Sie sind auf Seite 1von 117

BOILER INSPECTION

TUBE THICKNESS, CORROSION INSPECTION


Contents
1. The purpose of boiler life assessment
2. Life Evaluation by Inspection
3. Preparations for Inspection
4. Data requirement
5. Inspection of high pressure parts.
6. Sample tube inspection.
7. Visual inspection for other parts of boiler .
8. Water quality survey.
9. Visual Inspection for aux Equipment
10. high pressure parts Inspection details
1-The Purpose of boiler life assessment
o Evaluate the present state and the condition of the boiler
components in order To continue stable and reliable boiler
operation
o Evaluate the remaining life for Superheater and Reheater by
metallurgical inspection
o Evaluation of creep life and future inspection scheme by
metallurgical inspection for water wall, economizer,
Superheater and Reheater tubes
o Evaluation degree of creep damage for Superheater and
Reheater by hardness test
o Evaluate the remaining life based on thickness Measurement
for water wall,
o Evaluate the remaining life based on thickness thinning for
economizer due to low Temperature Corrosion,
o Evaluate the remaining life based on thickness thinning for
Superheater and Reheater tubes due to high Temperature
Corrosion
o Confirm the cause of the inner scale generation
o Evaluate the remaining life based on check of metal structure
,inner scale ,etc for sample tube
2-Life Evaluation by Inspection
FAILURE DAMAG PHENOME LIFE INSPECTION ITEM
CAUSA NON EVALUATION
 Clogging Swelling Outside Metallurgical
CREEP with Metal diameter and crack
foreign structure thickness
material change measurement
Depositi Metallurgica l
on and inspection
growth of
scale on
Inner
surface
Long-
term
stress
FATIG Cycle Growth Stress
UE thermal of crack analysis
stress Surface
inspecti SH and
on for RH
SH, RH Tube
header,
Met
allurg
ical
inspe
ction and NDT (UT) for main steam pipe line and high temperature RH pip

NDE
(PT,
MT)
of
spacer
welde
d for
●CORR Cyclic Interacti Ultrasonic Sample tube
OSION thermal on of test inspection for SH, RH
FATIGUE stress corrosion Sample tube and water wall
under and inspection Check of Burner
corrosive fatigue Nozzle and Wind Box
environme Damper
nt

●CORR High Thickne Annual  measurement of


OSION temp ss thickness tube thickness for
corrosion thinning measurement SH ,RH, Water Wall
●EROSI Low and Eco by UT
ON temp Steam drum
corrosion Boiler aux
Ash Eco Hanger tube by
erosion endoscope, etc
3-Preparations for Inspection
• Before inspection
– Superheater, reheater, economizer and water wall cleaning
– Air heater washing
– Scaffolding
– Removal of insulation
– Open man holes, inspection holes, flanges etc
• During inspection
– Surface preparation of inspection parts
– Surface finishing (grinding) of inspection parts
– Instrument of apparatus of inspection
– Cutting tubes
– Welding tubes
• Material requirement
– New tubes
– Man hole packing
– insulation
• Period of inspection
– Two weeks
4- Data requirement

• Boiler reference data


– Steam temperature c
0

– Maximum Steam flow Ton/hr


– Boiler design pressure Kgm/cm2
– Feed water temp 0c

– Reheated inlet steam temperature 0c

– Reheated outlet steam temperature 0c

– Reheater design pressure Kgm/cm2


– Kind of fuel Coal,Gas, Oil

• Functional inspection with boiler in operation


– Collection of drawings and main technical data
– Recording of actual operating and functional data at different loads and
conditions at MCR and Verification of the operation of the boiler
– Collection of data relevant to the thermal history and interventions ,if any
made on the boiler during his operation life
5-Inspection of high pressure parts
• NON Destructive test for the following item
1. Economizer headers, coils, Piping from economizer to steam drum,.
2. Steam drum.
3. Furnace water walls, screen, roof wall, feeders, riser ,Water walls headers.
4. Saturation steam pipe.
5. Primary, secondary super heater.
6. Connecting pipe between primary superheater and secondary superheater.
7. Reheater.
8. Main SH steam pipes

