The document discusses inspection of shell and tube heat exchangers. It covers:
- Manufacturer and purchaser responsibilities for inspection during fabrication. The manufacturer performs required inspections unless specified otherwise.
- Common non-destructive testing (NDT) methods for inspecting heat exchanger tubing, including eddy current testing, remote field eddy current testing, ultrasonic testing, and magnetic flux leakage testing.
- Capabilities and limitations of different NDT methods for inspecting straight tubes and U-bends. Methods vary in their ability to detect flaws, size accuracy, and material compatibility. Tube cleanliness also affects test performance.
Here's a presentation on piping engineering in PDF format, now available for all. This presentation covers the basics points of piping for our EPC industry. This presentation covers various aspects of piping engineering
This Presentation is about the basic fundamentals one needs to know to begin Piping Engineering. All the basic formulas and questions that are usually asked in interviews are answered in this presentation. Feel free to ask any doubts in the comments and iI may try my best to answer them for you.
This manual covers the basic guidelines and minimum requirements for
periodic inspection of heat exchangers used in petroleum refinery.
Locations to be inspected, inspection tools, frequency of inspection &
testing, locations prone to deterioration and causes, corrosion
mitigation, inspection and testing procedures have been specified in
the manual.
Documentation of observations & history of heat exchangers,
inspection checklist and recommended practices have also been
included.
Heat exchanging equipment is used for heating or cooling a fluid.
Individual heat transfer equipment is named as per its function.
Cooler
A cooler cools the process fluid, using water or air, with no change of
phase.
Chiller
A chiller uses a refrigerant to cool process fluid to a temperature below
that obtainable with water.
Condenser
A condenser condenses a vapour or mixture of vapours using water or
air.
Exchanger
An exchanger performs two functions in that it heats a cold process
fluid by recovering heat from a hot fluid, which it cools. None of the
transferred heat is lost.
Piping Training course-How to be an Expert in Pipe & Fittings for Oil & Gas c...Varun Patel
Course Description
Piping a must know skill to work in Oil & Gas and similar Process Industries.
Oil and Gas industry is become a very competitive in the current time. Getting right mentor and right exposer within industry is difficult. With limited training budget spent by company on employee training, it is difficult to acquire the knowledge to success.
Knowing cross-functional skill give you an edge over others in your career success.
This course design based on years of field experience to ensure student will comprehend technical details easily and enjoy overall journey.
Learn in detail every aspect of Pipe & Pipe Fittings used in process industry
•Different types of Pipe, Pipe fittings (Elbow, Tee, reducers, Caps etc.), Flanges, Gaskets, Branch Connection, Bolting materials
•Materials (Metal-Carbon Steel, Stainless Steel, Alloy Steel etc. Non-Metal- PVC/VCM, HDPE, GRE-GRP etc.)
•Manufacturing methods
•Heat treatment requirements
•Inspection and Testing requirements (Non Destructive Testing, Mechanical & Chemical testing)
•Dimensions & Markings requirements
•Code & Standard used in piping
Content and Overview
With 2 hours of content including 30 lectures & 8 Quizzes, this course cover every aspect of Pipe, Pipe fittings, flanges, gaskets, branch connections and bolting material used in Process Piping.
This Course is divided in three parts.
1st part of the course covers fundamental of process industries. In this Part, you will learn about fundamental process piping. You will also learn about Code, Standard & Specification used in process industries.
2nd part cover various types of material used in process industries. In this part, you will learn about Metallic and Non-Metallic material used to manufacture pipe and other piping components.
3rd parts covers in detail about pipe and piping components used in Process piping. In this part we will learn about Industry terminology of Piping components, types of industrial material grade used in manufacturing and entire manufacturing process of these components. You will learn about different manufacturing methods, Heat treatment requirements, Destructive and Non-destructive testing, Visual & Dimensional inspection and Product marking requirements.
Upon completion, you will be able to use this knowledge direct on your Job and you can easily answer any interview question on pipe & fittings.
Here's a presentation on piping engineering in PDF format, now available for all. This presentation covers the basics points of piping for our EPC industry. This presentation covers various aspects of piping engineering
This Presentation is about the basic fundamentals one needs to know to begin Piping Engineering. All the basic formulas and questions that are usually asked in interviews are answered in this presentation. Feel free to ask any doubts in the comments and iI may try my best to answer them for you.
This manual covers the basic guidelines and minimum requirements for
periodic inspection of heat exchangers used in petroleum refinery.
