TUBE INSPECTION SOLUTIONS 1

TUBE
INSPECTION
SOLUTIONS

Selection of heat exchanger

tube inspection techniques
2 TUBE INSPECTION SOLUTIONS

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 TUBE INSPECTION SOLUTIONS 3

SUMMARY Page

Introduction 4
Tube inspection selection chart 6
Conventional Eddy Current 8
Full Saturation Eddy Current 10
Remote Field Technique 12
Partial Saturation Eddy Current 14
Magnetic Flux Leakage 16
High Frequency Eddy Current 18
IRIS 20
Remote Visual Inspection 22
Epilogue 23
Notes 24

4 TUBE INSPECTION SOLUTIONS

INTRODUCTION

In the power, petrochemical and oil/gas industry a big variety of heat exchangers
is being used. Heat exchangers are being used to heat up, cool down, evaporate
or condensate process flows. Depending on the application, heat exchangers
come in all kinds of shapes, dimensions and materials. Construction models
most widely used are the so called tube/shell exchangers and fin/fan coolers.

Proper working heat exchangers are of major importance for cost effective
operation of a plant. Failing or leaking heat exchangers can lead to lower
efficiency, unplanned shutdowns or even accidents which in turn can result in
damage to equipment, environment or people.

During operation, heat exchangers are susceptible to several degradation

mechanisms that smight eventually result in leakages. Depending on construction,
material and operation condition mechanisms like corrosion, erosion, cracking or
impingement can deteriorate construction materials.

Frequent inspection of heat exchangers is required to detect and respond in

time to active degradation mechanisms. Likewise, the choice of the available
Non Destructive Test technique is of high importance.

In general there are two main locations where leakages will occur in a heat
exchanger:
 TUBE INSPECTION SOLUTIONS 5

. At the tube / tube sheet joints

. Along the length of the tubes

Tube/ tube sheet joints can be visually inspected and standard NDT techniques,
like Penetrant Testing or Magnetic Testing can be utilized.

Inspection of the entire length of heat exchanger tubes however brings along
a few extra challenges. Visual inspection is only possible when borescopes or
camera’s are used. And even this will only give information about the condition
of the interior of the tubes.

Besides remote visual inspection a range of heat exchanger tube inspection

techniques is available. Because the big variety of materials being used for heat
exchanger tubes and the various degradation mechanisms that can occur, it’s not
possible to use a single inspection technique for all situations. Selection of the
right technique(s) for each situation is essential for good inspection results. Widely
applied techniques are:

. Eddy Current Testing

. Full saturation Eddy Current
. Remote Field Technique
. Partial saturation Eddy current
. Magnetic Flux Leakage
. High Frequency Eddy Current
. Internal Rotary Inspection System
. Remote Visual Inspection
Selection of the right technique depends on tube material, expected defect types
and the purpose of the inspection. Often more than one technique will be applied
to increase the level of confidence of an inspection.

This booklet is provided to you by Dacon Inspection Services and is to assist

plant inspectors in selecting the right techniques for their specific inspection needs.
6 TUBE INSPECTION SOLUTIONS

TUBE INSPECTION SELECTION CHART

Material Tecnique Defect types Determines Cleanliness

type requirements

Pits, Pin holes,

Non
ET Cracks, Defect depth % Access
Ferrous Wall - loss

Pits, Pin holes,

FSEC Cracks, Defect depth % Access
Wall - loss

Pits, Cracks,
RFT Defect depth % Not critical
Wall - loss

Pits, Pin holes,

Ferrous PSEC Defect depth % Critical
Wall - loss

Pits, Pin Holes,

MFL Defect depth % Critical
Wall - loss

Internal
Internal
Diameter
HFEC diameter Access
enlargements
enla rgement %
(erosion)

Remaining wall
IRIS Pits, Wall - loss 100%
thickness
All
materials
Pits, Overall
Defect shape
RVI corrosion Critical
(internal only)
(internal only)
 TUBE INSPECTION SOLUTIONS 7

Probability of Detection (POD)

