TUBE

INSPECTION
THE BEST NDT METHOD FOR YOUR  HEAT
EXCHANGER, FEEDWATER HEATER, CONDENSER,
BOILER AND AIR COOLER INTEGRITY ASSESMENT

PT TIGA SEKAWAN ENJINIRING

tse-groups.com +62 (21) 222 31548 info@tse-groups.com
 CONTENTS
F O
E L B A T
3 I N T R O D U C T I O N

5 T U B E S E L E C T I O N C H A R T

7 E D D Y C U R R E N T T E S T I N G

9 E D D Y C U R R E N T A R R A Y

11 R E M O T E F I E L D T E S T I N G

13 N E A R F I E L D T E S T I N G

15 M A G N E T I C F L U X L E A K A G E

17
I N T E R N A L R O T A R Y

I N S P E C T I O N S Y S T E M

19 R E M O T E V I S U A L I N S P E C T I O N

20 E P I L O G U E
TUBE INSPECTION PAGE | 03

INTRODUCTION

The petrochemical and oil/gas industry

depends on many heat exchangers and
boilers for efficient operation. A heat
exchanger is a system used to transfer
heat between two or more fluids. Heat
exchangers are used in both cooling and
heating processes.

Heat exchangers are vital components

in numerous process plants. Failing or
leaking heat exchangers can lead to
lower efficiency, unplanned shutdowns
or even accidents which in turn can
result in damage to equipment,
environment or people.

In general there are two main locations

where leakages will occur in a heat
exchanger:

1. At the tube/tube sheet joints

2. Along the length of the tubes
PAGE | 04 TUBE INSPECTION

Examination and condition monitoring of heat exchangers are performed using a

variety of techniques. Selection of the best suited technique depends on whether the
objective is fabrication control, preventive in-service inspection, or inspection due to
failure as for example leakage and depends on the type of defects which is expected
to be detected by the examination. Widely applied techniques are:

1. Eddy Current Test

2. Eddy Current Array
3. Remote Field Testing
4. Near Field Testing
5. Magnetic Flux Leakage
6. Internal Rotary Inspection System
7. Remote Visual Inspection

Each of the NDT techniques has its advantages and limitations. 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 to increase the level of
confidence of an inspection.

This booklet is provided to you by PT Tiga Sekawan Enjiniring and is to assist plant
inspectors in selecting the right techniques for their specific inspection needs.
 TUBE INSPECTION PAGE | 05

TUBE INSPECTION SELECTION CHART

Tube Inspection Selection Chart legend (Table A, B, C)

The test method has proven results for the specific application

The test results obtained from the test method can be interpreted reasonably

Test method is either not suitable for the sought application or non-reliable in
terms of repeatability

Table A. Tube Testing Technique Suitability According to Material

Material type/Tech ECT ECA RFT NFT MFL IRIS RVI

Tube
Non-
Ferromagnetic Integral
finned

Tube
Low
Ferromagnetic Integral
finned

Tube

Integral
Ferromagnetic
finned

Alumunium
finned
PAGE | 06 TUBE INSPECTION

Table B. Tube Testing Detection Capabilities According to Defect Type

Defect / Tech ECT ECA RTF NFT MFL IRIS RVI

ID Pitting

OD Pitting

Axial cracking

Circumferential cracking

ID corrosion

OD corrosion

At tubesheet

Table C. Tube Testing Sizing Capabilities According to Defect Type

Defect / Tech ECT ECA RFT NFT MFL IRIS RVI

ID Pitting

OD Pitting

Axial cracking

Circumferential cracking

ID corrosion

OD corrosion

At tubesheet
 TUBE INSPECTION PAGE | 07

EDDY CURRENT TESTING (ECT)

Eddy Current Testing (ECT) is an effective way of assessing the condition and lifespan
of tubes, particularly in the power generation, petrochemical, chemical, fertilizer and
air conditioning industries. It is a high-speed inspection method and one of the major
advantages is that it can be performed through paint and coatings. This technique is
only suitable for non-ferrous material such as Brass, Copper, Copper-Nickel and
Austenitic Stainless steel.

ECT can pinpoint minute flaws using sophisticated software and detection probes.
Analysts can scan for anomalies on a surface and subsurface level with ease and
accuracy. ECT 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 extent quantified.

