OPTIMIZINGCONDENSERTUBELIFEWITHNONDESTRUCTIVETESTING

ByJeffreyGamza,MarketingSpecialist,ConcoSystems

Nondestructivetestingisaneffectivewaytodeterminethelifespanofyourcondenserandheatexchangertubes.
Theresultsareanalyzedanddiscontinuitiesoranomaliescanbecategorizedandreportedbydefecttypeand
depth.Thisprovidesmanagementwithanaccurateassessmentofunitconditionandremainingusefullife.
Additionally,precautionarystepscanbetakentoplugdamagedtubesoravoidanypotentialfailuresreducing
costlycondensertubeleaksandpreventingforcedoutages.

Caption:Aqualifieddataacquisitiontechnicianinsertsaneddycurrentprobeintoatubeforexamination.

EDDYCURRENTTESTING

Eddycurrenttestingisawellestablishedformofnondestructivetestingusedtoexaminenonferritictubingin
condensersandheatexchangers.Tubingsuchasausteniticstainlesssteel,titanium,brassandcoppernickelare
oftentestedwitheddycurrentmethodology.

Theeddycurrentmethodisavolumetrictestingprocessthatusesanelectromagneticfieldtoidentifydefectsin
thetubing.Anelectronflow(eddycurrent)isinducedinelectricallyconductivematerialandanelectromagnetic
fieldisgeneratedbyaprobe.Theprobeisfirstplacedinastandardandcalibratedtoknowndefectsproducing
representativesignals.Theprobeisthenplacedinsidethetubingtobetestedandpulled.Variationsintheeddy
currentsarerecordedandcomparedtothoseproducedbythestandard.Variationsarecausedbythefrequencies
applied,thecharacteristicsofthematerialandanyflawsordefects.Ananalysisontheresultsisperformed
followingthetests;successfulandaccurateanalysisisbasedonanalystexperience,propercalibrationtostandard,
andselectionoffrequencies.

Anydefectoranomalyinthetubingthatdisruptstheflowoftheeddycurrentscanbedetected.Dependingonthe
numberoffrequenciesandchannelsused,defectswithuniquecharacteristicscanbefound.Smalldefectssuchas
pittingandcrackingcanbedetectedinthedifferentialmode.Wallthinningdefectssuchassteamerosionorinlet
enderosionaredetectedintheabsolutemode.Additionally,higherfrequenciesaremoresensitivetonearsurface
flaws,andlowerfrequenciesaremoresensitivetosubsurfaceflawsandconditionsontheouterdiameter(OD)
tubesurface.Thecomplexandvariednatureofanomaliesanddefectsnecessitatetheuseofmultiplefrequencies
foraccurateidentification.

Caption:Asastandardbobbincoileddycurrentprobepassesthroughthetube,theelectromagneticfield(ingreen)
isdisruptedbyadefectinthetubewall.IllustrationcourtesyofZetec.

MULTIPLEFREQUENCIES

Anessentialelementintheeddycurrenttestingprocessistheuseofmultipletestingfrequencies.Atrue
volumetricinspectionrequirescompletepenetrationofthetubewallfromvariousperspectives;asprime
frequencyissetaffordingfullwallpenetration;additionalfrequenciesarerequiredtogainanaccurateand
detailedperspectiveofthedefect.Multiplefrequenciesoffertheabilitytobetterdetect,measure,andconfirm
flawsinallareasofatubewallandallowforamorethoroughevaluationwithhigherconfidence.Infact,additional
frequenciesarevitaltoconfirmcertaindefects,suchasunderdepositcorrosionandmicrobiologicallyinfluenced
corrosion.

Aminimumofthreefrequenciesishighlyrecommendedtoperformoptimumtesting.Whilepresentdayeddy
currenttestinginstrumentshavethecapacitytocarryuptoeightfrequencies,atleastthreeareutilized,ormore
commonlyfour,togainafullperspectiveonthedefect.Fromthechosenoptimumfrequency,thealternate
frequenciesareusuallyandoftheprimefrequencyformixingoutsupportplatesandotherunwantedsignals
fromstructuresornoise.Theoptimumfrequencieswillvaryfromlow,tomidrange,tohighdependingonthe
materialundertest.