Locations to be inspected, inspection tools, frequency of inspection &
testing, locations prone to deterioration and causes, corrosion
mitigation, inspection and testing procedures have been specified in
the manual.
Documentation of observations & history of heat exchangers,
inspection checklist and recommended practices have also been
included.
Heat exchanging equipment is used for heating or cooling a fluid.
Individual heat transfer equipment is named as per its function.
Cooler
A cooler cools the process fluid, using water or air, with no change of
phase.
Chiller
A chiller uses a refrigerant to cool process fluid to a temperature below
that obtainable with water.
Condenser
A condenser condenses a vapour or mixture of vapours using water or
air.
Exchanger
An exchanger performs two functions in that it heats a cold process
fluid by recovering heat from a hot fluid, which it cools. None of the
transferred heat is lost.
Piping Training course-How to be an Expert in Pipe & Fittings for Oil & Gas c...Varun Patel
Course Description
Piping a must know skill to work in Oil & Gas and similar Process Industries.
Oil and Gas industry is become a very competitive in the current time. Getting right mentor and right exposer within industry is difficult. With limited training budget spent by company on employee training, it is difficult to acquire the knowledge to success.
Knowing cross-functional skill give you an edge over others in your career success.
This course design based on years of field experience to ensure student will comprehend technical details easily and enjoy overall journey.
Learn in detail every aspect of Pipe & Pipe Fittings used in process industry
•Different types of Pipe, Pipe fittings (Elbow, Tee, reducers, Caps etc.), Flanges, Gaskets, Branch Connection, Bolting materials
•Materials (Metal-Carbon Steel, Stainless Steel, Alloy Steel etc. Non-Metal- PVC/VCM, HDPE, GRE-GRP etc.)
•Manufacturing methods
•Heat treatment requirements
•Inspection and Testing requirements (Non Destructive Testing, Mechanical & Chemical testing)
•Dimensions & Markings requirements
•Code & Standard used in piping
Content and Overview
With 2 hours of content including 30 lectures & 8 Quizzes, this course cover every aspect of Pipe, Pipe fittings, flanges, gaskets, branch connections and bolting material used in Process Piping.
This Course is divided in three parts.
1st part of the course covers fundamental of process industries. In this Part, you will learn about fundamental process piping. You will also learn about Code, Standard & Specification used in process industries.
2nd part cover various types of material used in process industries. In this part, you will learn about Metallic and Non-Metallic material used to manufacture pipe and other piping components.
3rd parts covers in detail about pipe and piping components used in Process piping. In this part we will learn about Industry terminology of Piping components, types of industrial material grade used in manufacturing and entire manufacturing process of these components. You will learn about different manufacturing methods, Heat treatment requirements, Destructive and Non-destructive testing, Visual & Dimensional inspection and Product marking requirements.
Upon completion, you will be able to use this knowledge direct on your Job and you can easily answer any interview question on pipe & fittings.
Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid
Industrial process piping (and accompanying in-line components) can be manufactured from wood, fiberglass, glass, steel, aluminum, plastic, copper, and concrete. The in-line components, known as fittings, valves, and other devices, typically sense and control the pressure, flow rate and temperature of the transmitted fluid, and usually are included in the field of Piping Design (or Piping Engineering). Piping systems are documented in piping and instrumentation diagrams (P&IDs). If necessary, pipes can be cleaned by the tube cleaning process.
"Piping" sometimes refers to Piping Design, the detailed specification of the physical piping layout within a process plant or commercial building. In earlier days, this was sometimes called Drafting, Technical drawing, Engineering Drawing, and Design but is today commonly performed by Designers who have learned to use automated Computer Aided Drawing / Computer Aided Design (CAD) software
Piping components, materials, codes and standards part 1- pipeAlireza Niakani
The course is focused on four areas: piping components, pipe materials and manufacture, sizes, codes and standards. Applicable piping codes for oil and gas facilities (ISO, B31.3, B31.4, B31.8, etc.), pipe sizing calculations, pipe installation, and materials selection are an integral part of the course. The emphasis is on proper material selection and specification of piping systems.
Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid
Industrial process piping (and accompanying in-line components) can be manufactured from wood, fiberglass, glass, steel, aluminum, plastic, copper, and concrete. The in-line components, known as fittings, valves, and other devices, typically sense and control the pressure, flow rate and temperature of the transmitted fluid, and usually are included in the field of Piping Design (or Piping Engineering). Piping systems are documented in piping and instrumentation diagrams (P&IDs). If necessary, pipes can be cleaned by the tube cleaning process.
