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 	ferrx electromagnetic steel examination	 
 	
Bridge and railway	Oilrig and risers
 Game-changing technology for monitoring integrity of steel structures 



The unique Ferrx technology directly measures all the steel parameters influencing the steel structures’ condition in real time, giving the best basis for safe and economic operation and more precise prediction of remaining life.		Risers and 3 templates
 
 	



INFRASTRUCTURE HEALTH MONITORING

 
 	
Monitoring traffic loads and condition of bridges

To be able to assess a bridge’s condition and remaining safe service life, the status of the integrity of the structure is crucial information. Residual service life can be estimated more accurately by the combination of data for actual traffic loads and accurate condition data from critical points combined with predictive modelling of the whole structure. Early detection of deterioration of the structure may reduce operational costs as any required maintenance can be planned in due time and optimized with respect to the schedule for repair.

The patented FEMM (Ferrx ElectroMagnetic Method) is well suited for such applications with its unique monitoring features. FEMM measures directly the stress response in the steel structure caused by the traffic loads, and also the stress due to any resonance vibration. Furthermore, it monitors the effect these stresses have on the monitored steel, e.g. changes of residual stresses in welds and material degradation as well as crack initiation and growth.

 
 	
Girder bridge


 
 	
	
 
 	
This girder bridge is more than 60 years old. FEMM sensors are retrofitted on the lower and upper flanges of the girder to monitor traffic loads. The bridge will in periods be used for the European route E6 traffic with a high number of heavy vehicles that may exceed the bridge classification. Therefore the traffic is monitored. Data is transmitted to Ferrx daily and provides for near realtime monitoring. This installation is also part of an R&D project where SINTEF Ocean has made a digital model of the bridge which, when integrating with the FEMM system, makes a digital twin of the bridge. The project is financially supported by Trøndelag’s regional research fund (RFF Trøndelag) which has been decisive for running the project.	 
 	

Framework bridge

 
 	
Framework bridge	Framework bridge sensor and wiring
 
 	
This framework bridge is more than 80 years old. Four FEMM sensors are installed on different truss elements for monitoring different types of stress. The traffic is heavy and the stress is measured for monitoring the highest vehicle load in a period, and also stresses caused by 10Hz resonance vibration. The picture above right shows one of the sensors.
 
 	

Railway rail stress monitoring

 
 	
This autonomous system measured the stress in railway rails for monitoring the rail′s neutral temperature to prevent buckling-related derailments. This was a demonstration installation run successfully for one year.	
 
 	



OIL AND GAS APPLICATIONS

 
 	
Non-intrusive pipe monitoring

 
 	
Non-intrusive corrosion monitoring
 	The picture shows installation of the sensor matrix on an 8-inch pipe for field application (before installation of protection). The whole area covered by the sensor is monitored for internal localized corrosion. One autonomous system monitors three pipes, each with two sensor interfaces.  Read more...

 
 	
Fatigue monitoring of subsea riser

 
 	
fatigue monitoring of subsea riser
 	FEMM system installed on an 8" work-over riser pipe for monitoring stress and fatigue. It is designed for operation down to 1500m water depth and has an internal battery with capacity for approx. five years of autonomous monitoring. The system for riser inspection has been qualified by DNV in accordance with DNV-RP-A203 Technology Qualification.  Read more...

 
 	


FEMM MONITORING CAPABILITIES

 
 	The FEMM method and technology was certified in 2016 by DNV in accordance with DNV-RP-A203. A FEMM system is used for monitoring all the different parameters just by selecting appropriate location and configuration of sensors and processing data with the dedicated algorithms to get the best results.
 	

Stress monitoring

Stress measurements in ferromagnetic steel are relative to a previous measurement. Calibration curves for elastic stress can be established based on measurements at known loads, either on the actual structure or on specimen of the same type of steel.  Read more...

 
 	
Fatigue monitoring

The material changes in ferromagnetic steel during a fatigue process are measured by FEMM long before cracks are visible.  Read more...

 
 	
Crack detection and monitoring

The sensor matrix is located to cover the area where cracks are expected, most likely a weld, and it will be detected whether the crack starts in the outside surface or inner surface of a pipe or even inside the weld or HAZ area.  Read more...

 
 	
Corrosion monitoring

Corrosion internal in pipelines is more or less uneven and the degree of corrosion attack can vary around the pipe’s circumference e.g. be more severe in the bottom section. This makes it advantageous to monitor a continuous area of the pipe to be able to get a representative picture of the distribution.  Read more...

