`

STANDARD PROCEDURE FOR TUBE INSPECTION BY

REMOTE FIELD TESTING

Client : M/s.
Contractor : M/s..

THIS OPERATING PROCEDURE IS CONTROLLED BY THE TECHNICAL INSPECTION AND CORROSION

CONTROL COMPANY AND MAY NOT BE AMENDED, REVISED OR ALTERED IN ANY OTHER WAY
WITHOUT THE CONSENT OF THAT COMPANY.

THE SIGNATURES BELOW AUTHORISE ALL PAGES OF THIS PROCEDURE FOR USE FROM THE DATE
OF APPROVAL SHOWN

PREPARED BY REVIEWED BY APPROVED BY

NAME MD ABDUL WAHEED

POSITION ASNT NDT Level II
SIGNATURE
DATE 19-06-2018

Address:
 REVISION CONTROL SHEET

Revision Revision
Sr. No. Clause No Amendments Details Reason for Amendments
Number Date

1 All Sections Issued For Approval 00 12-04-2018

2 5.2-5.3 RFT Probe & Data Storage As Advised by Level-III 01 19-06-2018

3 7.0-7.1 Calibration Standards As Advised by Level-III 01 19-06-2018

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 INDEX
Sr. No. DESCRIPTIONS PAGE No.
INDEX 3
1.0 SCOPE 4
1.1 Codes 4
2.0 REFERENCE 4
3.0 PERSONNEL QUALIFICATION 5
4.0 PRINCIPLE OF RFT 5
5.0 COMPONENTS OF THE RFT SYSTEM 6
5.1 Equipment and Accessories details 7
5.2 Probe 7
5.3 Equipment Data storage 7
6.0 SURFACE PREPARATION 7
7.0 CALIBRATION STANDARD 8
7.1 Calibration Check 9
8.0 BASIC INFORMATION REQUIREMENTS 9
9.0 EXAMINATION TECHNIQUE 10
10.0 DATA RECORDING 10
11.0 RESTRICTIONS OF TEST 11
12.0 DATA ANALYSIS 11
13.0 ACCEPTANCE CRITERIA 11
14.0 LIMITATIONS OF RFT 12
15.0 REPORTING 12
REPORT FORMAT 13-15

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1.0 SCOPE
This practice describes requirements for Remote Field Testing (RFT) of
installed ferromagnetic heat exchanger tubing using an ID bobbin probe in the
differential and the absolute mode. The objective of the Remote field
inspection, in regard to this procedure, is to detect inside or outside wall
thickness reduction(s) of heat exchanger tubes (for example pitting, surface
corrosion, erosion damages) and to size its percentage depth in respect to the
nominal wall thickness.
Scope for the Tube inspection will be as provided by the Heat exchanger
owner or the client.

1.1 CODES
This document is complied with all the Code & standards which are
necessary for the Non-Destructive Examination.
International Codes
This practice meets the requirements for eddy current examination of Section V
of the ASME Boiler and Pressure Vessel Code
National or Local Codes or Standards
When more stringent, jurisdictional requirements for NDT shall be followed
codes & standards and will supersede

2.0 REFERENCES

ASME Section V
2.1 Non Destructive Examination
2017 Edition
ASME Section V
2.2 Remote field Testing
Article 17- 2017 Edition
ASME Section V
2.3 Remote field Testing Standards
Article 32- 2017 Edition
Guidelines for Personnel Qualification &
2.4 ASNT SNT-TC –1A
Certification
2.5 User’s Manual Eddyfi Ectane-2

