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
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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

come in all kinds of shapes, dimensions and materials. Construction models

/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

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

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

6 TUBE INSPECTION SOLUTIONS

TUBE INSPECTION SELECTION CHART

Material Tecnique Defect types Determines Cleanliness

type requirements

Austenitic Pits, Pin holes,

and 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

Ferritic
and Pits, Pin holes,
Duplex PSEC Defect depth % Critical
Wall - loss

Pits, Pin Holes,

MFL Defect depth % Critical
Wall - loss

Internal Diameter
enlargements Internal diameter
HFEC Access
(erosion) enlargement %

All metals Remaining wall

IRIS Pits, Wall - loss 100%
and thickness
Non-
Coductive
Pits, Overall Defect shape
Materials
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
• Can only be used on non - ferrous

• 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

• Cleaning not critical Fair Good Good Poor Fair
• Pits need to have some volume in order
to be detected (diameter Pit >5 mm)

• Sensitive to pits in carbon steel

• Phase information available
for internal sizing Good Fair Good Good Good
•
• Cleaning critical
• Sensitive to pit in carbons steel
• Good Fair Good Poor Good
• Sizing of defects very limited
• Cleaning critical

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

• Accurate determination of wall thickness

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

• 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 Austenitic Stainless steel.

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

Theory
The probe used in Eddy Current examination contains a coil which generates

of the tube at the location of the coils. The Eddy currents will in their turn generate

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
(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

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

Theory
The probe used in Eddy Current examination contains a coil which generates a

the tube at the location of the coils. The Eddy currents will in their turn generate

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
• 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 ferritic
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.

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

coupled to the receiver coil as a direct coupling between the two coils is shielded

generated in the tube. At a low enough frequency the shielding will lose some of
 TUBE INSPECTION SOLUTIONS 13

along the tube with little further attenuation. Research found that a portion of the

a certain location.

Now the indirect coupling path between send and receiver coil is complete. The

of material that was crossed in the indirect coupling path. If wall-loss occurs in a

the receiver coil. Signals that represent the changing in the received magnetic
uter screen.

Advantages / possibilities Disadvantages / limitations

• Possible to examine carbon • Relatively insensitive to small

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

PARTIAL SATURATION EDDY CURRENT (PSEC)

PSEC is a technique used for the inspection of tubes made of ferritic materials.

technique will be applied on normal ferrous tubes as well.

Using PSEC internal as well as external pits can be detected in ferritic materials.
PSEC can detect and distinguish between internal and external defects.
Sensitivity is biggest for external defects but internal defects can be more
an 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 ferritic tubes. The permeability

electromagnet in the PSEC probe is used to partly cancel out the magnetic

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

• 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
16 TUBE INSPECTION SOLUTIONS

MAGNETIC FLUX LEAKAGE (MFL)

MFL is a technique used for the inspection of tubes made of ferritic 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

MFL is sensitive to sharp type defects like pits and grooving. In- and external

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

will be picked up by the coils and the Hall-effect sensors in the probe. Size of
y the shape, the
dimensions and the location of defects. Signals that represent the size of the
 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
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
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
18 TUBE INSPECTION SOLUTIONS

HIGH FREQUENCY EDDY CURRENT (HFEC)

HFEC is a technique that was developed to detect and quantify internal diameter

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

the tube at the location of the coils. The Eddy currents will in their turn generate
coil.

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

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)
• 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.

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 •
• 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
•
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
 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

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
[email protected]
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 TECHNOLOGIES CO.,LTD.

78/4 Moo 6, Sukhumvit Road, Ban Chang Rayong,
21130, THAILAND
Phone: +66 33 012484-7
Fax: +66 33 012530
Email: [email protected]

www. dacon-inspection.com