CHEMICALS CORP

P. O. BOX 1234
ANYWHERE, USA 12345

EDDY CURRENT INSPECTION

BASCO: Heat Exchanger

Serial: 17-111-0

Location: COMPANY

ANYWHERE, USA 12345

Inspected: July 18, 2001

Inspected By: MICHAEL D. JOHNSON

LEVEL III ANALYST

Reviewed By:
TECHNICAL MANAGER, LEVEL III
CHEMICALS CORP
P. O. BOX 1234
ANYWHERE, USA 12345

EDDY CURRENT INSPECTION

BASCO: Heat Exchanger

Serial: 17-111-0

Location: COMPANY

ANYWHERE, USA 12345

Inspected: July 18, 2001

Inspected By: MICHAEL D. JOHNSON

LEVEL III ANALYST

Reviewed By:
TECHNICAL MANAGER, LEVEL III
 TABLE OF CONTENTS

Section A ............... Inspection Report

Part I ........... Vessel Information

Part II ........... Summary of Inspection

Part III ........... Defect Summary

Part IV ........... Recommendations

Part V ........... Data Sheets

Part VI . . . . . . . . . . . Tube Chart Layout

Part VII . . . . . . . . . . . Tube Strip Charts

Section B ............... Calibration Settings

and Graphs

Calibration Procedures

Section C ............... Explanation of

Abbreviations
 VESSEL INFORMATION

MANUFACTURER: BASCO MODEL: Heat Exchanger

STYLE: Hermetic SERIAL: 17-111-0
TYPE: Vacuum Condenser

VESSEL: Heat Exchanger

TEST END: Opposite Inlet/Outlet
TUBE COUNT: 305
TUBE TYPE: Prime Surface
TUBE MATERIAL: Stainless Steel
OD: .750
*NWT: .065
#/TYPE SUPPORT: 6 Staggered Mild Steel
TUBE NUMBERING: Top to Bottom
ROW NUMBERING: Left to Right
TUBE LENGTH+2": 155 Inches

ANALYST: MICHAEL D. JOHNSON, LEVEL III

* Nominal Wall Thickness

 S/N: 17-111-0

SUMMARY OF INSPECTION

An eddy current tube inspection was performed as part of a preventive maintenance program
with the following results.

SIGNIFICANT/MEASURABLE NUMBER PERCENT

INDICATIONS OF TUBES OF BUNDLE

HEAT EXCHANGER: 305 TUBES

DENT, EXCESSIVE 3 0.98

DENT, NOMINAL 4 1.31

OD PIT 20% - 39% 44 14.43

OD PIT 40% - 59% 62 20.33

OD PIT 60% - 79% 29 9.51

PREVIOUSLY PLUGGED 16 5.25

RESTRICTED 1 0.33

TOTALS 159 52.14%

 S/N: 17-111-0

RECOMMENDATIONS

The tubes in this machine were tested for normal wear patterns using accepted test methods for
eddy current inspections. The possibility does exist that tubes could contain abnormal wear
patterns, defects and/or leaks not detectable by normal eddy current test methods.

The following suggested repair actions are based on accepted industry standards. After
removing sample tubes to confirm the inspection results, a determination of corrective action
should be made by the repair agency and end user. Only these parties have knowledge of the
critical applications and long-term use of the equipment. If plugging is selected over
replacement, both efficiency and capacity should be considered.

HEAT EXCHANGER:

Tubes marked for Excessive Dents showed indications of stress or wear, or were located in the
bundle where further damage is a concern. We recommend these tubes be isolated from the system
at this time. Tubes marked for Nominal Dents require no corrective time.

We recommend tubes indicating OD Pits of 60% or more be isolated from the system. Tubes
indicating OD Pits of less than 60% require no corrective action at the present time.
However, the damage mechanism and growth rate are unknown. This damage should be monitored
for growth.

Tubes marked as Previously Plugged, had been plugged prior to this inspection.

Tubes marked as Restricted contained defects, or foreign material which prevented the probe
from passing. The condition of these tubes at and beyond the obstruction remains unknown.

SUMMARY:

We recommend that a follow-up inspection be performed after 1 year of operation. A copy of

this report should be retained in your files to be used for comparison at that time.

If you should have any questions concerning this report, or if we may be of further
assistance, please feel free to call upon us.
 DATA SHEET