**Inspection item

1. External visual inspection


2. Internal visual inspection with endoscope
3. UT for thickness measurements
4. MT and UT on circumferential welds
5. MT on piping attachments
6. Metallographic inspection
7. MT on nozzles welds of the coil tubes
8. MT on nozzles welds to the shell of the inlet/outlet pipe
the minimum required thickness

t = minimum required thickness.


D = outside diameter of cylinder.
e = thickness factor for expanded tube ends.
P = maximum allowable working pressure.
S = maximum allowable stress value at the design temperature
of the metal.
Design / Operating Information
for calculation of remaining time based on thickness

• Design information
– material type or grade
– Nominal outside diameter
– Designing pressure
– Design life
– Deign temperature
– Original nominal thickness
• Operating information
– Maximum tube metal
Thickness measurements
temperature of water wall tubes
– Normal operating pressure furnace
– Original measured minimum
thickness
– Metal thinning rate
Minimum required thickness for SA178-C

Minimum required thickness for different working


conditions for materials SA178- C
ASME Spec. ASME G rade ERW or Sm ls. Des criptio n Ty p ical uses

SA- 178 A ERW Low car b on steel - C=0.18 m ax. Bo iler tubes, e con o m izer s, low te m p. s u p er h eater s

SA- 178 C ERW Me dium c ar bon s teel - C=0.35 max. Boiler tubes, e con o m iz er s, low te m p. s u p er h ea ter s

SA- 178 D ERW C ar b on- manganese steel - C=0.27 m ax Not in com mon use

SA- 192 Smls. Low car b on steel - C=0.18 m ax W a ter wa lls , eco n o m izer s, low temp. su p er he a ter s

SA- 210 A1 Smls. Me dium c ar bon s teel - C=0.27 max. W a ter wa lls , eco n o m izer s, s up er he ater s

SA- 210 C Smls. Me dium c ar bon s teel - C=0.35 max. W a ter wa lls , eco n o m izer s, s up er he ater s

SA- 209 T1 Smls. Low alloy steel - low car b on, 1 /2% moly Superhea ters

SA- 209 T1a Smls . Low alloy steel - medium car b on, 1 /2% moly Superhea ters

SA- 209 T1 b Smls. Low alloy steel - low car b on, 1 /2% moly Superheaters

SA- 213 T2 Smls. I n ter media te alloy - 1/2% chr ome, 1 /2% moly W ater walls, s up er h e ater s, not in common use

SA- 213 T1 1 Smls. I n ter media te alloy - 1 1/4% chrome, 1/2% moly W a ter wa lls, sup er h e ater s

SA- 213 T2 2 Smls. I n ter media te alloy - 2 1/4% chrome, 1% moly W ater walls, s up er h e ater s

SA- 213 T5 Smls. I n ter media te alloy - 5% chr ome, 1/2% moly H igh te m per a ture superheaters, not in common use

SA- 213 T9 Smls. I n ter media te alloy - 9% chr ome, 1% m o ly Hig h te m per ature superheaters, no lo n g er in co m mon use

SA- 213 T9 1 Smls. I n ter media te alloy - 9% chr ome, 1% m o ly , 1/4% vana dium High te m per a ture superheaters - the late st and gr eatest

SA- 213 Tp- 304 Smls. Stain less s teel - 18% chrome, 8% nic kel Superhea ters

SA- 213 Tp- 304H Smls. Stain less s teel for high te m p er a tur e s er vice H igh te m per a ture superheaters

SA- 213 Tp- 316 Smls. Stain less s teel - 16% chrome, 11% nic kel Superhea ters

SA- 213 Tp- 316H Smls. Stain less s teel for high te m p er a tur e s er vice H igh te m per a ture superheaters

SA- 213 Tp- 321 Smls. Stain less s teel - 17% chrome, 9% ni cke l, 0.60% titanium Sup erheaters

SA- 213 Tp- 321H Smls. Stain less s teel for high te m p er a tur e s er vice H igh te m per a ture superheaters

SA- 213 Tp- 347 Smls. Stain less s teel - 17% chrome, 9% ni cke l, co lumbium + tan talum=1 .00% max. Sup erheaters

SA- 213 Tp- 347H Smls.


