012 Eddy Current

ASIC OFFSHORE & MARINE SDN.BHD.
Lot G02-G07,
Level 3, Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470
Kuala Lumpur, MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website:
www.asicoffshore.com
ASIC Doc. Name: NDT-ET ASIC Rev: Page
ASIC Doc. No.: ASIC‐ED/OP/WI/NDT-ET-012 00
PROCEDURE FOR EDDY

CURRENT TESTING OF HEAT
EXCHANGER TUBES
Nidhin Venkatesh
Rev Rev. Date Description Prepared By Reviewed By Approved By

.
CONTENTS
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07,
S.No. Title Page

No.
1.0 SCOPE 3
2.0 REFERENCE 3
3.0 PERSONNEL QUALIFICATION 3
4.0 PRINCIPLE 3
5.0 EQUIPMENT 6
6.0 APPARATUS 8
7.0 FREQUENCY OF CALIBRATION 15
8.0 CALIBRATION PROCEDURE 16
9.0 TESTING SEQUENCE PROCEDURE 16
10.0 PROBE SPEED 16
11.0 REPORTING 17
12.0 REJECTION 18
13.0 RECORD 18
14.0 REPORTING 18
- APPENDIX-A 19
ASIC Doc. Name: ASIC Doc. Name: NDT-ET ASIC Rev: Page
1.0 SCOPE:
This procedure is applicable for the Eddy Current inspection on tubes / tubing for nonferrous
heat exchangers, boiler, and any small diameter piping. This procedure is meant for
carrying out an eddy current inspection on non-ferromagnetic tube materials in order to
detect localized thinning and other defects as cracks pits etc.
The covers examination of nonferrous tubes ranging from 3.2 mm diameter to 50.8mm
(0.125” to 2”) and wall thicknesses from 1 mm to 6.4mm (0.039” to 0.25”)
2.0 REFERENCE:
2.1 ASME Section V, Article 8, Appendix 1
2.2 ASTM E-309 (Carbon Steel & Alloy Steel and Martensitic, Duplex)
2.3 ASTM E-426 (Stainless Steel.)
3.0 PERSONNEL QUALIFICATION:
3.1 Personnel performing the testing shall have at least Level II certified in
accordance with Standard QE Specifications, written practice, complying with
ASNT.
3.2
3.3 However, Level I personnel shall be under the general supervision of Level II/III
personnel & Interpretation & Evaluation of indications shall be performed
by certified Level II or Level III personnel in Eddy current Testing.
4.0 PRINCIPLE
4.1 PRINCIPLE
Eddy current testing is a noncontact method used to inspect non-ferromagnetic tubing.

This technique is suitable for detecting and sizing metal discontinuities such as corrosion,
erosion, wear, pitting, baffle cuts, wall loss, and cracks in nonferrous materials.
• Two coils are excited with an electrical current, producing a magnetic field around them.
The magnetic fields penetrate the tube material and generate opposing alternating
currents in the material. These currents are called eddy currents.
• Any defects that change the eddy current flow also change the impedance of the coils in
the probe.
• These changes in the impedance of the coils are measured and used to detect defects
in the tube.
Examining non-ferromagnetic, heat exchanger tubing using the eddy current

method and bobbin coil technique. By scanning the tubing from the bore side,
information will be obtained from which the condition of the tubing will be
determined. Scanning is generally performed with a bobbin coil attached to a flexible
shaft pulled through tubing manually or by a motorized device. Results are obtained
by evaluating data acquired and recorded during scanning.
When an electromagnetic coil carrying alternating current held closed to

conductive material, eddy current is produced on the surface of the material, which
opposes the primary current.
The change in impedance in the primary circuit is the measure of eddy current
produced in the conductive material. If the material is having cracks, the eddy
currents are distorted and hence effect of these eddy currents on the primary
circuit will be changed. Similarly, due to thinning, distance between the coil & the
material (lift-off / fill factor) is increased
and so there will a change in impedance in the primary circuit.
With the help of reference calibration blocks (drawing attached), sensitivity is

