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I began my career in the Petrochemical and Refinery industry 27 years ago' I am currently employed b

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Title: I began my career in the Petrochemical and Refinery industry 27 years ago' I am currently employed b


1
Introduction
  • I began my career in the Petrochemical and
    Refinery industry 27 years ago. I am currently
    employed by Acuren Inspection Services (Formally
    known as Longview Inspection Services), as
    Manager of Advance Services Tubing Inspection
    Group for the last 12 years, and a certified
    Level- III in Eddy Current. I host mock-up test
    qualification for numerous plants and facilities
    throughout the United States in locations such
    as Electrical Power Research Institution (EPRI)
    Lyondell/Equistar ShellMotiva Chevron BP
    Corporation Bayer Corporation Valero Refinery,
    etc. I have developed testing applications and
    procedures for a multitude of tubing application
    needs in todays industry, which I feel share a
    lot of experience and knowledge in the Advance
    Tubing Service.

2
DISCUSSION OF ADVANCE TECHNOLOGIES FOR CARBON
STEEL HEAT EXCHANGER TUBING
3
INTRODUCTION
  • 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.

4
Introduction Inspection Techniques
  • NDE techniques which are most common and
    currently being used in the industry include
    (ET) Eddy Current, (RFT) Remote Field Testing,
    (IRIS) Internal Rotating Inspection System, (MFL)
    Magnetic Flux Leakage (SteelTest).
  • The discussion today will focus on three of most
    commonly used tube inspection applications for
    ferrous materials (Remote Field Testing, IRIS,
    and MFL), along with the advantages and
    disadvantages associated with each test.
  • Also, several other new and emerging technologies
    will briefly be discussed RFT Array Coils X-RFT
    (External Reference Remote Field Testing).

5
WHY PERFORM TUBE INSPECTION?
  • Component Reliability Safety Environment

  • Reliability Reduce the Chance of Unscheduled
    Downtime lost revenue.
  • Predictive Maintenance Determine Corrosion
    Rate/Remaining Life Calc., Trending
  • Failure Analysis Provides data for prevention of
    future failures
  • Quantitative Data Hydro-Test is not sufficient.
    Bore-scope inspection can be
    misleading, limited to visual examination.

6
REMOTE FIELD TESTING (RFT)
7
REMOTE FIELD TESTING (RFT) PRINCIPLE
  • REMOTE FILED TESTING IS AN ELECTROMAGNETIC
    TECHNIQUE THAT UITILIZES AC EXCITATION TO
    GENERATE AC MAGNETIC LINES OF FLUX.
  • A THROUGH WALL TRANSMISSION WHICH IS DETECTED 2-3
    TUBE DIAMETERS AWAY BY INDUCING A VOLTAGE INTO
    PASSIVE SENSORS.
  • WITHOUT ANY MAGNETIZATION OR SATURATION.
  • RFT PROBES CONTAIN TWO TYPES OF COILS USED
    COMMONLY IN A SINGLE OR DUAL ARRANGMENT.
  • ONE COIL IS THE EXCITER COIL, WHICH TRANSMITS AN
    ELECTROMAGNETIC FIELD THROUGH THE TUBE WALL AND
    THE RECIEVER COIL WHICH SENSES THE FIELD AS IT
    COMES BACK IN THROUGH THE TUBE WALL.

8
RFT is the inspection of ferromagnetic material
such as
  • SA-214 CARBON STEEL (Welded)
  • SA-179 CARBON STEEL (Seamless)
  • SA-213 SA-199-T1 T11 (Chrome-Molly material)
  • SA-178 (Boiler Tubes)
  • SA-789 (2205 Duplex)
  • SA-268 (EBRITE)
  • Any other materials with magnetic domains.

