INNOVATIVE PRODUCTS & SERVICES FOR NON-DESTRUCTIVE TESTING

T
esTex, Inc. was established in 1987 with a clear mission
to develop innovative products and services for the
Non-Destructive Testing industry.
After years of continuous effort, TesTex has a vast
array of products and services to offer to both industrial site
end users as well as companies providing NDT services.
Our unique and proprietary technologies are focused mainly
in electromagnetics along with an increasing number of
ultrasonic devices.
To date, TesTex has approximately fifteen operating
locations worldwide. Through our own operations and the
operations of those who have acquired our systems, our
technologies are being applied daily, on a worldwide basis.
Future plans include the continuing effort of ongoing
applied Research and Development as well as the continuous
expansion of service operations and technology applications.
We proudly present to you this offering which details
our current slate of products and services for your review.

Regards,
The staff of TesTex USA, TesTex UK, TesTex India, TesTex France,
TesTex SA Argentina, and TesTex Canada.

Headquarters/Research and Development

Manufacturing Facility.
Pittsburgh, PA

TesTex is looking for outstanding

Manufacture‘s Rep Firms around the World.
Please inquire.
 Low Frequency Electromagnetic Technique Applications:
(LFET) was developed to inspect flat bottom stor- n Boiler Waterwalls n Fire Protection Piping
age tank floors. Over time, scanners have been n Reheaters/Superheaters n Coal Mill Piping
contoured to inspect convex or concave ferrous and n Storage Tanks n General Piping
nonferrous metal tubing/piping surfaces. Various
scanners are available for most applications.
n Pipelines n Pressure Vessels
n Service Water Piping n Heat Exchanger Shells

Waterwall Inspections TS-2000

Inspection Benefits: Equipment Features:
n Approx.
 2000 linear feet (610m) per shift n Inspects
 up to 0.500" (12.7mm) thick
n Uniform
 rust, scale, and coatings are not ferrous material
a problem n No
 couplant needed
n Hot-side
 surface scan n High
 resolution color graphics with 3D
n Easily
 detects corrosion cells, hydrogen display
damage, caustic gouging, pitting, and n Variety
 of contoured scanners to fit any
general wall loss tube diameter
n Inspects
 both ferrous and nonferrous n Up
 to 32 sensors to achieve maximum
tubing coverage in a single scan

Tank Floor Inspections Falcon Mark II

Inspection Benefits: Equipment Features:
n Detects
 both topside and bottomside n Falcon
 features 32 channels of data and
defects a 13" (330mm) wide scan area
n Inspects
 through any type of coating n Flaw
 Threshold LEDs
n Minimal
 floor preparation required n Over
 speed alarm
n Inspects
 heat affected zones n High
 resolution color graphics with
n General
 wall loss and pitting easily 3D display
detected n Real
 time display with advanced signal
n Inspects
 both ferrous metals and processing
aluminum n Battery power option
n Encoder
 option
n Mapping
 software option

O.D. Pipeline Inspection LineCat Plus

Inspection Benefits: Equipment Features:
n Inspection
 speeds of up to 10-15 ft/min n System
 can be adapted to fit many pipe
(3.05-4.57m/min) sizes with interchangeable parts and
n 360°
 coverage on pipe diameters ranging components
from 3"-6" (76.2mm-152.4mm) n Features
 up to 288 channels of data
n Two
 (2) linear scans required on pipes from n On-board
 computer with wireless option
8" (203.2mm) up to 42" (1066.8mm) to n Threshold LEDs to pinpoint corrosion
achieve 360° coverage n Aluminum
 construction for weight reduction
n Ability
 to scan through uniform scale, rust, n Encoder
 options, X and Y directions
or coatings (Including Polyken Tape) n Battery
 option
n Inspects
 both ferrous and nonferrous piping n Mechanically
 driven option
n Inspections
 can take place on-line

General Piping Inspections PS-2000

Inspection Benefits: Equipment Features:
n Inspects
 both straight sections and bends n Light
 weight scanner attachments
n Inspects
 through both I.D. and O.D. scale n Large
 frequency range 5Hz to 30KHz
n Detects
 MIC attack, FAC, erosion, corrosion, n Real-Time
 Display
pitting and cracking n Operates
 manually or with motorized
n Testing
 is performed on-line with the crawler
product inside having no impact n Scanner
 cable lengths up to 100' (30.5m)
n Discriminates
 I.D and O.D. defects

