ect MAD 8D Calibration Procedure

Using The Vertical Volts Method

This procedure was written using the example of calibrating to inspect a 1" x .049 inch wall 90/10
copper nickel tube.

GENERAL INFORMATION

The vertical volts method uses lower frequencies than are used for phase analysis. The technique relies
on having some knowledge of the pit size and relies on the assumptions that the pits to be measured are
created by one mechanism and have the same depth to diameter ratios for any given depth of pit.

In the case of this example, a tube as described above had been removed from service. Pits were visibly
evident on the inside surface of the tube. Eddy current testing was used to locate the deepest pit
available close enough to the end of a tube that it could be measured mechanically. The pit was
measured mechanically and was found to be .004 inch deep or eight per cent of wall. The diameter of
the pit was estimated at one quarter inch diameter. As a calibration standard, a one quarter inch
diameter (same diameter as the pit) 100 per cent hole was drilled through the wall of the tube. This pit
is used for the 100 per cent of wall reference. (In an actual application, it will be necessary to use a hole
the diameter of the pits to be measured as the calibration defect in the calibration tube.)

For background information on this technique, please refer to the AUTOMATIC SIZING OF INTERNAL
PITS IN HEAT EXCHANGER TUBING USING EDDY CURRENT Report, the EDDY CURRENT PIT SIZING
TECHNIQUES FOR COPPER ALLOY TUBING Report, the EDDY CURRENT PIT SIZING: REVISITED Report,
the FOURTH EPRI BALANCE OF PLANT HEAT EXCHANGER NDE SYMPOSIUM Report, and
ELECTROMAGNETIC NDE GUIDE FOR BALANCE OF PLANT HEAT EXCHANGERS, Revision 1, Section
3.1-1, Recommended NDE Procedures for Non-Ferromagnetic Tubing, 90/10 Copper Nickel Prime
Surface Tubing published by the EPRI NDE Center.

PREPARATION

Follow the sections for probe selection, cable connections, and selecting frequencies from the ect MAD
8D Calibration Procedure.

In this example, the wall thickness of the tube is thinner than in the example given in the ect MAD 8D
Calibration Procedures. The frequencies selected in this section are: Channel 1, 64 kHz; Channel 2, 32
kHz; Channel 3, 64 kHz; Channel 4, 16 kHz.

Follow the procedure given in the ect MAD 8D Calibration Procedure for frequency channel phase
adjustment.

FREQUENCY CHANNEL GAIN ADJUSTMENT

As discussed earlier, the defects to be measured in this example are very large, with a diameter of about
one quarter inch; therefore, a comparatively low gain setting is required than in the general calibration
procedure. Set each of the differential channels 1, 2, and 4 to .25 volts per division and adjust the gain
controls so that the amplitude of the signal from the through wall hole is one volt peak-to-peak
minimum. Note that due to the clearance between the outside diameter of the probe and the inside
diameter of the tube, the distance between the probe coils and the defect will vary each time the probe
is pulled past the defect. For this reason, the amplitude of the signal will vary somewhat.

When the through wall hole signal has been adjusted to one volt, it will be four divisions, or one half the
screen size. This meets the requirements of the ASME Code.
For the absolute channel, Channel 3, adjust the 20 per cent I.D. groove in the ASME Calibration Tube to
be five or six volts in amplitude. A high volts per division screen sensitivity (low volts per division
number) may be used to meet the requirements of the ASME Code if this is a requirement of the
inspection; however, it is more useful to use a low screen sensitivity so that large defects will remain on
the screen in the Absolute Channel.

MIXER ADJUSTMENT

The vertical volts method relies on using relatively low frequencies; therefore, select Mixer 1 to mix the
signals from Channels 2 and 4, the 32 kHz and 16 kHz differential channels. Follow the procedure given
in Mixer Adjustment in the ect MAD 8D Calibration Procedure to cancel the signal from a support plate
and to adjust the mixer output phase control.