6-Sample tube -
Destructive test for the Sample tube For Water Wall ,SR and RH tubes

– Life diagnoses based on check of metal structure, thickness, inner scale, etc
– Sample tube takes according to the result of hardness measurement

• Investigation Items
– Visual inspection
– Non destructive test
– Chemical analysis
– Measurement of the tube dimension
– Hardness measurement
– Cross sectional microstructure observation
– Steam oxidation observation
– Creep rupture test
– Measurement of the inner scale thickness

• Information
– Material of Sample tube
– tube dimension
sample tubes

Thinning of bulged zone Internal surface scale External surface scale


Optical micrograph

Optical micrograph of non-bulged zones tube wall side


showing ferrite –pearlite structure with no
internal defects
Normal and deteriorated microstructure

normal microstructure deteriorated microstructure


( good condition tube) which shows the
Which shows a decomposition of the pearlite
typical ferritic pearlite colonies
structure
lid ess as e t

220

a
. .- .
-o ..,_
...
c -
.................
.....

140
17% 0 Q
44%
120L-._._-- -L-L
0 20 40 60 BO 100
Creep life consumption rate(%)

EvaIuation curve for estimatingcreep damage! in T91


7-Visual inspection for other parts of boiler
– Burner
– Wind Box
– Hanger for riser pipe
– Outer casing
– Skin casing
– Buckstay
8-Water Quality Survey

This inspection to confirm the cause of the scale generation


• Inspection items
– Check of laboratory analysis method for quality items
– Confirmation of water quality results at previous load operation
– Check of instrument condition on sampling rack used for water
quality control
– Confirmation of PH value and iron/copper balance in the cycle
9-Visual Inspection for aux Equipment
This inspection to confirm the cause of the scale generation

– Condenser hot well.


– Condenser tube side
– Deaerator.
– LP-feed water heater.
– Feed water tank.
– HP-feed water heater.
10-high pressure parts Inspection details
1. Economizer headers ,coils, Piping from economizer to steam drum,
2. Steam drum
3. Furnace water walls, screen, roof wall, feeders, riser ,Water walls headers
4. Saturation steam pipe
5. Primary, secondary superheater
6. Connecting pipe between primary super heater and secondary superheater
7. Reheater
8. Main SH steam pipes
10-1 Economizer
• NDE For headers
– External visual inspection
– Internal visual inspection with endoscope
– Measurement of thickness by UT
– MT on nozzles welds of the coil tubes and headers attachments
– MT and UT on circumferential welds between header and conical pieces

• NDE For tube


– External visual inspection
– Measurement of economizer tube and hanger tube thickness with endoscope
– UT for thickness measurements

• NDE For Piping from economizer to steam drum


– External visual inspection for piping, hangers and supports
– UT for thickness measurements
– MT and UT on circumferential welds
– MT on piping attachments
– MT on the elbows extrados
10-2 steam drum
• Before the NDT inspections, the internal parts of
the drum shall be dismantled
• NDE For steam drum
– External visual inspection
– Internal visual inspection
– UT for shell thickness measurements
– UT for head thickness measurements
– MT and UT on circumferential and longitudinal welds
– MT on steam drum attachments (saddles and accessories)
– MT on nozzles welds