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Remote Field Electromagnetic Technique (RFET) is designed Applications:
to quickly and accurately inspect ferrous tubing from the I.D. TesTex n Boiler Gen. Banks
has pioneered the advancement of this technique for both the inspec- n Feedwater Heaters
tion of small diameter tubing and large diameter piping. This method n Service Water Piping
is effective in detecting a variety of internal and external defects such n General Piping
as general corrosion, erosion, pitting, etc. n Heat Exchangers

Feedwater Heater Inspections Eagle-2000 Plus

Inspection Benefits: Equipment Features:
n U
 -bend Inspections possible n Up to 8 channels/32 sensors
n Tests 300-500 tubes/shift (RFET) n Lightweight and compact
n Tolerates low fill factors n Windows/PC based
n I.D./O.D. flaw detection n Modular
n Requires no couplant n U
 p to 100' (30.5m) probes without

n Requires little tube cleaning amplification

n H
 igh resolution color graphics with 3D display

Heat Exchangers/Boiler Inspections

Inspection Benefits:
n Inspects through scale
n Tests 300-500 tubes/shift (RFET)
n Tolerates low fill factors
n I.D./O.D. flaw detection
n P
 robes down to 0.250" (6.35mm)
in diameter
n Inspects bends
n Inspects from either drum in boilers

Small Diameter Pipeline Inspection

Inspection Benefits:
n I.D. based inspection
n Tethered
n Inspects up to 12" (305mm) diameter pipes
n Up to 32 channels

Intermediate Diameter Pipeline Inspection

Inspection Benefits: Equipment Features:
n I.D. based inspection n Internal RAID for data storage
n Tethered n Water/shock resistant
n Inspects
 12"-30" (305-762mm) n 10' (3.05m) per minute inspection rate
diameter pipelines n PC based storage/analysis
n Up to 160 channels of data n Distance encoder
n L inear and angular position embedded n U
 nmanned self-contained probe
in scan data (no umbilical)
n Negotiates most bends n Tethered for horizontal or vertical runs

Larger Diameter Pipeline Inspection

Inspection Benefits: Equipment Features:
n I.D. based inspection n T
 hree pass inspection; 130° coverage arc
n 72 channels of data with overlap
n Linear
 and angular position embedded n E nvironmentally sealed
in scan data n 1 0' (3.05m) per minute inspection rate
n Up to 500' (152m) runs n A ll components fit through a 24” (610mm)
n Inspects up to 42" (1.07m) diameter pipes manway
n Negotiates limited bends n D istance encoder
n M anned vehicle
4
 Eddy Current Technique (ECT) was developed to test nonferrous Applications:
metals. TesTex expanded upon this technique with the help of auto- n Condensers
mated software and high speed probe driving and pulling mechanisms. n Feedwater Heaters
TesTex has also added the ability to inspect ferrous metals with the
Coolers
introduction of the Mag-Wave technique
n

n Evaporators
n Chillers

ECT Tubular Inspection TX-4400

Inspection Benefits: Equipment Features:
n F
 our frequencies for better flaw sizing and n E
 ight standard channels with a multiple
detection of mixing channels
n A
 utomated and Manual analysis done n 1 KHz to 1.2MHz frequency range
on-site n R eal-time mixing
n U
 nwanted signals such as support plates n C ompatible with any standard ECT probe
can be suppressed or magnetic saturation probes
n C
 ompatible with TS-MAP and AR-Wizard so n W ide variety of special data filters
final report is delivered on-site n F ully digital

High Speed Inspection PD-6K

Inspection Benefits: Equipment Features:
n I nspection speeds of up to 3-7 ft/sec n L
 ight weight, only 13.2 lbs (6kg)
(1.52m/sec) n H
 igh speed probe insertion
n P robe insertion speeds of up to 22 ft/sec n Connects
 directly to TX-4400 and
(6.71m/sec) utilizes the same software
n I nspects up to 8 tubes per minute n A
 dapts to different air fittings
n 2 k-3k tubes inspected per team per n N
 eeds only plant air
12 hour shift n C
 an be used with RFET probes and
n C an be used on ferrous and nonferrous the Eagle-2000 plus electronics