established so that discontinuity and wall thinning equal to or greater than those in
the reference blocks can be detected.
4.2 Eddy current testing is conducted by using a coil system (generator / sensor
coil) which generates varying magnetic field when alternating current
passes through it. Therefore, when conductive material is placed near the test
coil, Eddy currents are induced. The presence of a discontinuity in the part
affects the normal flow of eddy currents and therefore, when the sensor detects:
this change in the eddy current flow produces suitable indication for evaluation.
4.3 The detectable discontinuities include the defects like cracks, lamination,
pinholes blisters, slivers and other defects which cause changes in the eddy
current flow and gets detected by the sensor coil and a signal is passed on to
the indication system of the equipment.
5.0 EQUIPMENT :
5.1 The eddy current instrument shall have the capability of generating multiple
frequencies simultaneously or multiplexed and be capable of multiparameter
signal combination. In the selection of frequencies, consideration shall be given to
optimizing flaw detection and
characterization.
(a) The outputs from the eddy current instrument shall provide phase and
amplitude information.
(b) The eddy current instrument shall be capable of operating with bobbin coil
probes in the differential mode or the absolute mode, or both.
(c) The eddy current system shall be capable of real time recording and playing back
of examination data.
(d) The eddy current equipment shall be capable of detecting and recording
dimensional changes, metallurgical changes and foreign material deposits, and
responses from imperfections originating on either tube wall surface.
A non-destructive testing system based on the principle of Eddy Current testing is

available with Olympus MS 5800 or equivalent may be used for this ET inspection.
The equipment shall be calibrated at least once a year or whenever the equipment
has been overhauled or repaired as a result of malfunction or damage.
i. Olympus MS 5800
ii. Test Range: From 6.00 mm OD to 114.3 mm OD
iii. Coil System: Self comparison type Deferential
iv. Maximum Tube Length: 30 Meters (Can be extended as Req.)
v. Speed: 30/ 60 Meters/ minute.
vi. Indicators on the system: computerized display
vii. The system is designed to cover the range of tubular from 6.00 mm
OD to 114.3 mm OD and with wall thickness up to 5.00 mm.
6.0 APPARATUS:
6.1 Electronic Apparatus:
6.1.1 The test apparatus shall be capable of energizing the test coil with
alternating current of suitable frequencies and be capable of sensing the
changes in the electromagnetic response of the sensors.
6.1.2 The test systems include, a phase discriminator, filter circuits,

modulation circuits, recorders, self-reference differential coil systems,
signaling devices and demagnetizing coil.
6.2 Test Coils:
6.2.1 Test coils shall be capable of inducing strong eddy currents in the tube
and sensing any changes in eddy currents produce by the tube.
Basically test sensitivity depends on fill factor between outside
diameter of the tube and test coils inside diameter, fill factor is to be
maintained 90% or more for obtaining high sensitivity.
6.2.2 For examining carbon steel & alloy steel, coil set with magnetic
saturation system shall be used.
6.3 Driving Mechanism:
6.3.1 The Mechanical drive system shall be capable of passing the

tube/pipe through & parallel to the axis of the test coil. It shall operate
at a uniform speed of adjustable speed suitable with the machine and
reference standard with minimum adjustment of coil and tube, and
at the same time it must maintain the tube concentricity with
the test coils.
6.3.2 For a self-reference deferential coil test system, if a defect runs