9
REMOTE FIELD TESTING (RFT) PRINCIPLE
Receivers
Direct field
Exciter
ILLUSTRATION OF SINGLE EXCITER / SINGLE PICKUP
10
PROBE TYPES SINGLE EXCITER / SINGLE PICKUP
11
COMMONLY USED PROBE DUAL EXCITER / SINGLE PICKUP
12
TYPICAL REMOTE FIELD CALIBRATION(MULTI-PURPOSE
STANDARD)
13
RFT GRAPHICS OF WASTAGE SMALL PITTING
14
LINEAR ISOLATED PITTING
15
LINEAR I.D. PITTING
16
RFT SENSITIVITY TO SMALLER INDICATIONS THAT HAVE
LOWER PERMEABILITY
17
DETECTION OF MIC IN 2205 DUPLEX / USING RFT
18
ADVANTAGES OF REMOTE FIELD TESTING
  • Applies to any Ferrous material (Carbon Steel).
  • Tubes require little cleaning prior to
    inspection.
  • Inspect tubes with low fill-factor and still
    maintain good sensitivity.
  • Data acquisition rate of 50 up to 70 tubes per/hr
    (Depends on wall thickness and sample rate).
  • Good sensitivity to gradual wall loss, pitting,
    vibration, and steam erosion and cracking
  • Capable of testing heavy wall tubes (Up to .180)
  • Capable of inspecting up to 3 inch diameter tubes
    (Larger diameters w/special probe designs).
  • Repeatability Compare historical test results
    to establish corrosion rates and remaining life
    calculations.

19
DISADVANTAGES OF REMOTE FIELD TESTING
  • Limited detection and sizing of small defects
    (lt1/8 Dia. depending on material type).
  • Permeability and geometry will affect sensitivity
    to small defects and sizing.
  • Not sensitive to small cracks and pitting
    (w/special probe designs such as Array Coils are
    becoming alternative methods for detection).
  • Cannot distinguish between I.D. or O.D. defect
    orientation (Historical information or service
    would assist in narrowing down orientation of
    defects).
  • Has difficulty in detection of lt20 wall loss
    under baffle or support structures (Signal is
    suppressed by structures).
  • Pull speed is dependent on frequency, sample
    rate, and defect type.
  • Accuracy of interpretation is highly dependant
    upon operator experience.
  • Equipment is both sophisticated and expensive.

20
  • IRIS
  • (INTERNAL ROTATING INSPECTION SYSTEM)

I.D.
I.D.
O.D.
21
IRIS INSPECTION PRINCIPLE
  • 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.
  • This technique used to inspect all tube material
    types, (ferromagnetic and nonferromagnetic) in
    diameters ranging from 5/8 up to 3 inch large
    diameter boiler tubes (Large tubes or pipes have
    been inspected with special probe designs).
  • IRIS accuracy is operator dependant, measurements
    can be within or - 0.005 if tube conditions
    are good.

22
BOILER TUBE O.D. EROSION CORROSION (APPROX. 270
Deg.)
IRIS COMPUTERIZE COLOR B-SCAN C-SCAN DISPLAY
23
BOILER TUBES O.D. EROSION/CORROSION
24
IRIS SCAN OF RFT MULTI-PURPOSE STANDARD
25
RFT IRIS comparison of 50 degradation (SA-214
.750 x .083)
26
INTERMITTING AREAS OF DATA
27
I.D. SCALE AND DEPOSITS / DIFFICULTIES OF IRIS
TESTING
28
ADVANTAGES OF IRIS INSPECTION
  • Used to inspect any tube material type ferrous or
    nonferrous.
  • Provides accurate remaining wall thickness,
    (empirical data /- .005).
  • Can detect gradual wall loss, pitting, baffle
    fretting, steam erosion, and impingement erosion
    at tube sheet area.
  • Can distinguish between I.D. and O.D. defect
    orientation.
  • Can be used as prove up to other test methods
    such as RFT and MFL.

29
DISADVANTAGES OF IRIS INSPECTION
  • Cleanliness of the tubes is a major factor and
    requires thorough tube cleaning (removal of all
    scale, deposits, chemical residue and/or oil
    residue prior to inspection.
  • Slow inspection speeds of 20 to 40 tubes per/hr.
  • Requires flooding the tube with water for sound
    coupling.
  • Can not detect cracks (Special probe design is
    needed).
  • Limited to isolated pit detection and pit size
    (diameter).
  • Instruments, probe cables, and head assembly is
    expensive.