Ultra High Speed Inspection PDP-22

Inspection Benefits: Equipment Features:
n I nspection speeds up to 10 ft/sec n P
 robe inspection speeds are held constant
(3.05m/sec) n C
 onnects directly to TX-4400 and utilizes
n P robe insertion speeds of up to 22 ft/sec the same software
(6.71m/sec) n F its in 16" (406mm) manway
n C an inspect up to 12 tubes per minute n D urable and reliable
n T housands of tubes inspected per team per n O ver designed for long life
12 hour shift n M odular components for easy
maintenance/repair

Ferrous ECT Inspection Mag-Wave ET (MWET)

Inspection Benefits: Equipment Features:
n Small
 pitting can be detected and quantified n 1
 KHz to 500KHz frequency range
n Large
 volume flaws can be detected and n C
 omputer automated analysis available
quantified n W
 ide variety of MWET probe sizes
n Saturation
 can n P
 robes can be inserted automatically with
be adjusted the above Probe Driver (PD-6k)
to eliminate n U
 ses TX-4400 Eddy Current unit plus
signal noise an external amplifier/power supply
due to finned
tubes
n Differentiates

between I.D.
and O.D. flaws
5
Ultrasonic inspections have been enhanced at TesTex for Applications:
many different applications. In addition to manual ultrasonic n T
 ank Shells n C
 olumns
thickness determinations, a line of crawlers were created to n U
 T Prove Up n P
 ipes
accommodate various inspection challenges. TesTex also developed n F
 inned Tubes n S
 tacks/Chimneys
it's own I.R.I.S. (Internal Rotary Inspection System) technology n W
 aterwalls n P
 ressure Vessels
to address tubular inspection needs.

UT Tank Shell Inspection Viper

Inspection Benefits: Equipment Features:
n N
 o scaffolding required n C
 ontrolled with a handheld joystick
n I nstant thickness readings n S
 trong magnetic wheels
n A ble to inspect 100' (30.5m) from n A
 dheres through several layers of paint
one location n A
 vailable in several designs for the
n A ble to scan horizontal or vertical inspection of tanks, stacks, pipes, etc.
n O
 ptional encoder available

UT/LFET Tank Shell Inspection LFET Viper

Inspection Benefits: Equipment Features:
n 4
" (102mm) wide inspection swath n C
 arries a 4" (102mm) wide LFET scanner
n N
 o scaffolding required n C
 ontrolled with a handheld joystick
n A
 ble to scan horizontal or vertical n S
 trong magnetic wheels

n A
 ble to inspect 100' (30.5m) from
n A
 dheres through several layers of paint

one location n O
 ptional UT prove up
n C
 ontours for curved surface inspection
n High
 resolution color graphics with
3D display
n Real
 time display with advanced signal
processing

I.R.I.S. Tubular Inspection Helix-XT

Inspection Benefits: Equipment Features:
n I nspects tube lengths up to n U
 ser friendly setup panel and UT board
100' (30.5m) control interface
n I nspects tube sizes from n F ull color acquisition and data viewer
.340" (8.6mm) to 3.5" software with A, B, and C scans
(88.9mm) (larger sizes n 4 different turbines and 5 different
possible on a custom basis) centering devices
n A ctual wall thickness n C ompact and rugged design
readings recorded n H igh speed 100MHz A/D
n 1 00% of tube is covered n U p to 20k PRF (Pulse Repetition Frequency)
through a helical path

API inspections are offered by TesTex. Our team of fully certified inspectors service
the pipeline, petroleum, chemical, nuclear, and power generation industries.

n A
 PI 653 certified tank inspectors, including
settlement surveys
n A
 PI 570 certified piping inspectors
n A
 PI 510 certified vessel inspectors

6
 Balance Field Electromagnetic Technique (BFET) Applications:
was developed by TesTex as an alternative to traditional surface n Pressure vessels n S
 torage tank
eddy current. It is used to detect surface and subsurface cracking n Tube to header welds floor/shell welds
in metals. With scanning speeds from a few inches/second to n Dissimilar metal welds n Bridges
1 ft/sec, the Hawkeye 2000 is much faster than conventional NDT n Windmill towers n Columns
techniques such as Liquid Penetrant and Magnetic Particle testing.
General vessels DA tanks
This technique can virtually be used anywhere cracking is an issue.
n n

