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Inspecting HVAC and Heat Exchangers using the NORTEC® 600D Flaw Detector

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Heat exchangers come in many shapes and sizes. Several variables, such as material, outside diameter, and wall thickness, have an effect on which technology and probe are appropriate to inspect the exchanger.

Tube testing can be confusing, but this webinar will help to demystify it by exploring the theory behind tube testing and showing a complete hands-on demo using the NORTEC 600D flaw detector with the HVAC and Heat Exchanger kit. This kit enables inspectors to use eddy current technology (ECT), remote field technology (RFT), and near field technology (NFT) just as they would with a MultiScan 5800™ tube inspection system, but with much greater portability.

This solution is ideal for newcomers to the tube testing market as well as experienced inspectors that want to revamp their fleet with a highly portable system. This presentation is technically advanced and is addressed to NDT operators and engineers.

Presenter: Terence Burke
Product Applications Leader, Eddy Current and Bond Testing

Based in Quebec City, Canada, Terence has been with Olympus for several years. He started as an intern and worked his way up to the Product Management team. Today, his responsibilities include answering customer questions about tube testing and conducting training on Olympus eddy current products.

Learn more: https://www.olympus-ims.com/en/resources/webinars/inspecting-hvac-and-heat-exchangers-using-the-nortec-600d-flaw-detector/

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Inspecting HVAC and Heat Exchangers using the NORTEC® 600D Flaw Detector