Evaluationofinnerdiameter(ID)andouterdiameter(OD)defectsorvaryingsizemayalsorequiredifferent
frequencies.Eachfrequencymaybecarriedontwochannelstofurtherevaluatevariationsandinordertoconfirm
thereading.

Utilizingmultiplefrequenciesinthetestingprocessprovidestheanalystwithsufficientinformationtocallthe
defectswithgreateraccuracyandreliability.Utilizingamultifrequencytestinstrumentandstandardprobes
commonlyusedfortestingcondensertubes,tubesampleswithvariousdefectswillbeexaminedutilizingone,two,
threeandfourfrequencies.Defectacquisitionrateswillalsobevariedandtheresultsreported.

Theexperienceoftheanalystisanotherimportantfactorinthetestingprocess.ECTtechniciansshouldbecertified
to(ASNT)SNTTC1Aguidelines.Additionally,levelIIIAandseniorlevelIIAanalystshouldhavepassedbothElectric
PowerResearchInstitutes(EPRI)Datareviewandevaluationofbalanceofplant(BOP)HeatExchangersclass.All
analystsshouldhavepassedanindustryapproveddataanalysislevelIIAclass.

Notonlyisitimportanttousemultiplefrequencies,itisessentialtoselectthecorrectrangeorvalues.Foran
exampleoflowerrangefrequenciesconsider30kilohertz(KHz),atypicalprimefrequencywhentestingadmiralty
brasstubeswith.049wallthickness,reducingtoofprimeor15KHzandeventoofprimeonthelowerendof
therange.Forhigherrangefrequenciesconsidertestingof304stainlesssteeltubingwith.028wallthickness,the
typicalprimefrequencymaybe800900KHz,reducingtoprimeor400KHzandthento200KHz.Thenumber
andvalueoffrequenciesalsoaffectstherateatwhichdefectscanbedetected.Thoughlowerfrequenciesare
preferredforcopperalloysandsubsurfaceflaws,theytakelongertopropagatereducingthespeedatwhich
acquisitioncanbeperformed.

UsesofMultipleFrequencies

HighFrequencies LowFrequencies
Use StainlessSteels(.028) Brass/CopperAlloys(.049)
Nearsurfaceflaws SubsurfaceFlaws
IDPitting SeverePitting

Range 800to900KHz(High) 30KHz(High)
400KHz(Mid) 15KHz(Mid)
200KHz(Low) 7to8KHz(Low)

Theuseoffewerfrequenciesmayexpeditetesting,butmayresultinlessaccurateresults.Thepurposeoftestingis
toachieveaccurateidentificationofdefectsandtheircauses,andasignificanteconomicorremedialdecisionis
usuallydependentontheoutcome.Thespeedandcostoftestingshouldbesecondaryconcerns.Considerthe
following:

DepthofPenetration:Depthofpenetrationisthedepthatwhichthemagneticfieldstrengthorintensityof
inducededdycurrentshasdecreasedto37%ofitssurfacevalue.Thedepthofpenetrationisanexponential
functionofthefrequencyofthesignal,andtheconductivityandpermeabilityofthematerial.Theeffectivedepth
ofpenetrationisthedepthbeyondwhichatestsystemcannolongerdetectchangesinspecimenthicknessorthe
presenceofdiscontinuities;theeddycurrentdensityatthatpointissimplytooweak.

MisleadingODSignals:Anyindividualfrequencyhaslimitationsonitsdepthofpenetrationanditsabilityto
determinethecontinuationofthetubewalltotheOD.Thepresenceofotherconductivematerials,suchastube
supportplatesandmetallicdepositelements,canleadtoambiguoussignals.Inmanycases,magnetitedepositson
thetubeODhavebeenmistakenforerosion.AnothercaseofmisleadingODsignalsisfromMicrobiologically
InfluencedCorrosion(MIC).Duetothenatureofthesecorrosionphenomena,asmicroorganismshollowoutthe
tubewallandleaveonlyasmalldefectinthenearsurface,theeddycurrentscanbemisleadingandindicatethe
defectasbeingODinitiated.Withouttheaidofadditionalfrequencies,theanalystcanmischaracterizethe
conditionofthetubes.