"Piping" sometimes refers to Piping Design, the detailed specification of the physical piping layout within a process plant or commercial building. In earlier days, this was sometimes called Drafting, Technical drawing, Engineering Drawing, and Design but is today commonly performed by Designers who have learned to use automated Computer Aided Drawing / Computer Aided Design (CAD) software
Piping components, materials, codes and standards part 1- pipeAlireza Niakani
The course is focused on four areas: piping components, pipe materials and manufacture, sizes, codes and standards. Applicable piping codes for oil and gas facilities (ISO, B31.3, B31.4, B31.8, etc.), pipe sizing calculations, pipe installation, and materials selection are an integral part of the course. The emphasis is on proper material selection and specification of piping systems.
Corrosion monitoring in petroleum refineriesK R SONI
In petroleum refineries, corrosion of equipment takes place all through its operating life. It is essential to monitor the corrosion damage so that timely corrective actions like maintenance / repairs / rehabilitation of equipment can be undertaken before it causes unsafe plant operations.
The techniques employed for systematic corrosion monitoring of refinery equipment have been described in this presentation.
Final strip and sheet steel product is commonly inspected with great scrutiny to qualify material for high-end product requirements. Surface flaws such as slivers, cracks, laps, etc., disqualify these materials from being used in automotive and big box applications. Internal defects such as voids, cracks, laminations, porosity and segregation may remain undetectable with surface inspection methods as they have not yet manifested at the surface. These internal defects often propagate to the surface where ultimately they are detectable in the finished product stage in the form of slivers, blisters, etc., although remaining undetectable in the steel making, hot-rolling, pickling, cold rolling and subsequent finishing operations. Surface flaws are a key cause of down grading of finished product and a significant cost to the steel maker as all value added operations are complete before detection and down grading are possible.
In today’s competitive environment, it is key to maximize utilization of mill assets and to avoid adding value to material which can be known early in the manufacturing process to contain deleterious defects. Using proven methods of volumetric material inspection in two separate case studies, methods have been developed to allow the steel maker to identify poor material early in the process thus avoiding the value added processes on these materials and only processing materials which with a probability of final inspection passage.
Advance NDT method are much efficient than conventional NDT methods. these methods have great amount of automation which help in understanding and comparing the data occupied by different reading. These data can be used for the future references and can be saved and stored. these Advance NDT method can test or inspect any shape such as complex shape very easily and effeciently.
Eddy Current Testing is one of the most widely used Non-destructive Testing techniques to detect flaws or defects inside a material. There are several different eddy current testing methods. Eddy Current Testing PDF guides about the various methods of Eddy Current Testing.
Electric Resistance Weld (ERW) tubes and pipes are extensively used un many applications including Oil Country Tubular Goods (OCTG) and high quality structures. Efficient in-line nondestructive testing techniques are needed to ensure that the weld quality meets applications standards.
Introduction to the non destructive testing explains the methods for evaluating and verifying many types of Materials as plastics, structures, metals, chemicals, leakage, physical properties. It's very used in the concrete engineering world and in the scientific world.
Nondestructive Testing (NDT) has evolved from being a “necessary evil” to being an essential source of competitive advantage. The right technique not only helps control the quality of the final product, but also provides valuable process control feedback to improve productivity, reduce cost, and increase the
efficiency of the welder. This is especially important in high-volume, continuous processing lines where a few minutes of bad production can result in significant losses.
In the last decade, powerful Ultrasonic EMAT technology has come of age with tremendous success, becoming the technique of choice for many applications.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
2. Heat Exchangers Baher Elsheikh – Nov. 2020
G-2.1 MANUFACTURER'S INSPECTION
Inspection and testing of units will be provided by the manufacturer unless otherwise specified. The
manufacturer shall carry out the inspections required by the Code, customer specifications, and also
inspections required by state and local codes when the purchaser specifies the plant location.
G-2.2 PURCHASER'S INSPECTION
The purchaser shall have the right to make inspections during fabrication and to witness any tests when
he has so requested. Advance notification shall be given as agreed between the manufacturer and the
purchaser. Inspection by the purchaser shall not relieve the manufacturer of his responsibilities. Any
additional tests required by the purchaser, above those already agreed to, will be to the purchaser's
account. Cost for remedial work as a result of these additional tests will also be to the purchaser's
account.
