ACOUSTIC
EMISSION & NDT SCIENTIFIC PUBLICATIONS
Tube Scan: Rotating Internal Scanner for Ultrasonic Tube
Inspection
4th National Conference of H.S.N.T. and 2nd
Balkan Conference of BSNDT Athens,
November 2, 2002
R.
Kazares and A. Anastasopoulos
The system has been
used in several applications for the industry and ha proved reliable
and accurate when inspecting tubes. C-Scan results offer and
immediate comparison between tubes and thus decisions for
maintenance-replacement or repair can be made quickly and be
targeted to the problematic areas with good confidence of the
outcome.
With such systems
large-scale tube inspection has been made possible and economical
for the industry, thus increasing plant efficiency and improving
maintenance-replacement or repair decisions.
Boiler and
Heat-Exchanger tubes are exposed to an adverse operating environment
due to the fluid in conjunction with pressures and temperature in
such equipment. In many cases corrosion and/or erosion play an
important role in the life of such tubes. In other cases the
operating conditions lead to flaw development in the tubes’
material. In addition, failure of one or more tubes in such
equipment may cause significant problems to operations. The need for
inspection has been recognized but the inspection itself proves
difficult and is restricted to simple methods.
Ultrasonic
Non-Destructive Inspection (NDI) has been widely used for
corrosion/erosion and flaw detection and assessment of nearly all
metallic structures. Their application to tubes has proved
difficult, though, due to the restricted access to these equipment
and due to the large surface to be inspected. Boiler and
Heat-Exchanger tubes are in a confined space and they are usually
packed together so access is restricted. Their size (diameter) and
their large number make it difficult to inspect by manual
techniques.
Advances in the
field of Automated Ultrasonic Testing (AUT) have given a tool that
can be utilized for fast large-scale tube tests. Several problems
had to be addressed in order to achieve practical application
systems.
The present work
outlines the basic operating principles of Rotating-Mirror Internal
Tube Scanner - TubeScanä
developed specifically to address the problem of boiler and
heat-exchanger tube ultrasonic inspection.
TubeScan, is a
fully automated, TurnKey Ultrasonic Inspection System, designed to
perform high-speed ultrasonic C-Scan imaging of small to medium
diameter tubes. Typical applications such as inspection of Boiler
Tubes, Heat Exchangers and Coolers are presented and advantages and
limitations of inspection are discussed.
TubeScan is based
on a PC based ultrasonic system with high resolution digital
ultrasonic pulser-receiver (PR) and analog to digital converter (AD)
board. Internal encoders are used to move the probe inside the tube
and track the motion with high accuracy.
The easiest access
to the surface of tubes is through their inside diameter. TubeScan
uses a flexible stainless steel tube to advance the UT probe inside
the tube using motors that are controlled from internal PC encoder
board. Water is used for acoustically coupling the probe and the
tube. Mirrors are used to reflect the beam at right angles to the
tubes surface so that corrosion/erosion effects can be observed in
the form of a C-Scan. The mirrors can be used to deflect the beam at
intermediate angles so that the equipment can be used for flaw
detection in the tubes’ material.