Defects under
Axial cracks

support plate
Circ. cracks
Wall - loss
Main Advantages
and Disadvantages

Pits
• Fast (450 -700 tubes/6 meter/day)
• Hi gh sensitivity Good Good Poor Good Good
• Accurate sizing possible

• Fast (450 -700 tubes/6 meter/day)

• High sensitivity
Good Good Poor Good Good
• Accurate sizing possible
• Can only be used on slight permeable

• Good overall performance on

carbon steel
Fair Good Good Poor Fair
• Cleaning not critical
• Pits need to have some volume in order
• Sensitive to pits in carbon steel
• Phase information available
Good Fair Good Good Good
for internal sizing
• Can be used on finned tubes

• Sensitive to pit in carbons steel

• Can be used on finned tubes Good Fair Good Poor Good
• Sizing of defects very limited

• Fast
• Can only detect limited amount No Internal No No No
of defect types

• Accurate determination of wall thickness

• Provides information about defect
Good Good No No Good
geometry
• Slow (70 -100 tu bes/6 meter/day)

• Can be used on every material

• Visualization of defects possible Poor No Fair Fair No
• Only information of interior of tube
8 TUBE INSPECTION SOLUTIONS

CONVENTIONAL EDDY CURRENT

Eddy Current is the notably the fastest and most preferred tube inspection
technique available. Eddy Current however can only be used on non-ferrous
materials like Brass, Copper, Copper-Nickel and Stainless steel.

Local defects as well as overall wall-loss can be detected and quantified.

EC can detect both internal and external defects and can distinguish between
them. Cracks can be detected depending on their size and orientation. By applying
Multi frequencies, defects under support plates can be detected and to some
extent quantified.

Theory
The probe used in Eddy Current examination contains a coil which generates
a changing magnetic field. When the probe is inside a tube of a conductive
material this magnetic field will cause eddy currents to flow in the tube material.
The amount of eddy currents that can flow in the tube depends on the condition
of the tube at the location of the coils. The Eddy currents will in their turn generate
a magnetic field which opposes the original magnetic field of the coil. The resultant
of the two opposing magnetic fields influences the impedance of the coil in the
probe. This means the impedance of the test coil depends on the condition of the
tube. Signals that represent the impedance of the test coil and thus the condition
of the tube are presented on a computer screen.
 TUBE INSPECTION SOLUTIONS 9

Advantages / possibilities Disadvantages / limitations

• Fast (450-700 tubes per day) • Only on thin or slightly permeable

• Overall wall-loss and local defects materials
can bedetected • Gradual defects could be under
• High sensitivity to small defects classified
(diam. holes/pits > 0.5 mm)
• Accurate sizing of defects possible
• Possible to distinguish between
in-and external defects
• Possible to detect and quantify
defects under support plates
• Cracks can be detected
depending on size and orientation
• Only basic cleaning of tubes
required
10 TUBE INSPECTION SOLUTIONS

FULL SATURATION EDDY CURRENT (FSEC)

Full saturation Eddy Current is a technique that can be used on thin ferro
-magnetic materials like Duplex or on materials that are only slightly magnetic
like Monel Nickel-Copper alloys.

Local defects as well as overall wall-loss can be detected and quantified.

EC can detect both internal and external defects and can distinguish between
them. Cracks can be detected depending on their size and orientation.
Defects under support plates can be detected and to some extent quantified.

Theory
The probe used in Eddy Current examination contains a coil which generates a
changing magnetic field. When the probe is inside a tube of a conductive material
this magnetic field will cause eddy currents to flow in the tube material. The
amount of eddy currents that can flow in the tube depends on the condition of
the tube at the location of the coils. The Eddy currents will in their turn generate
a magnetic field which opposes the original magnetic field of the coil. The resultant
of the two opposing magnetic fields influences the impedance of the coil in the
probe. This means the impedance of the test coil depends on the condition of the
tube. Signals that represent the impedance of the test coil and thus the condition
of the tube are presented on a computer screen.
 TUBE INSPECTION SOLUTIONS 11