TEMA G-2 Inspection
Inspection Responsibility
3. Non-Destructive Testing is used extensively for the condition
monitoring and remaining life estimates of heat exchanger tubing.
The tube pitch is typically a minimum of 1.25 times the tube outer
diameter which usually limits external inspection access to the
accessible outer tubes of a tube bundle. Subsequently, inspection of
the remaining heat exchanger tubes is limited to internal tube
inspection
Shell and tube exchanger tubing is inspected primarily using two
different NDE techniques, electromagnetic and ultrasonic.
Pitch
Pitch
Flow Flow
NDE for Heat Exchanger Bundles
Heat Exchangers Baher Elsheikh – Nov. 2020
4. NDE for Heat Exchanger Bundles ASME PCC 2
Article 312
Eddy Current
Examination [ET]
Generally selected
for inspection of
nonferromagnetic
tubes, or those that
are slightly magnetic.
Note that the
sensitivity of this
method decreases
for the U-bend
portion of U-tube
bundles.
Remote Field
Eddy Current
[RFET]
Generally used for
inspection of
ferromagnetic tubes.
Its sensitivity and
accuracy may be
less than desired or
required and will
require a higher
number of tubes to
be inspected. It is a
quicker method than
ultrasonic methods
Partial Saturation
Eddy Current
[PSET]
Can locate and size
cracks in
ferromagnetic tubes.
It might not be
sensitive to O.D.
defects.
Magnetic Flux
Leakage [MFL]
May also be selected
for inspection of
ferromagnetic tubes.
However, sensitivity
of this method can be
poor for carbon steel
tubes, and might only
be best at determining
the overall condition
of the tube, not
determining individual
defect location
Ultrasonic systems designed
to measure tube wall
thickness
may be used for HE, where
damage may be localized, or for
validation of other NDE results.
These ultrasonic examination
systems are particularly suited
for CS tubes due to the lack of
sensitivity of other NDE methods
One type of system is the
Internal Rotary Ultrasonic
Inspection (IRIS) system. IRIS is
an accurate NDE to detect and
size I.D. and O.D. metal loss
Another type of system is Shear
Wave IRIS (SWIRIS) and this
can be effective for detecting I.D.
and O.D. cracks. Both IRIS and
SWIRIS require clean tubes
Heat Exchangers Baher Elsheikh – Nov. 2020
5. NDE for Heat Exchanger Bundles
Common tubing NDE methods for straight shell and tube heat exchanger
• Multi-Frequency Eddy Current Testing (MFECT ECT)
• Segmented Eddy Current Array (ECA)
• Remote Field Eddy Current (RFT)
• Partial Saturation Eddy Current (PSET)
• Full Saturation Eddy Current (FSET)
• Magnetic Flux Leakage Testing (MFL)
• Magnetic Flux Leakage Array Testing (MFA)
• Near Field Testing (NFT)
• Near Field Testing Array (NFA)
• Internal Rotary Inspection System (IRIS)
• Acoustic Pulse Reflectometry (APR)
• Tube end calliper
New API Under Development
API RP586
on NDE Techniques
Heat Exchangers Baher Elsheikh – Nov. 2020
6. Preparation for tube bundle for ID Tube Inspection
Tube cleanliness can have a significant impact on the performance and probability of detection of some NDE
methods. The IRIS technique generally provides the most accurate data however it requires rigorous cleaning.
Electromagnetic technique accuracy decreases exponentially with tube fouling
Tube Probe Fill Factor
FF is as measure of the magnetic coupling between the coil and tube surface. Distance between probe coil and
defect has effect on signal forming, causing problems with sizing of indication
The fill factor is calculated by
PD=outside probe diameter TD= tube inside diameter
A large fill factor (e.g. 85%) is desirable for optimal NDE performance (70% for RFT/RFA)
defect
d
D
defect
𝐹𝐹 =
𝑑2
𝐷2
𝐹𝐹 =
𝑃𝐷2
𝑇𝐷2X100
Heat Exchangers Baher Elsheikh – Nov. 2020
7. Eddy Current Inspection (ECT)
Eddy Current Testing (ECT): Non-destructive testing method in which eddy current flow is induced in
the material under examination (inside surface of he tube).
An alternating current is applied to an exciting coil generating a magnetic current. This induced current
is then monitored by either the exciting coil or a separate pickup coil for changes.
