Eddy Current Testing of Tubes in Air Conditioning: Equipment Eddy current testing (ECT) is a type of nondestructive test (NDT) that can be used for a variety of purposes. Through the use of various types of ECT equipment, the thickness of plating and coatings can be measured, metals and alloys can be sorted, and cracks can be located in’a wide range of compo- ants and structures. Defects can also be located in hibes. For vse reasons, the eddy current test is the quickest way to coHably inspect a large rumber.of nudes that are found in ‘lers and condensers of large air conditioning equipment. Although ECT may be tottlly new to air conditioner owners, it is a well established, reliable technique used in ctitical commercial and military operations. This nondestructive test is widely used for quality control by tube mills, and the petrochemical industry has used the technique for years in refineries and chemical plants. ECT is also extensively used by the commercial nuclear power in- dustry to inspect a variety of heat exchangers and hes been used on submarines for almost 20 years by the nuclear Navy, ‘The first step in an eddy current test consists of calibrating the instrument to known ‘defects in a sample tube by inserting an inspection probe along the full length of the tube. The probe contains coils which set up a magnetic field in the tube. ‘The magnetic field in tum creates electrical disturbances in the tube called ‘eddy currents’. When the probe passes by pits, cracks, gouges, worn areas or other defects, the eddy current field is forced’ to change shape. This change of shape creates an electrical signal which is displayed on the test unit-attached the probe. The final step in the inspection is to interpret the meaning this signal in tenns of the type and severity of conditions deh produced the signal, Like all NDT techniques, eddy cusrent testingis only a tool and like all tools, it has very definite limitations, Eddy current testing is effective in preventing air conditioner tube failures only when it is used by a qualified inspector who can correctly and fully interpret the results. It is then up to the owner to act upon the recommendations submitted by the inspector. ‘The Importance of inspecting Air Conditioners The best reason for having an air conditioner inspected, from an owner's standpoint, is to save money. Savings can be realized in several ways. Eddy current inspections ‘can detect tube corrosion, pits, and vibrational wear before leaks and a resulting unscheduled shutdown can occur, Subsequent reinspections that are Scheduled at 2 defined interval can measure the deterioration rates as well as predict the remaining tube life. This permits planning and budgeting for retubing well if advance of the actual retubing Retubing costs can be minimized because ECT can delineate the exact, localized acca affecied. As a result, this non- destructive test is cavable of determining the exact area where However, if a leak does occur, ECT-can reduce costs and risks by determining the type of deterioration, identifying any _-other potential leaks, and directing the investigator.toward the cause.-A complete eddy current inspection of an exchanger establishes whether 2 total retubing is needed or if only'one area of the bundle is affected. The inspection will also deter- mine which tubes should immediately be plugged to permit, the unit to complete the cooling season. Once the cause of the problem has been pinpointed and the most severely affected tubes identified, ECT can aid the owner of an alr conditioner unit in avoiding recurring leaks. The selective removal and laboratory analysis of the leaking tubes helps to identify changes in water chemistry, lithium bromide solution, or other changes that ‘are required to arrest the condition. ‘The savings realized in leak avoidance, retubing costs, and avoidance ‘of recurring leaks should far outweigh the cost of the inspection. ‘The Types of Defects Located by ECT Eddy current testing can identify virtually all the common forms of defects that cause tube leaks, Watér side corrosion pits, for example, are readily detected, The depth of such pitting can be- approximated’ by eddy current inspection generally within + 10% up to about S07 wall Joss. Above 50% wall loss, the accuracy can drop off. Although the eccuracy of ECT decreases when testing tubes with 50% wall loss, the eddy current inspection can still adequately establish the suitability of the tubes for continued service. Acceptance criteria should also be determined in part by the service history of the audit. Field data indicates, however, that tubes with pitting wall loss in excess of 40% to 50% may'not last the full season. This will depend, of course, on the rate of corrosion, which can be erratic and very rapid depending on conditions within the unit once it is back in service. ‘Stress Corrosion Cracking is -eadily. detected but depth approximations can be very difficult. By proper analysis of the ECT results, stress cracks can be distinguished from other defects, Once'the presence of stress cracks is firmly established, the commonly aecepted criteria is to plug or replace any tubes recording any crack, regardless of depth. This is done on the ‘basis thal any crack Can propagate a leak ot failure quickly and unpredictably. When stress cracking is found, the equipment manufacturer should be eénsulted to correct the. conditions which led to this form of corrosion. Corrosion on tha Outside (OD) of tubes can take several forms, depending on whether the tubes are finned or prime surface. Corrosion on the outside can be differentiated from corrosion in the water side by eddy current test, The depth of corrosion also can be approximated by an eddy current test within 2 typical accuracy level of # 20%, This is due to the very erraticWear at the Tube Support Sheets is detectable and can be measured with good accuracy at + T0% or better by ECT. Wear at the tube support sheet caused by vibration or a combination of corrosion and vibration can be identified. Support wear will usually accelerate with time because as the tube weats, the clearance between itself and the support increases: This results in increased amplitude of vibrational motion, and consequently the rate of wear increases. Plugging or replacing tubes that record a wall loss.of 20% or greater is normally sufficient