MIXER GAIN CONTROL ADJUSTMENT

Set the mixer volts per division to two volts per division and adjust the mixer gain control so that the
signal from the one quarter inch hole in the calibration tube almost, but not quite, fills the screen.

CALIBRATION TABLE

From the Analysis Menu, type <C> to enter the Calibration Table Menu. Select Table 1 and clear it by
typing a <C> followed by a <Y>. Type the letter <P> one, two, or three times as necessary to set the
parameter to vertical volts.

Return to the Analyze Menu by typing <A>. Note that the first line of the menu reads ANALYZE: V MAG
indicating that the analyzer is in vertical volts mode. Pull the probe through the calibration tube to
obtain a signal from the one quarter inch hole. Use the Analyze function to measure this defect in Mixer
1. Record the reading for the one quarter inch hole. In this example, the value was five volts. It may be
necessary to set the Don't Analyze Less Than to zero per cent and the volts to zero in the Setup Menu in
order to make this measurement.

Move to the Calibration Table Menu by typing <C>. Enter the values of 0, 25, 50, 75, and 100 as the top
four lines in the per cent wall column. In column M1 (for Mixer 1), enter 0 for zero per cent wall and the
value measured for the one quarter inch through wall hole for the one hundred per cent value (In this
example, five volts). Note that as volts are recorded in this table to a resolution of .1 volts, it is necessary
to type <5> <0> <Enter> to enter the value of five volts in the M1 column.

The Table is now set up for straight line linear interpolation of defect sizes with the values entered;
however, in real life, this function is a curve and not a straight line. The best way to determine this curve
is to build a calibration tube that has 25, 50, and 75 per cent I.D. pits with a diameter of the actual pits
that are to be measured (In this example, one quarter inch). As this is difficult to do, you may follow this
procedure to approximate this curve as follows: Multiply the value for 100 per cent by 60 per cent and
enter this value for the 75 per cent wall loss. In this example, that value is three volts. Multiply the value
for 100 per cent by 40 per cent and enter this value for the 50 per cent wall loss. In this example, that
works out to two volts. Multiply the value for 100 per cent by 20 per cent and enter this value for 25 per
cent wall loss. In this example, that works out to one volt.

DATA ANALYSIS

Collect data in the usual manner. Set the AutoMAD features as desired.

In the Analyze Menu, make sure that Table 1 is selected and that Mixer 1 is selected for analysis.
Analyze the data in the usual manner.

RESULTS

In this example, the eight per cent (.004 inch deep) pit that was physically measured close to the end of
the tube measures as eight per cent wall loss. The deepest pit in the sample of tube that was tested
measures eighteen per cent wall loss.
Automatic Sizing of Internal Pits in Heat Exchanger Tubing
Abstract

When internal pitting occurs in heat exchanger tubes, there are often thousands of pits per tube, making
completely automated detection and sizing of these pits highly advantageous.

The best method for sizing I.D. pits in 90-10 copper nickel tubes according to EPRI (Electric Power
Research Institute) research is to use the vertical volts method. As the occasional external defect is
encountered, this would result in erroneous readings if these signals were analyzed by using vertical
volts in order to calculate the depth of an internal pit. To apply the vertical volts method for internal pit
sizing with the ect MAD 8D software, it was necessary to first measure defect depth by phase angle to
make a determination as to whether the signal originated from an internal or external surface. If phase
indicated the pit was on the internal surface, then the vertical volts calibration curve was applied to
measure the internal pit. (Citation) Electromagnetic NDE Guide for Balance-of-Plant Heat Exchangers,
Revision 2, Sections 3.1 and 5.1.

The result was a software package which without dependency upon the user to find and record the
depth of the deepest internal pits in tubes. The software has been tested in an EPRI round robin and
was recommended for automatic detection and sizing of internal pits.

