Transcript 20% ID pit - Independent Electronic Inspection Inc.

MATRIX probe
Progress Report 2008
By Jay Zimmerman
Independent Electronic Inspection (IEI)
Presented at the
10th EPRI BOP Heat Exchanger NDE Symposium
June 16-18, 2008
San Antonio, TX
“Good ideas are not adopted automatically.
They must be driven into practice by
courageous patience”.
Hyman Rickover
What is MATRIX?
Multi Axis Transmit Receive Inspection (X)
Proof of concept in 2003 under EPRI member
utility sponsorship (Nuclear Management Co.)
Introduced at 2004 EPRI BOP and SG NDE
conferences with patent pending
Despite showing great promise, MATRIX was
placed in mothballs in 2005 when problems
arose on several projects and funding ran out
Investors were sought from 2005 to 2007
Back to life in late 2007 thanks to IEI
What does MATRIX offer?
Axial crack detection
Circumferential crack detection
Diagonal crack detection
Pit detection
Suppression of tubesheet expansion
Suppression of TSP
Suppression of tube pilger noise
Suppression of fin noise (internal or external)
Single channel operation (like bobbin)
High acquisition speeds (like bobbin)
How does MATRIX work?
0 degrees
TUBE AXIS
360 degrees
DIAGONAL COIL SEGMENTS (CONNECTED IN SERIES) INSURE
DETECTION OF CIRC, AXIAL, AND VOLUMETRIC DEFECTS
BOTH COILS (GREEN AND GOLD) OCCUPY THE SAME AXIAL
POSITION ON THE PROBE, THEREBY SUPPRESSING TSP,
EXPANSION TRANSITION, RADIAL DENTS
= Optional Transmit Coil
TRANSMIT/RECEIVE BENEFITS = NOISE REDUCTION
AND IMPROVED SENSITIVITY
= Receive coil “A”
= Receive coil “B”
Successful field deployment
May 2008
1.312” OD X .109” wall 316L SS tubes
Tubes carry sulfuric acid
Exchanger less than one year old
Replacement for 12-year old exchanger with
severed tubes at tubesheet (hard rolled)
Indicative of circumferential cracking problem
MATRIX was chosen to check for early signs
Mag bias MATRIX with wide grooves was used
4 coils, each covering 90 degrees (plus overlap)
Successful field deployment
May 2008
Probes were fully encased in stainless steel to
resist extremely corrosive environment
No centering devices were present, but a vertical
exchanger and very good tube cleaning allowed
for use of Teflon tape to maximize data quality
This was a full length test, but only the tubesheet
area was analyzed (bobbin data used for the
remainder of HTSA)
Data shown in this presentation may not reflect
actual analysis results
Clean expansion signal
Suppressed expansion signals
12’ long tubes
with no supports
Tube sheet
thickness = 2”
Data presented courtesy of The Young Group
100% circ notch, 45 degree extent
Data presented courtesy of The Young Group
indication at tubesheet
Data presented courtesy of The Young Group
indication at tubesheet
Data presented courtesy of The Young Group
indication at tubesheet
Data presented courtesy of The Young Group
Indication in free span
Data presented courtesy of The Young Group
Speaking of indications….
Negative indication
Negative indication
Negative and/or positive indication
Positive indication
indication at tubesheet
Data presented courtesy of the Young Group
indication at tubesheet
Data presented courtesy of the Young Group
indication at tubesheet
Data presented courtesy of the Young Group
indication at tubesheet
Data presented courtesy of the Young Group
MATRIX strengths and limitations
“MATRIX is an effective tool for inspection of tubesheet
expansions” (per Young Group level III)
“At $1,000 each, MATRIX probes were a cost-effective
alternative to array or RPC probes”
$800 each for non-mag-bias version
MATRIX/bobbin hybrid could be used for next inspection
to save time (price TBD)
Wide grooves were required to fully penetrate thick wall
tubes in poor fill factor conditions
Though most MATRIX probes offer substantial pit
detection, these probes did not because of wide grooves
Copper Air Conditioner tubing with
enhanced fins (OD and ID)
Coils must be somewhat perpendicular to internal fins
Not parallel
Lesson learned in 2004;
helical undulations in tubing
Barely visible in RPC
data shown here
Rare helical undulations wreaked
havoc on MATRIX data because coils
were parallel to the “waves”
Flaw clearly detected,
but distorted by
horizontal noise = DQ
Must therefore aim “canoe” into waves,
or else there will be problems
YES
NO
Figgedabadit
MATRIX goals in HVAC
Replace Tri-tip probe as the industry
standard
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Tri-tip is IEI’s patented probe for
comprehensive HVAC tube testing
Includes AC3, bobbin, and Cross-Axis in one
probe
MATRIX already outperforms in many areas
Undergoing optimization right now
Final product will probably be a
MATRIX/bobbin hybrid
How does MATRIX suppress fins?
