Introduction to Tubular Inspection

 Refinery and Chemical plants can employ hundreds of heat

exchangers or condensers in a single process unit, each having its
unique process, service and damage mechanism.

 Heat exchanger tubing is subjected to process chemistry on both

sides (I.D. & O.D.) such as; water, steam, process, or even air.

 This fluid and heat transfer conditions, contributes to either process

corrosion and/or mechanical damage within the heater exchanger
such as; corrosion, thinning, pitting, cracking, erosion, vibration or
a combination of those mentioned.
 Why perform Tubular Inspections?

Component Reliability: Safety & Environment

Reliability: Reduce the Chance of Unscheduled Downtime lost

revenue.

Predictive Maintenance: Determine Corrosion Rate/Remaining Life &

Calculate Trending

Failure Analysis: Provides data for prevention of future failures

Quantitative Data: Hydro-Test

Hydro Test is not sufficient.
sufficient Bore-scope
Bore scope inspection
can be misleading, limited to visual examination.
 Tubular Inspection Techniques
NDE techniques which are most common and currently being used in
the industry include; (IRIS) Internal Rotating Inspection System, (ET)
Eddy Current, (RFT) Remote Field Testing, (FLT) Flux Leakage Testing
or ((Steel Test),
), Near Field Testing
g ((NFT)) for air cooler tube inspection.
p

The discussion today will focus on the five applications mentioned

above, along with the advantages and disadvantages associated with each
test.

Also, I will briefly discuss certification and training for tube inspection
personnel.
personnel
 Tubular Inspection Services
TechCorr utilizes five techniques to
perform tubular testing
p g on heat exchangers,
g ,
air coolers, boilers, etc.

Four of the five techniques are

El t
Electromagnetic
ti based
b d techniques
t h i (ET) and
(ET), d
the last technique is IRIS an Ultrasonic
Technique (UT).

Having all five techniques at our disposal

makes our Tubular Division a much
diversified inspection group.

Being this diversified can help meet the

needs of our customers, as well as each
crew having the capability of these
techniques to perform complimentary
inspections providing the most
comprehensive inspection possible.
 Eddy Current Testing (ECT)
Eddy Current Testing (ECT) is the most commonly used method, but limited too
non-ferromagnetic and slightly magnetic alloys (Monel 400).
The Eddy Current technique is based on the induction of an electromagnetic
field in the tube being examined and can detect various forms of internal and
external damage.
damage
The purpose of this application is to detect I.D. and O.D. degradation such as
cracking, corrosion, erosion, pitting, fretting and gradual wall loss generally found
in non-ferromagnetic tubing.
 Eddy Current Testing (ECT) - How it works
Two coils
T il are excited
it d with
ith an AC current,
t producing
d i an
alternating magnetic field around them.
 Eddy Current Testing (ECT) - How it works
Two coils are excited with an AC current, producing
g an
alternating magnetic field around them.
The magnetic field penetrates the tube material and generates
pp g AC currents in the material. These currents are called
opposing
“eddy currents”
 Eddy Current Testing (ECT) - How it works
Two coils are excited with an AC current, producing
g an
alternating magnetic field around them.
The magnetic field penetrates the tube material and generates
pp g AC currents in the material. These currents are called
opposing
“eddy currents”.
Any defects that change the eddy current flow will change the
impedance of the coils in the probe.
Eddy Current Testing (ECT) - How it works
Eddy Current Testing (ECT) - Data Interpretation

Indications of Stress Corrosion Cracking

 Eddy Current Testing (ECT) - Data Interpretation

Indications of Micro Biologically Induced Corrosion

Eddy Current Testing (ECT) - Data Interpretation

Indications of ID Pitting / Corrosion.

