGURE 103 VERIFICATION TAB ............................................................................................................ 84
APRIS User Manual 7

APRIS User Manual
FIGURE 104 SMALL DEFECTS TABLE .......................................................................................................85

FIGURE 105 DEFECT PROPERTIES ..........................................................................................................86
FIGURE 106 DIRECT CONTROLS.............................................................................................................86
FIGURE 107 SHORTCUT KEYS ................................................................................................................88
FIGURE 108 REVIEW TAB .....................................................................................................................89
FIGURE 109 FAULT DISTRIBUTION CHART .............................................................................................90
FIGURE 110 PRINT THE FINAL INSPECTION REPORT ..............................................................................91
FIGURE 111 ADD PICTURE TO REPORT ..................................................................................................92
FIGURE 112 ISSUE REPORT ...................................................................................................................92
FIGURE 113 P1 CALIBRATION TUBE MOUNTED ON SOUND GUN .............................................................94
FIGURE 114 SOUND GUN CALIBRATION, STEP 6 .....................................................................................95
FIGURE 115SOUND GUN CALIBRATION, STEP 7 ......................................................................................95
FIGURE 116 SOUND GUN CALIBRATION, STEP 8 .....................................................................................96
FIGURE 117 NETWORK AND SHARING CENTER ..................................................................................... 106
FIGURE 118 CONNECTION PROPERTIES ............................................................................................... 106
FIGURE 119 INTERNET PROTOCOL SELECTION .................................................................................... 107
FIGURE 120 IP ADDRESSES DEFINITION .............................................................................................. 107
FIGURE 121 CLOSE PROPERTIES WINDOW........................................................................................... 108
FIGURE 122 NETWORK ADAPTER PROPERTIES ..................................................................................... 108
FIGURE 123 NETWORK ADAPTER CONFIGURATION .............................................................................. 109
FIGURE 124 AUTO NEGOTIATION DEFINITION ..................................................................................... 109
FIGURE 125 OPEN COMMAND PROMPT ................................................................................................ 110
FIGURE 126 PING SOUND GUN IP ADDRESS ......................................................................................... 110
FIGURE 127 PING RESULTS ................................................................................................................. 110
FIGURE 128 PING FAILURE .................................................................................................................. 111
8 APRIS User Manual

GENERAL
1 GENERAL
1.1 SCOPE
This manual provides the specifications and instructions for the safe and effective
operation of TALCYON Acoustic Pulse Reflectometry Inspection System (APRIS) based on
proprietary Acoustic Pulse Reflectometry technology.
The APRIS is designed for on-site inspection and evaluation of tubular systems for defects
such as holes pits, erosion, blockages, etc. Utilized in a variety of industries such as power
plants, refineries, chemical plants, etc., inspections are conducted through the injection of
excitation signal through one open end of the tube under test and analysis of the reflected
waves.
The system consists of a handheld Sound Gun with a probe, connected to PC. It also
includes a reference tube bundle to perform system functional tests.
Reference tube bundle comprises of 10 tubes. On which few tubes are with holes,
blockages and wall loss. By doing the measurements on those tubes and recording the
reflection shall ensure the working condition of the APRIS system.
While this user manual covers basic instructions for performing inspections and generating
an inspection report, it is intended to be used primarily as an installation and operation
instruction manual. It is not a substitute for an operator’s training course offered by
TALCYON.
Screen shots provided in this manual are based on Version 1 of the APRIS system
application software (APRIS Pulse Test Software (PTS)) and may differ slightly
from the actual screen shots in your particular version.
Before reading any further, please start with the How to Use This Manual section
below.
All illustrations in this document are for demonstration purposes only, intended
solely to provide a visual explanation text.
1.2 INTENDED AUDIENCE

This Manual is intended for use by maintenance personnel: field operators (technicians).
1.3 HOW TO USE THIS MANUAL

Review the table below to locate the relevant to your needs information:
Subject Chapter Section
Understanding the System operation General system description 3, 4
APRIS User Manual 1

GENERAL
Preparation for measurements and Standard Operating Procedure and 5, 6

conducting measurements SW Operation
System maintenance Maintenance 7
2 APRIS User Manual

SAFETY AND OPERATIONAL WARNINGS
2 SAFETY AND OPERATIONAL WARNINGS

2.1 GENERAL
Please read the following safety information before using the product. Attention to these
warnings will help prevent personal injuries and damage to the equipment.
Before each use please check there are no signs of damage to the equipment. If some
components appear damaged, do not use the product.
The basic safety instructions and the product documentation should be kept in a safe
place and passed on to subsequent users.
2.1.1 LEGEND
The following safety signs and symbols are used in the manual:
Indicates a hazardous situation which, if not avoided, may result in death or
injury.
Indicates the possibility of incorrect operation which can result in damage to the
product.
Indicates information related to safety or system proper use.
2.1.2 GENERAL WARNINGS
Safety cannot be overemphasized.
Do not abuse mechanically: do not crush, mutilate or puncture to reduce the risk
of fire.
Do not dispose into the fire.
The protection provided by the equipment can be impaired if used in a manner

not specified by the manufacturer
The APRIS is not waterproof or dustproof outside of the carrying case.
In extreme wet or dusty conditions, the unit should be stored in its carrying case.
APRIS User Manual 3

2.2 ELECTRICAL SAFETY

The following information on electrical safety must be observed, failing to follow these
instructions may result in electric shock, fire and/or serious personal injury or death.
Do not wet or immerse in water
Handling operations are relatively safe only if all directives are strictly
followed.
All instructions and recommendations detailed in this Manual are subject to
local laws and regulations
Power supply cord usage – Use only with suitably rated main supply cord (having
3 conductors minimum of 18 AWG or 1 mm2, rated minimum of 300V, Harmonized
Type for Europe and UL Listed/CSA Certified for North America, with a molded
plug rated minimum of 6A).
Verify that electrical equipment is not located in a hazardous environment,

such as a damp/wet location or where it is exposed to high temperatures
and flammable gases and vapors
Make sure overcurrent and safety devices, such as fuses, circuit breakers
and ground fault circuit interrupters (GFCI), have not been tampered with
and are working correctly
Inspect the power cord and plug to ensure there are no defects, such as
cuts in the insulation exposing the bare wiring
Identify if the equipment has an emergency shutoff switch and where it is
located prior to use
Make sure there is sufficient space around the electrical equipment or circuit
to allow for operation and maintenance
Remove all personal metal jewelry prior to using or working on electrical
equipment or circuits
2.3 OPERATIONAL SAFETY
Hearing hazard – Do not point the Sound Gun toward the head as the sound
omitted from the probe end may damage hearing (see figure below):
FIGURE 1 HEARING HAZARD WARNING LABEL
Observe all safety precautions at all times when handling the equipment
2.4 STORAGE SAFETY

Store the equipment in its original shipping container (carrying case) at room
temperature-
4 APRIS User Manual

Do not store equipment below -20°C or above +70°C
Beware of possible loose or broken parts that might cause injury. Do not touch
them and contact customer support immediately.
If possible, the system should be stored in its carrying case.
APRIS User Manual 5

APRIS TECHNOLOGY INTRODUCTION
3 APRIS TECHNOLOGY INTRODUCTION

APRIS uses the Pulse Reflectometry for tube inspection.
3.1.1 OVERVIEW
Pulse Reflectometry is a Non-Destructive Testing (NDT) technique that sends acoustic
pulses through air medium and measures any ensuing reflections.
Any change in the cross-sectional area in the tubular system creates a reflection.
Defects in a tube create reflections
Each defect has its own signature and our patented algorithms identify and report
location, type and size of defects
FIGURE 2 ACOUSTIC PULSE REFLECTOMETRY
3.1.2 ACOUSTIC PULSE REFLECTOMETRY SIGNATURES

The Acoustic Pulse Reflectometry (ARP) is based on the fact that different defects provide
different acoustic signatures as follows:
6 APRIS User Manual

APRIS TECHNOLOGY INTRODUCTION
3.1.3 UNIQUENESS OF APRIS

Non-Invasive (uses only sound waves)
Applicable to any shape or configuration (Straight/ multiple bends, finned, coiled,
spiral, helical tubes etc.,)
Inspects any tube materials (Ferrous, Non-ferrous, graphite, composites etc.,)
Ultrafast inspection (Less than 10 seconds per tube)
Easy to use
The sophisticated algorithm to identify the precise location, type and size of defects
Intuitive software with artificial intelligence to generate reliable and quality report
Seamless communication with a portal to enhance user interactions
3.1.4 limitations OF APR TECHNOLOGY

Defects in the outer diameter can’t be detected
Inept to detect the defects under deposits/scales
Cracks under pressure (Closed Cracks) are not detected
3.1.5 INTERNATIONAL STANDARDS

ASTM E2906/E2906M-13: Standard Practice for Acoustic Pulse Reflectometry
Examination of Tube Bundles
ASME BPVC.V-2017: Article 18-Acoustic Pulse Reflectometry (APR) Examination
APRIS User Manual 7

SYSTEM DESCRIPTION
4 SYSTEM DESCRIPTION
This section describes APRIS hardware and software components, and their purpose.
5 4 3 2 1
FIGURE 3 MAIN SYSTEM COMPONENTS GENERAL VIEW
The system consists of the following components:
Max. Weight,
# Item OEM P/N Qty. Notes
kg
1 Sound Gun with strap ARG 01-000 1 1.5
2 Sound Gun to POE Box cable ARG 45-008 1 7 m length
0.23
maximum
3 110-240VAC POE Box ARG 01-004 1 110/240VAC
0.45
power input
4 POE Box to PC Ethernet cable ARG 45-010 1 0.1
5 Software application APRIS_M 1 The laptop is
N/A
not supplied
6 (Optional) 24VDC POE Injector TP-DCDC- 1 5VDC power
0.1
2USB-24 input
7 (Optional)Ethernet Cable 1 Standard USB
cable with
Type A 0.1
connectors
on both sides
8 Tube adapters ARG-45014 13 0.5
9 Calibration tube Need to add 1
11 Reference tube bundle ARG45015 1 10 tubes 5.0
8 APRIS User Manual