Theory

Eddy current testing uses electromagnetic induction to identify defects in tubing. A

probe is inserted into the tube and pushed through the entire length of the tube. Eddy
currents are generated by the electromagnetic coils in the probe and monitored
simultaneously by measuring probe electrical impedance. The information revealed by
the probe will detail the tube defects. The scanning data will be recorded by the
software and kept us as a backup for future reference.
PAGE | 08 TUBE INSPECTION

Advantages Disadvantages

Fast (450-700 tubes per day) Limited to only non-magnetic tube

Overall wall-loss and local defects material
can be detected Application is limited to 3 inch tube
High sensitivity to small defects sizes and 0.125 wall thickness
(dia. holes/pits > 0.5 mm) Pin holes are difficult to detect and
Accurate sizing of defects possible evaluate
Possible to distinguish between in- Discontinuities adjacent to end
and external defects sheets are difficult to detect
Possible to detect and quantify Tubes must be cleaned
defects under support plates
Cracks can be detected depending
on size and orientation
Only basic cleaning of tubes
required
Permanent records can be
obtained on test results
 TUBE INSPECTION PAGE | 09

EDDY CURRENT ARRAY (ECA)

Eddy Current Array (ECA) is the supercharged version of Eddy Current Testing (ECT).
They consist of arrays of coils that activate in sequences in order to eliminate
interference between them. The array slides on top of surfaces, offering an overall
wider coverage and increased sensitivity to defects compared to ECT. The Eddy
Current Array technology is able to not only detect surface-breaking defects but to
some degree also subsurface defects. Most conventional Eddy Current flaw detection
techniques can be reproduced with an ECA inspection. With the benefits of single-pass
coverage, and enhanced imaging capabilities, ECA technology provides a remarkably
powerful tool and significant time savings during inspections.

Theory

Traditional Eddy Current and Eddy Current Array technology follow the same
fundamental principle. When alternating current is introduced in a coil, a magnetic field
is produced (in blue). When the coil is positioned over a conductive part, opposite
alternating currents or eddy currents (in red) are created. The path of the eddy
currents (in yellow) is disturbed by the defects in the part. ECT is a simple and
accurate inspection method used to identify surface as well as near-surface defects in
conductive material. The method can be employed to calculate the electrical
conductivity of materials and can even be used to measure nonconductive coating. In
addition, ECA testing covers a huge area in a single pass and considerably reduces
inspection time. It enhances reliability and probability of detection and reduces the
requirement for mechanical and robotic scanning systems.
PAGE | 10 TUBE INSPECTION

Advantages Disadvantages

Larger area can be scanned in a Limited to only non-magnetic tube

single-probe pass, while material
maintaining a high resolution Application is limited to 3 inch tube
Easier analysis because of simpler sizes and 0.125 wallthickness
scan patterns Tubes must be cleaned
Improved flaw detection and sizing
with C-scan imaging
Inspection of complex shapes
using probes customized to the
profile of the part being inspected
More sensitive to circumferential
cracking
Can distinguish between defect
signal and tube sheet signal
If only testing tube ends 5 sec per
tube vs 40 sec per tube for rotating
techniques
 TUBE INSPECTION PAGE | 11

REMOTE FIELD TESTING (RFT)

Remote Field Testing (RFT) is primarily used to inspect ferromagnetic tubing since
Conventional Eddy Current techniques have difficulty inspecting the full thickness of
the tube wall due to the strong skin effect in ferromagnetic materials. This technique is
very suitable for detection and quantification of overall wall-loss. Local defects can be
detected and quantified provided that they have some volume (diameter pit >5 mm).
Remote Field Technique can detect both internal and external defects but it is not
possible to distinguish between them. Defects under or close to the tube sheet are
hard or not possible to detect. Only a basic cleaning of the tubes will be sufficient.

Theory

The probe used in Remote Field Technique examination contains a send and a
receiver coil. In the bigger send coil an alternating magnetic field is generated. This
field is indirectly coupled to the receiver coil as a direct coupling between the two coils
is shielded by the strong magnetic fields originating from the eddy currents that are
being generated in the tube. At a low enough frequency the shielding will lose some of
its strength allowing the exciter field to penetrate the tube wall in axial direction. Once
the magnetic field reaches the exterior of the tube it will spread rapidly along the tube
with little further attenuation. Research found that a portion of the magnetic field re-
diffuses back through the pipe wall to the interior of the tube at a certain location. At
this position the smaller receiver coil is placed to detect the remaining field. Now the
indirect coupling path between send and receiver coil is complete. The magnitude and
the phase of the received magnetic field depend on the amount of material that was
crossed in the indirect coupling path. If wall-loss occurs in a tube there will be less
attenuation and delay of the exciter field before it reaches the receiver coil. The signal
on the computer screen represents the change in the received magnetic field, and thus
the condition of the tube.