Weld Inspection Hawkeye-2000

Inspection Benefits: Equipment Features:
n D
 etects surface and subsurface cracking n R
 eal time data processing
with or without coatings n D
 ata displayed in horizontal, vertical, and
n T est speeds from a few inches/second to impedance planes
1 ft/sec (0.30m/sec) n N oise and liftoff signals can be rotated
n M inimal surface preparation away from flaw signals
n D etects cracks within 0.375" (9.5mm) of n U p to 8 channels
the surface n F requency range 5Hz-30KHz
n I nspects ferrous and nonferrous metals

Surface Inspection Single/Multi Channel Hawkeye Scanner

Inspection Benefits: Equipment Features:
n D
 etects surface and subsurface cracking n U
 p to 8 channels
with or without coatings n D
 etects surface and subsurface cracking to
n T est speeds from a few inches/second to 0.125" (3.2mm)
1ft/sec (0.30m/sec) n L ightweight ergonomic design
n M inimal surface preparation n S cans circumferentially around object
n I nspects ferrous and nonferrous metals

Vessel Inspection Deep Penetrating Pencil Hawkeye Probe

Inspection Benefits: Equipment Features:
n No
 couplant needed n D
 etects defects up to 0.375" (9.5mm) from
n Minimal
 surface preparation the surface in carbon steel
n Detects
 cracks, undercuts, porosity, n S cans 0.500" (12.7mm) wide path
slag, etc. n C ompact design
n Test
 speeds from a few inches/second to n E asy to use
1ft/sec (0.30m/sec)

General NDE inspections are offered by TesTex. In addition to the TesTex developed
brand of NDE methods, TesTex also provides the following general NDE inspections.

n L
 iquid penetrant inspections
n M
 agnetic particle inspections
n V
 acuum box inspections
n B
 oroscope inspections

7
Specialized software has been developed by Compatibilities:
TesTex for a variety of inspection applications. n T
 S-MAP: TesTex RFET and ECT software
These applications include, but are not limited n A
 R-Wizard: TesTex Tube Sheet Mapping software
to, tube sheets, report writing, tank floors, and n T
 F-Map: TesTex WinTank software

automated analysis. n T
 X-Solution: TesTex ECT software
n 3
 D Mapping; TesTex RFET, ECT, IRIS software

Tube Sheet Mapping TS-MAP

Software Features:
n E
 xtensive help menu
n A
 ny tube layout can be made
n T ube dimensions can be in either
inches or millimeters
n M aps can be inverted so units can
be viewed from both ends
n F ive standard legends to choose from
n E xtremely user friendly

Automated Reporting AR-Wizard

Software Features:
n A
 ll data can be imported from the analysis
program with a simple click of the mouse
n O n screen, step by step instructions for
generating a preliminary or final report
n E ither report can be generated within

minutes of completing the inspection

Tank Floor Mapping TF-MAP

Software Features:
n P
 lates can be numbered
n E
 ach plate can be sized individually
n R esize by row
n A nnular rings can be created
n U nlimited plate entry
n Ability to add patch plates
n I mport sweep data
n G enerate reports that include
individual plates

Automated Analysis TX-Solution

Software Features:
n C
 ontrols are all set from just one panel
n A
 full length tube can be analyzed in less
than one second
n A
 1,000 tube unit can be analyzed in less
than 20 minutes
n C
 an be set to compare all 4 frequencies to
rule out false positives
n S
 orts indications and moves waveforms
into 10% wall loss folders

8
 3D Mapping TS-3D

Software Features: n User

 interface to create nozzle
n User
 friendly and easy to use configurations
n Create
 3-D model of Heat Exchangers, n Display
 a 3-D representation of indications
Condensers, or Air Coolers along length of the tube
n User
 interface to create multiple baffle n Configurable
 shell, front and rear
configurations (quarter, half, etc.) components
n Baffle
 numbers displayed along with baffle n Range
 of selectable materials for each
n Bundle
 types available include straight bundle component
section, or u-bend section n 3-D
 text insertion tool
n Screen
 capture control
n Use
 of controls with one mouse click
n Turn
 display of bundle components on/off
n Turn
 transparency of bundle components
on/off
n Toggle
 selected rows/tubes to view the
inner bundle