• NDE For downcomers


– External visual inspection for piping, hangers and supports
– UT for thickness measurements
– MT and UT on circumferential welds
– MT on piping attachments
10-3 furnace water walls, screen, roof wall,
Feeders and Riser
• NDE for furnace water walls, screen, roof wall
– External visual inspection
– UT for thickness measurements
– Metallographic examination by plastic replicas
– Samples for destructive test

• NDE for feeders and riser


– External visual inspection
– UT for thickness measurements

• NDE for headers


– External visual inspection
– Internal visual inspection with endoscope
– UT for thickness measurements
– MT on nozzles welds of the coil tubes
– MT on branches welds and headers attachments, including drains tubes
10-4 Saturation steam pipe
• NDE for each pipe
– External visual inspection
– UT for thickness measurements
– MT and UT on circumferential welds
– MT on piping attachments
– MT on the elbows extrados
10-5 Primary,Secondary Superheater
• NDE for the headers
– External visual inspection
– Internal visual inspection with endoscope
– UT for thickness measurements
– UT for head thickness measurements
– MT on nozzles welds of the coil tubes
– MT on nozzles welds to the shell of the inlet/outlet pipe
– MT and UT on circumferential welds between header and heads/ piping
– MT on headers attachments
– Metallographic examination by plastic replicas

• NDE for Coils


– External visual inspection
– UT for thickness measurements
– Internal visual inspection with endoscope
– Hardness measurements
– Samples for destructive examinations
10-6 Connecting pipe between primary and
Secondary Superheater, Desuperheater ATPS
• NDE for connecting pipe
– External visual inspection
– UT for thickness measurements
– MT and UT on circumferential welds
– MT on piping attachments
– MT on the elbows extrados
– Metallographic examination by plastic replicas
• NDE for desuperheater ATPS
– External visual inspection
– Internal visual inspection with endoscope
– UT for thickness measurements
– MT on circumferential welds
– Metallographic examination by plastic replicas
10-7 Reheater
• NDE For each one of the headers
– External visual inspection
– Internal visual inspection with endoscope
– UT for thickness measurements
– UT for head thickness measurements
– MT on nozzles welds of the coil tubes
– MT on nozzles welds to the shell of the inlet/outlet pipe
– MT and UT on circumferential welds between header and heads/ piping
– MT on headers attachments
– Metallographic examination by plastic replicas
• NDE For Coils
– External visual inspection
– UT for thickness measurements
– Internal visual inspection with endoscope
– Hardness measurements
– Samples for destructive examinations
10-8 Main SH steam pipes
• NDE for each pipe
– External visual inspection
– UT for thickness measurements
– MT and UT on circumferential welds
– MT on piping attachments
– MT on the elbows extrados
– MT on nozzles welds to the pipe
– Metallographic examination by plastic replicas
Inspection results of boiler and pre-boiler

Inspection item Conde1ser hot well

Inside of condenser hot well Condensate pump suction strainer

Bottom corner of hot well Inside wall of hot well


Inspection results of boiler and pre-boiler

Water box

Internal tube surface


Inspection resul ts of boil er and pre-boiler

Inspection item : LP-No-3 heater

Water box Tube wall


Inspection results of boiler and pre-boiler

Inspection item LP-No-4 heater

Water box Tube wall


Inspection results of boiler and pre-boiler

Inspection item Deaerator

Inside of Deaerator Interior part(lost boltl

Sliaht erosion ooint


Inspection results of boiler and pre-boiler

Inspection item HP-No-7 heater

Water box Tube wal!(1l

Outlet of HP-No7 heater


NDT

Inspect or measure without doing any harm


Various Terms used for NDT

Non-destructive Testing:
Technology for assessing the soundness of a component

Non-destructive Inspection:
Technology for inspecting material to known standards

Non-destructive Evaluation:
Art of developing NDT techniques arriving at acceptance standards
for components
Activities Come under NDT &E

•Flaw detection and evaluation


•Leak detection
•Metrology
•Microstructure characterization
•Estimation of mechanical /physical properties
•Stress (strain) and dynamic response determination
•Chemical composition
•Corrosion monitoring
Selection of NDT

• Reason for performing NDT


• Types of flaws of interest
• Size and orientation of flaws that is rejectable
• Anticipated location of flaws in the object
• Size and shape of the object
• Characteristics of the material to be evaluated
Selection of NDE

Question to be asked:

What is the reason for choosing an NDE procedure?