During signal analysis, the signals acquired during a Remote Field 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.
PAGE | 12 TUBE INSPECTION

Advantages Disadvantages

Can inspect ferromagnetic tubes Some limitation to distinguishing

up to 3.5 inches in diameter with
0.125 inches wall thickness
Inspection speed (up to approx. 40
feet per minute)
Can detect large area
discontinuities such as steam
erosion and baffle wear
Amplitude changes in the signals
sensed are not speed-sensitive
Flexible probes can be used to
inspect and travel through U-bend
areas
Permanent records can be
obtained on test results
ID from OD defects
Evaluation of small flaws such as
pits can be difficult
Examination of finned tubes has a
lot of limitations unless fins are in
axial direction
Instrumentation and test probes
can be very expensive
Tubes must be cleaned
 TUBE INSPECTION PAGE | 13

NEAR FIELD TESTING (NFT)

Near Field Testing (RFT) is a rapid and cost-effective solution intended specifically for
fin-fan carbon-steel tubing inspection. This technology relies on a simple driver-pickup
eddy current probe design providing very simple signal analysis. NFT is specifically
suited to the detection of internal corrosion, erosion or pitting in carbon steel tubing.
The NFT probes measure lift-off or ‘fill factor’ and convert it to amplitude-based
signals. Because eddy-current penetration is limited to the inner surface of the tube,
NFT probes are not affected by the fin geometry on the outside of the tube.

NFT is specifically suited to detecting corrosion, erosion, and pitting inside carbon
steel tubing. NFT is perfect for fin-fan tube heat exchangers because eddy currents do
not go through the wall of the tube. NFT is also much more sensitive to defects close
to structures such as support plates and tubesheets.

Theory

NFT technology uses two coils, a transmitter and a receiver. Typically the receiver coil
is close to the transmitter coil, taking advantage of the transmitter’s near-field zone —
that is, the zone where the magnetic field from the transmitter coil induces strong eddy
currents, axially and radially, in the tube wall.

NFT probes operate within the same frequency range as Remote-Field Testing
(RFT) probes. Remote field is a send/receive through the wall technique that uses the
send and the receive coils separated by approximately two and a half tube diameters,
or there may be two send coils the same distance on both sides of the receive coils.
Near Field has the sensor coils close together and is not a through wall transmission
technique. The signals that result from the RFT are dependent upon the condition of
the tube near the send coils, near the receive coils, and to some degree, in between
the coils. Also, as the RFT travels outside the tube wall, the signals are also very
dependent upon support structure, such as support plates and tube sheets that may be
between the send and receive coils. On the other hand, the signals that result from
NFT are dependent only upon the condition of the tube close to the coils and as the
signal barely penetrates outside the tube wall, is only slightly dependent upon support
structures, such as support plates.
PAGE | 14 TUBE INSPECTION

Advantages Disadvantages

Fast when used as screening Cannot detect external defects

technique Sizing defects limited (based on
Possible to examine carbon steel signal volume)
(finned)tubes Less suitable as stand alone
Both pits and overall wall-loss can technique
be detected (dia. Pits > 3 mm)
Detection of internal thinning and
pitting based on sensitivity of eddy
current lift off
No need for an external reference
coil
Cleaning of tubes less critical
The results is unaffected by
support plates and Tube sheets
 TUBE INSPECTION PAGE | 15

MAGNETIC FLUX LEAKAGE (MFL)

Magnetic Flux Leakage 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 technique is not often used as a stand-alone technique. Verification by other
techniques is recommended. MFL can also be used on airfin cooler tubes.

MFL is sensitive to sharp type defects like pits and grooving. In- and external pits can
be detected. Depending on probe configuration MFL can distinguish 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 consists of a magnet and two flux leakage sensors, which set up a flux field
in the tube wall as it passes through the tube. The field fluctuates when it encounters a
flaw. The flux rate fluctuation effect is picked up by the coils and displayed on
the display apparatus and chart recorder. A Hall effect element can be added as a
combined-type probe, which is used to detect absolute flux such as gradual wall loss.
The output of the Hall effect detector depends on the orientation of the sensor in the
probe relative to the discontinuity and whether the location of the discontinuity is on
the inside or outside surface.The output of the magnetic flux leakage coils is related to
the change of flux caused by the discontinuity but not the discontinuity size.
PAGE | 16 TUBE INSPECTION

Advantages Disadvantages

Fast when used as screening Less suitable as stand-alone

technique technique
Possible to examine carbon Very sensitive to inspection speed,
steel (finned) tubes accuracy of test results can
Distinguishes ID from OD flaws fluctuate with probe speed
Can inspect ferromagnetic tubes Sizing of in- and external defects
up to 3.5 inches in diameterand limited (based on signal volume)
0.120 inches wall thickness Probe speed dependant
Non volumetric defects like Can not inspect U-bend tubes
crackscan be detected depending Cleaning of tubes very critical
on size, shape and orientation because use of big fill factor probe
Defects under support plates can is required
be detected and to some
extent quantified
Instrumentation can withstand
adverse field conditions
Permanent records can be
obtained on test results
 TUBE INSPECTION PAGE | 17