FEATURED PRODUCTS
Falcon S Series Tank Floor Scanning
The Falcon S Series is a tank floor through non-metallic coatings of Equipment Features:
scanner based on the Saturation up to 0.500" (12mm). The system is n Adjustable
 scanning speed
Eddy Current Technique. It scans also self-propelled with adjustable n Inspection
 speed up to 10" (254 mm) per
tank floors by saturating them scanning speeds. second
with an electromagnet and then n Inspection
 of floor thicknesses up to
uses eddy current coils to detect 1.2" (30 mm)
defects in the plate as it scans
n Inspection
 through various non-metallic-
coatings up to 0.500" (12 mm)
over it. With this technique, we are n High
 sensitivity and differentiation of
able to detect pits, holes, crack- topside and bottomside defects
ing, wall loss, and differentiate the n Pitting
 can be detected and sized
orientation of the flaw depending n Localized
 Wall Loss can be detected
on if it is a topside or bottomside and sized
flaw. This scanner is the latest in n Cracks
 can be detected depending on
tank floor scanning technology. orientation
The underlying technology is what n High
 resolution 14" (355 mm) wide
makes this scanner a better tool scanner with 16 channel array
for sizing flaws. The Falcon S Se- n Real
 time encoded data acquisition
ries uses similar technology to our n Compatible
 with a handheld 5" (127 mm)
Mag Wave system, in that it brings wide scanner for inaccessible areas
eddy current accuracy to ferrous n Preliminary
 report can be issued immedi-
ately after testing is completed
plates. The highly sensitive nature
n Report
 includes color-coded tank floor
of eddy current allows the scan- maps so that location of problem areas
ner to detect and size topside and can be identified immediately
bottomside pitting, and localized
wall loss. Additionally, the Falcon
S Series can detect cracks. One
other exciting feature is the abil-
70% bottom
ity of the Falcon S Series to scan side flaws

9
FEATURED PRODUCTS

Off Surface Electromagnetic Technique (OSET) Corrosion Under insulation (CUI)

TesTex introduces one of the Equipment Features: n  ortable computer and electronics
P
most innovative systems for the n  ulti Frequency System with absolute and
M with battery power supply
detection of both Butt Welds and differential signal indications n Light
 weight hand held scnners with ad-
Corrosion Under Insulation (CUI) n Software
 analysis package designed to justable wheel brackets to fit various
using our proprietary Off Surface differentiate welds from CUI, heat traces, insulation diameters
Electromagnetic Technique (OSET). wire ties, etc n Scanning
 through stainless steel
Don't waste time & money need- n Ability
 to detect differences in pipe sched- jacketing with up to 4" (102 mm) of
lessly stripping insulation or doing ule where they are joined together (for insulation, aluminum jacketing with up
example: schedule 40 from schedule 80) to 3" (76 mm) of insulation, and
random thickness checks. With our
galvanized jacketing with up to
advanced electronics, software, n Encoded
 data
1" (25 mm) of insulation
and specially designed scanners, n Scanning
 through any type of
you can pinpoint the areas that insulation: calcium silicate, mineral
require attention. wool, fiberglass, etc
n Locating
 butt welds
n Detection
 of surface corrosion
(wall loss, pitting)
n Detection
 of larger zones of ID corrosion
Continuing Development:
n Real time mixing
n Scanning
 through thicker insulation
n Scanning
 deeper through galvanized
jacketing
n Improved
 detection of smaller areas
Waveform shows two pits 30% of I.D. corrosion
and 60% (blue circles) and a weld
(red circle)

Prodigy II One Man Multichannel NDT System

The Prodigy II is the latest system ligaments, bends, space con- Equipment Features:
to be released out of the Prodigy stricted areas, and small diameter n 8-12
 channels of data
family of NDE electronics. Several tubing. The system is fast, accurate, n Frequency
 selection from 5 to 2000 Hz
key upgrades have been added, cost effective, and field proven. n PC
 Based
including an expanded number n USB
 interface
of channels and a wider frequency n Powered
 from a computer USB port or a
range. It is the most innovative separate supply
O.D. scanning system and method n Environmentally
 sealed connections
for the testing of tubing and pip- n AC
 or DC operated
ing to date. The Prodigy is a one n Standard
 6' (1.83m) or optional 25' (7.62m)
man, multichannel NDT system scanner cable
for scanning most any boiler tube/ n Total
 weight under 12 lbs (5.45kg)
pipe from the O.D. It detects n 5 hours of battery life
and quantifies both I.D. and O.D. n Compatible
 with any TesTex LFET (Low Fre-
defects in ferrous and nonfer- quency Electromagnetic Technique) based
rous metals. The system uses a scanner or BFET (Balanced Field Electro-
dry non-contact method based magnetic Technique) Probes
on the principles of TesTex's n Upgradable
 to 40 channels of data at a
Low Frequency Electromagnetic frequency Range of 5-200 Hz
Technique (LFET). The system
can be adapted to many differ-
ent applications such as testing