 Eddy Current Testing (ECT) - Applications
1. Inspection of Non-Ferromagnetic Tubing. Stainless Steel, Inconel,
hastalloy, Copper, Brass, etc.
2. Accuracy of plus or minus 10%.
3. Can detect and size wear (wall loss) at baffle locations. With the use
of mixing techniques.
4. Can inspect low fin tubing. A/C Refrigeration Units, Skip fin tubing.
Using Cross-Axis probes or other probes designed for this.
5. Can detect and size isolated pitting, corrosion, cracking, fretting, and
gradual wall loss.
6. Can inspect tubes from 3/8 to 2-1/2” diameter. (Larger with special
probe
b designs
d i i Array,
i.e. A M ti )
Matrix).
7. Can inspect tubing that has been coated with non-conductive
coating.
8
8. Can detect
C d t t circumferential
i f ti l cracking
ki with
ith the
th use off specialized
i li d
probes. (i.e. Pancake, Matrix, Array, or SPNR probes)
 Eddy Current Testing (ECT) - Advantages
1. Inspection of Non-Ferrous tubing. (Non-magnetic & slightly
Magnetic)
2. High examination Rate 80-150 tubes per hour. (Depending on
tube length, conditions, etc.)
3. Repeatability - compare historical and subsequent test results
to establish corrosion rates and remaining life.
g
4. Can distinguish between ID and OD Orientations. Using
g Phase
analysis techniques.
5. Highly sensitive to ID/OD cracking, Micro-Biological Induced
Corrosion ((MIC),
), and other small volume indications.
 Eddy Current Testing (ECT) – Disadvantages
1. Cannot inspect Ferrous tubing. (i.e. Carbon Steel, 400 series
Stainless Steels,
Steels Alloy 2205,
2205 etc)

2. Permeability changes caused by magnetic deposits can

cause unwanted signals.

3 Accuracy of interpretation is highly dependant upon operators

3.
experience.

4 Equipment
4. E i t is
i both
b th sophisticated
hi ti t d and
d expensive.
i

5. Standard bobbin coil application

pp cannot inspect
p tube sheet
roll area looking for circumferential cracking (Special probes
designs are available).
Eddy Current Testing (ECT) – Site Requirements
1. Customer Safety requirements in plant or unit. Orientations,
Permits etc.
Permits, etc

2. Exchanger Information (Service, Material, Diameter, Number of

tubes, and Length.

3 110 VAC Power Source.

3. Source Instrumentation is not intrinsically safe

4. Tubes require cleaning (15,000-25,000 psi). Removal of all

magnetic
ti deposits
d it is
i a must.
t

5. Scaffolding
g and Covering
g ((if needed).
)
 Remote Field Testing (RFT)
Remote Field Testing (RFT) is an electromagnetic examination which utilizes the
through transmission effect to produce a resultant field that is effected by
anomalies and is measured a few or more tube diameters away from the AC
excitation source without any tube magnetization or saturation.
The purpose of this application is to detect I.D.
I D and O.D.
O D degradation such as
corrosion, erosion, pitting, fretting and gradual wall loss generally found in
ferromagnetic tubing.
 Remote Field Testing (RFT) - How it works
The Remote
Th R t Field
Fi ld Technique
T h i i an electromagnetic
is l t ti examination,
i ti which
hi h
utilizes a through-transmission process. The resultant field is affected by
either ID or OD tube wall anomalies. RFT signal measurements are made
a few tube diameters away y from the AC excitation coil without any y
attempt at tube wall magnetization or saturation.
A pair of pick-up coils located in the remote field zone measures the
resultant field to give both a differential and an absolute signal. The
signal phase and amplitude information is used to determine defect
depth and volume.
Remote Field Testing (RFT) - How it works
Remote Field Testing (RFT) - Data Interpretation

Indications of Wastage & Small Pitting

Remote Field Testing (RFT) - Data Interpretation

RFT & IRIS comparison of 50% degradation (SA-214 .750” x .083”)