Advantages / possibilities Disadvantages / limitations

• Speed similar to conventional • Only on thin or slightly permeable

eddy current materials
• Overall wall-loss and local • Gradual defects could be under
defects can be detected classified
• High sensitivity to small defects
(diam. holes/pits > 0.5 mm)
• Accurate sizing of defects
possible
• Possible to distinguish between
in- and external defects
• Possible to detect and quantify
defects under support plates
• Cracks can be detected depending
on size and orientation
• Only basic cleaning of tubes
required
12 TUBE INSPECTION SOLUTIONS

REMOTE FIELD TECHNIQUE (RFT)

Remote Field is a technique used for the inspection of tubes made of ferrous
materials, like Carbon steel and Chrome-Molybdenum. RFT is only one of the
techniques available for inspection of carbon steel tubes. Since al inspection
techniques that are available for carbon steel have limitations compared to
conventional eddy current, it is even more important to select the most suitable
technique for each different situation. For the inspection of carbon steel tubes
it is often recommended to use a combination of one or more techniques.

Overall wall-loss can be easily detected and accurately quantified. Local defects
can be detected and quantified provided that they have some volume (diameter
pit >5 mm). RFT can detect both in- and external defects but it is not possible to
distinguish between them.

Theory
The probe used in RFT examination contains a send and a receiver coil. In the
bigger send coil an alternating magnetic field is generated. This field is indirectly
coupled to the receiver coil as a direct coupling between the two coils is shielded
by the strong magnetic fields originating from the eddy currents that are being
generated in the tube. At a low enough frequency the shielding will lose some of
its strength allowing the exciter field to penetrate the tube wall in axial direction.
Once the magnetic field reaches the exterior of the tube it will spread rapidly
 TUBE INSPECTION SOLUTIONS 13

along the tube with little further attenuation. Research found that a portion of the
magnetic field re-diffuses back through the pipe wall to the interior of the tube at
a certain location.

At this position the smaller receiver coil is placed to detect the remaining field.
Now the indirect coupling path between send and receiver coil is complete. The
magnitude and the phase of the received magnetic field depend on the amount
of material that was crossed in the indirect coupling path. If wall-loss occurs in a
tube there will be less attenuation and delay of the exciter field before it reaches
the receiver coil. Signals that represent the changing in the received magnetic
field and thus the condition of the tube are presented on a computer screen.

Advantages / possibilities Disadvantages / limitations

• Possible to examine carbon • Relatively insensitive to small

steel tubes
• Overall wall-loss and local defects
can be detected and quantified.
• Accurate sizing of defects possible
• Possible to detect volumetric
defects under support plates
• Fill factor not so critical which
makes cleanliness less critical.
• Very big tube diameters can be
examined
diameter pitting
• Distinguishing between in- and
external defects is not possible
(both in- and external can be
detected).
• Examination of finned tubes has
a lot of limitations unless fins are
in axial direction
14 TUBE INSPECTION SOLUTIONS

PARTIAL SATURATION EDDY CURRENT (PSEC)

PSEC is a technique used for the inspection of tubes made of ferrous materials.
Combined with RVI or IRIS verification this is the most suitable technique to
assess the condition of airfin coolers. If small diameter pitting is expected the
technique will be applied on normal ferrous tubes as well.

Using PSEC internal as well as external pits can be detected in ferrous materials.
PSEC can detect and distinguish between internal and external defects.
Sensitivity is biggest for external defects but internal defects can be more
accurately quantified. Both in- and external overall wall-loss can be detected.

Theory
The probe used in PSEC examination contains normal eddy current coils. In
addition to that the probe contains two coils that are used as an electro magnet.
Conventional eddy current can not be applied on ferrous tubes. The permeability
causes a very big magnetic field in the tube material to be generated. This magnetic
field opposes the magnetic field of the probe which makes it impossible for
the probes’ magnetic field and eddy currents to penetrate the material. The
electromagnet in the PSEC probe is used to partly cancel out the magnetic
properties of the tube material. The electromagnets’ field is mainly active at the
inner surface of the tube where it compensates for the skin effect.
 TUBE INSPECTION SOLUTIONS 15

This allows some eddy currents to penetrate the material. Defects in a tube will
cause changes in the permeability and in the amount of eddy currents at that
location. The impedance of the test coil will be affected by a combination of
changes in permeability and eddy current strength. Signals that represent the
impedance of the test coil and thus the condition of the tube are presented on
a computer screen.