10
 Solution Provider Group (SPG) We directly solicit feedback from
industrial companies and trade groups in order to determine emerg-
ing needs in the field of NDT. Once a set of needs are established, cracking, the tower sections had to be
TesTex conducts applied R&D to develop an inspection solution. inspected from the outside as well as
Once a solution is developed, TesTex can then offer it in the form of the inside of each section.
The initial teams were inspecting the
an inspection service. sections with surface eddy current using
a .250" (6.35mm) transducer. Inspection
time was one tower length every 7 to 11
Underground Service Water Intermediate Diameter days using (4) teams.
Piping Inspection Piping Inspection TesTex was contacted to investigate
alternatives that would provide accuracy
In response to a request by the Electric In response to a request by the Electric while improving productivity.
Power Research Institute (EPRI), TesTex Power Research Institute (EPRI), TesTex
(in partnership with Nova Technology (in partnership with Nova Technology
Inc.) has developed a prototype system Inc.) has developed a prototype sys-
to inspect 42" (1.07m) diameter bur- tem to inspect piping of the intermedi-
ied piping. TesTex created a custom ate diameter range of 12" to 30" (305
Remote Field Electromagnetic Technique to 762mm). Based on instrumentation
instrumentation package which, when in- previously designed for EPRI, TesTex
tegrated with a specialized pipe crawler created a custom small-footprint Remote
built by Nova Technology, provides an Field Electromagnetic Technique payload
package which, when integrated into a
specialized delivery vehicle, provides
an unmanned inspection capability for
horizontal and/or vertical intermediate
diameter piping systems.
With 64 to 160 sensors (pipe diam- TesTex applied its Balanced Field
eter dependent), the electronic pack- Electromagnetic Technique (BFET)
age has the sensitivity to detect a .500" which, enables penetration up to .125"
(12.7mm) diameter pit of 50% wall loss (3.2mm). The probes were arranged in
an array that enabled a scan width of 4"
in .500" (12.7mm) pipe wall. Regardless
(102mm) to 8" (203mm). By arranging
of pipe diameter, the sensors provide
the probes in an array, scanning speeds
complete 360° circumferential coverage
were enhanced exponentially. The
with a single scanning pass. In addi-
inspection capability not previously avail- inspection productivity increased to 1
tion, the sensors are designed for up to
able to any industry with buried large tower per day scanning both the inside
1" (25.4mm) liftoff from the inner pipe and outside with no increase in the num-
diameter piping systems. surface to allow for sediment build-up on
With 72 sensors, the instrumenta- ber of teams.
the I.D. surface.
tion has the sensitivity to detect a .500" Prior to deploying the probe down
(12.7mm) diameter pit of 50% wall loss the pipe, the electronics configuration Pipelines
in a 42" (1.07m) carbon steel pipe with and system functionality are validated
.500" (12.7mm) wall. The 72 sensors through a maintenance monitor port.
have a circumferential coverage of a Once configured, the electronics are fully
130° arc, allowing the entire pipe surface functional without the need of user inter-
to be scanned in three passes with cov- action. Sensor, positional, and system
erage overlap. In addition, the sensors status data are simultaneously collected
are designed for up to 1" (25.4mm) liftoff and easily off-loaded on completion of
from the inner pipe surface to allow for the scanning pass.
sediment build-up on the surface. TesTex developed a full suite of analy-
The inspection system (crawler and sis and mapping application software in
instrumentation) has been designed for support of this project.
quick assembly and disassembly. Each