throughout the length of the detector coils, then there is no change in
the coil's impedance and as such this type of defect can only be
detected at ends by this machine. I f such defects are detected
visually tube/pipe shall be rejected.
6.4 Calibration:
6.4.1 The standard (reference tube is selected from the finished tube lot to be
tested) and it undergoes the careful quality control checks and it should
be free from any defect.
6.4.2 On this selected tube the artificial reference defects will be planted
(holes or notches are prepared) as per the requirements of the
procedure.
6.4.3 These artificial defects on the selects on the tube shall be measured for
accuracy and then the record of measurements to be offered to the
client or their authorized inspection agency for final approval.
6.4.4 Then the standard tube is allowed to pass through the Eddy Current
System and proper centering of tube through the probe (coil) shall be
verified. Frequency in to be selected depending on type of alloy,
sensitivity and amplitude are set so as to pick up the defects clearly
shown on screen.
6.4.5 The speed of drive should be set to 30 meters/minutes and be used for
testing the reference standard tube, and the same speed shall be used
when the actual tubes are tested.
6.4.6 After setting the frequency, sensitivity and amplitude & feed speed, the
same reference standard tube is once again allowed to pass through
the coil system and the results are observed. This shall be repeated at
least three times by reorienting the tube by 120˚ each time to ensure
the uniform detection sensitivity around the circumference and
consistency of result on the audio-visual indication.
6.4.7 If the results are consistent the machine is ready for the testing of the
tube lot.
6.5 Calibration tube:
6.5.1 Calibration tube shall be manufactured in the manner as the product

being inspected. The dimension and nominal composition shall be
identical with the tubes to be inspected. Calibration tube for eddy
current inspection shall consist of pit 100%, 80%, 60%, 40% and 20%
four flat bottom holes plus support plate.
6.6 Method of calibration:
6.6.1 Acquire data acquisition from calibration tube by pulling the probe out.
The channel calibration dialog box is used to adjust the differential
channels and absolute channels. The HOLE point is used to calibrate the
differential channels in the following manner:
6.6.2 Differential Channels: Calibration

point HOLE
Angle 40 degrees
Amplitude 1 volt
6.6.3 Absolute Channels:

Calibration point HOLE
Angle 40 degrees
Amplitude 0.25 volt
6.6.4 The test shall be carried out with reference to E-309 (For C.S & A.S).
The tubes will be tested in the final condition. This standard and
code, calls for preparing a standard (reference) tube, in which the
artificial discontinuities are introduced in conformity with the specified
standard. These artificial discontinuities are used as reference
(standard) for selection of test frequency and proper setting of the
sensitivity control of the equipment.
6.6.5 Reference standard of convenient length (min.4 feet) shall be

prepared from a length of acceptable tube of same alloy, size and
surface finish of the tubes to be examined.
6.6.6 The reference standard shall contain drilled holes or notch as per
customer requirement / product specification as an artificial defect.
Prior to the introduction of artificial defects (Drilled Holed/Notch) into the
standard tube, it shall be inspected to ensure that it is free from defects
that mask or complicate the indications received from the artificial
defects. If any defect indications are found, another acceptable tube
shall be chosen.
6.6.7 The reference standard shall contain four holes, equally spaced
circumferentially, separated by a sufficient distance around the tube and
longitudinally separated by sufficient distance to allow distinct

identification of the signal from each hole. The holes shall be drilled
along the radius and completely though the wall with care being
taken to avoid distortion of the tube while drilling
6.7 The Drilled Hole Size:
6.7.1 The Drilled Hole Size shall be selected from Table -1, Table X1.1 & table
X1.2. Each reference standard shall have a suitable identification
mark as per ASTM SE 243.
6.7.2 Drill Hole Size for Carbon Steel and Ferritic Alloy Steel Pipe as per
specification SA/A-106, SA/A-335, SA-333 & SA/A 999 as per ASTM SE
2096
6.8 Transverse Tangential Notch:
6.8.1 Using a round tool or file with a 1/4 in. (6.4 mm) diameter, a notch shall
be milled or filed tangential to the surface and transverse to the
longitudinal axis on the out-side of the tube.
6.8.2 Said notch shall have a depth not exceeding 12 .5 % of the specified
wall thickness of the tube or 0.004 in. [0. I mm], whichever is greater.
6.9 Longitudinal Notch:
6.9.1 A notch 0.031 in. (0.8 mm) or less in width shall be machined in a
radial plane parallel to the tube axis on the outside surface of the
tube, to have a depth not exceeding 12 .5 % of the specified wall
thickness of the tube or 0.004 in. (0.1 mm], whichever is greater. The
length of the notch shall be compatible with the testing method.
7.0 FREQUENCY OF CALIBRATION:
7.1 The instrument calibration is verification using calibration standard at the