To find:
•If the object is acceptable after each fabrication step (in-process)
•If the object is acceptable for final use (final NDE)
•If the object/component in use can continue (in-service NDE)
Non-destructive Testing & Evaluation Methods

ACTIVE DETECTOR
RADIOGRAPHY
NDT&E ULTRASONICS OUTPUT
EDDY CURRENT INTERROGATING SIGNAL
MPI/ LPT MEDIUM

PASSIVE DETECTOR
ACOUSTIC EMISSION

DETECTOR
THERMOGAPHY DETECTOR
VIBRATION MONITORING

DETECTOR
Common NDT Methods

•Visual Inspection
•Liquid Penetrant Testing
•Magnetic Particle Testing
•Ultrasonic Testing
•Eddy current Testing
•Radiography
•Thermography
•Acoustic Emission
Liquid Penetrant Testing
Phenomenon used

Capillary action of liquid

Capillary action, or capillarity, is the ability of a liquid to flow in


narrow spaces without the assistance of external force.
Methodology

A. Ponolfenl eppled to tno surlace an<! e.. Elfcesspenettanlremoved trom


Cti:GI$ dc'cct sutlaoe

l
1
C. Oovclopot powdot appiod to <!raw o. AccontuatOd intk<ltion o4 ClliCI< as
pMetranr oiJt of aac:k. peneuant spreads around the
opontnc.

Cracks open to the surface


Ultrasonic Testing
Ultrasonic is the most versatile NDT
technique

Uses high frequency sound energy to


conduct examinations
Phenomena used

.
Reflection
Refraction
Difraction
Attenuation
Reflection, Refraction

Snell’s law
Reflection, Refraction

Snell's law - -
Diffraction

Have you ever wondered


why you can hear someone
who is round the corner of
a building, long before you
see them?
Attenuation
when sound travels through a medium its intensity diminishes with
distance due to:
Spreading of waves
Scattering
Absorption

Scattering: Is the reflection of the sound in the directions other than


its original direction of propagation

Absorption : is the conversion of the sound energy to other form of


energy

The combined effect of scattering


and absorption is called attenuation
ATTENUATION:

A = A0 exp [i (kx - t)]exp (-x)


k = 2/  = 2f/v = / v
AMPLITUDE

(+) EXPONENTIAL DECAY of  = f (Absorption, Scattering)

(-) TIME AXIS

BACKSCATTERED SIGNAL
Types of waves

The following types of waves are useful for Ultrasonic


testing:

a) Longitudinal or compressional wave


b) Transverse or shear wave
c) Surface or Rayleigh waves
d) Lamb or plate waves
Longitudinal Waves
Also called, Compression Waves, Primary Waves

Excitation

Direction of Travel Direction of Particle Motion

Can propagate in Solids,


liquids and gases

E(1- ν)
vL 
Wave Velocity: ρ1 ν 1  2ν 
Transverse Waves
Also called, Shear Waves, Secondary Waves

Excitation

Direction of Travel Direction of Particle Motion


Does not propagate in
liquids and gases

E
v 
Wave Velocity: T 2ρ1  ν 
Acoustic impedance
The acoustic impedance (Z) of a material is defined

as the product of its density () and acoustic velocity (V).