Windmill Tower Cracking An oil company, in Prudhoe Bay, Alaska,

with a transit pipeline, experienced two
A provider of windmills purchased steel leaks within a year from internal pitting
that contained a number of surface corrosion caused by MIC Attack. The oil
cracks that needed to be investigated company inspection department needed
before the erection of 27 windmills. The a screening technique to be able to de-
tower portion of these windmills were tect a 30% deep, .250" (6.35mm) diam-
250' (76.2m) in height and are built from eter pit. The pipeline was 34" (864mm)
4 sections. The bottom diameter is 13' in diameter, .375" (9.53mm) thick carbon
of the disassembled components can be (4m) and narows at the top to a diameter steel. There were two 5 mile (8km) sec-
inserted into the buried pipe through a of 9' (2.74m). The towers have a wall tions of transit piping with one pipeline
standard 24" (610mm) manway. System thickness between .875" (22.2mm) and having a thin polyken tape wrap ap-
assembly within the pipe is performed by 1.125" (28.6mm). proximately .008" (0.203mm) thick. The
a two-man team. Assembly, inspection, These tower sections were coated inspection method needed to cover from
and disassembly can all be performed in with an epoxy paint. As such, visual the 4 o'clock to the 8 o'clock position.
a wet environment of up to 5" (127mm) inspection for cracks was not pos- Using the principles of Low Frequency
of standing water. sible. Because the problem was surface Electromagnetic Technique (LFET), TesTex

11
developed the "LineCat" that combined by the Electric Power Research Institute
16, 2" (50.8mm) wide pods into a rig for (EPRI). The scanner is able to fit in a 2"
a coverage area of 32" (813mm) in width. (50.8mm) horizontal space and a .625"
This inspection rig (15.9mm) vertical space. The LFET
was moved along scanner can size small diameter pits and
the pipe through O.D. erosion.
the use of a
remote controlled
magnetic wheel
Corrosion Fatigue Cracking
crawler. This Corrosion fatigue cracking is a leading
inspection system cause of boiler tube failures. A tube The internal probes are able to travel
scanned the pipe failure due to corrosion fatigue cracking through bends for boiler tubes with an
at 4" (102mm) per can be catastrophic and will usually bring inside diameter of 2" or greater. For
second and was a unit off line immediately. The cracking smaller diameter
able to detect a often occurs at an attachment or buck- tubes, TesTex
.250" (6.35mm) di- stay and starts on the inside diameter has developed
ameter pit with 30% wall loss. The use of of the tube and propagates through the a probe that can
the LineCat allowed up to a 1000' (305m) wall. Detecting corrosion fatigue cracks examine straight
of pipe to be inspected per shift. from the outside diameter is difficult due runs of tubing.
to the obstacles attached to the tubes. Each size tube
Radiography has had some limited suc- and wall thick-
cess in detecting the corrosion fatigue ness takes a specially design probe to
cracks under optimal conditions but ensure the BFET coils expand properly
sizing of the cracks is challenging. Bal- to fit inside the tube for optimal results.
anced Field Electromagnetic Technique For corrosion fatigue cracking along
(BFET) can detect cracking from the out- the ligament, TesTex has hand held
side diameter if there are no attachments BFET probes that can be scanned along
and there is access to the crack location. the ligament to detect corrosion fatigue
Sizing is available with supplemental cracking as long as there is access to
NDT techniques. the tube side that has the cracking.


Detection of Magnetite Due to
Exfoliation of Stainless Steel
Superheater Tubes
New super critical boilers are designed
with austenitic stainless steel super-

Inspection of Economizers, heater tubes that operate above 1005°F
(541°C). These elevated temperatures
The picture above shows a tube sample
Reheaters, and Superheaters with corrosion fatigue cracking. cause the stainless steel tubes to pro-
BFET coils send an electromagnetic duce magnetite on the inside surface of
Tubes are spaced tightly together in signal into the metal. A detector coil the tube. When taken off
Economizers, Reheaters, and Superheat- measures any disturbances in the signal line, the tubes cool causing
ers. The inspection of these tubes is a and can size cracking within a 10% the internal magnetite scale
major challenge for utilities. These tubes accuracy through the use of calibra- to exfoliate and accumulate
experience small diameter I.D. pitting tion standards. TesTex has developed in the lower tube bends.
caused by oxidation. customized rotating BFET probes for Large amounts of loose
The tubes may also the sizing of corrosion fatigue cracking scale in the bends can
experience O.D. ero- when access to the inside of the tube is block steam flow and lead
sion from fly ash, flue provided. to a tube rupture.
gas, or soot blowers. LFET is able to detect
TesTex developed and quantify the amount of magnetite in
an "Inspection Arm" a stainless steel tube through the use of
that places a scan- calibration tubes. The LFET scanner can
ner on a tube deep pinpoint the location of the magnetite, al-
in the bank to inspect the tubes for wall lowing the plant to pinpoint which tubes
loss. The inspection arm reduces the to cut and clear of magnetite. A total of
amount of time needed to spread tubes 1000 bends can be inspected per team
for accessibility and provides thick- per shift.
ness readings on tubes in hard to reach
areas. This project was partially funded
The picture above shows the white BFET
sensors in a retracted state. The sensors
are circled in red.
The BFET waveform, top, next column,
shows an indication that sizes to be
50% deep with BFET. The defect was
scanned twice by both sensors in this
waveform. The picture below the BFET
waveform was taken with a borescope.

