Tubing Inspection Using Multiple NDT Techniques
Tubing Inspection Using Multiple NDT Techniques
Tubing Inspection Using Multiple NDT Techniques
net - 3rd MENDT - Middle East Nondestructive Testing Conference & Exhibition - 27-30 Nov 2005 Bahrain, Manama
ABSTRACT
This article describes the use of advanced tubing inspection NDT methods for boiler and heat exchanger
equipment in the petrochemical industry to supplement major turnaround inspections. The methods presented
include remote field eddy current, magnetic flux leakage, internal rotary inspection system (IRIS) and eddy
current. Cost savings include lower inspection costs, lower turnaround costs, avoiding lost production, and allow
better planning of inspection and maintenance intervals. To achieve these savings and improve integrity, the
owner-user must understand the capabilities and pitfalls of the NDT technologies in order to select, apply and
interpret the results of these methods. A methodology of providing rapid qualitative screening techniques before
applying slower quantitative techniques is presented to maximize heat exchanger integrity while minimizing
inspection costs.
INTRODUCTION
The petrochemical industry depends on many heat exchangers and boilers for efficient operation. As these
components consist of many tubes tightly held together, they are very hard to inspect visually or with normal
ultrasonic or radiographic thickness measuring techniques. Inspections used to take two to three weeks to assess
the condition of a boiler or heat exchanger. New NDT Technology has developed portable equipment that
combines simple operation, reliable flaw detection, and easy reporting. In the past, tests were limited to visual
inspection and destructive testing (splitting) of small-bore tubing in heat exchangers and boilers. Based on total
number of tubes inspected at that time, engineering decisions normally led to either a risky approach involving
possible unscheduled shutdowns or a too conservative approach where tubes were plugged or replaced too early
at a high cost to the petrochemical industry. As a result the local petrochemical industry now adopts and uses
field portable inspection systems to thoroughly inspect small-bore tubing. These field portable systems provide
the capability of four NDT techniques, which are Remote Field Eddy Current Testing (RFT), Eddy Current
Testing (ET), Magnetic Flux Leakage (MFL), and Ultrasonic- Internal Rotary Inspection System (IRIS). They
all operate on one hardware and software platform. These systems allow for fast screening (around 400 tubes
per day) with one technique with the ability to simply change a probe head and validate accurately defective
areas with a more accurate method. In this manner high risk or over conservatism in replacement decisions can
be avoided. Detail description of each technique will be explained below.
Energy Flow
Tube
Probe lead
Exciter Coil
Detector Coil
Corrosion
object. This current is known as the eddy current. Eddy current flow in the test material produces a secondary
electromagnetic field in the material that opposes the primary electromagnetic field. The magnitude of the
secondary electromagnet field is directly proportional to the magnitude of the eddy current. When eddy current
varies, secondary electromagnetic field also varies. Hence the impedance of the coil changes as the
electromagnetic field interacts with the material. Characteristic changes in test object such as conductivity,
permeability and geometry will cause eddy current to change. Variations of eddy current are reflected to the test
coil by changes in the primary electromagnetic field.
Typical eddy current instrument contains 4 frequencies in both differential and absolute modes. The differential
mode detects pits and cracks and the absolute mode detects gradual wall loss. The multi frequency testing is
done for two reasons:
1. To differentiate between defects and metallic deposits. This is essential because metallic deposits can produce
eddy current signals that resemble defect signals. Improper resolution of signals will result in unnecessary
plugging of tubes.
2. To detect defects under the support plates. This is done by using a two-frequency mix to cancel the support
plate signal and detect defects under the support plate
Tube Length
0
90
180
270
360
C-scan Presentation
Cross Section
Figure 6 - IRIS display includes the C-scan and the tube cross-section - OD wall loss in carbon steel tubing
CALIBRATION
We will focus on RFT and IRIS techniques due to the nature of the field case study that we will discuss in
this paper.
To calibrate the instrument for RFT [5] testing, a calibration tube must be of same material and size to be tested.
The calibration tube contains man made defects to simulate corrosion. Normally, the man made defects are used
with various depths such as 20%, 40%, 60%, to establish calibration curves. The calibration curves are used to
compare unknown signals to artificial defects to estimate actual wall loss. For IRIS [6] testing, calibration must
be done on known wall thickness of same material tube (see Figures 7A &7B).
FIELD TRIALS
Field trials of this system were conducted on more than eight thousands tubes of several high pressure boilers
at several locations in local petrochemical industries. The examinations were performed on ferrous tubing
exhibiting general corrosion and pitting.
The trials were successfully completed and general corrosion and pitting corrosion were easily detected.
INSPECTION TECHNIQUES
The tubes were screened with RFT to locate areas of wall loss. These areas were then followed up with IRIS
to determine actual wall loss. The RFT method is relatively quick to perform but cannot detect pitting unless a
sizable volumetric wall loss is associated. On the other hand, IRIS provides a map of the tube wall thickness and
can detect internal wall loss or external wall loss. The RFT results are given in percentage of wall loss, as this is
averaged around the whole circumference, while IRIS results are given as the minimum wall thickness reported
for a tube area.
EXAMINATION RESULTS
Generating tubes:
RFT and IRIS were used to examine this section of the boiler. The analysis of the examination data showed
indications on 6 tubes out of 1206. The minimum wall thickness measured was 0.078. T min was 0.0965.
CONCLUSIONS
Based on the results of the field trials data, a system providing multiple NDT techniques provides a
qualitative and fast screening (around 400 tubes per day) with one technique with the ability to simply change a
probe head and validate accurately defective areas with a more quantitative method. In this manner high risk or
over-conservatism in replacement decisions can be avoided.
INSPECTION RECOMMENDATIONS
For boiler tubing inspection use:
ACKNOWLEDGEMENT
The author would like to acknowledge the outstanding effort contributed to this project by the key
technicians:
Mirza Al-Thunian and Abdulhai Al-Mahasnah
REFERENCES
[1] R/D Tech Operating Manual, TC-5700, October, 1998
[2] R/D Tech Operating Manual, TC-5700,
October, 1998
[3] R/D Tech Operating Manual, TC-5700, October, 1998
[4] R/D Tech Operating Manual, TC-5700,
October, 1998
[5] ASNT Handbook, 2nd edition, Vol.4, ET, R. McMaster, P. McIntire, M. Mester, 1986
[6] ASNT Handbook, 2nd edition, TU, Vol.7, A. Bikes, R. Green, P. McIntire, 1991