 
 	
Erosion monitoring

Erosion internal in pipes is usually localized metal loss that most frequently occurs in bends and tends to be most severe in the outer radius of the bends, however, due to turbulence also at other locations in the bend. The shape of the erosion varies related to the pipe geometry and internal flow. Both carbon steel and duplex steel can be monitored.  Read more...
 
 	



INSTRUMENTATION

ferrx femm system concept

 
 	
Example of installation for monitoring of four different areas for stress and cracks in a bridge coverplate. One system with eight SI’s can monitor 32 locations within approx. 20m. The above system is an autonomous standalone online system with several options for data transfer to the user.

A FEMM system consists of four main modules:
Sensor arrangement on the steel structure
Sensor Interface unit (SI)
Data Acquisition Unit
Dedicated SW running MS Windows

This modularity provides for extensive flexibility to optimize the system configuration and performance for the different applications. The system design based on many years of relevant field experience has also been optimized with respect to reliability and ease of installation, e.g. there is no steel reference needed, which significantly simplifies the preparation and installation on the steel structures. Sensors and all fixed installed components shall have the same operational lifetime as the monitored structures. The sensor interface is designed for at least 25 years of operation. The sensor and sensor interface design provides for redundancy and improved reliability.

One system comprising one instrument and up to eight sensor interfaces can e.g. monitor one to eight nearby pipes or on a structure up to 32 locations within 20m from the data acquisition unit.
 
 	

Instrumentation modules
 
 	
Sensor matrix

non-intrusive monitoring of pipes
 	

The picture shows an example of sensor layout, for monitoring a pipe buttweld, and for monitoring defects both in outer and inner surfaces of the pipe wall. The sensor comprises the sensing electrodes and the excitation wires, both requiring electrical contact with the steel. One or more temperature sensors monitor the structure′s surface temperature. Different connection methods for making electrical contact to the steel for the sensor arrangement are available: soldering (heat controlled max 300oC), stud-welding, and spring-loaded pin arrays glued or clamped to the steel. After installation, all the connection points and wires are properly protected for the actual application.  Read more...

 
 	
Sensor interface

non-intrusive monitoring of pipes
 	

The Sensor Interface (SI) unit contains circuits for signal conditioning and digitalization and for high current excitation. Each unit handles up to four matrices with a total of 28 sensing pin pairs and four pairs for current excitation. Communication with the instrument is linked via a multidrop digital bus, with up to eight SI units (altogether 224 pin pairs) on one cable per instrument and system. The picture shows SI encapsulation for use in onshore applications.  Read more...

 
 	
Portable instrument

non-intrusive monitoring of pipes
 	

This instrument is used for examination of a number of inspection points (tags) fitted with sensor matrices and Sensor Interfaces. The configuration setup for all tags to be measured are downloaded from the PC SW to the instrument before the inspection tour. Data from all tags are intermediately stored until downloaded to the PC. In this way, a high number of inspection points can be evaluated at low cost. The instrument is powered by a rechargeable battery.  Read more...

 
 	
Autonomous instrument

ferrx data data acquisition unit for autonomous monitoring
 	 

This data acquisition unit for autonomous monitoring in harsh environments is powered by an internal battery or by external power. Operation is offline or online, by cable or wireless for real-time condition data. Miscellaneous protocols are available.  Read more...

 

 	
FEMM data analysis software

ferrx femm steel infrastructure data analysis software	 	 

The Windows-based PC software handles measurement data and housekeeping data from the instruments. Features and algorithms are implemented for data pre- and post-processing for the different types of defects. Results can be presented in 2D or 3D graphical plots. Software functions also include programming and configuration of monitored tags and instrument setups.
 
 	



About Ferrx and FEMM

Ferrx is an independent company located in Trondheim, Norway with the business idea to provide the FEMM technology for different onshore and offshore markets.

Ferrx patented the method called FEMM (Ferrx ElectroMagnetic Method), and with support from several oil companies and Innovation Norway and The Research Council of Norway developed and industrialized the technology. A system for monitoring fatigue in steel risers has been certified by DNV

This technology measures directly the actual response and condition of steel structures in selected locations and thus makes possible in a simple way more accurate estimates of the condition of the whole structure and the safe operational life.

Resources

We appreciate the importance of having a team of highly qualified and motivated employees. We offer interesting opportunities within advanced methods and technology in close cooperation with clients. The employees will receive competitive compensation and be invited to share in the values they create as team members at Ferrx.

Contact us

Ferrx as
Brøsetvn 168
N-7069 Trondheim
Phone no: <PRESIDIO_ANONYMIZED_PHONE_NUMBER>
info@ferrx.no



 
 
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