MixingOutTubeSupportPlates:Controlledprobespeedandtheuseofmultiplefrequenciesareessentialto
identifyingdefectsneartubesupportplates.Thetubesupportplatemayhideordistortadefectasthesupport
platematerialisconductive.Commondefectsincludeaxialcracking,tubesupportplatefrettingwearand
condensategrooving.Absenceofalowerfrequencytodifferentiatethetubesupportplatewillleavetheanalyst
withinsufficientdataandpoortestresults.Thereducedfrequenciescanalsoaidindeterminingtheconditionof
thetubesupportitself.

TheShapeofPits:Thegeometricshapeofapitisnotaperfectcircle,nordoesittypicallyhaveaflatbottom,as
machinedintoacalibrationstandard.Thesignalresponsetoanaturalflawmaydifferfromthatofanartificialor
referenceflaw.Pitsofagivendepth,elongatedinthedirectionofwaterflow,haveadifferenteffectonthesignal
phasethandoroundpitsofthesamedepth.

OTHERVARIABLESINEDDYCURRENTTESTING

WhilemultiplefrequenciesaresignificantvariablesintheEddyCurrentTestingprocessthereareothervariablesto
consider.Someoftheothervariableswhichaffectresultsare:

thecalibrationstandard
fillfactor
tubecleanliness
probespeed

CalibrationStandard:Astandardisusedtocalibratethetestinginstrumentationandisnecessarytodetermine
applicablefrequencies.Thestandardismanufacturedfromalengthoftubingofthesamesizeandmaterialofthe
tubingtobetestedandcontainscalibrationdiscontinuitiesanddefectsmachinedintothetube,includingIDand
ODpittingandincrementaldegreesofwallloss.

FillFactor:FillfactoristhevolumeatwhichtheprobeoccupiestheIDofthetube.Fillfactorissuchasignificant
variablethatmanyqualityassuranceguidelinescallforaminimumof80%,thoughideally,theprobewouldoccupy
asmuchofthediameterofthetestedtubeaspossible.Highfillfactorprovidesbettermagneticcouplingwiththe
tubeanddecreasestheeffectsofcenteringvariables.Alowfillfactorreducesthesensitivityoftheexamandmay
resultintheprobetravelingclosertooneportionofthetubewall.

ProbeSpeed:Probesmaybeinsertedintothetubesmanuallyorbyanautomatedprobepusher.Probetraveling
speedsrangefrom30to48persecond;somehighfrequencyapplicationscanrunupto60persecond.
Commonprobespeedsforcopper,averylowfrequency,mayberestrictedto24persecond.Theamountofdata
collectedbytheprobe,thesamplerate,islimitedbytheinspectionfrequencyandthenumberofchannels
activated.Basedonthesamplerate,aprobetravelingtooquicklyusingalowfrequencyandslowsampleratecan
missflawsandgiveerroneoussignals.Additionallythepresenceofdepositsandobstructionswillcause
inconsistentprobespeedspotentiallyincreasingsignaltonoiseratioanddistortedsignals.

CalculatingFillFactor:

FillfactoristheratioofthesquareoftheprobeouterdiametertothesquareofthetubeID.
Forexample,a1ODx22BWGtube(where22BWG=.028wall)anda.900ODprobecalculatestoa90.8%fill
factor.

1(2x.028)=.944tubeID
0.9002/.9442=.81/.8911=.908or90.8%fillfactor

TUBECLEANLINESS

Thecleanlinessofthetubesisanotherimportantfactorinsuccessfuleddycurrenttesting.Fouledtubes
compromisetheintegrityandcompletenessofthetestingprocess,generatingunreliabledataandincomplete
analysis.Athoroughinspectionofthetubeisnecessarytoproducesuccessfultestresults.Foulingcanpreventthe
probesfromexaminingthefulllengthofthetubeandanymetallicdepositscangeneratemisleadingsignals.
Depositsandobstructionscancompromisefillfactor,orworse,cancausedamagetotheprobes.Overallnoiseto
signalratioisalsoimprovedbycleantubes.