SYSTEM DESCRIPTION
4.1 HARDWARE
4.1.1 SOUND GUN
Sound Gun P/N ARG 01-000 components are as follows (see figures below):
# Item Qty. Notes
1 LED 4 Indicates current MOP:
Ready
Inspection in progress
Inspection error
TBD
2 LCD 1 Displays visual information about the
measurement
3, 7 Push button 2 Turns front illuminating LEDs (8) ON/OFF
4, 10 “INSPECT” push button 2 Activates measurement
5 Handle 1
6 Connector 1 1GBE LAN, RJ45 connector
8 Illuminating LED 4 Illuminate UUT if needed
9 Tube adapter locking nut 1 Holds adapter attached to the gun
11 Anchor for strap 2
12 Receptacle 1
13 Tube adapter 1
FIGURE 5 SOUND GUN FRONT SIDE

FIGURE 4 SOUND GUN BACK SIDE VIEW
VIEW
APRIS User Manual 9

SYSTEM DESCRIPTION
FIGURE 6 SOUND GUN ASSEMBLY
4.1.1.1 LCD DISPLAY

The sound gun and the Talcyon SW communicate with each other. The graphic LCD
display on the Sound gun provides visual information during the inspection, based on the
input and status of the SW.
The following information is displayed on the screen:
Status Guidance Failure to measure
On the Sound Gun LCD screen, an arrow-based navigation tool shows the location
of the next tube to be tested.
In the example below, the next tube to be tested has:
a. 4 columns to the right and one column to the left
b. 10 rows above and 5 rows below
10 APRIS User Manual

SYSTEM DESCRIPTION
4.1.1.2 STATUS LEDS

During system initialization, the two LEDs on the back of the Sound Gun are turned on. A
green LED light on the Sound Gun indicates that the initialization is complete and the
system is ready to perform tests. Specific messages are displayed on the Sound Gun LCD
screen
The LED color indications on the Sound Gun are defined as follows:
System Ready for inspection.

The last test was performed properly.
Ready for next test (or step to the next tube to be tested).
Inspection in progress
SNR level is below acceptance level (75dB)

The last test was not performed properly, probably due to a measurement
quality control (QC) error/warning. If applicable, repeat the test. The same
indication is displayed on the Sound Gun LCD screen and the PC display.
TBD
4.1.1.3 SPECIFICATIONS
Sound Gun power consumption: 2 Watts.
Size and Dimensions:
FIGURE 7 SOUND GUN DIMENSIONS
APRIS User Manual 11

SYSTEM DESCRIPTION
4.1.2 TUBE ADAPTER

A specialized component attached to the Sound Gun and inserted into the tube being
inspected:
FIGURE 8 TUBE ADAPTER EXAMPLE (SPONGE REMOVED)
List of supplied Tube adapters

Tube
Adapter
Adapter INSPECTION
# Adapter P/N diameter, Qty.
Series diameter
mm/inch
range, mm
1 ARG 45014-B1 7/0.27 1 B1 7.1-9
2 ARG 45014-B2 9/0.35 1 B2 9.1-11
3 ARG 45014-B3 11/0.43 1 B3 11.1-13
4 ARG 45014-B4 13/0.51 1 B4 13.1-15
5 ARG 45014-B5 15/0.59 1 B5 15.1-17
6 ARG 45014-B6 17/0.67 1 B6 17.1-19
7 ARG 45014-B7 19/0.75 1 B7 19.1-21
8 ARG 45014-B8 21/0.83 1 B8 21.1-23
9 ARG 45014-B9 23/0.91 1 B9 23.1-25
10 ARG 45014-B10 25/0.98 1 B10 25.1-27
11 ARG 45014-B11 27/1.06 1 B11 27.1-29
12 ARG 45014-B12 29/1.14 1 B12 29.1-31
13 ARG 45014-B13 31/1.22 1 B13 31.3-35

SYSTEM DESCRIPTION
4.1.3 POE BOX, 110-240VAC POWER INPUT

Power Over Ethernet (POE) box OEM P/N ARG01004 converts 110/220 VAC to 24 VDC
required for the Sound Gun operation.
POE Box components are as follows (see figures below):
# Item Qty. Notes
1 Green status indication LED 1 The green indication LED is lit when
+24VDC exists at the POE box output.
2 APR - Connector with protection cap 1
3 PC - Connector with protection cap 1
4 AC - C14 Type connector 1 110/220 VAC, Ends by C14 Type
connector
5 Nameplate 1
1 5
3 2
2
FIGURE 10 POE BOX P/N ARG01004

FIGURE 9 POE BOX P/N ARG01004 GENERAL VIEW
INDICATION LED

SYSTEM DESCRIPTION
FIGURE 11 POE BOX P/N ARG01004 DIMENSIONS

SYSTEM DESCRIPTION
4.1.4 (OPTIONAL) POE BOX, 24VDC POWER INPUT

The POE injector P/N TP-DCDC-2USB-24 provides 24 VDC electrical power required for the
Sound Gun operation by converting 5VDC USB power from Power bank.
Use power bank with capacity at least 20,000 milliAmp*hour.
POE Injector components are as follows (see figures below):
TO SSOUND GUN
CONNECTOR
GREEN
INDICATION LED
TO PC
ETHERNET PORT
TO POWER BANK
USB CONNECTORS
FIGURE 12 POE INJECTOR P/N TP-DCDC-2USB-24 GENERAL VIEW
The green indication LED is lit when PC is connected via Ethernet cable.

SYSTEM DESCRIPTION
4.1.5 REFERENCE TUBE BUNDLE

Reference tube bundle comprises of 10 tubes. On which few tubes are with holes,
blockages and wall loss. By doing the measurements on those tubes and recording the
reflection shall ensure the working condition of the APRIS system. The reference tube
bundle P/N ARG 45015 contains aluminum tubes with deliberately manufactured defects.
This bundle shall be used every time prior to inspection.
FIGURE 13 REFERENCE TUBE BUNDLE
4.1.5.1.1 TUBES BUNDLE DIMENSI ONS
Hole Wall Loss Blockage
Tube # Cross Section

Position Diameter Position Wall Reduction Position
Reduction
[m] [mm] [m] [%] [m]
[%]
1 Flawless
2 0.3 40%
3 0.6 1
4 1.1 50%
5 1.1 2 0.3 5%
6 0.6 2
7 Flawless
8 1 2 0.3 5%
9 1 1 0.3 10%
10 0.075 20%
10 0.475 20%
10 0.65 40%
10 0.825 60%
10 1 80%

SYSTEM DESCRIPTION
Tube Outer Diameter (OD): 25.4mm/Tube Material: Aluminum

Tube Thickness: 2.11mm
Tube Length: 1.2m

SYSTEM DESCRIPTION
4.1.6 CARRYING CASE

The APRIS system is supplied in a carrying case P/N iM2450, which provides protection for
the system components during air and ground transportation, storage, and handling.
FIGURE 14 CARRYING CASE GENERAL VIEW
Carrying case dimensions are: 488 x 386 x 229 mm
4.1.7 PHYSICAL CHARACTERISTICS

4.1.7.1 ENVIRONMENTAL CONDITIONS
Name Requirement Comment

Vibration Random 10-500Hz Per MIL-PRF-28800 Procedure 4.5.5.3.1, Class 2
Shock 30g, Half Sine Per MIL-PRF-28800 Procedure 4.5.5.4.1, Class 2
Transit Drop 30cm, within transit Per MIL-PRF-28800 Procedure 4.5.5.4.2, Class 2
case
Bench handling 45º / 10cm tilt, Per MIL-PRF-28800F Procedure 4.5.5.4.3,
which is higher Class2
Water proof Per IP52
Temperature: -10ºc to +50ºc Per MIL-PRF-28800F Procedure 4.5.5.1.1,
Operating Class2
Temperature: -20ºc to +70ºc Per MIL-PRF-28800F Procedure 4.5.5.1.1,
Non-operating Class2
Humidity 5 to 95±5 %, Per MIL-PRF-28800F Procedure 4.5.5.1.1.2, Class
Non – condensing 2
5 to 45±5 % RH@ >
40ºc
Salt exposure 48Hrs, within transit Per MIL-PRF-28800F Procedure 4.5.6.2.1,
case 4.5.6.2.2, Class2
Dust resistance Per IP52

SYSTEM DESCRIPTION
Safety and EMI FCC part 15, Subpart Per UL and CE directives
/ EMC B, Class A
EN 61326-1:2006
4.2 SYSTEM SOFTWARE

The SW provides the following capabilities:
Define Unit Under Test (UUT) parameters
Receive measurement results from the Sound Gun and detect defects
Analyze and store results
Print Report
For detailed SW description and operation see section 6.
4.2.1 HW REQUIREMENTS
The PC shall meet the following minimal requirements:
Processor: Intel i5 or equivalent
RAM: 8GB minimum
Hard Disk space:
500GB (for the comfortable storage of the session data)
300MB for the installation
Ethernet port (100Mbps for stand-alone APRIS gun).
Supported OS: Windows 10 (64-bit) or Windows 7 SP1 (64-bit)
4.2.2 SW INSTALLATION PREREQUISITES

Make sure that the SW below is installed on your PC before you begin PTS SW installation.
Matlab 2015b runtime
VC2013 runtime
TBD: ftp client for the cloud
4.2.3 SW INSTALLATION
1. Download the PTS software from TBD.
2. Run the installer.
The Installer will guide you through the installation process.
4.2.4 SW REGISTRATION PROCEDURE

After the software is installed there is a registration process – the user needs to provide
his Customer_ID at the portal, and needs to copy the unique installation identifier from
the PTS form to a website. Hope we’ll have it by next week.

