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NDE Types - Tube Application PDF
NDE Types - Tube Application PDF
S
everal NDE examination methods are currently being used to Limitations
inspect heat exchangers and boiler tubes. The tube material 1. Limited to only non-magnetic tube material.
of this equipment is made from various ferromagnetic and 2. Application is limited to 3 inch tube sizes and 0.125 wall
non-ferromagnetic alloys. The tubes’ sizes vary from 0.5-3.5 inches thickness.
in outside diameter and from 0.028-0.120 inches in wall thickness. 3. Test instrumentation, systems and software packages could be
This paper outlines the principles, applications, advantages and very expensive.
limitations of each of the following NDE methods used for these 4. Requires high inspection skills for data analysis and
inspections: evaluation.
q Eddy Current (ET). 5. Pin holes are difficult to detect and evaluate.
q Remote Field Eddy Current (RFT). 6. Discontinuities adjacent to end sheets are difficult to detect.
q Partial Saturation Eddy Current (PSET). 7. Tubes must be cleaned.
q Flux Leakage (FL).
q Internal Rotating Ultrasonic Inspection (IRIS).
q Laser-Optic.
Remote field eddy current examination
method
Eddy current examination method Principles
Principles The remote field inspection method is based on the transmission of
an electromagnetic field through the tube material. The exciter coil
This method employs a probe (bobbin type) that contains one or generates eddy currents at a low frequency in the circumferential
more AC coils, which induces an electrical field around the tube. direction.
The impedance of the coil/coils changes as the electromagnetic The electromagnetic field transmits through the thickness and
field interacts with the material being tested. travels on the outside surface. A receiver coil placed in the remote
The coil is placed in the tube and the instrument is calibrated on field zone of the exciter picks up the field. The separation between
a reference standard having known, machined discontinuities. The the two coils is two to four times the tube’s inside diameter.
probe is pulled through the tube and variations in coil impedance Any flaws or defects in the vicinity of the exciter or the receiver
are recorded. These changes, which are related to the types and coil will cause a disturbance in the through-transmission path.
sizes of discontinuities, can be displayed on a screen for final Discontinuity sizing with remote field eddy current is carried out
analysis and evaluation. using the voltage plane curves. These curves measure wall loss and
Phase analysis and signal amplitude are utilised to assess the relate discontinuity depth, length and circumference to the phase of
depth, origin and size of flaws. the remote field signal.
Conventional eddy current examination can be performed in
either the differential or absolute modes. The differential mode Advantages
detects small discontinuities such as pitting and cracking, whereas 1. Can inspect ferromagnetic tubes up to 3.5 inches in diameter
the absolute mode detects wall loss. with 0.125 inches wall thickness.
2. Inspection speed (up to approx. 40 feet per minute).
Advantages
3. Can detect large-area discontinuities such as steam erosion and
1. Inspection speed up to approximately 60 feet per minute. baffle wear.
2. Distinguishes between ID and OD flaws. 4. Amplitude changes in the signals sensed are not speed-sensitive.
3. Reliability and accuracy of test results. 5. Flexible probes can be used to inspect and travel through
4. Can detect gradual wall thinning and localised flaws. U-bend areas.
5. Provides both phase and amplitude information. 6. Permanent records can be obtained on test results.
6. U-bend tubes can be inspected with some radius limitation.
7. Permanent records can be obtained on test results. Limitations
8. By using multi-frequency techniques, flaws under the support 1. Some limitation to distinguishing ID from OD defects.
plates (baffles) can be found and evaluated accurately. 2. Evaluation of small flaws such as pits can be difficult.
3. Impingement erosion and wall loss detectability is limited to
approximately 20% and greater.
4. Requires high inspection skills for data analysis and
evaluation.
5. Instrumentation and test probes can be very expensive.
Hussein M Sadek is NDE Consultant/ACCP Professional Level III with 6. Tubes must be cleaned.
Technologies Consulting International, Inc, PO Box 2749, Charlotte, North 7. Inaccuracy in test results could occur if a discontinuity
Carolina, USA. Tel: +1 704-321-3052; Fax: +1 704-321-7272; E-mail: encountered differs in geometry from calibration
Tci4u2002@alltel.net; www.tciintl.com discontinuities.
Enquiry No 603-14
Insight Vol 48 No 3 March 2006 183