Remote Field Testing (RFT) - Data Interpretation

LINEAR ISOLATED ID PITTING

Remote Field Testing (RFT) - Data Interpretation

OD Fretting / Baffle Wear

Remote Field Testing (RFT) - Data Interpretation

DETECTION OF M.I.C. IN 2205 DUPLEX / USING RFT

 Remote Field Testing (RFT) - Applications
1. Inspection of Ferromagnetic
g Tubing.g Carbon Steel, Chrome-
Moly, Alloy 2205, and 400 series Stainless Steel
2. Accuracy of plus or minus 10%.
3 Can detect and size wear (wall loss) at baffle locations.
3. locations
Defects typically need to have depths of 20% or greater.
4. Can inspect low fin tubing.
5. Can detect and size isolated pitting, corrosion, cracking?,
fretting, and gradual wall loss.
6. Can inspect tubes from 5/8 to 3” diameter. (Larger with special
probe designs i.e. Array).
7. Can inspect tubing that has been coated with non-conductive
coating.
8. Can inspect Boiler tubing with slight to moderate bends (Mud
Drum-Steam Drum
 Remote Field Testing (RFT) - Advantages
1. Tubes require little cleaning prior to inspection. (obviously the
cleaner the tubes the better the examination))
2. Data acquisition rate of 50 to 80 tubes per/hr (Depending on tube
length, conditions, wall thickness, sample rate etc.)
3
3. Repeatability - compare historical and subsequent test results to
establish corrosion rates and remaining life.

4
4. Good sensitivity
G i i i to gradual wall loss, pitting,
i i vibration,
i i and steam
erosion and cracking

5
5. Capable of testing heavy wall tubes (Up to .220”)
220”)
 Remote Field Testing (RFT) - Disadvantages
1. Limited detection and sizing of small defects (<1/8” Dia. depending
on material type).
type)
2. Permeability and geometry will affect sensitivity to small defects and
sizing.
3. Not sensitive to small cracks and pitting (w/special probe designs such
as; Array Coils are becoming alternative methods for detection).
4. Cannot distinguish
g between I.D. or O.D. defect orientation. ((Signal
g
characteristics, tube service, or past history can assist in this)
5. Has difficulty in detection of <20% wall loss under baffle or support
structures ((Signal
g is suppressed
pp by
y structures).
)
6. Pull speed is dependent on frequency, sample rate, and defect type.
7. Accuracy of interpretation is highly dependant upon operator
experience.
experience
8. Equipment is both sophisticated and expensive.
Remote Field Testing (RFT) – Site Requirements
1. Customer Safety requirements in plant or unit. Orientations,
Permits etc.
Permits, etc

2. Exchanger Information (Service, Material, Diameter, Number of

tubes, and Length.

3 110 VAC Power Source.

3. Source Instrumentation is not intrinsically safe

4. Tubes require cleaning (15,000-25,000 psi). Removal of all

magnetic
ti deposits
d it is
i a must.
t

5. Scaffolding
g and Covering
g ((if needed).
)
 Near Field Testing (NFT)
Near Field Testing (NFT) is intended specifically for fin fan carbon steel tubing
inspection without the requirement for externally referenced coils. This
technology relies on a simple driver-pickup eddy current probe designed to
provide very simple signals for analysis.
NFT probes are specifically designed to detect internal corrosion,
corrosion erosion,
erosion or
pitting on the ID of carbon steel tubing. These probes actually measure the lift-off
or “fill factor” and convert it to amplitude-based signals.
 Near Field Testing (NFT) - How it works
NFT probes b are specifically
ifi ll designed
d i d to
t detect
d t t internal
i t l corrosion,
i
erosion or pitting on the inside of carbon steel tubing. These probes
actually measure the lift-off or “fill factor” and convert it as amplitude-
based signals
g ((no p
phase analysis).
y ) As the p penetration capability
p y is
limited to the inside surface, that makes the NFT probes insensitive to fin
geometry on the outside of the tubes.

There is one exciter coil and

one pick-up coil place on either
side of the exciter within the
Near Field Zone. With the Coils
in this zone generally only
internal (ID) indications are
d t t d
detected.
 Near Field Testing (NFT) - Data Interpretation

NFT“AIR COOLER INSPECTION / EROSION/CORROSION UP TO FERRULE”

 Near Field Testing (NFT) - Data Interpretation

NFT“AIR COOLER INSPECTION / EROSION/CORROSION UP TO FERRULE”

Near Field Testing (NFT) - Data Interpretation

INLET EROSION/CORROSION @ FERRULE END

Near Field Testing (NFT) - Data Interpretation

INLET EROSION/CORROSION @ FERRULE END

 Near Field Testing (NFT) - Applications
1. Inspection of Ferromagneticg Tubingg With externally
y attached
fins. (i.e. Aluminium fins, Spot Welded fins,)

2 Excellent technique for detection and sizing of ID Inlet erosion

2.
in air coolers.