STANDARD OPERATING PROCEDURE (SOP)
5 STANDARD OPERATING PROCEDURE (SOP)

This chapter describes the recommended Standard Operating Procedure (SOP) for the
Talcyon APRIS system.
The SOP has TBD steps:
# Step Description
1 Gather Field Collect all applicable information on site a UUT layout
information
2 Tubes Mapping Create new session, map and number the tubes
3 Purchase clicks If needed, purchase clicks per required adaptor and tubes
quantity.
4 Field Inspection Setup the APRIS system and inspect the UUT
5 Review and Export Review inspection data and export for analysis
6 System Teardown
The sub-sections below describe the SOP steps in detail.
5.1 GATHER FIELD INFORMATION
Make sure all essential details such as tube total length, tube OD, tube thickness,
,total number of tubes to inspect and tube configuration is gathered either from
the data sheet or from plant operator/asset owner. In case of the inspection of U
tube/fin fan air cooler/boiler/HRSG (super heater/economizer), data sheet as well
drawing ought to be reviewed meticulously to know the bends, header box details
etc.
Contact us for any suggestions register such special applications.
Clarify the following:
a. How old is the equipment that to be inspected?
b. Was any inspection performed on the equipment prior to APR inspection? If
so, when and which method of inspection? (It shall aid in corrosion growth
rate computation)
If APR inspection was performed on the same equipment, make sure the
equipment to be inspected from the same side (face) for all periodic inspections.
Inform clients that Ambient/Tube temperature must be below 350C to proceed
inspection.
Borescope shall be carried/ requested from client to check tube cleanliness.
Verify that your account has enough click quota to proceed with the site tubes’
inspection. .

5.2 TUBES MAPPING/NUMBERING

Create inspection sessions and map the tubes.
If some of the tubes were repaired or replaced, They must be inspected in a
separate session.
5.2.1 CREATING A NEW INSPECTION SESSION

Go to File->New to create a new inspection session.
All parameters will be restored to default values
To name this session, go to File->Save Session As; choose a unique name and location for
this session (see figure below):
FIGURE 15 MENU “FILE”
The measurement data is saved automatically to the hard drive as it is acquired

(no data is lost due to a crash/outage problem).
By default, all acquired data is saved to a temporary directory on the disk as it
is acquired – Path\TempDir_XX.
In order to avoid overwriting this temporary directory, use the Rename or the
Save Session As options.
The Save As button can be used to make a copy of the acquired data, but will
entail copying large amounts of data to the new directory, cluttering the disk
and taking some time to execute.
See Chapter TBD for Tube Mapping instructions.

5.3 CLICKS PURCHASE

tbd

5.4 FIELD INSPECTION

5.4.1 SYSTEM ASSEMBY AND SET-UP
This section describes steps required for system preparation for inspection.
The APRIS is designed to work with or without mains 110/220VAC power supply, as
shown in the figures below:
FIGURE 16 110/220VAC POE CONNECTION DIAGRAM
FIGURE 17 48VDC POE CONNECTION DIAGRAM
External Power bank is not supplied by Talcyon. Any standard 5VDC power
source to POE Injector is applicable
Ethernet cables are not supplied by Talcyon


5.4.1.1 ASSEMBLY PROCEDURE

This section describes the assembly procedure for the 110/220VAC connection diagram.
Notes are added inside the steps for the 48VDC connection diagram
Remove the Adapter Locking Nut Insert adapter and the locking nut
from the gun by rotating counter into the Sound Gun receptacle
clock-wise
Rotate the nut clockwise and Remove the protective cover

tighten by hand Connect one side of the Sound Gun
to POE Box cable
For 48VDC use standard Ethernet
cable.

POEbox to PC
Sound Gun to
POEbox
Remove the protective covers

Connect Sound Gun to POE Box cable to APR interface
Connect the protected side of the POE Box to PC cable to PC interface
For 48VDC use standard Ethernet cables.
To 100/200 VAC
Connect the unprotected side of the Connect POE Box to Mains.

POE Box to PC cable to the NIC interface
For 48VDC – connect 2 USB cables
of the PC
to the external power bank

5.4.1.2 HW VERIFICATION
Connect the system and verify the following:
1) The green LED on POE box is lit
2) LCD at the Sound Gun back panel is lit during 1-2sec
3) Four (4) head white Sound Gun LEDs are lit
If one of the test objectives is failed – see Troubleshooting section 7.7
If system initialization and functionality test fail, try once again by switching off the system
and switch on.
If it keeps on failing, proceed to gun calibration (see section 7.4) and then commence
taking 2 measurements to ensure that the signal recorded is good with the end of tube
signal.
If inappropriate signals are observed as per APPENDIX I, switch off and redo from the
start.
If it’s observed again, change the gun and continue the measurement.
5.4.1.3 SYSTEM CALIBRATION

Perform calibration as described in section 7.4.

5.4.2 MEASUREMENT PROCEDURE

Prepare the UUT
Make sure that ambient/tube temperature is below 50 0C prior and during the
inspection.
Inspect tubes from outlet side for Heat Exchangers.
The second inspection of same tubes must be taken from the opposite
side/end also in cases if you find/suspect initial leak as per the signal after site
verification of signals after inspection. Access to both sides is required.
All Tubes must be clean and dry (No water stagnation)
Launch the APRIS PTS software and load the applicable session
Run System Initialization
During system initialization, the system verifies that all hardware modules are functioning
properly.
System calibration is not conducted in this step
skip the initial 8 seconds of waiting time and go directly to the system initialization
process, click “OK” on the initial message window (see figure below).
FIGURE 18 SYSTEM INITIALIZATION
During software start-up, system initialization is performed.
FIGURE 19 SYSTEM INITIALIZATION

Hearing hazard – Do not point the Sound Gun toward the head as the sound
omitted from the probe end may damage hearing:
Then a system initialization message will be displayed (will be elaborated in the following
section).
FIGURE 20 INITIALIZATION FAILURE MESSAGE
If one of the modules fails during the initialization process, click “Retry” to repeat. If it still
fails, try restarting the system.
FIGURE 21 RETRY SYSTEM INITIALIZATION
LAN connectivity issue: failure with the LAN connectivity will cause a power up the
error in the SGCM module.
if the problem persists do not use the system and contact TALCYON customer
support.

5.4.2.1 RUN FUNCTIONAL TEST

Verifies the system functionality using the TALCYON reference tube bundle which is
composed of 10 aluminum tubes with planted defects.
The test must be completed successfully before starting an inspection session.
The reference tube bundle parameters are defined in the section 4.1.5
TEST SEQUENCE
Press
Insert the probe into the first tube (marked Tube #1) and click “Measure” (see
figure below).
FIGURE 22 “MEASURE”
Follow the same sequence for the remaining 3 tubes. To abort the test click the
“cancel” button.
Upon test completion, the following message will be displayed (see figure
below):

FIGURE 23 FUNCTIONAL TEST FINISHED
The test results will be analyzed. At this stage, the system compares current
results to factory values
FIGURE 24 FUNCTIONAL TEST FINISH MESSAGE
The inspection can’t continue until the issues are resolved and the
functional test is passed successfully.

5.4.3 START TUBES INSPECTION

Choose correct tube adapter
This should be done before the inspection process.
Inspect tubes, one-by-one, according to tube mapping and instructions on the Sound Gun
display
Once the measurement is taken for 5 tubes, check the quality & end of tube
signal. If you are unable to find the end of tube signal because of intermittent big
blockage signal, inform client register this and request to clean tube again. If the
client doesn’t nod for it, explain to them that report would be issued only for it
If bad measurement notification is received, first go to View → Signal and check the
signal leakage at the beginning of signal as compared to the reference signal.
If signal leakage is found, delete the measurement, verify the adapter is tight and
sealed and repeat the inspection. See an example of good signal and signal with
leakage in the APPENDIX I
If any leakage signature is observed in the initial part of the signal, reinspect from
another side for verification.

If signal leakage is not there as compared to the reference signal check the SNR
and verify it is less than 75 db.
IF signal leakage is not there and SNR is also in the operational range:
Check the signal quality as per examples are given in APPENDIX I. If signal quality
is bad, delete it and redo the shooting and check again the signal quality. If it is
still bad, ignore the bad measurement warning and carry on with the shooting of
other tubes. This signal can be manually analyzed in detail later during analysis.
5.5 REVIEW AND EXPORT

Once all measurements are taken, go to View→ Signal
Check the signal quality by enlarging especially 3 specific areas such as: Initial part, U
bend and End of the tube.
If the signal is too disturbed for its entire length or at the beginning, make a note of it
and redo those measurements. It shall be different due to the influence of external
factors such as cleanliness/water stagnation, noise factors.
Then create a new session to reshoot them from the same side which you have
taken measurements earlier and the other end of the tube if the access is
available. Take at least 2 measurements of each tube for verification.
Check and ensure the signal quality. The probability of detection (POD) depends
on the signal quality. As long as SNR is greater than 80dB, POD shall be high.
See an example of good signal, signal with leakage and signal with no end of tube
signature in APPENDIX I.
Go to File →Save before closing the PTS version of the software.
To send the file for analysis, go to File →Compress to Zip and save is under a
specific folder with a specific name.
This file can be exported to Portal for analysis and report generation. In order to
access Portal, make sure laptop computer is connected to the internet. Shortcut for
Portal shall be created either during training or it shall be accessed via address
http://www. talcyon.com/portal

5.6 SYSTEM TEARDOWN

To 100/200 VAC
Disconnect POE Box from Mains. Disconnect the unprotected side of

the POE Box to PC cable from the
NIC interface of the PC
Disconnect the protected side of the POE Box to PC cable to PC interface

Disconnect Sound Gun to POE Box cable from APR interface
Place the protective covers on the interfaces

Disconnect the Sound Gun to POE Remove the Adapter Locking Nut
Box cable from the gun by rotating counter
Place the protective covers on the clock-wise
interfaces Remove the adapter
Store all components inside the carrying box.

SW OPERATION
6 SW OPERATION
This chapter describes the APRIS PTS software Graphic User Interface.
6.1 SW MAIN MENU BAR

Main menu options are shown below.
FIGURE 25 SW MAIN MENU
6.1.1 FILE
The following options are available:
FIGURE 26 "FILE" MENU OPTION
New session Creates a new measurement session

Load session Loads previously saved session
Save session Saves current session
Save as Saves current session under the custom defined name
Compress session to zip Reduces the size of the session and saves as an archive
file in ZIP format
Rename Renames the session
Import setup parameters Imports saved setup parameter
Export setup parameters Exports setup parameters
Unload session Unloads current session
Exit Exits the application
Restart Restarts the application.

