Tube Inspection Services
Mistras provides a comprehensive Tube Inspection program, consisting of multiple tube inspection techniques, to determine the integrity of ferrous and non-ferrous tubing.
Our extensive experience in Tube Inspection provides the assurance that components are properly evaluated to detect damage or defects thereby ensuring that the tubing is safe to remain in operation. Failures can result in unplanned shutdowns, dangerous catastrophic failures or severe costly damage. Our tube inspection department offers a comprehensive programme to determine the integrity of heat exchanger, condenser, feed-water heater, boiler, and air coolers tubing etc., by ensuring tubes are properly evaluated to detect damage or defects in both ferrous and nonferrous tubes. Our tube inspection specialists are cross trained to perform work in power generation, oil & gas and other industries. Tube data is analysed directly at the job site, or is transferred via a web portal to enable remote data analysis that helps minimise the total project inspection costs using state-of-the-art inspection software and 2D and 3D reporting tools. Using the same colour coding scheme as standard tube sheet layouts, our tube inspection software informs our customers of the location of the tube defects within the length of the tube. This directs you to the exact location of the defects and allows you to make more informed decisions regarding the need to re-tube these locations or possibly modify the operating conditions to mitigate the damage mechanism.
Inspections included are:
- Eddy Current Testing
- Partial Saturation Eddy Current Testing (Magnetic Bias)
- Remote Field Testing
- Near Field Testing
Read more about our Tube Inspection Services below
Eddy Current Testing
Eddy Current Testing (ECT) is the fastest way to assess the condition of non-ferrous tubing in chillers, condensers, feed water heaters and evaporators. The inspection is performed swiftly and efficiently, with data collection speeds faster than any other inspection method. Analysis is performed on site to provide immediate results. On larger projects, analysis can be performed at a remote location, saving mobilization costs to the customer. These quality inspections, with real-time results, are available throughout our nationwide network of facilities.
PARTIAL SATURATION Testing (PSEC & Magnetic Bias)
Partial Saturation Eddy Current (PSEC) is predominately used as a scanning system on carbon steel heat exchanger tubing. This technique is an efficient way of inspecting large volumes of tubing. Although sizing defects is limited PSEC is sensitive to small pitting and has an excellent ability to discover fretting around tube support plates. On permeable materials it is not possible to use conventional Eddy Current because the permeability prevents eddy currents from penetrating the material and permeability variations can cause false indications. Magnetic saturation of a magnetisable material will result in the material to behaving like a non-ferromagnetic material. Now the same laws of physics as for conventional eddy current will be in force again. Main concern is to assure that the material is completely saturated. Mistras recommend that where possible PSEC is backed up with IRIS.
REMOTE FIELD TESTING (RFT)
At Mistras, we feel that, with the recent advances to both probe technology and software measurement tools, RFT has to be considered the best method of examining carbon and alloy steel tubing. Although RFT doesn’t differentiate between ID & OD defects is sizing capabilities of both localised and general wall loss has been greatly increased due to the application of the voltage plane technique, which also give a very precise approximation of the extent of the wall losses around the circumference of the tubing. Like ECT, RFT is commonly used as a standalone method although it is just as common that IRIS is also utilised as a verification of anomalies, critical sizing and differentiation of ID & OD defects.
NEAR FIELD TESTING (NFT)
NFT is now a well-established technology, specifically design to inspect air cooler (Fin Fans) tubes found in the Oil & Gas Industries. The NFT probes are designed to detected internal corrosion, inlet erosion, and I.D. pitting commonly found in air coolers. This application has proven itself in the industry as cost saving alternative.
Mistras also utilizes the Internal Rotating Inspection System (IRIS) to perform examinations. This Ultrasonic inspection system is used at the request of the customer or when inspection results warrant the need for additional prove-up information. IRIS is a relatively slow technique but gives a high level of accuracy particularly when measuring ID/OD wall loss. Although bends cannot be examined by IRIS it is commonly used for boiler tube examinations as both the primary and prove-up inspection technique.
Heat Exchanger & Chiller Tubes
Fin Fan Air Coolers
Eddy Current Testing
|Partial Saturation Testing||Remote Field Testing||IRIS UT||Near Field Testing||IRIS UT||Eddy Current Testing||Partial Saturation Testing|
Remote Field Testing
Ferro Magnetic Material
Non Ferro Magnetic Material
Flaw Detection Capability
|General Wall Loss, Localised Pitting, Baffle Wear & Cracking (Orientation Dependant)||Localised Pitting & Baffle Wear||General Wall Loss, Localised Pitting & Baffle Wear||General Wall Loss, Localised Pitting & Baffle Wear||ID General Wall Loss, ID Localised Pitting, Inlet & Outlet Erosion||General Wall Loss & Localised Pitting||General Wall Loss, Localised Pitting, Baffle Wear & Cracking (Orientation Dependant)||Localised Pitting & relatively small areas of wall loss||General Wall Loss & Localised Pitting||General Wall Loss, Localised Pitting|
Average Production for 12 Hours
500 to 800 Tubes
300 to 500 Tubes
300 to 500 Tubes
|80 to 120 Tubes||300 to 500 Tubes||80 to 120 Tubes||400 to 700 Tubes||300 to 500 Tubes|
300 to 500 Tubes
|If tubes are pre-flooded 150 to 300|
|Minimum Fill Factor of 80% on Straight Tubes and 70% on U-Bends. Any remaining scale must be free from conductive or magnetic material||Minimum Fill Factor of 70%. Any remaining scale must be free from conductive or magnetic material||Minimum Fill Factor of 75% on Straight Tubes and 70% on U-Bends. Any remaining scale must be free from conductive or magnetic material||Bare metal is required as this is an ultrasonic technique||Minimum Fill Factor of 70%. Any remaining scale must be free from conductive or magnetic material||Bare metal is required as this is an ultrasonic technique||Minimum Fill Factor of 80%. Any remaining scale must be free from conductive or magnetic material||Minimum Fill Factor of 70%. Any remaining scale must be free from conductive or magnetic material||Minimum Fill Factor of 70%. Any remaining scale must be free from conductive or magnetic material||Bare metal is required as this is an ultrasonic technique|