Adapting Eddy Current Array Technology for NDT

Adapting Eddy Current Array Technology for
NDT Inspections
© Zetec Inc. – All rights reserved

Agenda
• Eddy Current Array Technology
• Why Eddy Current Arrays?
• HX Solution – CXB
• Surface Solution – Surface Array Flex Probe
• Encircling Solution - RCCA
• Eddy Current Engineered to Order (ETO)
2© Zetec Inc. – All rights reserved

Eddy Current Array Technology

• Instrument improvements enable use of ECAs
• Large number of small coils
• High sensitivity and wide coverage
• Probe shapes conform to complex surfaces
• Enable inspection in tight access areas
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Eddy Current Arrays (ECA)
Individual coils

ECA System Components
MIZ®-200 InstrumentSurface Array Flex Probe
Velocity®
Software

Why Eddy Current Arrays?

• Augment or replace PT and MT
– Reduced inspection time - data acquisition is fast and easy
– Does not require surface preparation
– Does not create a dirty environment that needs cleaning
– Enables flaw sizing
– Inspections are digitally recorded for archiving and historical comparison
– Improved flaw detection and sizing with C-scan imaging
• Complement UT
– Sensitive to surface flaws which are in the ultrasonic “dead zone”
• Couple with an auto-analysis system
7
Why Eddy Current Technology?

8
Why Eddy Current Arrays?
• Fast inspection
• Improved probability of detection
• Accurate defect positioning using encoded data
• Reliable results from better stability during the
inspection
• C-scan imaging for quick and easy data analysis
• Coil configurations for various applications
Single coil: slow n coils: n times faster

HX Solution - CXB

• Circumferential cracking
• Cracking in the expansion areas
• Close proximity pitting
• Stress corrosion cracking
• Bobbin signals require further characterization
• Mixed-mode signals and complex defects
Inspection Challenges in HX Tubing

• Array and bobbin coils in one probe
• Leverages proprietary X-Probe™ technology developed for
highest reliability steam generator inspections
• Bobbin coils provide general detection
• Array coils provide axial and circumferential flaw detection
and characterization
• Titanium body for long probe life
CXB Tubing Array Probe
Array coils
Bobbin coils

• Bobbin inspection speeds
• Single pass inspection
• Array probe resolution
• Complementary inspection methods
• Reduce false positives
Why CXB?

• Application
– Turbine Generator Condenser Inspection
• Challenge
– Multiple tube leaks were causing condensers to be taken off line
– Dual tube sheet structures with multiple expansions
– Tube leaks not detected with bobbin probes
• Solution
– CXB4 probe identified numerous defect morphologies
– Detected inlet end erosion, circumferential and axial cracking
CXB4 In Use

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Easy to Analyze
Axial Flaw

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Easy to Analyze
Circumferential Flaw

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Easy to Analyze
Volumetric Flaw

Pitting

Pitting Detection
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Two Pits in Close Proximity

Pitting Detection
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Row of Pits

Stress Corrosion Cracking

Stress Corrosion Cracking Detection
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Circumferential Crack at an Expansion

Pitting and Stress Corrosion Cracking

Pitting and Stress Corrosion Cracking Detection

Array Confirmation

Array Call/Bobbin Miss

Surface Solution – Surface Array Flex Probe

• Use surface array probes to
– Augment or replace PT and MT
– Replace single coil ECT
27
Surface Inspections

Surface Array Flex Probe
• Applications
– Surface and non-ferromagnetic sub-surface inspections
– Smooth weld inspection including crown, toe, and HAZ
– Successfully used in low pressure turbine rotor weld inspection
• Quick and Accurate
– Inspection coverage up to 2 inches in a single pass
– Longitudinal, transverse, and oblique cracks as small as 0.020 in.
• Conforms to Various Surface Applications
– Flexible pad wraps around weld beads up to 0.197 inches tall
– Detects corrosion under paint without stripping and repainting

• An encoder can be attached to an ECA probe to enhance
the quality of the inspection
– Provide distance measurements for signals of interest
– Control the sampling rate of the MIZ-200
• Sample rate automatically adjusts based on encoder speed
• Consistent data density regardless of speed
– High encoding resolution aids flaw sizing
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Encoded Inspections

Encircling Solution – RCCA

• Designed for Taiwan Power (ISI solution)
– Examine 24 rodlet clusters in 2 passes
– Encircling array probe to identify and characterize flaws
– RevospECT to provide fast and consistent results
• Processing power to perform auto-analysis
• Automatically analyzes the data quickly and accurately
• Consistent results using validated analysis techniques
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RCCA Inspection

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RCCA Inspection
MIZ-200 #1
MIZ-200 #2

Eddy Current Engineered to Order (ETO)

Eddy Current Engineered to Order (ETO)
• Leverage Zetec patented array technology experience
• Solutions for a variety of inspection applications
– Rod Cluster Control Assembly
– Fuel Rods
– Turbine Blades, Rotors, Blade Slots
– Carbon Steel Welds
– Complex Welds
– Tank Bottom Integrity

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Eddy Current Array Technology Provides
Fast, one-pass inspections  Helps achieve outage excellence
Recordable replacement to PT and MT  Helps achieve outage excellence
Complementary inspections to PAUT  Helps achieve outage excellence
Enhanced defect detection and characterization  Supports operational excellence
Leveraged technology for custom applications  Enhances your cost management

Thank You!
Learn more at: www.zetec.com/eddy-current-surface-array-solution/

Adapting Eddy Current Array Technology for NDT

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