beginning of the testing, any change in the test system setting, change of
shift, equipment repair, interruption due to power loss or shutdown, after
one hour of continuous production testing or after examination of every
20 tubes whichever is minimum. During calibration verification, if the
equipment found to be incorrectly adjusted or fail to give a signal
similar to the calibration set up, all tubes inspected since last
acceptable calibration verification shall be re-tested.
7.2 Selection of Test Frequency:
The Optimal Frequency dialog box is used to select the operating frequency
according to the thickness and type of the tube wall to be inspected. The
optimal frequencies can be determined by the wizard option and also by
manually selected in the appropriate text box. The suitable inspection
frequencies shall be determined so that it will be able to supply reliable
defect detection and ensure sufficient phase separation as well as depth of
defects. All further test frequencies will be selected in accordance to the test
requirements.
7.3 For eddy current testing, the excitation coil frequency shall be noise ratio
depending on type of alloy. The operating frequency shall be as low as
possible consistent with the reliable detection of the artificial defects. Test
frequency to be selected as per Table -2
Table-2 Frequency
Specification Wall Thickness, mm (Maximum), KHz

Up to 1.30 100
Up to 3.80 50
≥ 3.80 and above 10
8.0 CALIBRATION PROCEDURE:
8.1 Each tube from the lot is allowed to pass through the Eddy Current Testing
System and Compared with response obtained from the reference
calibration tube.
8.2 The tube showing signal amplitude equal to or higher than reference
calibration tube signal shall be rejected.
8.3 Tubes causing non-relevant signals because of moisture, soil and like effect shall
be reconditioned and re-tested to cheek that the tube meets the product
specification.
8.4 When tube end sense by sensor, automatically pinch roller gets disengage.
8.5 Tubes reached on exit conveyor.
9.0 TESTING SEQUENCE PROCEDURE:
9.1 Since this technique is sensitive to probe lift-off or wobble, the good fill factor
shall be used for the inspection. The probe shall be selected among which have
a fill factor (f.f) within the range of 0.8 < f.f <0.9.The probe selected shall be
capable to operate in differential mode as well as absolute mode in the time.
9.2 In ET, the probe balancing is important. Multi View provides a special electronic
probe balancing function that does not required a reference probe. Probe
balancing can be calibration tubes to the free defect area, and make sure it
stays motionless. On the Operation menu, click Pod Balance. If the balancing is
succeeded, the balancing icon will appear in status bar.
9.3 After the probe balancing, starting the data acquisition for each tube by pulling
the probe until end of tube then is stopping the acquisition. All acquisition
signals produced can be viewed and analyzed in real time or can be stored
in the hard drive.
10.0 PROBE SPEED:
10.1 The nominal probe speed during the inspection shall not exceed 2
m/second done, only during the calibration and in inspection' mode. Insert the
probe inside the calibration tube.
10.2 Qualified personnel shall perform data analysis by comparing the inspection
signal with the corresponding calibration curve that has been recorded prior to
inspection.
10.3 By determining the amplitude and phase angle of inspection

signal, corresponding reduction of wall thickness of the inspected tubes
can be estimated. The evaluation of the Inspection data shall be
made in accordance with the reference Code & Standard.
10.4 Rejection and acceptance criteria shall be made in accordance with the
reference Code & Standard or the agreement specified between client and
contractor.
11.0 REPORTING:
11.1 All results of the evaluation shall be recorded in a Standard report. Each
test reports shall include at least the following information:
i. Date of inspection.
ii. Tube material, and wall thickness

iii. Size and type of probe
iv. Mode of operation
v. Test frequencies
vi. Make & Model of Eddy Current Equipment.

vii. Pulling speed
viii. Identification of the calibration tube

ix. Test and evaluation results
x. Drawing of the tubes arrangement.