Cleaningthetubes,preferablywithmechanicaltubecleaners,ispreferredpriortoaninspectionandthemost
effectivedepositremovaltechniquesshouldbeapplied.

Caption:Amechanicaltubecleaner,suchastheConcoC4S,canremovedepositsandfoulingthatwouldotherwise
distorttheprobesignalorobstructitspassagethroughthetube.

SidebySideComparisonofFoulingImpactonDataQuality


IneffectiveCleaning EffectiveCleaning

Caption:Analysisofthesampledataontheleftisdistortedanddifficultfortheanalysttoread.Thedataonthe
rightisthesametubeafterbeingadequatelycleaned.

THEEFFECTSOFUTILIZINGMULTIPLEFREQUENCIESONSPECIFICTUBES

Testshavebeenconductedthatclearlydemonstratethattheproperselectionanduseofmultiplefrequencies
provideabetterperspectivefortheanalystandmoreaccurateeddycurrenttestingresults.Whilespeedmaybe
compromised,theproperidentificationofdefectswillbeachievedwithahigherlevelofconfidence.

TestandTestProcedure

EddycurrenttestingwasperformedonanumberoftubesattheConcotestfacilityinVerona,Pennsylvania.
Testingwasperformedwithone,twoandfourfrequenciesorhigh,midrangeandlowfrequencyontwo,fourand
eightchannelsrespectively,withandwithoutatubesupportringsimulatingatubesupportplate.Thetubeshad
knowndefects,bothIDandOD,andinsomecasesinexcessof40percentwallloss.Thestandardbobbincoil
probeshadafillfactorofgreaterthan85%.AndtheprobespeedwascontrolledbytheuseofaZetec3Dhigh
speedprobepusher.Theresultswereconsistent.

Eachindicationwascapturedforreviewbyananalyst.Overall,distortionofthesignalwaspresentathigher
speeds,makingitdifficulttoread.Thesinglefrequencytestcouldnotaccuratelymeasureoridentifydefectswhen
placedunderatubesupportringortubesupportstandardduetotheabsenceofasubtractorfrequency.Testing
withatleastthreefrequencieswasneededtoinspectpartswithknowndefectsofgreaterthan40%throughwall
indicationswhentheseindicationsareunderatubesupport.Thebestandmostaccurateresultswereachieved
usinglow,midrangeandhighfrequenciesatamoderatetolowprobespeed.

DELIVERABLES
Athorougheddycurrentexaminationwillyieldaconsiderableamountofdataforanalysis.Uponcompletion,
testingcompaniesshouldprovideadetailedfinalreport,summarizingtheconditionandintegrityofthe
condenser,aswellas:

Abriefsummaryontheconditionoftheindividualtubestested
Anyotherrelativeinformationorrecommendations
Graphicsofspecifictubesthatmaybeofinterestforfurtherreview
QuickreferenceDataMatrixchart
Acolorcodedtubesheetmapthatwillgraphicallydisplaytheindividualtubeconditionandveryquickly
identifyanyproblemareas

Caption:Agraphicrepresentationofthecondenserisdisplayedwithindividualtubescolorcodedforquickanalysis.

CONCLUSION

ThesuccessfulapplicationoftheEddyCurrentmethodfornondestructivetestingofcondenserandheatexchanger
tubesisdependentonanumberofvariables.Otherthananalystexperience,theuseofmultiplefrequencieshas
themostsignificantimpactonresults.Withpropercleaningofthetubes,theuseofmultiplelow,midrangeand
highfrequenciessimultaneouslyassuresthebestandmostaccurateresults.Betterqualitydataiscollected
allowingtheanalysttoassessaccurateidentificationandquantificationoftubedefectssuchaspittingontheIDor
ODdefectsundersupportplates.Theaccurateidentificationofthesedefectsisparamounttotheprocess.
Successfulremedialaction,properfutureoperation,suggestedmaintenancepractices,orusefullifeestimationare
dependentonthisassessment.

ThisarticleacknowledgespriorworkandcontributionsfromcolleaguesatConcoSystems.