SW OPERATION
6.1.2 PREFERENCES
FIGURE 27 PREFERENCES MENU OPTION
Allows choosing Metric or Imperial system to be used.
6.1.3 ADVANCED
FIGURE 28 ADVANCED MENU OPTION
Show logger Shows logger window

Open log file Opens the log file
Open pts folder Opens this folder
Open session folder Opens sessions folder
Noise Allows delete or recalculate noise
Database Allows to check database or restore default values
License Opens license management window

SW OPERATION
FIGURE 29 LICENSE MANAGEMENT WINDOW
Import session Imports a session while not in the “setup”

tab
Perform functionality test See section 5.4.2.1
Restore pre analysis measurements Restores measurements
System initialization Initializes the system
Purchased clicks status Opens a status window
FIGURE 30 CLICKS STATUS WINDOW

SW OPERATION
6.1.4 HELP
FIGURE 31 HELP MENU OPTION
Opens the “About” window with extended information about SW

About
configuration.
User manual Opens this User Manual
6.1.5 LANGUAGE
FIGURE 32 LANGUAGE MENU OPTION
Allows selecting a language for the SW.

SW OPERATION
6.2 SETUP TAB

The APRIS PTS software application is operated by means of the three main tabs and
applicable sub-tabs as described below:
Setup For the pre-testing steps
Measurement For performing the tests
Analysis For analysis and report generation
The basic workflow is to go through the tabs from left to right. Start with the Setup tab on
the left and go through all its sub tabs – from left to right. When finished, move to the
Measurement tab, then Analysis (see figure below) and so on.
FIGURE 33 SW OPERATION WORKFLOW
6.2.1 MAP TAB

The “Map” tab is used for tube sheet map creation. This is a map that will be used to
determine the inspection sequence (test plan) and is essential for synchronization during
the inspection (see figure below).
FIGURE 34 MAP CREATION - TUBE DETECTION
Two (2) stages can be defined during map creation process:

Tube Detection - Identifying tubes on a photo/drawing – can be done automatically or
manually.
Tube Ordering - Setting the tube attributes by row-column.
Four (4) buttons can be found on the left side:
New map New map creation.
Import map Import of pre-defined map element from an existing session or file.
Export map Export of an on-going/completed map element to an external file.
Apply Embedding map to the session.

SW OPERATION
6.2.1.1 CREATE A NEW MAP

Click on the “new map” button (Figure 54). Two maps can be defined as follows:
Photo based
Matrix Row X Column based
FIGURE 35 CREATE A NEW MAP
6.2.1.1.1 PHOTO BASED MAP
The map is based on a photo or drawing of the component to be inspected.

Click the “New map” option on the left, and then choose the “From photo” option
(see figure below).
FIGURE 36 CREATE A NEW MAP FROM PHOTO
Browse for the appropriate photo/drawing of the unit (see figure below).

SW OPERATION
FIGURE 37 SELECT PICTURE FOR MAP
Double click on the appropriate photo/drawing to open the image on the screen
(see figure below).
FIGURE 38 PICTURE FOR MAP EXAMPLE

SW OPERATION
6.2.1.1.2 TIPS FOR TAKING PICT URES OF TUBE SHEET S
Use a good quality camera, with at least 5 mega pixel resolution and optical zoom
capabilities.
Use flash photography under all circumstances, even in full sunlight, unless there are
safety limitations.
Position the Unit Under Test (Heat Exchanger) to assure that rows are horizontal and
columns are vertical.
Position the camera in front of the tube sheet, holding the camera centered (in line
with the tube sheet center).
The distance between the camera and the tube sheet should be at least 4-5 times the
diameter of the tube sheet. Make sure that most of the picture frame is occupied by
the tube sheet. Move closer to the tube sheet or use optical zoom if necessary to
achieve that goal.
6.2.1.1.3 MATRIX ROW X COLUMN BASED MAP
This option is suitable only for the creation of rectangular shaped maps.
Click the “New map” option on the left, and then choose the “Row X Col” option.
Fill in the desired count for rows and columns, then press OK (see figure below).
FIGURE 39 ROW X BASED MAP
Continue to set the tube naming in the “Tube ordering” tab (see figure below).

SW OPERATION
FIGURE 40 ROW BASED MAP EXAMPLE
Numbering inside the tubes becomes visible starting from a specific zoom level.
6.2.1.2 TUBE DETECTION

In this stage, tubes are detected automatically (or manually) on the image.
Click the “Tube detection” tab
On the left side are the automatic detection controls. On the right side are the
manual editing controls (used to fine-tune the results of the automatic operation if
needed).
Define the tube detection area by clicking
FIGURE 41 TUBE DETECTION AREA BUTTON
Border the image area in which you want the system to search automatically for
tubes (see figure below).

SW OPERATION
FIGURE 42 BORDER THE TUBES AREA
When done, click
Next, click
The image will be zoomed in to increase the accuracy (Figure 61). The zoom can
be changed using the mouse wheel or the “+” and “-“ keyboard buttons.
FIGURE 43 TUBE DIAMENER MEASUREMENT
Click to confirm.

SW OPERATION
Click the “Search tubes” button (see figure below).
FIGURE 44 “SEARCH TUBES” BUTTON
When done, the detected tubes will appear as white circles on the image (see figure
below).
FIGURE 45 DEECTED TUBES MARKS
If not all tubes were detected (see figure above) there are two options:
Press
Use the “Add tube/Delete tube” options at the manual editing mode.
In order to verify more easily that all tubes were detected, reduce the tube radius
size (see figure below)
FIGURE 46 TUBE RADIUS FIELD

SW OPERATION
FIGURE 47 ALL TUBES ARE PROPERLY DETECTED

SW OPERATION
6.2.1.2.1 MANUAL EDITING MODE
This mode is used to fine-tune the automatic detection results if needed.
Click on the “manual” button .

A control panel will be opened (see figure below):
FIGURE 48 MANUAL EDITING
6. 2. 1 .2 .1 .1 OP T ION S IN M AN U AL ED IT ING M O D E:
Select Choose type: Path (point to point) or Rectangle/Tube selection.

Add tube Choose this option then click on the map to manually add a tube.
Delete tube Choose this option then click on a tube to manually delete it.
Delete selection Delete the group of highlighted selected tubes.
Clear path Clear the point to point path.
Select from path Select the group of tubes bordered by the path.
Radius Alter the radius of the white circles presenting the tube.
6. 2. 1 .2 .1 .2 A D DI TI ON A L R IG H T CL IC K O PT I ONS :
View all Zoom out to see the entire map.

Instant zoom Zoom in on the mouse location.
Save as image Save screen capture.
Select all tubes Selects all the tubes and indicates the total tube count.
(xxx)
Invert selection Inverts selection
Holding the mouse Enables pan of the map.
right click and
moving it

SW OPERATION
FIGURE 49 ADDITIONAL RIGHT CLICK OPTIONS
6.2.1.2.2 MISCELLANEOUS
If a message is displayed in the tube detection phase indicating that there is not enough
memory for the operation, try selecting smaller portions of the map until the map is
completed.
If the tube set in “First tube ID” is not located in the corner of the map, the program will
display an appropriate warning message. Select the tube that can be set as the first tube.
To work without Row-Col-Zone, use the R (row) values by right clicking on the
measurements list and choosing “Measurement name” format (see figure below).
FIGURE 50 MEASUREMENT NAME EXAMPLE
The D field (Description) can also be used to type free text for certain tests.
By selecting tubes in the 2-D map, the corresponding tubes in the measurement list
will be selected. If tubes selected in the 2-D map don’t exist in the measurement list,
they will be immediately unselected.
By clicking on a single tube in the 2-D map, the tube Zone-Row-Column information
will be set at the “Measurement name control” panel.
An existing measurement can be renamed by right clicking on it and selecting
“Rename”. The Zone-Row-Column-Description info in the “Measurement name
control” will be set in the measurement’s name.

SW OPERATION
6.2.1.3 TUBE ORDERING (TEST SEQUENCE SETUP)

Order the tubes by row-column attributes.
Go to the “Tube ordering” tab .
6.2.1.3.1 AUTOMATIC T UBE ORDERING
Several parameters need to be defined in order to complete this process:

Define The First Tube - Click on the “Define the first tube” button.
On the map, click on the first tube of the inspection sequence, then recheck the “ Define
the first tube” button (see figure below)
FIGURE 51 DEFINE THE 1ST TUBE
Define The First Direction - Define the inspection sequence direction by selecting 2
adjacent tubes. This can be the first 2 tubes as long as they are in the same
row/column (see figure below)
FIGURE 52 DEFINE THE 1ST DIRECTION
Select Row / Column / Serpentine - Choose whether to order the tubes by rows,
columns, or serpentine.

SW OPERATION
When done click

A map showing the selected ordering will be displayed. The first tube of each row/column
is marked (see figure below).
FIGURE 53 DEFINED ORDER
Zoom in until the numbers of tubes appear and verify correct ordering (see figure
below).
Zoom In to see the numbering is needed.
FIGURE 54 ORDER MARKS DETAILS

SW OPERATION
6.2.1.3.2 WRONG TUBES ORDERING EXAMPLE
FIGURE 55 WRONG TUBES ORDERING EXAMPLE
6.2.1.3.3 MANUAL TUBE ORDERING
If the Automatic Tube Ordering method did not provide the desired results, the Row
Column Zone properties could be set using the manual method.
The manual ordering controls are located at the upper right part of the screen (see figure
below).
FIGURE 56 MANUAL TUBE ORDERING MENU
An example of Manual ordering of the map is described below.
Tube (1,1) is the upper tube in the left most column.
In the map, mark all the tubes in the left most column holding the “Ctrl” key (use
the “Rectangle or Tube” selection mode).
In the bottom orientation panel, set the C field to 1, select the desired starting
point (top in the example below)

SW OPERATION
Click “Apply”.
To determine the proper coloring orientation, verify that the “Order by:” is set to
“columns”.
By leaving the R field empty, the user indicates to the software to automatically fill in the
R values into the selected tubes (see figure below).
FIGURE 57 MANUAL TUBE ORDERING EXAMPLE – 1ST COLUMN
After setting the first column, mark all the tubes in the second column
Set the C field to “2”
Click “Apply” (see figure below).