Conventional eddy current examination can be performed in either the differential or absolute modes.
The differential mode detects small discontinuities such as pitting and cracking, whereas the absolute
mode detects localized or gradual wall loss.
Heat Exchangers Baher Elsheikh – Nov. 2020
8. Eddy Current Inspection (ECT) – Cont’
The magnetic permeability of ferromagnetic materials severely
limits the depth of penetration of induced eddy currents.
Saturated and partial saturated Eddy current testing for
magnetic materials to suppress the magnetic characteristics of
permeability.
Different techniques available and based on materials, configurations and
thickness; proper techniques to be selected
• ET for nonferromagnetic heat exchanger tubes
• ET for coated ferromagnetic materials
Heat Exchangers Baher Elsheikh – Nov. 2020
9. Partial Saturated and Full Saturated Eddy Current Testing
Partial Saturated Eddy Current Testing : Nondestructive partial saturation eddy current (using with
rare earth magnets) examination method Principles This inspection is applicable to partially
ferromagnetic materials such as nickel alloy or ferritic austenitic and thin ferromagnetic materials such
as ferritic chromium molybdenum stainless steel.
Full Saturated Eddy Current Testing : Full saturation eddy current (FS-ECT) uses a conventional
eddy current coil and a magnet. The magnetic field of the magnet saturates the material. Once
saturated the relative permeability of the material drops to one. The strength of the magnets used for
saturation is very critical in this technique. Weaker magnets will not saturate the material and will
produce a high signal to noise ratio. The application of a full saturation eddy current technique depends
on the permeability of the material, tube thickness and diameter.
Heat Exchangers Baher Elsheikh – Nov. 2020
10. Eddy Current Inspection (ECT) – Capabilities and Limitations
Capabilities
1. Inspection speed up to approximately 24 inches per
second
2. Distinguishes between ID and OD flaws
3. Good reliability and accuracy of test results
4. Can detect gradual wall thinning and localized flaws
5. U-bend tubes can be inspected with some radius
limitation
6. Permanent records can be obtained on test results
7. By using MFECT techniques, flaws under the support
plates (baffles) can be found and evaluated accurately.
8. Can detect axial cracks
Limitations
1. Limited to only non-magnetic tube material.
2. Requires a frequency mix to inspect tubing beneath a
tube sheet or baffle.
3. Does not detect circumferential cracks
4. Application is limited to 3-inch tube sizes and 0.125
wall thickness. Larger diameter and thicker wall
materials could be inspected with specialized
equipment.
5. Test instrumentation, systems and software packages
could be very expensive.
6. Requires high inspection skills for data analysis and
evaluation.
7. Discontinuities adjacent to end sheets are difficult to
detect.
Heat Exchangers Baher Elsheikh – Nov. 2020
11. Remote Field Eddy Current Testing (RFT)
Remote Field Eddy Current Testing: is quite distinct from standard eddy current testing in three of its
main characteristics
• RFT operates at frequencies typically below 1KHz; whereas, eddy current operates above 1KHz
• RFT can penetrate through thin-wall carbon steel heat exchanger and boiler tubes because of its
low frequency operation
• RFT is a pitch-catch method; whereas a sending coil transmits an electromagnetic field to a nearby
receiving coil. The resulting impedance measurement indirectly measures wall thickness.
• The RFT field passes right through the heat exchanger or boiler tube wall and far side defects are
equally well detected
Heat Exchangers Baher Elsheikh – Nov. 2020
12. Capabilities
1. Internal and external corrosion pits and under-deposit
corrosion
2. Internal and external erosion
3. General wall loss
4. Creep damage such as thermal fatigue cracking (if
orientated perpendicular to the resultant field)
5. Baffle wear and tube-tube fretting
6. Hydrogen damage and water treatment chemical-
induced damage
7. Steam impingement erosion
8. Cracking in tube wall (if orientated perpendicular to the
resultant field) and sometimes in membranes (with
special probes)
Limitations
1. Scanning speed is typically about half that of eddy
current technique (6-12 inches per second, but could
be slower based on the operating frequency.
2. Threshold of detection is typically 20% for local wall
loss and 10% for general thinning
3. Accuracy is quoted at +/-15% of actual wall-loss
4. RFT has limited sensitivity and accuracy at baffle
plates because the plates prevent the field from
traveling on the outside of the tube.