Introduction

Over the past two years, Kenji Krzywosz at EPRI, has been researching eddy current measurement
techniques for the accurate sizing of pits on the inside surface of heat exchanger tubes. As part of this
study, naturally occurring pits were studied in 90-10 copper nickel tubes that had been removed from
service. The conclusion of the study was that in this case, the most accurate method of sizing these
internal pits is to measure the vertical volts of the eddy current signal using a relatively low inspection
frequency.

The tube studied was a 5/8″ diameter by .049 wall 90-10 copper nickel tube. A primary test frequency
of near 50 kHz may have normally been chosen, but in this study the frequency with the best results
was 10 kHz.

Figure 1. Auto Analysis by Phase

A tube with an internal corrosion problem could easily have thousands of pits along its length;
therefore, there is a need to quickly, accurately, and reliably find the deepest pit or pits in a tube
without having to rely on a manual technique. The ect Auto Analysis Software has had this capability for
years (See Figure 1 and note the analysis of 83°, 1.46 Volts, 60% of Wall O.D. indicated in the sixth line
of the Menu), but did not have the ability to analyze from vertical volts. We at Eddy Current Technology
decided we should add this capability to our software for the ect MAD 8D eddy current system.

Figure 2. Auto Analysis of an I.D. Pit Using a Vertical Volts Calibration Curve

Auto Analysis Using a Vertical Volts Calibration Curve

To auto analyze internal pits by vertical volts, two changes had to be made to the software. The first was
to add the vertical volts capability as an analysis method. This was quite easy to accomplish since the
software already supported peak-to-peak measurement; so it was a simple matter to allow the selection
of a new parameter for measurement, and then to analyze based on only the vertical portion of the
signal (See Figure 2 and note the analysis of 25°, 3.81 Volts, 50% of Wall I.D. indicated in the sixth line of
the menu).

Figure 3. Auto Analysis of O.D. Defects Using a Vertical Volts

You cannot use a vertical volts to analyze all defects in a tube because when you use the vertical volts
calibration curve to analyze an outside defect, the resulting analysis is very incorrect (See Figure 3 and
note the analysis of 82°, 1.41 Volts, 45% of Wall I.D. indicated in the sixth line of the Menu). In this case,
the 60% O.D. pit in an ASME calibration tube has been analyzed as 45% I.D.

Figure 4

Figure 4. Phase Analysis for O.D. and Vertical Volts Analysis for I.D.

This is resolved by initially analyzing defects using a phase calibration curve. Based on this, if the angle
of the indication is greater than or equal to that of the through wall hole in a calibration tube, then the
signal is from an outside defect and is analyzed with the phase curve. If the angle of a defect falls
between that of liftoff (Horizontal) and the through wall hole, then the signal is considered to be an
internal pit and is analyzed by a vertical volts curve (See Figure 4).

Dealing with Support Plates

Internal pits will occur at or near support plates, making it necessary to deal with support plate signals.
A 40-10 kHz mix does a good job of eliminating the support plate signals; however, two factors make
the support plate signal problem more difficult to deal with than normal.

First, the vertical volts method for sizing internal pits as developed by Kenji Krzywosz at EPRI,
indicated that best results were obtained by using relatively low frequencies, specifically 10 kHz in this
case. This frequency is lower than what might have otherwise been chosen for analysis by phase. This
lower frequency penetrates the tube wall more easily, resulting in larger signals from support plates,
making it more difficult to cancel the larger signals.

A second factor which occurs in the round robin testing discussed below, the mockup heat exchanger
used in this round robin has non-ferromagnetic support plates. Non-ferromagnetic support plates give
substantially larger support plate signals than would be obtained from ferromagnetic support plates,
making it even more difficult to cancel the larger signals.

The two factors listed above result in relatively small defect signals in the mix channel. This problem is
overcome by using the Mixer Gain Control to amplify the mixer signals to a level that can be worked
with conveniently.
Round Robin Testing

Having made these software changes, it was then time to test the software on some real tubes.