2.6 /HSE/NDT-001 Rev. 00

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3.0 PERSONNEL QUALIFICATION
The personnel who operate the RFT test equipment with the exception
of the probe positioned / puller shall be a minimum Level-II in Eddy current
testing (ET) Method. Certification of the personnel shall be according to ASNT
SNT TC 1A.
The evaluation of the result of the RFT must be conducted by personnel
qualified to at least Level II in ET.
4.0 PRINCIPLE OF REMOTE FIELD TESTING SYSTEM
Conventional eddy current testing cannot be applied to ferromagnetic
tubes because of the effect that the high levels of magnetic permeability have
on the depth of penetration of the eddy current field and on background noise
levels. Remote Field Testing is one of the electromagnetic methods that have
been developed to overcome these difficulties.
An electromagnetic field travelling down the tube some distance from
the source is the basis of the Remote Field technique. An alternating current
flowing in a bobbin coil located inside a tube is the source of a low frequency
magnetic field. The field that propagates inside the tube, called the direct
field, attenuates rapidly as it travels down the tube due to induced eddy
currents in the inner tube wall. The direct field is barely detectable at a
distance of approximately 2 to 3 diameters. A small fraction of the field
penetrates through the tube wall and propagates down the tube along the
outside boundary without significant attenuation. This field, called the
remote field, penetrates through the tube wall again to return to the source.
This return remote field occurs at distances up to 5 tube diameters. When
placing a detector coil at a distance between 2 to 4 tube diameters, field
disturbances will be sensed due to the remote field component. The detector
coil can be absolute, differential or a more complex array of coils.

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 As with conventional eddy currents, the remote field has undergone
attenuation and phase shifting in response to the eddy currents that oppose
the penetration through the tube wall. The phase shift and the attenuation
measurements are the basis on which the remote field can be used to quantify
wall loss. When the tube wall is nominal wall thickness, the remote field
undergoes a strong attenuation and phase shift while diffusing through the
tube wall twice. With wall thinning, less tube material is present to induce
eddy currents that oppose the remote field. Weaker eddy current fields allow
a stronger remote field to reach the detector. Therefore, the remote field is
extremely reliable for detecting and assessing deep wall losses because of the
exponential increase in the signal amplitude reaching the detector.
RFT is most sensitive to general wall loss. Pitting type defects are detectable
and can be quantified to some extent.

5.0 COMPONENTS OF THE RFT SYSTEM:

A Computerized Multi Scan ET universal instrument ECTANE-II ([Link]:
175 of M/s. Eddyfi NDT Inc, made will used to carry out the inspection as per
the scope. This equipment has the facility for incorporating all the available tube
inspection options. All results were recorded to disk with manual analysis
conducted on screen.
IBM compatible computer for displaying, documentation, processing and storage
of the ET results will be used.
Dedicated software to enable displaying, documentation, processing, evaluation
and storage of all eddy current signals will be used.
The software should also have multiple parameter mixing capabilities for mixing
out tube support signals.

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5.1 Equipment and Accessories details
a) ECTANE’2 with software loaded laptop.
b) Probe with minimum length of 15m.
c) Magnifi Software
d) Magnifi key
e) Tube Pro Key.

5.2 Probe:
RFT probes shall be bobbin coils capable of operating in the differential mode,
the absolute mode or in both modes simultaneously.
The probe diameter shall be selected according to the fill factor. Min. allowable
fill factor for RFT is: 75% of the Tube id.
If this demand can’t before filled extra permission is needed from the
responsible NDT or inspection engineer to continue.
The probe shall be attached to a shielded cable of sufficient length to examine
100% of the tubes being tested.

5.3 Equipment Data Storage:

All ET data with the appropriate tube coordinates digitally stored on hard disc,
CD, DVD or other suitable digital means.
All EC data of the active inspection channels shall be digitally stored with
the appropriate tube coordinates to accomplish possible re-evaluation. The
automatic evaluation software if applicable shall evaluate all signals exceeding
the signal from a >20% flat bottom hole.

6.0 SURFACE PREPARATION

All tubes inner surface shall be adequately cleaned to remove any dust, loose
foreign particles, internal deposits or contaminants by suitable processes such
as pressurized water jet cleaning followed by Air blowing. It is also
recommended to clean the outer surface of tube if possible.

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7.0 CALIBRATION STANDARD:
The calibration standard(s) shall be manufactured from a length of tube of the
same nominal size (OD and gage or wall thickness), material specification and
heat treatment as the tubes to be tested.
As a minimum, the standard shall contain the following discontinuities to allow
calibration for the differential and absolute inspection modes. The following
standards can be used for 1” Dia Tube for calibrate of Remote field inspection.