3. Boiler inspection with external fins. (Special probes designs

needed)

4. Air Cooler or Fin Fan applications.

5 Accuracy of plus or minus 10%.

5. 10%
 Near Field Testing (NFT) - Advantages
1. Good sizing capabilities for Inlet Erosion & Corrosion.
2
2. Id l for
Ideal f Aluminum
Al i fi
finnedd tubing.
t bi
3. Detects gradual wall thinning (I.D.)
4. Detects small diameter pitting. (Possibly Axial Cracking)
5. No need for a Reference probe or extension (Standard probes are
30m)
6. Capable of inspecting 2” diameter tubes, (larger w/special probe array
designs)
7. High data acquisition rate, 60 – 70 tubes/hr. (Depending on tube length,
and configuration).
8. Repeatability
i i - compare historical
i i and subsequent test results to
establish corrosion rates and remaining life.
 Near Field Testing (NFT) - Disadvantages
1. Limited O.D. sensitivity; defect must be 60% through-wall before
detection
2. Volumetrically dependant; less sensitive to pits under 1/8” diameter.
3. Permeability and geometry will affect sensitivity to small defects and
sizing.
4. Probe must maintain good fill-factor (Centered) for sensitivity for
detection of small defects.
5. Accuracy of interpretation is highly dependant upon operator
experience.
6
6. Equipment is both sophisticated and expensive.
expensive
 Flux Leakage Testing (FLT)
Flux Leakage Testing (FLT) or Steel test inspection of ferromagnetic tubing. This
application is based on the magnetization of the part under inspection and the
detection of magnetic flux lines “leakage field” from the discontinuity in the
magnetized area.
The purpose of this application is to detect I.D.
I D and O.D.
O D degradation such as
corrosion, erosion, pitting, fretting, and gradual wall loss generally found in
ferromagnetic tubing. This method works extremely well on fin fan tubing in
conjunction with NFT testing.
 Flux Leakage Testing (FLT) – How it Works
 Two Strong
Strong, permanent magnets
magnets, coupled to a steel core,core generate a
magnetic field that saturates the tube wall.
 An absolute coil (ABS) is wound around the core to measure magnetic field
variation caused by general wall loss.
 When
Wh a small ll flaw
fl isi located
l d between
b the
h two magnets, theh magnetic i field
fi ld in
i the
h
tube wall is disturbed, resulting in a small amount of flux leakage into the inner
tube.
 This flux leakage is detected by a differential coil (Lead), located between the two
magnets.
 A trailing coil (Trail), at the end of the probe detects the residual magnetism from
internal pits.
 Flux Leakage Testing (FLT) – How it Works
 If an outside diameter defect is located in the tube.
 The magnetic flux lines are not only distorted into the air outside the tube, but also
within the tube.
 Since the tube wall is already saturated, the flux line distortions cannot be contained in
the remaining wall, and flux leakage is created on the ID.
 The LEAD coil can detect this flux leakage because it is located between the
magnets, in the middle of the magnetic circuit.
 The TRAIL coil, which is outside the magnetic
g circuit, cannot detect the defect
because there is no flux leakage inside the tube.
 Flux Leakage Testing (FLT) – How it Works
 If an inside diameter defect is located in the tube.
tube
 The magnetic flux lines are distorted in the tube when the magnetic circuit passes the
defect.
 At this point, the LEAD coil can detect the flux leakage.
 After the magnetic circuit passes the defect, some residual magnetism remains on
the defect.
 The TRAIL coil detects this residual magnetism and produces a signal output.
Flux Leakage Testing (FLT) – Data Interpretation

Typical Calibration Standard

Flux Leakage Testing (FLT) – Data Interpretation

MFL OF AIR COOLER (FIN FAN) / ISOLATED O.D. CORROSION

Flux Leakage Testing (FLT) – Data Interpretation

MFL OF AIR COOLER (FIN FAN) / ISOLATED I.D. CORROSION.