5. Although RFT is easier to understand than ECT, there
has been a lack of formal training and certification until
recently. This has led to the technique being quite
operator-dependent. ASNT has recently added RFT to
its family of electromagnetic test techniques and there
are now Codes and standards governing its use.
Remote Field Eddy Current Testing (RFT)
Heat Exchangers Baher Elsheikh – Nov. 2020
13. Segmented Eddy Current Array (ECA)
Segmented Eddy Current Array (ECA): ECA tubing probes are designed to inspect non-
ferromagnetic tubing. Instead of coils wound around a bobbin, the ECA uses a series of smaller
pancake shaped coils that are set in various array configurations according to design.
Heat Exchangers Baher Elsheikh – Nov. 2020
14. Capabilities
1. Inspection speed up to approximately 24 inches per
second
2. Distinguishes between ID and OD flaws
3. Can detect tube flaws beneath tube sheets or baffles
without a frequency mix
4. Reliability and accuracy of test results
5. Can detect gradual wall thinning and localized flaws
6. U-bend tubes can be inspected with some radius
limitation
7. Permanent records can be obtained on test results
Limitations
1. Limited to only non-magnetic tube material.
2. Application is limited to 3 inch tube sizes and 0.125
wall thickness. Larger diameter and thicker wall
materials could be inspected with specialized
equipment.
3. Requires high inspection skills for data analysis and
evaluation.
4. Tubes must be cleaned.
Segmented Eddy Current Array (ECA)
Heat Exchangers Baher Elsheikh – Nov. 2020
15. Internal Rotary Inspection System (IRIS)
IRIS: is an Ultrasonic system used for inspection and measurement of wall thickness of heat
exchanger tubes
In the IRIS system, the ultrasonic transducer is contained in a test head which fits into and is
centred in the heat exchanger tube, flooded with water for ultrasound transmission.
The ultrasonic pulses are emitted and reflected off a rotating mirror into the tube wall and back
again to the transducer via the same path.
Heat Exchangers Baher Elsheikh – Nov. 2020
16. Capabilities
1. 100% tube inspections converge (end to end).
2. Wall loss and pit detectability’s accuracy and sizing
plus or minus 0.002 inch.
3. Can examine both ferromagnetic and non-
ferromagnetic tubes.
4. Distinguishes ID from OD flaws and at support plates
5. Can inspect tube sizes up to 4.0 inches (or larger with
specialized equipment) with wall thickness up to 0.25
inches.
6. Final reports with applicable software can be generated
instantly.
7. Permanent records can be obtained on test results.
Limitations
1. Coupling medium (water) is always needed.
2. Tubes must be thoroughly cleaned.
3. ID surface corrosion and deposits can significantly
reduce test sensitivity due to the absorption and
scattering of sound waves.
4. Test speed is approximately 3-4 inches/second. 12
inches per second high-performance equipment. Some
systems cannot record the entire tube length due to
computer processing and file buffer size limitations.
5. Requires high inspection skills for data analysis and
evaluation.
6. Cannot detect cracking, small diameter pitting or
through wall holes.
Internal Rotary Inspection System (IRIS) – Cont’
Heat Exchangers Baher Elsheikh – Nov. 2020
17. Magnetic Flux Leakage (MFL)
A magnetic flux leakage (MFL) probe utilizes a powerful magnet to magnetize the material under
examination (i.e. Carbon Steel). If defects are present (corrosion or material loss), the magnetic field
“leaks” from the material. MFL probes incorporate magnetic detector(s) where it can detect the leakage
field.
Typically three sensors are used to measure the flux leakage received. The “Lead Differential Coil” is
used to detect ID/OD sharp indications. The “Absolute Coil” is part of the “Lead Coil” and is used to detect
ID/OD gradual defects. The “Trail Differential Coil” is placed outside the magnetic field to detect the
“residual” flux leakage left behind by ID sharp indications.
By comparing the information between all three coils, a defect orientation (ID or OD) can be established
Heat Exchangers Baher Elsheikh – Nov. 2020
18. Capabilities
1. Distinguishes ID from OD flaws.
2. Can inspect ferromagnetic tubes from 0.75 to 3.5
inches in diameter and 0.120 inches wall thickness.
3. Permanent records can be obtained on test results.
4. Instrumentation can withstand adverse field conditions.
5. Inspection speeds of up to 24 inches/second.
6. Can detect flaws under support plates as well as flaws
adjacent to end sheets.
7. Circumferential cracking may be detected with array-
type MFL coils.