EPRI had prepared a mockup heat exchanger which involved seven tubes: a calibration tube and six
tubes which had been removed from service with internal pits that formed while in service. The
capability of the software was to be tested by measuring its ability to detect all pits down to 20 per cent
through wall. To avoid missing defects that we may have under called by a few percentage points, we
were asked to report on all defects down to 15 per cent of wall.

For the inspection of the mockup heat exchanger, a probe drive with a speed of two feet per second was
used for collecting the data. Then the data was analyzed by the Analysis Software. At the analysis stage,
the software appeared to reliably analyze all defects in excess of 30 per cent of wall and all defects
down to 20 per cent through wall provided that the defects were not near a support plate. Defects less
than 30 per cent of wall that were close to or underneath a support plate required Operator
intervention to ensure an accurate analysis. The problem was that the residual support plate signal in
the Mix Channel moved the end points of the defect signal clockwise an amount that resulted in the Data
Analysis Software concluding that the defect was on the outside of the tube. The Operator had to move
the cursor slightly in order to force analysis by the vertical volts calibration curve. For these small
defects at the support plates, it is these numbers that were used in the final report.

Round Robin Results

The large signals from non-ferromagnetic support plates at the low frequencies used for the vertical
volts method of sizing internal pits played a significant roll in the result.

Requirement: Measure all pits over 20% of wall.

Tube: 90-10 Copper Nickel removed from river water service.

Results:

Auto detected and analyzed with the required accuracy:

1. All defects greater than 28%, regardless of location.

2. All defects not near support plates.

3. Possibly missed defects 28% or less that were near support plates. (Note 1)

Away from support plates all the required defects (all defects over 20 per cent) were detected and
analyzed with the required accuracy to meet the EPRI guidelines.

At support plates, all defects in excess of 28 per cent were detected and analyzed with sufficient
accuracy to meet the requirements of the EPRI guidelines.

There were a total of five participants in this round robin. Four used operator dependent manual
analysis. Three of the four operator dependent manual analysis participants failed to meet the flaw
detection criteria and failed to meet the sizing criteria. One participant used the ect MAD 8D eddy
current system with automatic analysis using a vertical volts calibration curve, and this system
exceeded the flaw detection and sizing criteria established in the EPRI Guidelines.

The overall result is that using the ect Auto Analysis Software for a vertical volts analysis of internal pits
is a recommended procedure now in the EPRI Guidelines.

Note 1: It is actually believed that all of the defects over 20 per cent and close to support plates were
correctly measured, but as the probe drive used did not have a position encoder, the exact position of
the defect was not accurately reported; therefore, there is some uncertainty that the correct defect was
measured for shallow defects near support plates.
Field Trials

The ect MAD 8D eddy current system was taken to the field for data acquisition and data analysis using
the Analysis Software on 5/8 inch diameter 90-10 copper nickel tubes in service in a K C heater known
to have an internal pitting problem.

Data was acquired from 28 tubes and analyzed, and then compared to the results of the traditional
manual inspection. Only the three deepest defects encountered in a tube with the automatic analysis
software was reported. Less significant defects were not to be reported. This data was compared to the
data from the conventional manual analysis in which only the deepest defect encountered was reported.
In all cases, the defect reported by manual analysis had been detected and analyzed correctly by the
Data Analysis Software accurately.

Conclusion

The ect MAD 8D eddy current system with ect Auto Analysis Software has been shown to analyze eddy
current tube data reliably with no missed calls of defects over 20% of wall loss away from support
plates and all defects over 28% of wall loss at support plates. This software is a reliable, accurate, fast,
Operator-independent method for analyzing eddy current data.

References

1. Kenji Krzywosz, “Eddy Current Pit Sizing: Revisited”, Paper No. Krzywosz-23:1, presented at the
Third EPRI Balance-of-Plant Heat Exchanger NDE Workshop, Myrtle Beach, South Carolina, USA (June 6-
8, 1994). [conference paper]