SW OPERATION
FIGURE 58 MANUAL TUBE ORDERING EXAMPLE – 2ND COLUMN
Repeat the procedure for the entire map.
If the map is at a certain angle, the tubes for each row or column can be chosen by the
“Path” selection mode (see figure below).
FIGURE 59 “PATH” SELECTION
Define the path to border the desired Row or Column (see figure below):

SW OPERATION
FIGURE 60 DEFINING BORDER
Choose the “Select from path” option to select the bordered tubes. (see figure
below).
FIGURE 61 "SELECT FROM PATH" EXAMPLE
Once the desired row has been marked, set the “R” value to “1”. Choose the
numbering starting point for this row and click “Apply” (see figure below).

SW OPERATION
FIGURE 62 “SELECT FROM PATH” RESULTS
Finalizing the map is done by repeating the action for the remaining rows.
To set different zones in the map, select the tubes in the desired zone, clear the
“R” and the “C” fields, set the Z value to the desired zone number, and click
“Apply” (see figure below).
FIGURE 63 DEFINING ZONE MUMBER
6.2.1.3.4 TUBE NAMING
R [X] Represents the row number.

C [X] Represents the column number.
Z [X] Represents the zone number.
N [X] Represents the test sequence number. Meaning: a tube with N=17 will be the 17th
tube to be inspected.
See for example a figure below:
FIGURE 64 TUBE NAMING

SW OPERATION

SW OPERATION
6.2.1.4 IMAGE RIGHT CLICK OPTIONS
FIGURE 65 IMAGE RIGHT CLICK OPTIONS
View all Displays all

Instant zoom Zoom In
Save as image Saves as image
Selection type Selects type of selection (Rectangle/Tube or Path)
Clear selection Clears selection
Select all tubes Selects all tubes
Invert selection Inverts selection

SW OPERATION
6.2.1.5 STRUCTURAL ELEMENTS

Fill fields by relevant structural (landmarks) data to define TSP locations.
Enter First Baffle Location in meters.
FIGURE 66 STRUCTURAL ELEMENTS DEFINITION
6.2.2 PARAMETERS TAB

Go to the Setup->Parameters sub tab. All of the parameters in the list must be completed
in order to proceed with the session setup (see figure below.
FIGURE 67 TUBE PARAMETERS EXAMPLE
Pay close attention to the units in each field.

The unit type (Metric/Imperial) can be changed using the Preferences-
>Units in the menu bar.
When moving to the Inspection tab for the first time, the system will ask
you to fill in the nine parameters shown above.
Filling in these parameters correctly is crucial for proper system performance
For the tube length, use the value to which the tubes were designed (can be extracted
from the unit drawings).
When inspecting U-Tubes, set the “identical geometry tubes” parameter to “no”.
Checking the “show Advanced” box opens a list of all the advanced parameters.
Don’t change any advanced parameter values without consulting with
TALCYON support first!

SW OPERATION
Allows the user to import the parameter set from an existing

session. This option is useful when setting up a unit that was previously inspected or when
inspecting identical units.
Allows the SW to calculate the applicable adapter for the

measurements.
The parameters can be divided into 3 main categories described below.
6.2.2.1 CATEGORY 1 - TUBE PROPERTIES
Tubes’ total length Tube Length

Tubes’ outer diameter Tube Outer Diameter (nominal)
Tube wall thickness Tube Wall Thickness (nominal)
Identical Geometry tubes Yes/No
6.2.2.2 CATEGORY 2 - SYSTEM PROPERTIES
Probe APR - X. specifies the probe size that is named based

Probe type
on the target tube OD.
Allows the SW to calculate the
Recommended adaptor
applicable adaptor for the measurements.
Yes/No – Calculated field that displays clicks’ status for the
Recommended adaptor recommended adaptor. If the field shows No – purchase
Has Clicks clicks.
6.2.2.3 CATEGORY 2 - ENVIRONMENTAL PROPERTIES
Because the speed of sound is affected by the air temperature inside the tube, it is
important to measure and update it in the software.
Temperature Measure the temperature of the tube wall with a surface thermometer (see
figure below). The assumption is that in steady state conditions both should
be equal.

SW OPERATION
FIGURE 68 TERMOMETER
NOTE
The temperature update affects only the location reporting accuracy and NOT the
system sensitivity.
The thermometer is not supplied with the system.
THERMOMETER REQUIREMENTS
Accuracy Up to 5 degrees Celsius variation (±2.50 Celsius).
Surface thermometer The measurement is done on the tube wall
Time to a steady reading 1 minute
6.2.3 INSPECTION DETAILS TAB

Fill in the relevant fields to appear in the final report header page (see figure below).
Free text can be used for recording internal inspection notes. These will NOT appear in the
final inspection report but are intended to be used as a log book to document the
inspection or to communicate data to the session analyzer.
FIGURE 69 INSPECTION DETAILS
Allows the user to import the inspection details from an existing

session.

SW OPERATION
6.3 MEASUREMENT TAB

Under the Measurement tab, you will find 2 sub-tabs (see figure below):
Inspection Where the actual inspection job is taking place

Signal Shows the measured signal
FIGURE 70 MEASUREMENT
6.3.1 MEASUREMENT INSPECTION

In this tab, the actual data acquisition is performed.
Three goals to keep in mind during data acquisition:
Inspect as many tubes as possible during available time.
Verify the measurement label in the software with the actual tube that has been
tested.
Use built in safeguards (error messages, warnings, etc.), to ensure that the tests are
good.
This main module consists of a color coded 2-D map which enables visual synchronization
between the SW GUI and the actual job progress (see figure below):
FIGURE 71 COLOR CODED 2D MAP
All the performed measurements are listed on the measurements list located on the right
side of the screen (see figure below).

SW OPERATION
FIGURE 72 LIST OF PERFORMED MEASUREMENTS

SW OPERATION
Each measurement has the following indicators:

Q Measurement quality control indicator.
G The measurement group number (in use during U-tube analysis).
R Represents whether this tube is contained in the reference averaging.
S Represents tube status (dirty, etc.)
The measurement name control represents the tube row-column-zone attributes (see
figure below).
FIGURE 73 TUBE ROW-COLUMN-ZONE ATTRIBUTES
[R] Row
[C] Column
[Z] Zone
[D] Description. The user can use free text to note the tube condition (plugged, dirty,
corroded, etc.)
6.3.1.1 BOTTOM MENU

Some general functions can be found below the 2D map (see figure below).
FIGURE 74 BOTTOM MENU
Refresh colors To update tube color (Post analysis status)

Reset colors To update tube color to their initial state
View all Zoom out on the entire 2D map
Zoom <> Zoom in/out arrows
Measure To trigger measurement acquisition for the software GUI
Measurement notes Add a description to a measurement
Snr[Db] Signal-to-Noise scores of the selected measurement

SW OPERATION
6.3.1.2 MEASUREMENT LIST RIGHT CLICK OPTIONS

Right click options in the measurement list include (see figure below):
FIGURE 75 MEASUREMENT LIST RIGHT CLICK OPTIONS
Delete selected Delete selected measurement. The counter is decreased

automatically.
Select all measurements Select and highlight all measurements on the 2-D map.
Rename Set measurement name from the measurement name
control.
Change reference and noise to Several options: the selected tube, an average of
selected tubes, an average of all tubes.
Change group of selected Change the group number of the selected tubes.
measurements
Change status of selected Set tube status as dirty.
measurements
Measurement name format Change the attributes by which the tube is defined (see
figure below).
FIGURE 76 CHANGE TUBE ATTRIBUTES
Expert tools\filter analysis Review and edit the UPR custom filter – will be elaborated
in the next section.
Expert tools\measurement qc Measurement quality control status – will be elaborated in
the next section.
Set measurement description Add a description to the measurement name

SW OPERATION
6.3.1.3 NOTES ON INSPECTION
6.3.1.3.1 WORKING WITHOUT ROW-COL-ZONE
If a user wishes to work without Row-Col-Zone, the R (Row) value can be used by right
clicking on the measurements list and then the “Measurement name format” (see figures
below).
FIGURE 77 “MEASUREMENT NAME FORMAT” FIGURE 78 “MEASUREMENT NAME FORMAT”

DEFINITION EXAMPLE
6.3.1.3.2 SYNCHRONIZATION CONS IDERATIONS
The first tube to be inspected (or the next tube during acquisition) is circled in red (see
figure below).
During the inspection, the tubes that were already tested are colored with light blue. The
tubes that have not yet been measured are colored in white. The next tube to be tested is
circled in red and its attributes are presented in the measurement name control on the
bottom right corner of the screen. See figure below.
FIGURE 79 1ST TUBE MARK FIGURE 80 SYNCHRONIZATION REPRESENTATION EXAMPLE
6.3.1.4 INSPECTION SEQUENCE

Inspect all of the tubes to be tested using the Sound Gun push button or the software
“Measure” button. Wait for the probe LED indication before moving on to the next tube.
When a measurement ends, the system pops up a notification presenting the next tube to
be inspected. The user has 3 options (see figure below):
Measure the next tube Either by clicking the probe push button or by clicking the
“measure” button.

SW OPERATION
Skip the next tube The measurement index will be increased by “1” without an
actual measurement being performed. This is relevant for
cases in which the next tube can’t be measured (plugged,
inaccessible, etc.)
Cancel Stops the inspection sequence.
6.3.1.5 MEASUREMENT QUALITY CONTROL

The purpose of the Quality Control (QC) is to identify and report hardware related
problems (i.e., not analysis issues).
The tick mark highlighted under Q in measurements represents the quality. If it is not a
green tick, repeat the measurement until the green tick is observed, otherwise look at the
SNR level and make sure its greater than 75dB.
Field users have a narrow range of corrective actions:

Repeat measurement (in case of, for instance, poor local contact to the tube).
Replace tube adapter (possibly replace only the sponge).
Two indications are given in parallel: SOUND GUN and PC Indication as follows:
6.3.1.5.1 SOUND GUN INDICATIONS:
Green LED indication indicates a good test.