30
MAGNETIC FLUX LEAKAGE (MFL)STEELTEST
31
MFL INSPECTION PRINCIPLE
  • Magnetic Flux Leakage inspection 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.
  • Coils are mounted near the magnets which will
    detect variations in the magnetic flux field
    created by the anomalies in the tube wall.
  • The MFL technique can differentiate between
    internal and external damage (Coils are spaced
    apart).
  • This technique relies upon the dynamic movement
    of the coils through the magnetic field
    (measuring the voltage across the coils) as its
    being pulled through the tube at a constant speed
    of 12 inches per/sec.
  • This application is used for the inspection of
    ferromagnetic materials such as SA-214, SA-179,
    SA-178, SA-213-T1, Thru T-11, and etc.

32
MAGNETIC FLUX LEAKAGE PRINCIPLE
The A- coil has more windings for sensitivity to
sharp external defects. The B- coil has less
windings for sensitivity to sharp internal
defects. The Hall Effect sensor measures the
total magnetic flux in the tube wall and detects
general wastage and baffle fretting.
33
TYPICAL MULTI-PURPOSE CALIBRATION STANDARD FOR MFL
34
MFL CALIBRATION / VOLTAGE AMPLITUDE BASED
35
MFL OF AIR COOLER (FIN FAN) / ISOLATED O.D.
CORROSION
36
MFL OF AIR COOLER (FIN FAN) / ISOLATED I.D.
CORROSION.
37
MFL OF AIR COOLER (FIN FAN) / DISTORTION MAKES
IT DIFFICULT TO IRIS TEST
38
MFL OF AIR COOLER (FIN FAN) / ANALYSIS BECOMES
COMPLEX
39
ADVANTAGES OF MAGNETIC FLUX LEAKAGE (SteelTest)
  • Applies to any ferromagnetic tubing (Carbon
    Steel).
  • Tubes require little cleaning for inspection.
  • High examination rate (Approx. 40-60 Tubes
    per/hr.)
  • Has high sensitivity detecting wall loss at
    baffle or support structures caused by fretting
    or vibration.
  • Sensitivity to gradual wall loss and steam
    erosion.
  • Can inspect up to 2 diameter tubes (larger with
    special probe designs).
  • Can differentiate between I.D. and O.D. defect
    orientation.

40
DISADVANTAGES OF MAGNETIC FLUX LEAKAGE (SteelTest)
  • Limited detection and sizing of small defects
    (lt3/16 dia.).
  • Permeability and geometry will affect sensitivity
    to small defects and sizing.
  • Not sensitive to small cracks and pitting
    (w/special probe design such as Array Coils).
  • 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).
  • Limited to minimum 20 wall loss.
  • Threshold for accurately sizing defects is
    approximately 50 depth.
  • Accuracy of interpretation is highly dependant
    upon operator experience.
  • Equipment is sophisticated requires special
    probes and instrumentation.

41
EMERGING TECHNOLOGY
  • REMOTE FIELD TESTING
  • ARRAY COIL TECHNOLOGY

42
RFT ARRAY COIL TECHNOLOGY
Bobbin probe Array probe
43
RFT ARRAY COIL DISPLAY 100 TWH (Determines size
or extent of Defect)
44
ADVANTAGES OF RFT ARRAY COIL
  • Applies to any Ferrous material (Carbon Steel).
  • Good sensitivity to gradual wall loss, pitting,
    vibration, and steam erosion and cracking.
  • Capable to determine extent of corrosion for
    sizing.
  • Capable of inspecting up to 3 inch diameter tubes
    (Larger diameters w/special probe designs).
  • Repeatability Compare historical test results
    to establish corrosion rates and remaining life
    calculations.

45
DISADVANTAGES OF RFT ARRAY COIL
  • Limited detection and sizing of small defects
    (lt1/8 Dia. depending on material type).
  • Permeability and geometry will affect sensitivity
    to small defects and sizing.
  • Probe must maintain good fill-factor (Centered)
    for sensitivity for detection of small defects.
  • Cannot distinguish between I.D. or O.D. defect
    orientation (Historical information or service
    would assist in narrowing down orientation of
    defects).
  • Pull speed is dependent on frequency, sample
    rate, and defect type.
  • Accuracy of interpretation is highly dependant
    upon operator experience.
  • Requires special software and equipment to
    operate.
  • Equipment is both sophisticated and expensive.