 Flux Leakage Testing (FLT) - Applications
1. Inspection of Ferromagneticg Tubingg With externally
y attached
fins. (i.e. Aluminium fins, Spot Welded fins,)
2. Accuracy of plus or minus 10%.
3 Excellent technique for detection and sizing of ID Inlet erosion
3.
in air coolers.
4. Air Cooler or Fin Fan applications.
5. FLT is a good technique for the detection of baffle fretting,
because the signal is unaffected by the support structures
and only detects the wall loss
6. FLT can also detect ID circumferential cracking. (With
specially designed Array FLT probes.)
 Flux Leakage Testing (FLT) - Advantages
1. Applies to any ferromagnetic tubing (Carbon Steel).

2. Tubes require little cleaning for inspection.

3
3. High examination rate (Approx.
(Approx 40-60
40 60 Tubes per/hr.)
per/hr )

4. Has high sensitivity detecting wall loss at baffle or support structures caused
by fretting or vibration.

5. Sensitivity to gradual wall loss and steam erosion.

6. Can inspect up to 2” diameter tubes (larger with special probe designs).

7. Can differentiate between I.D. and O.D. defect orientation.

8. Repeatability - compare historical and subsequent test results to establish

corrosion rates and remaining life.
 Flux Leakage Testing (FLT) - Disadvantages
1. Limited detection and sizing of small defects (<3/16” dia.).

2. Permeability and geometry will affect sensitivity to small defects and sizing.

3 Not sensitive to small cracks and pitting (w/special probe design such as:
3.
Array Coils).

4. Pull speed will affect analysis if not consistent (Permanent Magnets within the
probe make it difficult to maintain a steady pull speed for analysis purposes).

5. Limited to minimum 20% wall loss.

6. Threshold for accurately sizing defects is approximately 50% depth.

7. Accuracy of interpretation is highly dependant upon operator experience.

8. Equipment is sophisticated requires special probes and instrumentation.

 Internal Rotating Inspection System (IRIS)
Internal Rotary Inspection System (IRIS) technique uses unique water driven
rotating mirror to direct an ultrasonic beam, which is reflected 90 degrees to the
internal tube wall. The ultrasonic transducer is mounted axially in the tube and the
ultrasonic beam is directed toward the mirror, which is placed at a 45-degree angle
to the transducer. Using special ultrasonic electronics and computer a B B-scan
scan
and/or C-scan image is presented.
 IRIS – How it Works

This technique uses unique water driven

rotating mirror to direct an ultrasonic
beam, which is reflected 90 degrees to the
internal tube wall. The water acts as a
water couplant and transmit sound waves
from the ultrasonic transducer to the tube
wall.

The IRIS presentation can be displayed in

a B-scan (Cross-sectional view) or C-scan
showing the tube wall thickness and
isolated corrosion areas along the tube
length.
IRIS – Data Interpretation
 IRIS – Data Interpretation

Waste Heat Boiler Tube O.D. Erosion / Corrosion (APPROX. 270 Deg.)
IRIS – Data Interpretation

IRIS SCAN OF O.D. BAFFLE FRETTING

 IRIS- Applications
1. This technique is used as a stand alone inspection method as well as a
g method.
screening

2. IRIS is a good technique for the detection of baffle fretting, because the
signal is unaffected by the support structures and only detects the wall
l
loss if present.

3. IRIS is a good application for inspecting fin fans (Air Coolers) looking
for inlet erosion/corrosion and is not affected by the O.D.
O D fins.
fins

4. IRIS is a good confirmation tool if used to prove-up finding by RFT

and/or MFL if tube removal is not possible.

5. Can inspect Mud Drum – Steam Drum boilers with slight to moderate
bends.
 IRIS- Advantages
1. Used to inspect any tube material type ferrous or nonferrous.

2. Can inspect tube sizes from 5/8” to 3” and larger with special probe designs.

3
3. Provides accurate remaining wall thickness,
thickness (empirical data +/-
+/ .005”).
005”)

4. Can detect gradual wall loss, pitting, baffle fretting, steam erosion, and
impingement erosion at tube sheet area.

5. Can distinguish between I.D. and O.D. defect orientation.

6. Can be used as prove up to other test methods such as; ECT, RFT, NFT and
MFL.

7. Repeatability - compare historical and subsequent test results to establish

corrosion rates and remaining life
 IRIS- Disadvantages
1. Cleanliness of the tubes is a major factor and requires thorough tube
cleaning
l i (removal
( l off all
ll scale,
l deposits,
d it chemical
h i l residue
id and/or
d/ oilil
residue prior to inspection.