to obtain at least one season of operation. Fatigue, or Thermal Shock Cracks are very difficult to detect, but can be located with special wound probes. Here again, depth determination is questionable, but the presence of any measurable crack renders that tube potentially unreliable. Plugging ot replacement of such tubes should be very cost effective. Freeze Bulges can also be detected. Once a set of calibration standards are manvfactured, it may ‘be possible to quanti- tatively estimate the extent of the bulge. The significance of these bulges to the tube life is unclear. These areas are, how- ever, high stress areas and do represent a potential for failure. M--netic Deposits caused by nofmal corrosion of the air ¢{___jtioner shell or the piping systems wil produce significant et::3/ current signals. Magnetic deposits can usually be dis- tinguished from tube damage, but not in all cases, Tube clean- ing before inspection is helpful in minimizing these signals. Magnetic deposits are usually not corrosive, but they promote corrosion, They tend to mask out damage signals, and generally indicate the.sir conditioner is in need of some corrective action, Erosion can occur at the tube inlets in salt water cooled units or, in certain instances, can occur on the outside of absorber tubes, Eroston is detectable and the depths can be approxi: mated generally within + 25% Who Performs ECT There are three principal sources of ECT inspections. The three sources are commercial test labs, major air conditioner manufacturers, and companies specializing in eddy current field testing. ‘The success, however, of an eddy current inspection Jepends primarily on the training and experience of the individual performing the test, A reliable and error free inspection Feewires an inspector who is sufficiently experienced to assess u_everity of any problem areas encountered. These are clzisil requirements because eddy current test equipment ean respond (0 a wide range of variables in the tube. ‘The inspector must also be experienced in the interpretation of results and establishment of acceptance criteria because professional societies and user agencies have not developed acceptance standards or guidelines other than. for certain nuclear power applications. Therefore, interpretation of results and the establishment of acceptancescriteria rests entirely with the inspector, who must also obtain customer agreement. Mistakes can be very costly 10 the owner if he has failed to obtain the service of a well-trained, experienced inspector. A mistake of error can result in Jeaks immediately after startup as well as the complete. retubing of. bundles that only had magnetic deposits in the tubes. To. minimize mistakes’ there “are several key “factors to consider in the selection of any ECT source. Personnel Training:nd Certification ‘The American Society for Nondestructive Testing has established. guidelines for. personnel training which are set forth in their publication SNT-TC-1A. These recommended guidelines have-been voluntarily adopted by established ECT. service companies, 1 is advisable -t0, request the services of an inspector who is so qualified has had the specified amount of training and field experience. Specific Certification Certification “conducted in accordance with SNT-TC-1A covers the entire field of eddy current testing. Additional certification aimed specifically at demonstrating an individual's capability to inspect air conditioner tubes will give air condi- ioner owners an increased measure of confidence in the accur- acy of the results. One such program is being developed by 2 major manufecturer of air conditioning equipment. This testing program would require each inspector to qualify by passing a test consisting of inspecting a package chiller model that contains typical tube defects. This approach to personnel «qualifications is considered the best method to demonstrate an inspector's capabilities. Use of Calibration Standards Unless calibration standards are used at least once per shift, the validity, accuracy and reproducibility of the test results are questionable, Calibration standards must be the same nominal size, wall thickness, alloy, and configuration as the tubing being inspected. Evaluation of Results It is important to establish if an inspection source estimate depth of tube deterioration, can routinely provides” plot of “bad” tubes, has criteria to establish what bad means, Will interpret as required to help define the cause, and will recommend possible corrective action. Objective Evidence of the Inspection of Each Tube Objective evidence can be generated by most ECT equip. ‘ment in the form of paper tape records or more complex magnetic tape records. Objective evidence provides 2 basis for monitoring the rate of minor tube deterioration, therefore establishing if corrective actions have been effeciive, Paper tape records or magnetic tape records can also be used to determine if additional tube leaks: are due to new damage ‘mechanisms or tn prior damage overlooked by the inspector. Planning and Executing a Program, The basic steps in an air conditioner ECT program should + include the following: 1, Decide on an inspection schedule that is based on the age” the machines and prior leaks. 2, Select an ECT source. ~ 3. Schedule the eddy current test, Scheduling inspections with other owners can minimize travel charges and is cost effective if outside agencies are used, 4, Remove the heads, at least on one end, and thoroughly clean the tubes. This will minimize time and maximize accuracy. Tubes normally do not nieed to be dried before the inspection. 5. Perform ECT. On-site data interpretation is very useful because it permits the immediate marking of defective tubes and selection of acceptance’ or rejection criterion based on field results, 6, Pull a tube. If severe defects are recorded and it is suggested that these tubes.be plugged or replaced, pull one ar 1W0 of the most heavily -affected’ tubes, Any commercial “ECT source should welcome this for it is the best possible check on the validity of the-specific, inspection. Pulling random tubes for laboratory analysis, however, is no substitute for an eddy current test, Rarely are all tubes equally defective 7, Follownip. After effecting system changes, partial retw! ‘or other corrective actions, the owner should hove the unit