Advantages / possibilities Disadvantages / limitations

• Fast when used as screening • Sizing of external defects

technique limited (based on signal volume)
• Possible to examine carbon steel • Cleaning of tubes very critical
(finned) tubes because use of big fill factor
• Both pits and overall wall-loss can probe is required
be detected (diam. pits > 2 mm)
• Possible to distinguish between
in- and external defects
• Non volumetric defects like cracks
can be detected depending on
size, shape and orientation
• Defects under support plates can
be detected and to some extent
quantified
16 TUBE INSPECTION SOLUTIONS

MAGNETIC FLUX LEAKAGE (MFL)

MFL is a technique used for the inspection of tubes made of ferrous materials.
This technique will normally be applied as a fast screening technique if small
diameter pitting is expected. Because of limitations to its sizing abilities the
technique is not often used as a stand-alone technique. Verification by other
techniques is recommended. MFL can also be used on airfin cooler tubes.

MFL is sensitive to sharp type defects like pits and grooving. In- and external
pits can be detected. Depending on probe configuration MFL can distinguish
between in- and external defects and can detect gradual wall-loss. For ID/OD
discrimination the probe needs to be equipped with a second coil and to detect
gradual defects a Hall-effect sensor in the probe is needed.

Theory
The probe in MFL contains permanent magnets which are utilized to form a
magnetic flux field in the tube wall. Defects will influence the path of the magnetic
field and will cause some of the flux to leak out of the tube wall. This leakage field
will be picked up by the coils and the Hall-effect sensors in the probe. Size of
the leakage field is determined by pull speed of the probe and by the shape, the
dimensions and the location of defects. Signals that represent the size of the
leakage field and thus the condition of the tube are presented on a computer screen.
 TUBE INSPECTION SOLUTIONS 17

Advantages / possibilities Disadvantages / limitations

• Fast when used as screening • Less suitable as stand-alone

technique technique
• Possible to examine carbon steel • Sizing of in- and external defects
(finned) tubes limited (based on signal volume)
• Both pits and overall wall-loss can • Probe speed dependant.
be detected (diam. pits > 2 mm) • Cleaning of tubes very critical
• Possible to distinguish between because use of big fill factor
in- and external defects probe is required
• Non volumetric defects like cracks
can be detected depending on size,
shape and orientation
• Defects under support plates can
be detected and to some extent
quantified
18 TUBE INSPECTION SOLUTIONS

HIGH FREQUENCY EDDY CURRENT (HFEC)

HFEC is a technique that was developed to detect and quantify internal diameter
enlargements. The technique will normally only be applied when a specific
degradation mechanism (inlet erosion) is expected in carbon steel tubes. The
technique can be used as a stand-alone technique if the extent of the erosion on
the circumference of the tube is known.

Theory
The probe used in Eddy Current examination contains a coil which generates a
changing magnetic field. When the probe is inside a tube of a conductive material
this magnetic field will cause eddy currents to flow in the tube material. The
amount of eddy currents that can flow in the tube depends on the condition of
the tube at the location of the coils. The Eddy currents will in their turn generate
a magnetic field which opposes the original magnetic field of the coil.

The resultant of the two opposing magnetic fields influences the impedance of
the coil in the probe. This means the impedance of the test coil depends on the
condition of the tube.

Signals that represent the impedance of the test coil and thus the condition of the
tube are presented on a computer screen.
 TUBE INSPECTION SOLUTIONS 19

Advantages / possibilities Disadvantages / limitations

• Possible to examine carbon steel • Works well for only a limited

(finned) tubes amount of degradation mechanism
• Speed similar to conventional eddy • Only internal defects can be found
current • Sizing of defects limited
• Basic cleaning of tubes normally (based on signal volume)
sufficient • Insensitive to small defects
20 TUBE INSPECTION SOLUTIONS

IRIS

IRIS is a technique that can be applied on both ferrous and non-ferrous materials
and even on non-conductive materials like plastics.