Red LED together with an error message indicates a bad test.
SW displays a yellow sign under the Q in the measurements list for a bad
measurement quality
The failed parameters are listed below.
SNR and microphone balance. Probe usability &
Apr
explanation
6.3.1.5.2 PC INDICATION
Error message to the user, listing the failed components.

At the measurements list window on the right, under the QC column shows that a test has
been taken properly.
Indicates a bad measurement as shown in the example in the figure below.

SW OPERATION
FIGURE 81 FAILED TEST INDICATION EXAMPLE
6.3.1.6 APR
FIGURE 82 APR

SW OPERATION
6.3.2 SIGNAL TAB

After inspection, the signal appears in the signal tab. Figure 83 shows an example of this
tab.
FIGURE 83 SIGNAL TAB
In the Signal tab the following information appears:

Measurement’s name: Specific measurement unique identifier.
Measurement’s Notes: Notes field in which the operator can enter free text.
SNR: Shows calculated SNR value.

SW OPERATION
6.4 ANALYSIS TAB

In the Analysis main tab, the following sub-tabs can be found:
FIGURE 84 ANALYSIS SUBTABS
These tabs represent the different stages of a session analysis process. The entire analysis
flow is performed by going over the sub-tabs from left to right.
View Initial review of the data before running the auto analysis. Can be used
for quick manual detection of critical defects in emergency situations.
Pre-analysis Preparing the session for auto analysis by:
- Grouping and stretching the signals.
- Identifying structural elements (landmarks) along the tube (tube
support plates, u-bends, start/end tube). Different sensitivity thresholds
will be set at those locations. The user can edit the location of the
structures.
- Running an automatic analysis of the measurements.
There is a set of preliminary parameters that can be configured prior to analysis. The auto
analysis output is a set of defect candidates identified by type.
Defect table All detected defects are listed in separated tabs based on their type.
Sorting can be done as well.
Verification In this stage, the user validates the auto analysis results by reviewing
each defect candidate. This stage is performed at the single defect level.
Review Manual review of each signal to verify that no defects were missed. This
stage is performed at the single tube level.
Final report Printing an inspection report, fault distribution chart and 3-D
representations.
The analysis is available in the SW that can be accessed at TALCYON portal. During
training course the shortcut to the portal will be provided. The portal is available via
address http://www. talcyon.com/portal with the specific login credentials provided. Verify
that the laptop computer is connected to the Internet for portal access.

SW OPERATION
6.4.1 VIEW TAB

View Tab Objectives:
Initial review of the signals – evaluate the signal quality, noise, tube cleanliness level
and measurement conditions.
Ideal for quick detection of critical defects in emergency situations
Example: Hole detection in a heat exchanger during normal plant operation, not
during shutdown
Quick identification of defects can be made by overlapping the signals.
FIGURE 85 SIGNALS OVERLAPING
This tab has several modules:
Measurements list Same as in the measurement tab

Condensed detectable table Below the measurement list. Applicable after analysis.
(per tube)
Graph control windows APR graph control panel

SW OPERATION
FIGURE 86 FILTERS
Graph Enables graph. The user can display APR.

Noise Displays the (per measurement) noise sleeve.
Sizing lines Displays the sizing thresholds of a specific defect. (Not in use at this
stage.)
Subtract Displays the graph using subtract reference mode. Smooth out the
signal and eliminates common structural signatures. Effective mainly on
the APR signals.
Filter Toggles between different filter viewing APR modes
Snr [db] Displays the measurement signal-to-noise ratio
6.4.1.1 GRAPH RIGHT CLICK MENU

The menu includes the following capabilities:

SW OPERATION
FIGURE 87 GRAPG RIGHT CLICK MEU
Right clicking on a signal highlights, it in a bright orange color

Follow plot x and displays the tube name. Helps identify a specific tube
when displaying several tubes at once.
View all Zooms out to the entire tube length.
Undo zoom Return to the last zoom value.
Save as image Save the current screen capture.
Options Show/hide plot captions at the signal’s end.
Zooms the signal to a view that enables easy review of
Fitted view
defects throughout the entire signal length.
Shows various sizes of theoretical defect type signatures
Show hole signatures
under the selected view filter
Show blockage signatures
Show erosion signatures
Hide defect signatures Hides the selected signatures.
Deselect from Unselects the tube from the highlighted measurements list
measurement list
6.4.1.2 OTHER SCREEN OPTIONS

Displaying multiple signals can be done using the Ctrl key (one by one) or the Shift
key (selecting a group of signals) in the measurement list.
Zooming can be done using the “+” “-“ keys.
Panning can be done using the arrow keys.
6.4.1.3 APR FILTERS VIEW

To increase defect detectability while using the automatic analysis, the system applies 6
types of filters:
None
APR Basic
APR_High_BP
APR_Low_BP
APR_Low_N
APR_Wide_Band.
To allow the user to verify the defect with the same filter which was used by the system in
the auto analysis, this filter is presented.
The user can toggle between the filters to optimize the defect verification.

SW OPERATION
FIGURE 88 ARP FILTERS
The same defect looks completely different under different filters.
FIGURE 89 NO FILTER

SW OPERATION
FIGURE 90 APR_LOW_BP
FIGURE 91 APR_HIGH_BP
FIGURE 92 APR_LOW_N FILTER

SW OPERATION
FIGURE 93 APR_WIDE_BAND FILTER
FIGURE 94 APR_BASIC
To know how a certain defect type looks under a certain view filter, the user can apply the
theoretical defect signatures in the right click options menu:

SW OPERATION
FIGURE 95 RIGHT CLICK MENU

SW OPERATION
6.4.2 PRE-ANALYSIS TAB

This tab allows to prepare the session for auto analysis:
APR signals: Group all signals (to compensate for temperature changes that cause length
variations between the tubes) and stretch them to the nominal tube length – This process
is performed automatically once the button is triggered – the APR

signals are grouped and aligned per the tube length that is presented at the table on the
left.
Once the pre-analysis is complete, the following message will be displayed:
FIGURE 96 PRE-ANALYSIS FINISHED
Landmark table is populated automatically, as shown in section 6.2.1.5. It can be

also populated manually. To Fill in the landmark table – mark structural elements
(mainly tube support plates) in order to differentiate between them and actual
defects - will be elaborated below.
FIGURE 97 LANDMARK TABLE - STRUCTURAL ELEMENTS
Choose Measurements to inspect - Analyze all the tubes or only selected by the
user. Selection is made on the measurement list.
Impose reference This parameter defines which reference tube should be used by the
tube system while running the comparative automatic analysis:
No The system automatically defined the reference tube.
The system uses the user-defined reference tube (will be used mainly
Yes
on small statistic ensembles such as a demo rig).
Run auto analysis

SW OPERATION
Initiate the automatic analysis by pressing the Button.

The progress status and time left is displayed on the bottom of the screen bottom.
To stop the auto-analysis, use the “Abort” button located in the bottom right corner
When the automatic analysis process is finished, the following message will be displayed:
FIGURE 98 REPORT FINISHED MESSAGE
The pre-analysis tab screen is as follows:
FIGURE 99 PRE-ANALYSIS TAB SCREEN

SW OPERATION
6.4.2.1 LANDMARKS (STRUCTURAL ELEMENTS) TABLE

Structural elements along the tube should be marked (only if they are visible) in order to
avoid flagging them as defects.
Editing the landmarks table can be done by right clicking on it:
FIGURE 100 STRUCTURAL ELEMENTS (LANDMARKS) MANAGEMENT
Add new Used for adding a new landmark.

Delete For deleting an existing landmark.
Set location by graph Setting a landmark location based on the current graph view.
view
To add a new landmark Use the “add new” to add a new landmark to the table, then
zoom in on the landmark, finally right click on the new landmark
and choose “set location by graph view”.
6.4.2.2 SUMMARY OF PRE-ANALYSIS STEPS IN ORDER

Verify that all of the parameters on the bottom left table are correct and press the
“Run Pre Analysis” button. APR signals will be grouped and stretched to the user-
defined tube length and an initial landmark recognition is performed (tube start is
marked).
Align one signal (focus on a feature/EOT and press “align”).
If OK, apply the alignment to all the signals (“align all”).
If needed, in order to perfect the alignment, select all of the signals and focus on
their EOT. Chose “by EOT” and press “align”. This will align the signals to the
sample level.
Mark all of the tube support plates using the landmarks table.
Run the automatic analysis. Defect candidates by type will be flagged in the
“defect table” tab.

SW OPERATION
6.4.3 DEFECTS TABLE TAB

This tab allows storing the automatic analysis results using the type-based tabs.
FIGURE 101 DEFECTS TABLE
After the automatic analysis is finished, the results (the defect candidates), are stored in
type based tabs.
Now starts the second phase of the analysis process. The user reviews the auto analysis
results and confirms them.
It is recommended to start with the first defect on the left most tab (“Holes”), then
continue to review all the defects one-by-one until the last one.
In each tab, the defects can be sorted by clicking on the column headers.
6.4.3.1 EXAMPLE: APPROVING DEFECT BY THE TUBE ID

Click on the “status” header column, then on the “Tube ID” header.
Tip for Defect Table dab: It is recommended to review the defects after sorting them by
position.

SW OPERATION
Unlike the Measurement tab, in which the measurement recordings are being
saved to the computer hard drive without delay, in the Analysis tab, saving is
being performed every few minutes.
In order to trigger a save operation, use the button.
To load the last saved defect table, use the

button.
The “Unknown” class stands for variations in the signal which were flagged as
possible defect candidates but couldn’t be assigned to any specific defect class.
6.4.3.2 DEFECT TABLE RIGHT CLICK MENU

Right clicking on the defect table menu highlights the following:
FIGURE 102 RIGHT CLICK MENU
Approve Confirms an indication (to be printed in the final report).