12.0 REJECTION:
12.1 The location of defects on a defective tube is identified and it falls outside the
minimum length requirement of the tube, the defective portion can be cutoff
and the tube can be accepted.
12.2 If the defect falls within the minimum required length of the tube, the entire
tube will be rejected and given to planning department after identification
with red paint at the end
13.0 RECORD:
13.1 Records of report generated during the implementation of this work instruction
shall be retained for a period of Three (03) years in the Operations
Department’s Office whenever available and allowed by client. The records may
be kept by the client due to confidentiality and security status of the
document.
14.0 REPORTING
Eddy Current Test Report See Appendix A

ASIC Doc. Name: NDT- ET ASIC Rev: Page
APPENDIX A
Eddy Current Test

Report
Equipment Total No Tubes: Number of Tubes Was Inspected:

Name:
Dimension: Tube Material:
FIGURE
Legend: Remark:
Equipment Total No Tubes: Number of Tubes Was Inspected:

Name:
Dimension: Tube Material:
REPORT SUMMARY
Tube # Row Column Wall Loss Wall Loss

012 Eddy Current

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ASIC OFFSHORE & MARINE SDN.BHD.

PROCEDURE FOR EDDY

Rev Rev. Date Description Prepared By Reviewed By Approved By

S.No. Title Page

2.1 ASME Section V, Article 8, Appendix 1

2.3 ASTM E-426 (Stainless Steel.)

3.0 PERSONNEL QUALIFICATION:

Eddy current testing is a noncontact method used to inspect non-ferromagnetic tubing.

Examining non-ferromagnetic, heat exchanger tubing using the eddy current

When an electromagnetic coil carrying alternating current held closed to

With the help of reference calibration blocks (drawing attached), sensitivity is

A non-destructive testing system based on the principle of Eddy Current testing is

ii. Test Range: From 6.00 mm OD to 114.3 mm OD

iii. Coil System: Self comparison type Deferential

iv. Maximum Tube Length: 30 Meters (Can be extended as Req.)

v. Speed: 30/ 60 Meters/ minute.

vi. Indicators on the system: computerized display

6.1 Electronic Apparatus:

6.1.2 The test systems include, a phase discriminator, filter circuits,

6.2 Test Coils:

6.3 Driving Mechanism:

6.3.1 The Mechanical drive system shall be capable of passing the

6.3.2 For a self-reference deferential coil test system, if a defect runs

6.5 Calibration tube:

6.5.1 Calibration tube shall be manufactured in the manner as the product

6.6 Method of calibration:

6.6.2 Differential Channels: Calibration

6.6.3 Absolute Channels:

6.6.5 Reference standard of convenient length (min.4 feet) shall be

longitudinally separated by sufficient distance to allow distinct

6.7 The Drilled Hole Size:

6.8 Transverse Tangential Notch:

6.9 Longitudinal Notch:

7.0 FREQUENCY OF CALIBRATION:

7.1 The instrument calibration is verification using calibration standard at the

7.2 Selection of Test Frequency:

Specification Wall Thickness, mm (Maximum), KHz

8.0 CALIBRATION PROCEDURE:

8.5 Tubes reached on exit conveyor.

9.0 TESTING SEQUENCE PROCEDURE:

10.0 PROBE SPEED:

10.3 By determining the amplitude and phase angle of inspection

ii. Tube material, and wall thickness

vi. Make & Model of Eddy Current Equipment.

viii. Identification of the calibration tube

x. Drawing of the tubes arrangement.

Eddy Current Test Report See Appendix A

Eddy Current Test

Equipment Total No Tubes: Number of Tubes Was Inspected:

Dimension: Tube Material:

Equipment Total No Tubes: Number of Tubes Was Inspected:

Dimension: Tube Material:

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