  1. 1. 1 HVAC and Heat Exchanger Tubing Kit and NORTEC 600D Understand tube testing using the latest adaptor kit and NORTEC 600D September 2018 Olympus America Inc. | Terence Burke Quebec City, Canada
  2. 2. Agenda • What’s in the box • Key points for a great demo • Eddy current inspection • Common connections • Differential • Absolute • Remote field inspection • Common connections • Differential • Absolute • Near field inspection • Common connections • Differential • Absolute • Conclusion
  3. 3. What’s in the box 1- Splitter box: Used to connect the adaptor and footpedals into the instrument 2- ECT adaptor: Used to inspect non- ferromagnetic tubes 3- NFT differential adaptor: Used to inspect finned ferromagnetic tubes 4- NFT absolute adaptor: Used to inspect finned ferromagnetic tubes 5- RFT adaptor: Used to inspect ferromagnetic tubes HX-ADPT-KIT
  4. 4. What’s in the box 6- Foot pedal cable: Used to connect foot pedals to splitter box 7- Foot pedals HX-ADPT-KIT
  5. 5. What’s in the box 11- RFT calibration tube: Long defects for absolute calibration 12- ECT calibration tube: Pits for differential calibration 13- ECT finned calibration tube: Circumferential defect and hole to be used with A/C probe 14- ECT calibration tube: Long defects for absolute calibration 8- NFT calibration tube: Tapered ends and 3 pits in the middle section 9- RFT calibration tube: Pits for differential calibration 10 & 15- Support rings: One for ECT then other RFT N600-DEMO-KIT
  6. 6. What’s in the box All the necessary probes • TEA • TEC • TRS • TRX • TRD N600-DEMO-KIT
  7. 7. Key points for a great demo • The user must have a minimum knowledge of the NORTEC 600 and tube testing • The H Gain and V Gain must always be equal • The pedals must be shown to the client • Use the pedals to Null/Balance • Use Erase when: • A defect is found • Too much clutter on the screen
  8. 8. Eddy Current Inspection Connect as follows • Splitter to NORTEC 600D • Adaptor to splitter • Foot pedal cable to splitter • Foot pedal cable to foot pedal
  9. 9. Eddy Current Differential What you need • Bobbin probe (TEA/TEB) • Calibration standard with known diameter and wall thickness, and support ring
  10. 10. Eddy Current Differential Select ECT Pitting, Wear, and Cracks via the Applications menu
  11. 11. Eddy Current Differential – Frequency 1 Setup This method will allow us to use the Auto Mix function, thus allowing the user to see defects under the support. Freq 1 can be accessed with the Main/Filter button. • Step 1: Set Freq 1 to F90 • F90 is the frequency that will give an ID and OD defect a 90 degree phase difference • Step 2: Scan the calibration tube • Make sure the support is placed in a defect free area • Step 3: Set the hole signal at 40 degrees and 6 vertical divisions. • Step 4: Adjust the gain to avoid any signal clipping on the support signal Signal clipping is when the signal goes off-screen
  12. 12. Eddy Current Differential – Frequency 2 Setup To access Frequency 2 settings press the Main/Filter button. To see frequency 2 press DISP and select FREQ2. • Step 1: Set Freq 2 to F90/2 • F90/2 will be used to subtract the support signal. It is half of frequency 1. • Step 2: Scan the calibration tube • Make sure the support is placed in a defect free area • Step 3: Set the gain as high as possible to avoid any signal clipping on the support signal • Signal clipping is when the signal goes off-screen • Step 4: Set the support signal horizontal
  13. 13. Eddy Current Differential – Auto Mix Setup To access Auto Mix settings press the Main/Filter button. However, stay on the FREQ2 display for now. • Step 1: Press AUTOMIX • Scan the support ring only. • Step 2: Change the DISP to All-In-1 • Make sure the support is placed in a defect free area • Step 3: Set the rotation and the gain on the MIX channel • Set the hole at 40 degrees and 4 to 6 divisions • Step 4: Adjust the positioning of all 3 signals • Freq1 - Impedance • Freq2- Strip • Mix - Impedance
  14. 14. Eddy Current Differential – What you should see Once completed, the signals should be properly mixed out
  15. 15. Eddy Current Differential – Using a TEC probe • The bobbin coils are calibrated like the a regular TEA probe • The A/C coils are not calibrated
  16. 16. Eddy Current Absolute • Select ECT Erosion and Corrosion via the Applications menu • Only one frequency used • Simpler setup
  17. 17. Eddy Current Absolute What you need: • Bobbin probe (TEA/TEB) • Calibration standard with known diameter and wall thickness
  18. 18. Eddy Current Absolute – Frequency Setup • Step 1: Set Freq1 to F90/2 • F90/2 was calculated previously • Step 2: Scan the calibration tube • Make sure the support is placed in a defect free area • Step 3: Set the gain and rotation • Set the 20% outer diameter (OD) defect to 1 horizontal division and 4 vertical divisions. • The rotation of the defect should be 100 degrees from the origin
  19. 19. Eddy Current Absolute– What you should see Once completed, the signals should look like this
  20. 20. Remote Field Connect as follows: • Splitter to NORTEC 600D • Adaptor to splitter • Foot pedal cable to splitter • Foot pedal cable to foot pedal
  21. 21. Remote Field Differential What you need • Dual exciter RFT probe (TRX) • Calibration standard with known diameter and wall thickness, and support ring with pits
  22. 22. Remote Field Differential Select RFT Pitting and Wear via the Applications menu
  23. 23. Remote Field Differential – Frequency 1 Setup This method will allow us to use the Auto Mix function, thus allowing the user to see defects close to the support. • Step 1: Set Freq 1 to 400 Hz • Step 2: Scan the calibration tube • Scan the hole only • Step 3: Adjust the rotation and gain • The hole signal must be at 90 degrees and 4 to 6 vertical divisions. • Step 4: Set the gain as low as possible to avoid any signal clipping on the support signal • Signal clipping is when the signal goes off-screen
  24. 24. Remote Field Differential – Frequency 2 Setup To access Frequency 2 settings press the Main/Filter button. To see frequency 2 press DISP and select FREQ2. • Step 1: Set Freq 2 to 200 Hz • 200 Hz will be used to subtract the support signal. It is half of frequency 1. • Step 2: Scan the calibration tube • Make sure the support is placed in a defect free area or over the smallest defect • Step 3: Set the gain as low as possible to avoid any signal clipping on the support signal • Signal clipping is when the signal goes off-screen • Step 4: Set the support signal horizontal
  25. 25. Remote Field Differential – Auto Mix Setup To access Auto Mix settings press the Main/Filter button. However, stay on the FREQ2 display for now. • Step 1: Press AUTOMIX • Scan the support ring only. • Step 2: Change the DISP to All-In-1 • Make sure the support is placed in a defect free area • Step 3: Set the rotation and gain on the MIX channel • Adjust the hole signal so that it is 90 degrees and 4 to 6 vertical divisions • Step 4: Adjust the positioning and display type of all 3 signals • Freq1 – Impedance, Freq2- Strip, Mix - Impedance
  26. 26. Remote Field Differential – What you should see Once completed, the signals should be properly mixed out
  27. 27. Remote Field Absolute Select RFT Erosion and Corrosion via the Applications menu Only one frequency used Simpler setup
  28. 28. Remote Field Absolute What you need: • Single Exciter RFT probe (TRS) • Calibration standard with known diameter and wall thickness and short defects
  29. 29. Remote Field Absolute – Frequency Setup • Step 1: Set frequency to 400Hz • Step 2: Scan the calibration tube • Make sure your calibration has a 60% groove • Step 3: Set the gain and rotation • Set the 60% groove to about 90% of the screen height • The rotation of the defect should be about 85 degrees
  30. 30. Remote Field Absolute– What you should see Once completed, the signals should look like this
  31. 31. Near Field Connect as follows • Splitter to NORTEC 600D • Near field probe (TRD) • Foot pedal cable to splitter • Foot pedal cable to foot pedal
  32. 32. Near Field Differential What you need • NFT Differential adaptor • Calibration standard
  33. 33. Near Field Differential Only one frequency will be used. • Step 1: Set frequency to 400 Hz • Step 2: Scan the calibration tube • Make sure you identify the hole signal • Step 3: Set the hole signal at 90 degrees and 6 to 8 vertical divisions. • Step 4: Add a sweep display
  34. 34. Near Field Differential – What you should see Once completed, the signals should look like this
  35. 35. Near Field Absolute What you need • NFT Absolute adaptor • Calibration standard
  36. 36. Near Field Absolute Only one frequency will be used. • Step 1: Set frequency to 400 Hz • Step 2: Scan the calibration tube • Step 3: Set the 60% groove signal at 90 degrees and 6 vertical divisions. • Step 4: Add a sweep display
  37. 37. Near Field Absolute – What you should see Once completed, the signals should look like this
  38. 38. A few more things… • Watch the more advanced videos for more information on each technology • MS5800 probes are compatible with the adaptors, excluding the magnetic flux leakage probes and IRIS • HVAC (ECT only) and Full kit available • N600D only! • Will not replace the MS5800 • When in doubt contact Tubetesting@Olympus-ossa.com
  39. 39. Conclusion The demo portion has been covered. When visiting clients be careful of the following: • The probes will not work for all materials • Fill factor is important • The right technology for the right job

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