Limitations
1. Detectability is limited to flaws 20% and greater.
2. Large magnets that are difficult to move.
3. Very sensitive to inspection speed. Accuracy of test
results can fluctuate with probe speed.
4. Poor sensitivity to tubing flaws beneath tube sheets
5. Tubes must be cleaned. Scale or deposit can fill a flaw
which will make it difficult to qualify its depth.
6. Requires high inspection skills for data analysis and
evaluation.
7. Longitudinal or axial flaws cannot be detected.
8. Difficult to accurately size discontinuities
9. Cannot inspect U-bend tubes.
Magnetic Flux Leakage (MFL)
Heat Exchangers Baher Elsheikh – Nov. 2020
19. U Bend Tubing Inspection
U-bend tubing can be inspected by remote visual inspection (RVI)
Each of the straight tube NDE methods can partially inspect the straight sections of the U-tube. The U-
bend itself is not inspectable by these techniques unless a special probe configuration is used.
Special probes may be found in the multi-Frequency Eddy Current, Partial saturation EC, and RFT
single exciter coil categories. Acoustic Pulse Reflectometry can detect blockage >15% of the tube
diameter or through wall holes in U-bends regardless of type of tubing material.
Heat Exchangers Baher Elsheikh – Nov. 2020
20. Tube and Callipers
Many tubing NDE methods have difficulty inspecting tube ends within the tube sheets due to end-effects
and tube sheet interference. Mechanical gauging of the tube ends is performed to detect ID tube end
erosion. A common gauge for this purpose is an internal three point expanding dial calliper.
Capabilities
1. Direct mechanical measurements
2. Tube sizes from 0.375” to 2.00” (9.5 - 50.8 mm)
3. Easy to calibrate
Limitations
1. Limited measurement distance into the tube
2. Measurements may be affected by tube deposits
3. Relatively slow production
Heat Exchangers Baher Elsheikh – Nov. 2020
21. Examination of Tube-to-Tubehseet Joint (TTS)
a) Visual Examination
b) Surface examination by PT
c) Volumetric examination by UT
d) In situ replica examination
e) Helium leak test
f) Hydrotest
Heat Exchangers Baher Elsheikh – Nov. 2020
22. NDT Method Suitability
Material / Technique ECT / ECA FSECT IRIS RFT MFL PSEC
Non-Ferromagnetic Tube
Low Ferromagnetic Tube
Ferromagnetic Tube
2
3
4
4
1
3
1
1
1
4
1
1
4
3
1
4
2
2
Examples of non ferromagnetic tubes: Admiralty brass, 300 series stainless steels, Cu-Ni, Hastelloys, etc
Examples of Low ferromagnetic tubes: Monel, 2205 Duplex stainless steel, 2207 Super Duplex stainless steel, etc.
Examples of Ferromagnetic tubes: Carbons steels, Nickle Alloys
Suitability Rank
1 Preferred
2 Applicable
3 Less Applicable
4 Not applicable
ECT : Eddy Current Testing
ECA : Eddy Current Array
FSECT: Full Saturation Eddy Current Testing
IRIS: Internally Rotating Inspection System
RFT: Remote Filed Testing
MFL: Magnetic Flux Leakaghe
PSEC: Partial Saturation Eddy Current
Heat Exchangers Baher Elsheikh – Nov. 2020
23. NDT Method Flaw Detection Capability
Defect / Technique ECT / ECA FSECT IRIS RFT MFL PSEC
ID General Wall Loss B B A B B B
OD General Wall Loss B B A B B B
ID Pitting B B C B B C
OD Pitting B B B C C C
ID Grooving A A A A A A
ID Erosion B B A A A B
OD Erosion / Impingement B B A A A C
Cracking (Axial) A A D A A B
Cracking (Circ) C C D A A C
Metallurgical changes (De-allyoing, hydriding) B B D A A C
Suitability Rank
A Highly Effective
B Effective
C Less Effective
D Not Effective
ECT : Eddy Current Testing
ECA : Eddy Current Array
FSECT: Full Saturation Eddy Current Testing
IRIS: Internally Rotating Inspection System
RFT: Remote Filed Testing
MFL: Magnetic Flux Leakaghe
PSEC: Partial Saturation Eddy Current
Heat Exchangers Baher Elsheikh – Nov. 2020
24. Acceptable Loss and Tube Replacement
Impact on the efficiency and other operational characteristics of the heat exchanger due to the potential reduction of heat transfer area.