With IRIS the remaining wall thickness of tubes can be accurately measured. IRIS
is more accurate than other tube inspection techniques and has the advantage
of presenting information about the geometry of defects. Local defects and
wall-loss on both sides of the tube can be accurately measured. Defects under
support plates can be measured without any limitations.

Theory
The probe used in IRIS examination is made up of a centering device, an
ultrasound transducer and a rotating mirror. An ultrasound pulse will be
generated in the transducer that is mounted in axial direction. A 45 degree
rotating mirror in the probe will guide the sound bundle towards the tube wall.
An ultrasound reflection (echo) will take place at the inner and at the outer wall
of the tube. These echoes are reflected back and processed by the equipment.
The time between these two echoes represents the wall thickness of the tube.
Knowing the sound velocity in the material under test, an accompanying wall
thickness can be calculated. Water is used rotate the probe mirror and is also
needed as a couplant between the transducer and the tube wall.
 TUBE INSPECTION SOLUTIONS 21

A calibration standard of the same material and dimensions as the tubes to be

examined is used to check the IRIS system response. After an inspection an
“on-site” report detailing the condition of each tube will be presented to the client.

Advantages / possibilities Disadvantages / limitations

• Actual wall thickness can • Low inspection speed, High cost

accurately be measured • Wall thicknesses lower than 0.8 mm
• Both internal and external defects cannot be accurately measured
can be measured • Difficult to detect external defects
• Can distinguish between in- and when inner wall is heavily corroded.
external defects • Water is needed on site to function
• Defects under support plates as couplant
can be detected and sized • Cleaning of tubes is very critical
• Not influenced by changes
in permeability or conductivity
that can cause false indications
using electromagnetic methods
• Can be used on most materials
(ferrous, non-ferrous, plastics)
• Gives information about
geometry of defects
22 TUBE INSPECTION SOLUTIONS

REMOTE VISUAL INSPECTION (RVI)

RVI can be used to visually inspect every possible tube. RVI doesn’t provide any
information about defect depth. But it can be useful to obtain information about
defect geometry and the possibly present degradation mechanisms in a tube.
Defects can be photographed and the image of the whole tube can be video
taped. RVI is mainly used as a back up tool to verify the results of the other
techniques.

Advantages / possibilities Disadvantages / limitations

• Can be used on every material • Sizing of defects not possible

• Gives information about geometry • Only the internal tube wall can be
of defects examined
• Visualization of defects gives high • High level of cleanliness required
level of conifidence
 TUBE INSPECTION SOLUTIONS 23

EPILOGUE

For all Electro Magnetic techniques (ET, FSEC, RFT, PSEC, MFL, HFEC) that
were discussed, a calibration standard is essential for good results.

During signal analysis, the signals acquired during a heat exchanger inspection
will be compared to the signals from reference defects. Reference defects are
defects with known depth and shape and are machined into a calibration standard.
The calibration standard needs to be of the same material and dimensions as
the tubes to be examined.

For IRIS examination it is recommend to use a reference standard to verify

equipment response prior to an inspection carried out.

Note: This book is intended for informational purposes only. Named values have been
generalized and depend on specific situations. To the best of our knowledge, the information
in this publication is accurate however the publisher does not assume any responsibility
or liability for the correctness of such information.

Author:
Jarno de Jonge
Level 3 ET, Operation Manager
Dacon Inspection Services
jarno.dejonge@dacon-inspection.com
24 TUBE INSPECTION SOLUTIONS

NOTES
 TUBE INSPECTION SOLUTIONS 25

NOTES
26 TUBE INSPECTION SOLUTIONS

NOTES
 TUBE INSPECTION SOLUTIONS 27

NOTES
28 TUBE INSPECTION SOLUTIONS

DACON INSPECTION SERVICES CO.,LTD.

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Rayong, 21130, THAILAND
Phone: +66 38 880788
Fax: +66 38 880727
Email: info@dacon-inspection.com

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