46
X-RFT NEW EMERGING TECHNOLOGY
  • X-RFT
  • (EXTERNAL REFERENCE- REMOTE FIELD TESTING)

47
X-RFT NEW EMERGING TECHNOLOGY DESIGN FOR AIR
COOLERS
  • DEFINITION
  • External Reference Remote Field Testing (X-RFT)
    is an electromagnetic technique using the Remote
    Field Technology connected with an external
    reference to elimate extraneous noise by having a
    balanced system.
  • The X-RFT is used primarily for the inspection of
    air cooler tube inspection.
  • This method utilizes a 2nd probe placed in a
    reference standard or tube of similar material
    and dimensions of that to be inspected. This
    enables the system to mix out any unwanted noise
    to determine the defects depth.
  • The data is digitally collected and stored for
    analysis.
  • The purpose of this application is to detect I.D.
    inlet erosion/corrosion as well as isolated
    pitting, channeling, and etc.

48
X-RFT NEW EMERGING TECHNOLOGY
Similar to standard RFT probe except the coils
and sensors are much closer together to only
pick up the near-field portion of the induced
field.
49
X-RFT ILLUSTRATION
50
X-RFT AIR COOLER INSPECTION / EROSION/CORROSION
UP TO FERRULE
51
X-RFT (DISCOVERY OF TEST RESULTS)
52
X-RFT (Example of general wall loss from ferrule
end)
53
X-RFT (DISCOVERY OF TEST RESULTS)
54
X-RFT (Example of 50 degradation from ferrule
end)
55
ADVANTAGES OF X-RFT
  • Good sizing capabilities for Inlet Erosion
    Corrosion.
  • Detects small diameter pitting.
  • High data acquisition rate, (50 60 tubes/hr)
  • Detects gradual wall thinning (I.D.)
  • Capable of inspecting 3 diameter tubes, (larger
    w/special probe designs)

56
DISADVANTAGES OF X-RFT
  • Limited O.D. sensitivity defect must be 50
    through-wall before detection
  • Volumetrically dependant less sensitive to pits
    under 1/8 diameter.
  • Permeability and geometry will affect sensitivity
    to small defects and sizing.
  • Probe must maintain good fill-factor (Centered)
    for sensitivity for detection of small defects.
  • Accuracy of interpretation is highly dependant
    upon operator experience.
  • Equipment is both sophisticated and expensive.

57
Procedures, Certification and Training
  • Reference Documents being used are as follows
  • ASNT SNT-TC-1A (Recommended Practice for
    Nondestructive Testing of Personnel Qualification
    and Certification)
  • ASTM E-543 (Practice for Agencies Performing
    Nondestructive Testing).
  • ASTM E-1316 (Terminology for Nondestructive
    Examination)
  • ASTM E 2096-05 (Standard Practice for In Situ
    Examination of Ferromagnetic Heat Exchanger Tubes
    Using Remote Field Testing)
  • It takes years of training for a tube inspector
    to learn and demonstrate his/her ability to
    perform a specific application consistently
    accurate.
  • Example An individual can be trained to take
    thickness readings within a short amount of time.
    However, for tube inspection it takes repetitive
    evaluation and observing changing conditions to
    develop an understanding of the various process
    corrosion, mechanical, and manufacturing failures
    that occur on a day-to-day basis.
  • Certification in a particular test method does
    not necessarily qualify that individual to
    perform the inspection.
  • Qualifications and standards such as Mock-up test
    bundles are being generated throughout the
    industry to pre-qualify personnel, prior to
    performing work in there plant.

58
MOCKUP TEST QUALIFICATION BUNDLES
59
MOCKUP TEST QUALIFICATION BUNDLES
60
MOCKUP TEST QUALIFICATION BUNDLES
61
CONCLUSION
  • Some of these methods provide qualitative data
    and some quantitative results
  • Each of these different methods have distinctive
    advantages and disadvantages
  • 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 inspection results
  • Like most advanced inspection techniques, the
    techniques are operator dependent, and it is
    important to evaluate your inspection provider to
    assure they are qualified and experienced
    personnel

62
DIVERSITY IS A MUST!
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