Ignore Ignores an indication (will not be included in the final
report).
Delete Deletes an indication.
Add new Inserts a new defect to the marked tube (to be elaborated
in the verification tab).
Move to Move the current classification to any of the other options
(holes, blockages, wall loss).
Approve / ignore all All the indications in the same tube / class (depends on the
viewing scheme) will be approved / declined.
Add / remove graph from To add/remove all defect graphs from the final report.
all
Approve without adjacent Approves without adjacent
Fault filtering Approve defects in close proximity to one another.
Properties Defect ID, tube ID, defect location and size attributes are
displayed.

SW OPERATION

SW OPERATION
6.4.4 VERIFICATION TAB

6.4.4.1 TAB OBJECTIVES:
Review the automatic analysis results of one defect at a time.
FIGURE 103 VERIFICATION TAB
In this phase, the user reviews the automatic analysis results by defect and chooses
whether to approve or to ignore it.
As mentioned previously, it is recommended to start with the “holes” class, sort all
indications by location, and then review them one-by-one using the next defect arrow key.
If the user decides that the indication is real, it can be approved. If not, it can be ignored.
Only approved or undecided indications get included in the final report.
To aid in decision making, the user can:
Use one of the tools from the graph control window on the right –
Noise/Subtract/Fault signature/Filters view.
Overlap adjacent tubes from the measurements list.
Use the theoretical defect signatures on the graph through the right click menu.

SW OPERATION
6.4.4.2 TAB ELEMENTS
Measurements list Same as in the measurement tab

Graphs area Same as in the View tab
Small defects table (per This table lists all the defects in the tube in which the current
tube table) reviewed indication is located. All of the per tube defect types,
sizes and locations are detailed.
FIGURE 104 SMALL DEFECTS TABLE
Knowing the “history” of a tube can help get the right decision regarding the current fault
as the following example describes:
Knowing that there is a very big blockage prior to an indication might imply that it is a
reflection of the larger signal and, therefore it is not a real defect
The indications in the table can be sorted by each of the columns – type, size or location.
Clicking a defect on the table will zoom the graph on its signature on the signal.
Right click on defect will open two options menus
Delete the selected defect.

Show the defect properties

SW OPERATION
FIGURE 105 DEFECT PROPERTIES
Defect id Defect sequential order on the defect list.

Tube id The tube in which it is located.
X initial/final Defect start/end point on the longitudinal axis.
6.4.4.3 END OF TUBE MISSING INDICATOR

This is an additional indicator for assisting the user in reviewing the indication validity.
A missing end of tube signature means that there isn’t any energy reaching the tube end.
This might indicate the presence of a very significant defect or a measurement fault as the
following example shows:
The following three scenarios will yield no tube end signature on the APR signal:
Full blockage
Very big hole
Significant sealing problem
6.4.4.4 DEFECT CONTROL WINDOW

This element elaborates all the various defect properties:
FIGURE 106 DIRECT CONTROLS
The defect properties can be edited during the defect review process.
Tube id The tube in which in the defect is located.

SW OPERATION
Pos [m] The defect location on the X axis.

Score [%] Correlation score to the theoretical defect signature. Implies the
detection certainty.
Detected by Indicates the PR mode by which the defect was detected (APR).
Type Define defect type.
The Status area allows verifying auto analysis results. Several states are applicable:
Approved The indication is confirmed. The defect will be printed in the final report.
Ignored The indication is declined. The indication will not be printed in the final
report.
Undecided The user can’t make a clear decision on the indication status and doesn’t
want to decline it. This status is relevant to cases in which the user
identifies some irregularity in the signal but can’t classify it with certainty,
and prefers a cross-verification using an alternative technology or
advanced analysis support. It is recommended to add comments in these
cases. The defect will be printed in the final report with the status defined
as undecided.
Filtered Defects that are below thresholds level shall be listed as filtered.
For example: If user/analyst instruct SW to find wall loss greater than
40%, any defects with wall loss less than 40% shall be listed as filtered.
The functionality remains the same for other defect categories too.
Pending The initial indication state (post auto analysis). The indication will not be
printed in the final report.
Comments Free text comments. These comments will be printed in the final report.
Add graph Option to add a graph (defect signature) to the final report
Faults id Sequential indication number. Not in use by the user.
Next/previous indication arrows
Assigned keyboard buttons to improve usability during the analysis. The
list is shown when clicking on this button:

SW OPERATION
FIGURE 107 SHORTCUT KEYS
Add new Adding a new defect manually. To add a defect manually,

zoom in on the new defect, then press the “add new”
button. The defect will be colored and marked. Continue to
fill in all the other defect properties.
Set boundaries Refining the defect boundaries. To change the defect
boundaries, zoom in to the desired boundaries press the
“set boundaries” button.
2d map View the defect location on the tube sheet map (might
supply essential information for verifying the defect).
To return to the analysis tab, press the “return to analysis” tab on the measurement-
>inspection tab

SW OPERATION
6.4.5 REVIEW TAB

This tab allows a quick manual review of all the signals to verify that no defects were
missed by the automatic analysis.
FIGURE 108 REVIEW TAB
This review is performed at the tube level.

Starts with the first tube on the measurements list.
Generates a dedicated view mode for the manual review stage.
The signal is zoomed using “fitted view mode” throughout its length to a level which
enables easy manual review.
The fitted view mode is implemented in these ways:
Dedicated keyboard button: “F”
Mouse right click option on the graph: Choose “fitted view” option
Every time you move to a new tube using the arrow verify that all the defects you
see visually are indeed colored (and therefore approved for inclusion in the report).
Defects that are detected visually but are not part of the report can be added
using the “Add new” option as described above.
Use the “next tube” arrow key to move to the next tube for review
If a tube looks too dirty to be analyzed: change its status to “dirty” using the right
click menu. All dirty tubes are listed in a separate table in the final report.

SW OPERATION
6.4.6 FINAL REPORT TAB

This tab allows printing the final inspection report.
Fault distribution chart tab - A sub tab in which a distribution of all defects is
presented in % and absolute numbers. Some general statistics of the session are
presented as well as Figure 109 shows.
Issue report tab - Print the final inspection report (see Figure 110 below).
6.4.6.1 FAULT DISTRIBUTION C HART
FIGURE 109 FAULT DISTRIBUTION CHART

SW OPERATION
6.4.6.2 ISSUE REPORT
FIGURE 110 PRINT THE FINAL INSPECTION REPORT
To issue report follow these steps:

Define general report printing options:
Graph view options on the report:
With/without subtracting reference mode
With/without thresholds
Show fault signatures in graphs
Add logo(s) – either left, right, or both - to the header of each report page.
Edit general information to appear in the report’s first page.
Service Provided details
Report summary (Analysis Notes)
Picture of Signature
Click “Add pictures to report”
This option is useful for displaying zoomed-in zones of a big heat exchanger, areas
of visual damage or other pictures that add value to the report.

SW OPERATION
FIGURE 111 ADD PICTURE TO REPORT
Print the inspection report (see figure below).
FIGURE 112 ISSUE REPORT

MAINTENANCE
7 MAINTENANCE
7.1 PERSONNEL REQUIREMENTS
Maintenance personnel shall pass the training by TALCYON.
7.2 VISUAL INSPECTION

The preventive visual inspection of the system units should be done periodically at
intervals specified by the local maintenance regulations and at least once a year.
To perform the visual inspection, remove the units from the case and place them on a flat
surface covered by a dielectric material and appropriate illuminated.
Inspection Instructions
Check units external structure, covers and contacts for signs of dirt, corrosion damage
(cracks, bent parts, scratches, etc.), paint peeling or flaking, loose screws, loose rivets
or signs of blistering on the external surfaces indicating moisture has penetrated the
battery.
Verify that the connector cover and contacts are properly connected and tighten and
have no signs of corrosion or damage. Check mechanical serviceability of the contacts.
Verify that surfaces of units are clean. Check for signs of corrosion developing on the
surfaces or grime buildup.
Check controls and indicators integrity. Verify that the display doesn't have signs of
discoloration. Verify that the display is not cracked or scratched. If the display is dirty,
clean it using a clean lint-free cloth.
Verify that connectors are properly engaged with their mating connectors. Verify that
connectors are properly secured and have no loose, missing or broken parts.
Check that units do not show signs of discoloration or cracks.
If cables are not connected to the connectors, verify that the cover caps ae properly
installed and secured.
7.3 CLEANING
Clean the equipment if needed prior to inserting into the case. Use dry cloth only.
Do not use any cleaning materials or water.