Z = V

Important:
 Transmission and Reflection
 Sound absorption
 Design of ultrasonic transducers
Reflection and Transmission

Transmitted wave

T = (1-R) = 4Z1Z2/(Z2+Z1)2
Ultrasound Testing Methods

•Pulse Echo
•Through Transmission
Pulse-Echo using Contact Probe
Plate Testing

IP: Initial Pulse


BE: Back Wall
F: Flaw
Through Transmission
Plate Testing
Angle-Beam

Surface Distance

Depth
T

= Angle of Refracti.on
T = Mate ri,a I Thickness
Surface Dista nee = Sin8Rx Sound Path
Depth (,. st Leg) = cOS eR X Sound P'a th
Angle-Beam

-----SKIP D I STANC

V PATH
i
fJR = Refracted A ngle Leg =
Cos eR
T = Ma re n1a I Thic k n ss

Sk ip Dlsta nc e = 2T x Ta nOR V -Pa th = lT


Cos 8R
ABC’s of Ultrasonics
A-SCAN
100%
+ Phase

Amplitude %FSH 0%

_ Phase
-100%
Time / Depth

A-Scans provide the following


information:
1. Amplitude / % of full screen height (FSH)
2. Phase / positive or negative peak
3. Time / Depth
B-Scan
Front surface

Signal from
indication

Back surface

The yellow line (B-scan gate) represents the


depth of information recorded.

Back surface
Front surface Signal from
indication
C-SCAN
IP
Front surface Back surface

Area of interest

The red box (data gate) indicates the depth of


information.
Ultrasonic Time of flight Diffraction (TOFD)

Used for sizing a flaw


Ultrasonic Time of flight Diffraction (TOFD)

Used for sizing a flaw


Near Surface Crack

1 2
Concave Root

1
2
2 3
3

Distortion of back-wall echo


Lack of Fusion - Inter pass
Internal Rotary Inspection System
(IRIS)
IRIS
A computerized ultrasonic inspection system best suited for
integrity assessment of air fin cooler tubes, which are
inaccessible from external sides because of fins.

It consists of ;

• a high frequency, high-resolution transducer and


• a 45 deg mirror mounted on a small water driven turbine.

– The mirror rotates at high speed and reflects the ultrasonic beam
around the tube circumference to perform a 360 deg scan of the wall
thickness.

IRIS principle IRIS test head with centering


spider
IRIS

• An advanced technique for metal thickness measurement


of tubes in air fin coolers, heat exchangers, boilers etc.

• Developed in late 50’s by Shell Oil for inspection of their


Fin-Fan cooler tubes.

• Now this technique used world-wide for inspection and


integrity assessment of Air fin coolers.
Phased Array Ultrasonic
Phased Array Probes
Active surface

Basically,a phased-array is a long conventional probe

cut into many elements

Minimum element size o.lS-0.20 mm


Left: monocrystal single-angle inspection requires multiangle
scans and probe movement; right: linear array probe can
sweep the focused beam through the appropriate region of
the component without probe movement
Magnetic Particle Testing
Phenomenon Used

Magnetic Flux Leakage


Magnetic Particle Testing

Surface defects
MPT

N S
MPT

The presence of this leakage field, or the presence of the discontinuity:

•detected by the use of finely divided ferromagnetic particles


applied over the surface

•with some of the particles being gathered and held by the


leakage field.

Types of particles:
•dry particles, or
• wet particles in a liquid carrier such as water or oil.
MPT

Magnet jc MoQnetizing
f ield co; I

(b)

Magnetized bars showing directions of magnetic field (a) circular


(b) longitudinal
MPT

Effect of direction of magnetic field or flux flow on the detectability


of discontinuities with various orientations. (a) Circular
magnetization. (b) Longitudinal magnetization
currer:.z.
Magnetiz i g

O·oub1e prod C·ontact ·s

Single and double prod contacts. Discontinuities are detected by


the magnetic field generated between the prods
Eddy Current Testing
Eddy Current

Eddy currents are induced electrical currents that flow in a


circular path. They get their name from “eddies” that are
formed when a liquid or gas flows in a circular path around
obstacles when conditions are right.
Phenomenon Used

Electromagnetic Induction
Faraday's Experiment
1 A loop of wire is
connected to a
galvanometer
3
The bar magnet stops
moving. There is no
deflection on the meter
needle.