LOCATION: COMPANY

ANYWHERE, USA 12345

MODEL: BASCO, Heat Exchanger

SERIAL NO: 17-111-0

DATE: July 18, 2001

ROW TUBE DESCRIPTION AREA ROW TUBE DESCRIPTION AREA

******************SET UP CALIBRATE & STARTED 3 16 PREVIOUSLY PLUGGED TE

HEAT EXCHANGER 09:45 am
4 1 DENT, EXCESSIVE B04
2 6 OD PIT 40% - 59% B04 4 2 OD PIT 20% - 39% B04

2 7 OD PIT 40% - 59% B04 4 3 OD PIT 20% - 39% B04

2 9 OD PIT 40% - 59% B04 4 4 OD PIT 20% - 39% B04

2 13 OD PIT 40% - 59% B04 4 5 OD PIT 40% - 59% B04

2 14 PREVIOUSLY PLUGGED TE 4 6 OD PIT 40% - 59% B04

3 1 OD PIT 40% - 59% B04 4 7 OD PIT 40% - 59% B04

3 2 OD PIT 40% - 59% B04 4 8 OD PIT 40% - 59% B04

3 3 OD PIT 40% - 59% B04 4 9 OD PIT 20% - 39% B04

3 4 OD PIT 40% - 59% B04 4 10 OD PIT 20% - 39% B04

3 5 OD PIT 40% - 59% B04 4 11 OD PIT 20% - 39% B04

3 6 OD PIT 40% - 59% B04 4 15 OD PIT 20% - 39% B04

3 7 OD PIT 20% - 39% B04 4 16 DENT, NOMINAL S03

3 8 OD PIT 20% - 39% B04 4 17 OD PIT 20% - 39% B04

3 9 OD PIT 20% - 39% B04 5 1 OD PIT 40% - 59% B04

3 10 OD PIT 40% - 59% B04 5 2 DENT, NOMINAL S06

3 11 OD PIT 20% - 39% B04 5 3 OD PIT 20% - 39% B04

3 12 OD PIT 20% - 39% B04 5 15 DENT, NOMINAL S06

3 13 OD PIT 20% - 39% B04 5 16 OD PIT 40% - 59% B04

3 14 OD PIT 20% - 39% B04 6 1 OD PIT 20% - 39% B04

3 15 OD PIT 40% - 59% B04 6 2 OD PIT 40% - 59% B04
 Defect Summary/Comparison

Comparison of Tests Performed

05/15/2000 05/16/2000

Heat Exchanger Defects

62.0
58.9 OD PIT 40% - 59%
55.8 05/15/2000
52.7 PREVIOUSLY PLUGGED
49.6
05/15/2000
46.5
Number of Defects

43.4 OD PIT 20% - 39%

40.3 05/15/2000
37.2
DENT, EXCESSIVE
34.1
31.0 05/15/2000
27.9 DENT, NOMINAL
24.8
05/15/2000
21.7
18.6 OD PIT 60% - 79%
15.5 05/15/2000
12.4
RESTRICTED
9.3
05/15/2000
6.2
3.1 OD PIT < 20%
0.0 05/15/2000

(Shaded areas represent previous test.)

Location: CHEMICAL CORP

Model: Heat Exchanger
Serial: 17-111-0

Note: The Graph will indicate a Comparison Analysis

when the unit has been previously tested by TAI Services, Inc.
TAI Services, Inc.
Data Aquisition System
S/N 17-111-0

CALIBRATION PAGE

Tube Type: Prime Surface Vessel: Heat Exchanger

Material: Stainless Steel
Nom Wall Thick: .065

Channel: Differential Channel: Absolute

Frequency: 280.0 Khz Frequency: 90.0 Khz
Gain: 176 Gain: 76
Phase: 261 degrees Phase: 160 degrees
H/VD: 0.50 H/VD: 1.00
V/VD: 0.50 V/VD: 0.25
L P Filter: 65 L P Filter: 65
Angle Amp: Off Angle Amp: Off

DIFF

ABS

ABS DIFF
 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

NO SIGNIFICANT DEFECTS
 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

OD PIT 40% - 59%

 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

OD PIT 40% - 59%

 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

DENT, NOMINAL
 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

OD PIT 60% - 79%

 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

OD PIT 60% - 79%

 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

DENT, NOMINAL
 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

DENT, EXCESSIVE
 HEAT EXCHANGER SECTION

S/N 17-111-0

DIFF

ABS

ABS DIFF

OD PIT 40% - 59%

 CALIBRATION PROCEDURE

A calibration procedure is performed prior to an inspection, and is repeated

every 2 hours, or whenever improper operation of the test instrument is
suspected. Test frequencies are selected to produce a 90 degree phase separation
between the 20% outside diameter Flat bottom holes and the 100% through
wall hole in calibration reference standard. Instrument sensitivity shall be
adjusted to produce a 40% or greater full scale deflection for the 100% through
wall hole. Initial phase of the test instrument shall be adjusted to produce a 0 degree
(horizontal) deflection for the 20% ID groove milled in the calibration standard.
Probe coupling variations wiil typically be displayed along the axis as well.

CALIBRATION REFERENCE STANDARD

A Calibration Reference Standard representing a typical production run tube

of the same alloy, tube type and nominal wall thickness is used to adjust
test system response. The calibration reference standard used have been milled
in accordance with the American Society for Testing and Materials (ASTM)
Standard Recommended Practices, E-243-80, E-426-76, and E571-76.
The depth of the grooves and notches used for establishing instrument
response are calculated to compensate for the influence of the fins and/or
internal enhancements used on finned tubes. Where applicable, calibration
reference standards are milled in accordance with the American Society of
Mechanical Engineers (ASME), Section V, Article 8, Appendix I.

A strip chart recording of each calibration reference standard used for the
inspection has been included in this report. Each artificial discontinuity
has been identified on the strip chart recording.
 EXPLANATION OF ABBREVIATIONS

ABN IND .............. Abnormal Indication

B .............. Bay

FB .............. Freeze Bulge

FBH .............. Flat Bottom Hole

FM .............. Foreign Material

ID .............. Internal Diameter

ID CORROSION . . . . . . . . . . . . . . Internal Diameter, Corrosion

ID DEPOSIT .............. Internal Diameter, Deposit

ID PIT .............. Internal Diameter, Pit

IDML .............. Internal Diameter

Metal Loss

IE .............. Internally Enhanced

OD .............. Outside Diamter

ODML .............. Outside Diameter

Metal Loss

ODML@S .............. Outside Diameter Metal

Loss at Support

OD DEPOSIT .............. Outside Diameter, Deposit

PLF .............. Possible Longitudinal

Flaw

PRF .............. Possible Radial Flaw

PSC .............. Possible Stress Corrosion

S .............. Support

WAS .............. Wear at Support

> .............. Greater Than

< .............. Less Than

OTE .............. Opposite Test End

TE .............. Test End