EC-WORKS

Advanced Saturated Eddy Current (ASEC)

 
 
Eddy Current Inspection of Carbon Steel tubes and other ferro-magnetic tubes (e.g. Duplex or Nickel tubes) ec-works has developed a new generation of eddy current saturation probes and eddy current inspection software for the fast and reliable inspection of all kind of ferro-magnetic tubes including fin fan tubes and many more, Why? Eddy current inspections are an effective tool in ensuring trouble-free plant operations. When?

A.

Eddy current tube inspections during preventive maintenance or during scheduled shutdowns is the most comfortable and safest way to get detailed information about the current state of your heat exchangers. 

B.

Eddy current tube inspections during trouble-based tasks e.g. unplanned shutdowns of your process equipment due to leaks helps you to evaluate the remaining tube life and analyse the damage mechanism. 

 
 

Features

 
 
Benefit from the use of the ec-works probologTM Advanced Saturated Eddy Current technology for the sensitive and fast inspection of Carbon steel and Duplex tubes in all kinds of heat exchangers, reactors or many other tube and non-tube applications.

Technical and organisational requirements

 
 
Personal:
Provision of a certified level III eddy current expert permanent on side, who works as supervisor and system operator (we have six level III inspectors in our company) All the operators are certified with regards to the EN ISO 9712 (formerly EN 473) or the American ASNT-TC-1A.
 
Certified level II eddy current experts as system operators
 
Trained and skilled inspector assistants as second person in each inspection team
 
All personal hold an international SCC passport (safety contractors certificate) for all the HSE requirements
 
Provision of up to 10 teams with individual eddy current systems to inspect up to 200 heat exchangers or 60000 condenser tubes per week.
 
EC-WORK is using either German TMT eddymax systems, Rohman eddy current systems and our own probolog 4.0 systems. All probes and rotating drives are de- signed and manufactured inhouse.
 

 
Technique:
 
Inspection of carbon steel tubes with the use of the PSEC technique. The Partial Saturated Eddy Current technique is the only way to inspect carbon steel tubes with proper detection sensitivity with regards to the common tube defects as internal pit- ting corrosion or cracking. PSEC works with the use of an integrated DC magnet, which allows the use of a DC- magnetic field to eliminate the influence of the permeability variations of the fer- romagnetic tube materials. These permeability variations create strong noise sig- nals and make a proper eddy current inspection impossible. The use of the PSEC technique eliminates the noise signals and allows a proper eddy current inspection of ferromagnetic tubes.
 
The remote field technique homogenises these permeability variations by integra- tion over a larger tube section, in general three times the tube diameter. This ends up in a lower sensitivity to smaller defects as pitting corrosion or any kind of cracks.
 
This PSEC is a very special technology, which has not been standardised so far. Special designed calibration tubes have to be used, the common remote field cali- bration tube shows too large artificial. The design of these calibration tubes is a part of ec-works know-how. This PSEC technique is suitable for most common tube de- fects, only for defects of a very smooth increasing erosion type of non finned carbon steel tube the remote field eddy current might be a more accurate option. The most accurate wall loss measurement is the IRIS technique, which is very poor with re- gards to inspection speed and its high cleaning requirements.
 
Aluminium finned air cooler tubes could be only inspected with PSEC technique, the remote field eddy current technique doesn’t work at these types of tubes.
 
Use of fully digital multi-frequency eddy current system (minimum four channels with differential and absolute mode settings)
 
 Centralised Probes are used for all common non-ferrite eddy current inspection like condenser inspections. This guaranties an unique and high defect detection rate combined with an very high inspection speed.
 
 Instant online eddy current signal evaluation, no offline eddy current signal interpretation and evaluation by an additional expert. All inspection results all available just a second after each tube inspection. No separation between data collection and later data evaluation (what is mostly the bottle neck with regards to result documentation and presentation). Inspection department gets the results as soon as the heat exchanger has been inspected. No delay between inspection and further decisions to be made, e.g. increase of inspection scope.
 
Provision of 10 or more eddy current probes per tube dimension in OD-size steps of 0.5mm to ensure a continuous inspection progress even after several probe damages. All eddy current probes are ecworks “in-house” made in our own work- shops. In case of damage, the probes could be repaired or maintained by our spe- cialist and have not to be send to an overseas manufacturer.
 
Provision of special eddy current probe technologies without extra charge to inspection the tube sheet areas, e.g. rotating probes and special “Z” probes.
 
The rotating eddy current probe allows the inspection of the tubes in the tube sheet area. With the use of integral probes the complete systems become “out of range” because a massive conductive metal comes close or in direct contact with the tube to be inspected. The eddy current signal disappears from the screen and nothing could be “seen” because of the massive difference inside and outside the tube sheet. The rotating device “compensates” this effect by turning the eddy current probes 90° to the tube axis. The coils rotate to inspect the complete tube circumfer- ence and here the conductivity should by the same. This is the fact whenever the tube – tube sheet situation is good / without defects, otherwise a differential eddy current signal will occur.
 
This technical layout is not suitable for PSEC probes; here we use the so called Z- probes, which allow the eddy current inspections in the tube sheet area. The design is also an individual ec-works know how, and should be treated confidential.
 
Provision of more than one calibration tube set per dimension and material Several hundreds of calibration tube set are available, as they are stored in our lab and if one would be missing, we could manufacture additional one quite fast in our own workshop or on-site at the client workshops.
 
The calibration of each eddy current test requires a proper calibration tube set. The calibration tube should fit to the defects to be found during the inspection, any supplier should give a short description of his standard calibration tube.
 
Each material vs. dimension combination requires a separate calibration tube set!
 
Documentation:
 
The documentation of the heat exchanger / air-cooler inspections will be transmitted to the inspection department at the end of each shift or immediately after the termination of each single inspection. During the inspections are intermediate results throughout all the time available. The tube sheet layout with the inspection results could be given in the autocad format (dxf, dwg) for further internal use by the client, e.g. continuous plugging documentation. If the client needs the results in the excel format, this could be provided in a tailor made excel sheet format (the ec-works in-house software allows this). Immediate comparison between older inspections and new inspection results, de- fect progress based on former inspections without delay
 
Unique experience:
 
The performance of any eddy current inspection and the evaluation of carbon steel eddy current signals in particular require an experience of more than 5 years. Ec-works could provide you with experts with much more than 10 years (up to 30! years) experience and with 6 level III experts to fulfil all kinds of inspection task and challenges.
 
Especially the number of experienced crews is unique in the world of eddy cur- rent, up to 10 teams of experienced personal in parallel! This results in an inspection power of up to 200 heat exchangers per week!
 
Push-puller systems:
 

 
Have a look to our completely remote controlled or manual used automatic push puller system
 

+60 85-663 027 , +60 85-622 027

info@amserve.com.my

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