A. 60% External groove- 60% wall loss with length/width- 1.0 inch, which
should be 6.0 inch away from the Tube End.
B. 40% External groove- 40% wall loss with length/width- 1.0 inch, which
should be 6.0 inch away from the 60% OD Groove.
C. Through Hole- 100% Drilled through Hole of Diameter Ø 0.144 inch,
which should be 5.0 inch away from the 40% OD Groove.
D. OD Flat Bottom Hole- 60% Drilled FBH of Diameter Ø 0.188 inch, which
should be 5.0 inch away from the Through Hole.
E. OD 4*FBH – 4 X 20% FBH of Diameter Ø 0.250 inch place at
0°,90°,180°,270° which should be 5.0 inch away from the OD 60% FBH
And Other side tube end.

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7.1 Calibration Check.
Calibration shall include the complete RFT examination system. Any change of
RFT instrument, probe, recording devices, connecting cables or any other part of
the RFT examination system hardware, shall require recalibration.
The calibration shall also be checked in the following situations:
1. At the beginning of each production run of a given diameter and thickness
of a given material.
2. At the ends of the production run.
3. At any time that malfunctioning is suspected.
4. After a break.
5. A control of the calibration has to be conducted after a maximum of 4
hours of inspection. The resulting phase angles and amplitudes must
match the values from the preceding calibration with a deviation of
maximal 10%. If the deviation exceeds the 10% limit, all tests performed
since the preceding calibration shall be marked unacceptable and must be
re-inspected.
6. In addition Special RFT calibration for support/Baffle plate should be set
at each tube for the proper analysis of the signal interpretation.
If any calibration check determines that the RFT system is out of calibration, the
RFT system shall be recalibrated and all tubes examined since the last calibration
check shall be re-examined.

8.0 BASIC INFORMATION REQUIREMENTS

The following minimum information is required prior to conducting an
inspection:
 Tube dimensions: (Outside diameter, wall thickness, length)
 Tube material:
 Tube characteristics: (Finned, ‘U’ bends, swaged etc.)
 Scope of inspection: (Number of tubes, inspection pattern)
 Service: (E.g., tube side – water / shell side steam)
 No of Support plates in the Tube Bundle.
 Types of wastage taking place: (If known)
 Review of previous inspection reports (If any)
 Drawing, diagrams, maps or any other relevant information.

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9.0 EXAMINATION TECHNIQUE
First inspection:
Unless otherwise specified, a minimum of 10% of the heat exchanger
tubes, randomly selected, shall be fully examined. The selected tubes shall
represent the entire bundle. Extra tubes shall be examined in areas of suspected
damage. If, during these examinations, one or more tubes are detected that will,
based on the EC inspection results, not last until the next shut down, this will
result in 100% examination of all tubes.
 In all techniques measurements are taken whilst withdrawing the probe. The
pushing and withdrawing shall be done manually.
 The technician shall ensure that an even speed is maintained
 RFT data is collected by passing a probe through each tube. The electromagnetic
field transmitted from the exciter to the detector is affected by discontinuities;
by the dimensions and electromagnetic properties of the tube; and by objects in
and around the tube that are ferromagnetic or conductive.
 System sensitivity is verified using the RFT system reference standard System
sensitivity and setting are checked and recorded prior to and at regular intervals
during the examination.
 Data and system setting are recorded in a manner that allows archiving and
latter recall of all data and system setting for each tube. Interpretation and
evaluation are carried out using one or more flow characterization standards.
The withdrawing of probe shall be by hand. The technician shall ensure that an
even speed is maintained.
10.0 DATA RECORDING
For the purposes of this procedure all test results will be recorded on suitable
data acquisition system.
Each data storage unit shall contain the following information:
 Positive identification of the item under test.
 Data storage unit number.
 A reference to the contents.
 Date
Each trace shall be identified according to zone/row/tube number as applicable.

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11.0 RESTRICTIONS OF TEST
Tubes not fully inspected will be recorded using the following titles:
 Obstruction (OBS) - Any tube that has not been inspected over its entire
length due to the probe passage being impeded by dirt, dents etc. (If a
partly tested tube is found to contain a reportable defect indication the tube
shall be recorded as having such a defect and the reason for partial
inspection reported separately.
 Plugged (PLG) - Any tube no longer in service and fitted with a plug.
 Inaccessible (INA) - Any tube that cannot temporarily be inspected i.e. due
to scaffolding etc.
 PNG (Probe Not Going) - Any tube into which the probe cannot be
introduced.