TUBE AXIS
Each circuit (green and gold) sees
the same number of fins at any
moment in time allowing for
common mode cancellation
MATRIX response to 20% ID pit
Bobbin response to 20% ID pit
MATRIX response to 40% ID pit
Bobbin response to 40% ID pit
MATRIX response to tiny pin hole
(.039” diameter 100% thru wall)
Bobbin response to tiny pin hole
(.039” diameter 100% thru wall)
MATRIX response to ASME 100% TWH
Bobbin response to ASME 100% TWH
MATRIX response to 40% OD FBH
Bobbin response to 40% OD FBH
Tube obstruction
(efforts to remove in progress)
MATRIX response to 90% drilled
hole in skip fin transition
Same flaw with window open
MATRIX response to 50% OD circ
saw cut in opposite transition
Both flaws with AC3 probe
(first pull)
Both flaws with AC3 probe
(second pull)
.
DEAD SPOT
MATRIX probe has no dead spot
OVERLAP ZONE
What are other uses of MATRIX?
Radial dent suppression
Flaw detection at supports without mix
Flaw detection at TTS without mix
Mixed mode crack detection
Identification of over-roll and under-roll
conditions at tubesheet
Data from EPRI SG lab samples follows
(including real cracks grown in autoclave)
MATRIX probe radial dent suppression
(no mix required)
T/R ABSOLUTE CHANNELS
T/R DIFF CHANNELS
UP TO 25:1 SUPPRESSION
MATRIX probe TSP suppression
(no mix required)
T/R ABSOLUTE CHANNELS
T/R DIFF CHANNELS
UP TO 25:1 SUPPRESSION
ODSCC under TSP
ABSOLUTE TSP RESPONSE
IS OFF SCREEN
AXIAL ODSCC AT
SUPPRESSED TSP
Circ crack at expansion
Mixed mode cracks, RPC response
ID axial at expansion (behind circ)
OD circ at expansion
OD circ
ID axial
Same 2 cracks, MATRIX response
MATRIX
= 40”/sec
RPC =
0.4”/sec
100 X
FASTER
MATRIX response to under-rolled expansion
Low frequency
MATRIX signal
shows underroll condition
TUBESHEET
EXPANSION AREA
Very large OD indication
THAT’S JUST PLAIN COOL!
Actually a 600’ tall lava extrusion, Mt. St.
Helens, summer 2006 (USGS photo)
What’s next for MATRIX?
Revisit the transmit/receive (T/R) version of MATRIX first
attempted in 2004
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Why? T/R has better overall sensitivity and less noise
By carefully controlling polarity of T and R coils, we can achieve
flaw characterization in addition to suppression (this was proven
in 2004 lab studies)
We are working with a certain instrument manufacturer to
optimize a custom tester for MATRIX during the design phase of
the instrument
Revisit SeaCure TSP suppression building on recent
mag-bias success
Improve sensitivity in the coil overlap zone
Try building a MATRIX array probe
More field tests!!!!
Opinion
MATRIX should be used in tandem with
bobbin on a universal basis in BOP
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With bobbin alone there is NO reliable
detection in expansions…the most common
stress riser in heat exchangers
With bobbin alone there is no reliable
detection of circ cracks at any location
MATRIX channels replace mix channels, so
there really isn’t more data to analyze
Who is IEI?
27 years as a service company in HVAC
Doing nuclear for past 10 years
Several level IIA QDA analysts
Over 100 years combined EC experience
Headquarters in Goodyear, AZ (near Phoenix)
Offices in LA, SF Bay Area, Seattle
Probe department co-located with VM Products
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Access to another 100+ years combined EC exp.
Onsite access to machines, lab equipment, etc.
www.best-test.com