INTERNAL ROTARY INSPECTION SYSTEM

Internal Rotary Inspection System (IRIS) is an ultrasonic method for testing of pipes
and tubes. The ultrasonic beam allows detection of metal loss from the inside and
outside of the tube wall. It is a fairly sensitive technique. The sensitivity achieved will
depend on tube dimensions and tube cleanliness. Both ferromagnetic and non-
ferromagnetic tubes can be inspected. With IRIS the remaining wall thickness of tubes
can be accurately measured. Defects under support plates can be measured without
any limitations. IRIS is more accurate than other tube inspection techniques and has
the advantage of presenting information about the geometry of defects.

Theory

This examination method employs an ultrasonic immersion pulse echo technique. The
ultrasonic transducer is contained in a test head, which fits into and is centered in the
tube to be inspected. The ultrasonic pulses are emitted along a path parallel to the
tube axis. A rotating 45-degree mirror then reflects these pulses so that they are
directed radially on to the tube wall. Reflections from the inner and outer walls follow
the same path back to the transducer. The time interval between the first echo – from
the internal surface of the tube – and the first echo – from the outside surface of the
tube – can be used to represent the tube wall thickness. As the mirror rotates, the
ultrasonic beam is traversed around the tube circumference and each successive pulse
is mapped out as a horizontal scan line on the instrumentation screen. A typical
system can generate approximately 190 readings per revolution and approximately
2400 revolutions per minute.
PAGE | 18 TUBE INSPECTION

Advantages Disadvantages

100% tube inspections converge Low inspection speed (test speed

(end to end) is approximately 15 feet/minute),
Actual wall thickness can High cost
accurately be measured Wall thicknesses lower than 0.8
Wall loss and pit detectability’s mm cannot be accurately
accuracy and sizing plus orminus measured
0.002 inch Difficult to detect external defects
Can examine both ferromagnetic when inner wall is heavily corroded
and non-ferromagnetic tubes Water is needed on site to function
Both internal and external defects as couplant
can be measured Cannot detect circumferential
Can distinguish between in-and cracks
external defects Cleaning of tubes is very critical
Can inspect tube sizes up to 3.0
inches with wall thickness up to
0.25 inches
Can inspect U-bend tubes with
some radius limitations
Defects under support plates can
be detected and sized
Not influenced by changes in
permeability or conductivity that
can cause false indications using
electromagnetic methods
Gives information about geometry
of defects
 TUBE INSPECTION PAGE | 19

REMOTE VISUAL INSPECTION

Remote Visual Inspection (RVI) is the application of visual inspection at a position

remote from the position of the operator performing the inspection. As well as allowing
inspection of inaccessible areas, RVI is a safer alternative to an operator entering a
confined space to conduct visual inspection. RVI requires the use of optical equipment
to access the remote inspection site. Pan, tilt and zoom (PTZ) cameras have evolved
to a more compact size in order to access extremely confined spaces. Software
developments have enabled objective data to be viewed on screen, recorded for
analysis and reporting later. Continued advancements in the field of robotics has
empowered inspection cameras to travel into previously inaccessible areas. RVI is
used to examine a wide range of infrastructure. When utilized as a standalone tool or
part of a remote crawler system, RVI cameras can deliver high definition video with
advanced imaging options for detailed assessment of any industrial structure with
limited or unsafe access.

Advantages Disadvantages

Can be used on every material Sizing of defects not possible

Removes humans from potentially Only the internal tube wall can be
unsafe conditions examined
Gives information about geometry High level of cleanliness required
of defects
Visualization of defects gives high
level of confidence
PAGE | 20 TUBE INSPECTION

EPILOGUE

For all Electro Magnetic techniques (ECT, ECA, RFT, NFT, MFL) 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.

In conclusion, no single technique can be applied for testing all heat exchangers or
boiler tubing materials. Perhaps in some applications, more than one technique is
needed. Also proper technique selection leads to reliable tests and achievement of
accurate results.

Note: This book is intended for informational purposes only and all information in this
book is based on capability Olympus MS 5800 ER1U with fully loaded for tube
inspection duty. Named values have been generalized and depend on specific
situations. To the best of our knowledge, the information in this publication is accurate
however the publisher does not assume any responsibility or liability for the
correctness of such information.
PT. TIGA SEKAWAN ENJINIRING
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