Duration in service
Time to next planned outage
Criticality of the exchanger (process safety or to operation)
Suspected damage mechanism
Historical failure rate (increasing or decreasing)
Potential consequence of tube failure
Accuracy and effectiveness of the inception technique(s)
For critical exchangers:
• Total replacement of tube bundle where 40% loss or more of nominal thickness
• Tube or bundle replacement where 20%to 40% wall loss
Heat Exchangers Baher Elsheikh – Nov. 2020
25. Calculations of Tube Minimum Required Thickness
Heat Exchangers Baher Elsheikh – Nov. 2020
Download Sheet from the following link:
https://lnkd.in/dqa2xTWa
Video explanation for sheet usage on YouTube:
https://lnkd.in/dPaXUCa7
26. Methods for Determining Minimum Number of Tubes to Inspect ASME PCC 2
Article 312-I
312-1-1.1 Fixed Tube Count
The following minimum number of tubes inspected should be
considered:
a) 50 tubes or 25% of tube total, whichever is greater, for
heat exchangers with a total tube count of less than 500
tubes
b) 20% of tube total for heat exchangers with a total tube
count of 500 tubes or more, up to 750 tubes
c) 15% of tube total for heat exchangers with a total tube
count of 750 tubes or more, up to 1,000 tubes
d) 10% of tube total for heat exchangers with a total tube
count of more than 1,000 tubes
312-I-1.4 EVA
a) Use of Extreme Value Anlaysis (EVA) makes it possible to accurately assess the remaining life of large numbers of tubes using relatively minimal
data.
b) EVA assessment is based on ASTM E 2283, "Standard Practice for Extreme Value Analysis of Non metallic Inclusions in Steel and Other
Microstructural Features.
312-1-1.2 Tube Bundle
The following areas of the tube bundle should be examined at
a minimum:
a) the first three rows adjacent to the inlet nozzle and the last
two rows adjacent to the exit nozzle.
b) every second tube around the perimeter of the bundle. For
multipass heat exchangers, the perimeter of each pass
shall be included.
c) a selection of tubes in the interior section of the bundle.
d) areas with a history of active damage mechanisms.
e) areas that have not previously been examined.
f) failure of 10% of the tubes examined shall require an
additional 10% of tubes to be examined in the examined
area, as per (a) through (e).
Heat Exchangers Baher Elsheikh – Nov. 2020
28. Tube Plugging – Tapper Plug
• All tubes that are plugged should be pierced to provide venting and draining to prevent possible plug blowout.
Always puncture the tube before plugging
Tubesheet
Tubesheet
Tube
Friction Taper Plug to be used only when
• Shell side operating pressure <=1.5 Mpa
• Shell side operating temperature <=205 oC
• Tube to tubesheet are expanded not welded
Plug Map
Heat Exchangers Baher Elsheikh – Nov. 2020
29. Tube Plugging – Welded Plug
• Plugs with different shapes can be installed by welding to the tubesheet or to the inner surface of the tube
• Sometimes the plug is welded to ensure it doesn’t leak or blow out and turn into a projectile.
• When it is welded, the plug should have a material test report.
• The welding must be done in accordance with approved WPS, with care of requirements of Dehydrogenration
(if applicable) PWHT … etc.
• Mock-up to be prepared to ensure proper application and qualifications of the welders
• Plug map shall be prepared to record number of location of plugged tubes
Heat Exchangers Baher Elsheikh – Nov. 2020
30. Tube Plugging – Mechanical Plug
• Mechanical plugs should be considered in situations where friction fit
tapered plugs are not appropriate for the pressure and/or temperature of
service or other technical / environmental conditions.
• Mechanical plugs are typically installed by a pneumatic or hydraulic
system. Other styles of plugs may be considered for higher pressures.
Installation Video
Heat Exchangers Baher Elsheikh – Nov. 2020
31. Tube Plugging – TEMA NOTES
TEMA E-4.8 PLUGGING OF TUBES
• In U-tube heat exchangers, and other exchangers of special design, it may not be feasible to remove and
replace defective tubes. Defective tubes may be plugged using commercially available tapered plugs with
ferrules or tapered only plugs which may or may not be seal welded.
• Excessive tube plugging may result in reduced thermal performance, higher pressure drop, and/or mechanical
damage. It is the user's responsibility to remove plugs and neutralize the bundle prior to sending it to a shop
for repairs.
Heat Exchangers Baher Elsheikh – Nov. 2020