12.0 DATA ANALYSIS

All indications shall be evaluated based on the client’s acceptance criteria
Indication depth classification. The depth of indications shall be determined by
the analyst. All indications must be evaluated and defects classified into a
category of wall loss as follows.
0% - 20% WALL LOSS
21% - 30% WALL LOSS
31% - 40% WALL LOSS
41% - 50% WALL LOSS
51% - 60% WALL LOSS
61% - 100% WALL LOSS

13.0 ACCEPTANCE CRITERIA

The acceptance criteria or rejection of tubes based on wall loss is at the
discretion of the client.
Unless otherwise specified by Code or engineering standards, or by the
equipment owner, tubes shall be considered acceptable when they contain no
indications evaluated as being larger than 50% through wall. When indications
are greater than 50% through wall, engineering evaluation is recommended
when the indication is caused by erosion type defects. In case of pitting like
defects this is not necessary.
If, during the examinations, one or more tubes are detected that will, based
on the EC inspection results and lifetime, not last until the next shut down, this
will result in 100% examination of all tubes.

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14.0 LIMITATIONS OF TECHNIQUE
Limitations of standard RFT technique:
 Differentiation between ID and OD defects is not possible, As RFT is a
through wall transmission technique. The coils only measure the total
thickness of material.
 Bends cannot be inspected using Standard RFT probe.
 Limited sensitivity for detection of cracks.
 Very limited sensitivity to small defects under TSP’s and tubesheets.
 Evaluation of small flaws such as pits can be difficult.
 Tubes must be cleaned in order to avoid the Signal to Noise ratio, for
proper interpretation of the acquired RFTT data.

15.0 REPORTING
The following minimum information shall become part of the permanent record
of the inspection:
 Heat exchanger identification.
 Examination procedure number and revision.
 RFT instrument identification and serial number.
 Size and type of probes.
 Mode of operation (differential or absolute, or both).
 Examination frequency and auxiliary frequencies, if used.
 RFT instrument settings.
 Calibration standard identification.
 Result of the visual pre-examination of the tube plate and the inside surface
of the part of the tubes that is within the range of the tube plate.
 A sketch or drawing showing a tube plate view with the location of all tubes.
Per investigated tube the established defect depth and whether this defect is
acceptable should be indicated.
 In case of a re-examination the difference between both examinations
should be plotted in an extra tube plate view and should be part of the
documentation.
 Names and certification levels of examination personnel.
 Date of examination.

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 FINAL REPORT FORMAT
Final Report contains the following details:
1) Main Inspection Report
2) Tube sheet Layout
3) Remaining wall loss report.

RFT INSPECTION MAIN REPORT

Client : Exchanger :

Site : Tube material :

Date. Of Insp. : Tube Dimension :

Total tubes : Inspected Tubes :

Equipment : Probe Details :

SUMMARY
WALL LOSS PERCENTAGE NO OF TUBES PERCENTAGE (%)
0% - 20% WALL LOSS
21% - 30% WALL LOSS
31% - 40% WALL LOSS
41% - 50% WALL LOSS
51% - 60% WALL LOSS
61% - 100% WALL LOSS
PLUGGED
RESTRICTED

RESULT AND CONCLUSION:

Overall condition of the exchanger

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 ATTACHMENT II: REMAINING WALL LOSS REPORT

CLIENT : SITE :

ITEM : TOTAL TUBES :

ITEM NO. : TUBE MATERIAL :

[Link] : TUBE SIZE :

DATE INSP. : TUBES INSPECTED

:

COLUM WL [Link] COLUM [Link]

S. No. ROW S. No. ROW WL%
N % (mm) N (mm)

NAME: ….................................... SIGNED: .................................... DATE: ............................

CONDITION OF THE UNIT AND RECOMMENDATIONS:

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ATTACHMENT III: TUBE SHEET LAYOUT

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