A bar magnet is inserted The bar magnet is pulled


2 into the Loop. The meter
needle deflects to right
4 out. The meter needle
flickers to show negative
momentarily. value.

91
Faraday’s Law and Lenz’s Minus Sign
The electromotive force (EMF) induced in a coil of wire is
proportional to the time rate of change of magnetic field coupling
into that coil.

Lenz’s Crucial Extension:

A change in magnetic flux through a circuit induces an electric field


in the circuit, which causes a current to flow in the circuit, which in
turn gives rise to a magnetic flux that opposes the original flux.

92
Eddy Current Technique
When a metallic material is placed close to an alternating magnetic field, current is
induced within the materials which opposes the applied magnetic field. The current
induced within the materials due to the presence of external magnetic field is known as
eddy current

GENERATION OF EDDY CURRENT

Primary and secondary magnetic field opposing


in nature
=> a.c. coil impedance changes
=> any defect in the specimen reduces this
change
R0

i
0

V0=VR+VL
=iR0+L0 (di/dt)
=iR0+ jL0 ωi
i=i0ejωt where ω=2πf, j=√-i

di/dt =d/dt(i0ejωt )
Imag (Lo)
=jωi0ejωt Z
= jωi
Z0=V0/i 
=R0+j (ω L0) Real
imaginary Z2=R02+ω2 L02 (Ro)
real =tan-1(L0/R0)
R

XL ~

Resistance Reactance

Impedance Z2 = R2 + XL2

= R2 + 2L2
Inductance
 Phaser  = 2  f (frequency)
 Diagra
m
Reactance (L)

Resistance (R)
Resistance Reactance

Impedance Z2 = R2 + XL2

= R2 + 2L2
Inductance
 = 2  f (frequency)

Initial coil is chosen in such a way that Ro~ 0, Zo = Lo


Normalised Phaser diagram
Z=R+jω L
Normalised Reactance (L/L0)

Z/Z0=R/ ω L0+ jω L/L0


Ti Phaser
Diagra
Fe
m
Al

Cu

Normalised Resistance (R/L0)


Factors Affecting Eddy Currents

• Strength of exciting electromagnetic field


• Frequency of excitation
• Electrical conductivity of the material
• Magnetic permeability of the material
• Coupling between the exciter and the part under test
Depth of Penetration
Higher emf -> larger amplitude of currents
-> high opposing flux -> weaker flux at
lower levels -> lower δ.

Lower conductivity -> lower currents ->


lower opposing flux -> more flux deeper
in the metal -> higher δ.

The Standard Depth of penetration δ is defined as the depth at which


eddy current density is reduced to 1/e times (approximately 37%) the
density at the surface.

 = depth of penetration
= 1/ (fµ )1/2
δ At Different
At 10 KHz
Frequencies
At 240 KHz

Frequency needs to be selected with due consideration to δ.


Surface properties need a higher frequency.
Sub-surface defects require a lower frequency.
For conductivity measurements thickness must be more than
3δ.
Metal Sorting

100
Effect of Lift off

Application 1.6mm hole


:
5% ID Groove 10% OD Groove 0.25mm dent
2.5mm wide 2.5mm wide Carbon steel
support

Y-Channel

Distanc
e
Current trends:
Multiufrequency, approach, Modeling for defect size
determination, materials Characterisation
Coating Thickness Measurement

Coating is a measure of lift-off


Higher frequencies are used:

Crowded conductivity

Better angular separation

Higher sensitivity to liftoff

Can measure on thinner sheets


Can be calibrated against shims

102
Detecting Cracks with Eddy Currents

A crack interrupts eddy currents

An emf is still induced

It results in currents deeper below

Reducing opposing flux

That leads to higher inductance


Choice of Test Frequency

Ferrous Crack Detection &


Sorting Non-Ferrous Sorting Cladding
-

I I I I I
1Hz 10Hz 1OOHz 1kHz 1OkHz 1OOkHz 1MHz 1OMHz
Thank you
IRIS(InternalRotaryInspectionSystem)

• It is an ultrasonic system for inspection of heat


exchangers and boilers.