MAINTENANCE
7.4 SOUND GUN CALIBRATION PROCEDURE

Calibration on an annual basis is recommended for APRIS Probe/Gun.
Once calibration is done, perform the functional test and share test result with TALCYON.
Based on that, calibration certificate will be issued.
Follow the steps below:

Connect APRIS gun to the PC/laptop on which dedicated
(measurement)software is installed.
Connect APRIS gun to the power supply via POE box.
Open APRIS software installed on the dedicated PC/laptop.
Connect the P1 calibration tube* to APRIS Gun as it is shown in the figure
below
FIGURE 113 P1 CALIBRATION TUBE MOUNTED ON SOUND GUN
Enter parameters as follows:

Tube’s Total Length: 1.2m
Tube’s Outer Diameter: 25.4mm
Tube wall thickness: 2.11mm
Identical geometry tubes: Yes
Probe type: Probe APR-A
Temperature: 25°C
Go to “Advanced” menu option

MAINTENANCE
FIGURE 114 SOUND GUN CALIBRATION, STEP 6
Select ‘Run Command’ under ‘Advanced’
FIGURE 115SOUND GUN CALIBRATION, STEP 7
Type command “calib’’

MAINTENANCE
FIGURE 116 SOUND GUN CALIBRATION, STEP 8
Save the session file and send to TALCYON for further evaluation and to issue
the calibration certificate, if successful. Otherwise, ship the product back to
TALCYON for repair.
If unable to send the session file, connect TALCYON via TeamViewer utility, which will aid
TALCYON to evaluate the session and issue the calibration certificate.
*P1 Calibration Tube shall be purchased from TALCYON either separately or along with
the product.
7.5 SPARE PARTS

Item Description Recommended
Quantity
Data 10m in length 02
Communication 15m in length 02
Cable
20m in length 02
Adapter Foam To protect acoustic components in sound gun 05
Standard To inspect tubes from 7mm till 35mm 01 set
Adapter
Special Adapter To inspect tubes from 35.1mm till 100mm 01
POE Injector Supply power to the gun 01
APRIS PTS-M Measurement SW to be installed on an additional 01
laptop computer

MAINTENANCE
7.6 REPLACEMENT PROCEDURES

7.6.1 TUBE ADAPTER FOAM REPLACEMENT
Adapter foam shall be replaced by opening the locking nut on the Sound Gun. Old one
shall be replaced with new one.
7.6.2 ETHERNET CABLE REPLACEMENT

See RJF 544 ETHERNET CONNECTION SYSTEM for cable replacement procedure.
7.6.3 SW LICENSE UPDATE

TBD
7.7 HW TROUBLESHOOTING
Check the SNR. If it lower than 75dB, make a judgement, by taking a

measurement on the calibration tubes in a room environment, where the noise
level is low.
If signal quality is still low as per Appendix 1, perform calibration test as
described in the session 7.4.
Look at the indication given by POE box. If its connected to power supply and
there is no internal failure, green LED glows.
Replace the Data communication cable between POE box and laptop
Repeat steps 1 and 2.
Replace the communication cable between POE box and Sound Gun.
Repeat steps 1 and 2.
If signal quality is still low, contact service center/distributor/manufacturer.
If any failure of the Sound Gun occurs, send it to Service center operated by either
distributor or to the manufacturer for repair.

QUALIFICATIONS AND CONFORMITY
8 QUALIFICATIONS AND CONFORMITY

APPENDIX I. EXAMPLES OF TUBE SIGNALS

GOOD TUBE SIGNAL WITH EXTENSION

BAD TUBE SIGNAL LEAKAGE AND LOW SNR
BAD TUBE SIGNAL-LOW SNR
BAD TUBE SIGNAL WITH GOOD SNR, BITS, WITHOUT SIGNAL LEAKAGE

BAD TUBE SIGNAL WITH GOOD SNR AND BITS




BAD SIGNAL-SYSTEM HARDWARE FAILURE

APPENDIX II. CONFIGURE IP ADDRESS ON PC NIC
Connect PC to the Sound Gun as described in the section 5.4.1 and turn them ON.
Open the "Network and Sharing Center".
Open the "Control Panel" according to your windows version.
In the Control Panel, click on the "Network and Internet" category
Click on "Network and Sharing Center".
Open the "Change adapter settings" link.
Click on the "Change adapter settings" link on the left-hand side.
FIGURE 117 NETWORK AND SHARING CENTER
Open the "Local Area Connection" / " Properties".

Right-click on the "Local Area Connection" and choose "Properties".
FIGURE 118 CONNECTION PROPERTIES

Select Internet Protocol Version 4(TCP/IPv4) and choose Properties (Fig.5).
FIGURE 119 INTERNET PROTOCOL SELECTION
Select Use the following IP address (see figure below).

Type the following IP address: 192.168.0.201
Type the following Subnet mask: 255.255.255.0
Click OK to save the setting.
FIGURE 120 IP ADDRESSES DEFINITION

Click “Close” on Local Area Connection Properties window to save the setting.
FIGURE 121 CLOSE PROPERTIES WINDOW
Right-click on the "Local Area Connection" and choose "Properties".
FIGURE 122 NETWORK ADAPTER PROPERTIES

Choose "Configure…".
FIGURE 123 NETWORK ADAPTER CONFIGURATION
Choose "Auto Negotiation" on "Speed and Duplex" and click OK.
FIGURE 124 AUTO NEGOTIATION DEFINITION

Check the connection to APRIS.

Open Command Prompt by typing “cmd” in Windows Search field:
FIGURE 125 OPEN COMMAND PROMPT
Type “ping 192.168.0.204” in the command line:
FIGURE 126 PING SOUND GUN IP ADDRESS
The expected output on success:
FIGURE 127 PING RESULTS

The expected output on failure:
FIGURE 128 PING FAILURE

APPENDIX III. REFERENCED DIRECTIVES,

SPECIFICATIONS AND STANDARDS
The following documents referenced in this manual are pertinent only in the quoted
context and to the extent specified.
IEC 61010-1EDITION 2.0 Safety Requirements for Electrical Equipment for

2001-02 Measurement, Control and Laboratory Use - Part 1:
General Requirements
IEC 61326-1EDITION 1.0 Electrical Equipment for Measurement, Control and
2005-12 Laboratory Use - EMC Requirements - Part 1: General
Requirements
UL 1950 Safety Information Technology Equipment, Including
Electrical Business Equipment
MIL-PRF-28800F General Specification for Test Equipment For Use With
Electrical and Electronic Equipment
MIL-STD-810F Department of Defense Test Method Standard for
Environmental Engineering Considerations and Laboratory
Tests
EU DIRECTIVE 2006/95/EC Low Voltage Directive
EU DIRECTIVE 2004/108/EC EMC
EU DIRECTIVE 2002/95/EC Restriction on Hazardous Substances - ROCHS

APPENDIX IV. RJF 544 ETHERNET CONNECTION

SYSTEM




APPENDIX V. ARTIFICIAL TUBE MAPPING
Open PTS 3.4 Facilities MxN. Once we give a command like 3, 4 in MxN; the
software will generate tubes in 3 rows & 4 columns, whereas the numbering will be
from bottom to top without orientation & row column specification. In order to
overcome, kindly follow the procedure listed below
Open the map builder application, and then go file->open.

Open the MXN map (the name which u have given during creation) , it's location is:
C:\Program Files\AcousticEye\PTSv3.4\Facilities\Custom\mapname You ought to
change the searched file type to *.txt:
Continue with tube ordering/orientation process as usual below and ‘Save to

Custom’ with a specific name.

If you would like to delete the tubes, select the tubes and click ‘Delete’ option
available at the bottom of the page. Look below for example. Similarly, to add any
tubes in the row/column, click ‘add ‘icon.
Once addition/deletion is done, orient it based on row-column. Look below for
example.
This deletion of non-required tubes will be useful in artificially generating tube

sheet 2-D map for round tube bundles having a different number of columns in
rows, as well as other tube bundle configurations (not rectangle tube sheet map as
generated automatically by the system) for power plant condensers etc.
However, you need to generate the rectangular 2-D map as per maximum rows and
maximum column (x, y) in a tube bundle first and then delete the not required
tubes to match actual tube bundle tube map.
Generate CSV file after executing each & every project. Open PTS
[Full/Advanced/Run Command/Type CSV, Save it as current with a specific name
and send to TALCYON via email.

CONTACT TALCYON:
Email: sales@talcyon.com
ADDRESS:
Talcyon Pte Ltd
34 Toh Guan Road East
#01-11/12Enterprise Hub
Singapore 608579

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Acoustic Pulse Reflectometry Inspection

2 APRIS User Manual

APRIS User Manual 1

REV REVISION DATE DESCRIPTION OF CHANGE

ALC APR LCD Controller

2 APRIS User Manual

APRIS User Manual 3

4 APRIS User Manual

7.2 VISUAL INSPECTION 93

APRIS User Manual 5

6 APRIS User Manual

FIGURE 51 DEFINE THE 1ST TUBE ......................................................................................................... 50

APRIS User Manual 7

FIGURE 104 SMALL DEFECTS TABLE .......................................................................................................85

8 APRIS User Manual

1.2 INTENDED AUDIENCE

1.3 HOW TO USE THIS MANUAL

APRIS User Manual 1

Preparation for measurements and Standard Operating Procedure and 5, 6

2 APRIS User Manual

2 SAFETY AND OPERATIONAL WARNINGS

Indicates information related to safety or system proper use.

2.1.2 GENERAL WARNINGS

Safety cannot be overemphasized.

Do not dispose into the fire.

The protection provided by the equipment can be impaired if used in a manner

The APRIS is not waterproof or dustproof outside of the carrying case.

APRIS User Manual 3

2.2 ELECTRICAL SAFETY

Verify that electrical equipment is not located in a hazardous environment,

2.3 OPERATIONAL SAFETY

FIGURE 1 HEARING HAZARD WARNING LABEL

2.4 STORAGE SAFETY

4 APRIS User Manual

Do not store equipment below -20°C or above +70°C

If possible, the system should be stored in its carrying case.

APRIS User Manual 5

3 APRIS TECHNOLOGY INTRODUCTION

FIGURE 2 ACOUSTIC PULSE REFLECTOMETRY

3.1.2 ACOUSTIC PULSE REFLECTOMETRY SIGNATURES

6 APRIS User Manual

3.1.3 UNIQUENESS OF APRIS

3.1.4 limitations OF APR TECHNOLOGY

3.1.5 INTERNATIONAL STANDARDS

APRIS User Manual 7

FIGURE 3 MAIN SYSTEM COMPONENTS GENERAL VIEW

The system consists of the following components:

8 APRIS User Manual

FIGURE 5 SOUND GUN FRONT SIDE

APRIS User Manual 9

FIGURE 6 SOUND GUN ASSEMBLY

4.1.1.1 LCD DISPLAY

10 APRIS User Manual

4.1.1.2 STATUS LEDS

System Ready for inspection.

SNR level is below acceptance level (75dB)

FIGURE 7 SOUND GUN DIMENSIONS

APRIS User Manual 11

4.1.2 TUBE ADAPTER

FIGURE 8 TUBE ADAPTER EXAMPLE (SPONGE REMOVED)

List of supplied Tube adapters

12 APRIS User Manual

4.1.3 POE BOX, 110-240VAC POWER INPUT

FIGURE 10 POE BOX P/N ARG01004