2
2. Slow inspection speeds of 20 to 40 tubes per/hr.
per/hr

3. Cannot inspect Low Fin Tubing.

4. Requires flooding the tube with water for sound coupling.

5
5. Can not detect cracks (Special probe design is needed).
needed)

6. Limited to isolated pit detection and pit size (diameter).

7. Instruments, probe cables, and head assembly is expensive.

 Final Report
Final Report - After the inspections and final data analysis is completed a formal
report
p is g
generated showing g a tube sheet diagram
g with the tubes inspected
p color
coded to a percentage wall loss.
Additional tube sheet diagrams can be generated showing the worst case
scenarios for tube plugging or selective re-tubing.
IIn addition
dditi t this
to thi information
i f ti our reporting
ti f
format
t can generate
t corrosion
i rates,
t
and a projection based on the established corrosion rates.
Certification & Training
It takes yyears of training
g for a tube
inspector to learn and demonstrate
his/her ability to perform a specific
application consistently accurate.
Certification & Training

Example: An individual can be

trained to take thickness
readings within a short amount of
time. However, for tube
inspection it takes repetitive
evaluation (Reviewing thousands
of signal characteristics) and
observing changing conditions to
develop an understanding of the
various process corrosion,
mechanical, and manufacturing
failures that occur on a dayday-to-
to
day basis.
Mock Exchangers

Qualifications and standards

such as Mock-up test bundles
are being generated throughout
the industry to pre pre-qualify
qualify
personnel, prior to performing
work in there plant.

List of Mock Bundles Passed

by Technicians at TechCorr.
LyondellBasell Industries.
EPRI
Shell
Chevron
OxyChem
Rhodia
 Tubular Summary
 Some of these methods provide qualitative data and some quantitative results

 Each of these different methods have distinctive advantages and

disadvantages
g

 It is imperative to choose the correct tube inspection technique for the job at
hand

 Also, it has been proven that a combination of methods can provide the best
p
inspection results ((i.e. RFT / IRIS))

 Like most advanced inspection techniques, the techniques are operator

p
dependent,, and it is important
p to evaluate yyour inspection
p provider to assure
p
they are qualified and experienced personnel
 Tubular Conclusion

-------ECT
RFT----

IT TAKES DIVERSITY AND

EXPERIENCE IN DIFFERENT
TUBING APPLICATIONS TO MEET
INDUSTRY NEEDS, BECAUSE NOT
ONE APPLICATION DOES IT ALL!

----FLT
IRIS----
IRIS
---

IIn conclusion
l i T b l
Tubular I
Inspection
ti provides
id an immediate
i di t return
t on
investment, by identifying tubes requiring plugging so that failures do
not occur during service.
Tubular Testing References

– Valero Texas City - Hollis Wood - Chief Inspector – (409) 948-7299

hollis wood@valero com
[email protected]
– Texas Petrochemical Ron Potier – Pressure Equipment & Inspection Engineer (713)
740-2078 [email protected]
– SRP Arizona – Jonathan Lucas Lead NDE / QC Specialist (602) 236-5695
[email protected]
– Marathon Oil – Andy Wilson – Chief Inspector – (409) 943-7486
[email protected]
– Ineos Chocolate Bayou – Kenny Mills – Chief Inspector – (281) 581-3102
[email protected]
– LyondellBasell BCO – Dan Cockrell – Reliability Inspector – (281) 474-0729
[email protected]
– LyondellBasell CVO – Gary Frazer – Reliability Inspector – (281) 862-5771
[email protected]
– Rohm
R h &H Haas CCraig
i JJackson
k – Lead
L d IInspector
t (281) 228
228-3088
3088
[email protected]
– MEMC Pasadena, TX - James Cullison – Plant Fixed Equipment Engineer (713) 740-
1524 [email protected]
Thank You