• It employs the conventional pulse-echo technique for


measuring the wall thickness, but uses novel methods
for displaying the measurements.

• All measurements, made during a complete scan around


the circumference of the tube, are displayed on the
computer screen, producing real time rectangular or
circular pictures.
IRIS
EMAT(Electromag. Acoustic Transducer)
• This method generates ultrasonic wave directly in the
material (hence there is no need of couplant or close contact)
• Magnetite bounded to surface acts as an active element
EMAT (Electomagnetic Acoustic Transducer)
Advantages
• Notnecessarytoremoveoxidescale for measurements,
• Nocouplant required
• Scale thickness is notadded into the wall thickness
measurement,
Limitations
• Magnetostrictive EMAT worksonlywhenext.boundedscale is
present
• Minimum measurable wall thickness and measurement accuracy
inferior to conventional UT and EMATs are relatively insensitive
to small internal pits.
• Hence, EMATs are often used for quickinitialwallthickness
surveys, while conventional UT gauge used for detailed
Remote Field Eddy Current Testing
• RFT uses a low frequency signal which allows penetration of the
tube walls
giving approx. same sensitivity to ID & OD flaws.

• Where the tube grows thin, there is effectively less shielding.


Hence the
field arrives with less time delay (greater phase) and less
attenuation (greater
amplitude). Phase and amplitude traces are generated as the
probe is pulled
through the tube and are used to detect and size metal loss
MFL/LFET

MFL Technique is an electromag.


technique that is adapted to the
inspection of small-bore
ferromagnetic heat exchanger tubes .
Pickup- coil type (diff.) & Hall
element (abs.)

LFET:
(a) Electromag. driver creates
magnetic flux lines (nominal
condition with no discontinuities)
(b) flux lines that deviate from the
nominal condition (discontinuity)
Phase and amplitude of the induced
Internaloxidescalethicknessmeasurement(S/H&R/Htubes

• Internal oxide (magnetite) forms on the S/H &


R/H tubes at high temp.
3 Fe + 4 H20 = Fe3O4 + 4 H2

• Speed of this reaction increases with temp.


Magnetite scale acts as thermal insulation on
the pipe (thermal conductivity of scale is ~ 5%
that of steel), making heat transfer inefficient
and increasing the metal temp

• Long term exposure to overly high temp.


combined with the very high pressure inside
the tube, leads to intergranular micro-cracking
in the metal and to creep deformation.
DigitalRadiography

Progress of Digital Industrial Radiology, Uwert, INDE Apr., 2007


DigitalRadiography
Digital radiography gives the final image in the digital form.

• Digitizationofradiographed film
This is analogous to image scanner.

• Computedradiography

• In this form of digital radiography, flexible & reusable storage phosphor plate is used
for imaging in place of the radiographic film. Subsequent processing is necessary to
get the digital image as described below.
• When exposed to radioactive rays, electrons inside the phosphor crystals get excited
and are trapped in a semi-stable higher energy state. This impression of radiographic
rays (latent image) on phosphor screen is invisible.
• The phosphor screen is taken/moved to the laser beam unit. Very small scanning laser
strikes the screen and releases the trapped electron, causing visible light to be emitted
in proportion to the radioactive exposure.
• Light detector measures the brightness of light on the phosphor screen and the
analogous data measured for each pixel of the screen is digitized and stored in
computer as a digital image
ECT for assessing life/thick of coating
(ctd.)
 The Frequency scanning
eddy current system F-
SECT has been developed
for nondestructive
condition assessment of
new and serviced high-
temperature coatings
applied on the hot gas-path
components of modern gas
turbines.

Das könnte Ihnen auch gefallen