12
 HRSG Inspections
The design of many Heat Recovery
Steam Generators (HRSGs) does not
allow for easy access without the use of drum (pictured below). This crawler is
overly complicated robotics. TesTex has equipped with cameras and allows the
developed three different tools for the operator to insert one of our advanced
inspection of components that may fail Remote Field Electromagnetic Tech-
as a result of normal use. nique (RFET) probes. This probe is also
For the Tube to Header Welds, TesTex equipped with a camera that allows us
has developed a Balanced Field Elec- to line up the crawler with the tube for in-
tromagnetic Technique (BFET) Claw sertion and enables us to visually inspect
(pictured below), which uses a c-clamp the I.D. of the tube. The RFET probe
housing to attach to the tube. The twin itself is able to detect internal and exter-
BFET probes move circumferentially nal flaws such as corrosion, erosion and
around the tube to examine the weld for pitting. This type of inspection requires
cracking, lack of fusion, porosity, and the drum head to be removed.
other flaws. Cameras are also attached
to the claw so a visual inspection of the
tube to header weld can be performed.

developed Low Frequency Electromag-

netic Technique (LFET) scanner designed
to detect flaws in the tube from the O.D.
(pictured above). The LFET scanner is
able to detect, and quantify flaws in the
tubes even through the fins. This allows
us to look for pitting and general wall
losses like flow accelerated corrosion.
For the internal inspection of the
For the inspection of the finned tubes HRSG tubes, we have a specially de-
from the outside, we use a specially signed Crawler that travels down the

TesTex manufactures a wide variety of probes, scanners and accessories TesTex manufactures a variety of
to complement our systems. These items range from High Frequency Eddy Current I.D. probes for various applications.
In support of these applications,
probes to Low Frequency pipeline scanners.
TesTex also manufactures a wide
All probes, scanners and accessories manufactured at TesTex are of the highest variety of calibration tubes.
quality. TesTex is committed to supplying NDT equipment of the highest possible
performance and it is with that commitment, TesTex is able to provide equipment with
both excellent response signals and very low noise levels.

Eddy Current Probes MWET Probes RFET Single and RFET Submersible
Multichannel Probes Flex Probes

13
RFET Multichannel RFET Multichannel TesTex manufactures a variety of
8 Inch Hand Scanner
Flexible Probes Flexible Pipeline Probes scanners to support various ap-
plications such as waterwalls, tank
floors, and superheater bends.
In support of these applications,
TesTex also manufactures a variety
of calibration plates/tubes.

Tank Floor Scanners

Steam Generator Probes S Series

4 Inch Hand Scanner

Generator Bank Boiler I.D. LFET

Probes Probes
Falcon Mark II
O.D. Pipe scanners
Pipeline Scanners

Falcon JR.

Eddy Current Calibration Tubes

Large Diameter
Pipeline Scanners

Vessel Scanners
Remote Field Calibration Tubes 13 Inch Hand Scanner

14
Pipe Scanners Adjustable UT/LFET Viper Multichannel Hawkeye
Bend Scanners Tube Scanner

O.D. Tube Scanners

Tube Scanners Intrados Bend Scanners Crack Detection
Scanners
Hawkeye T-Weld Scanner
Hawkeye Lap
Weld Scanner

Small Diameter Extrados Bend

Tube Scanners Scanners

Near Drum Boiler

Hawkeye Probes
Multi-Hawkeye
Lap Weld Scanner

Limited Space Scanners Ligament Scanners

Multichannel Deep
Penetrating Hawkeye
Array

LFET Lap Weld Scanners

Sidewall Bend Scanners

Near Weld Tube Scanners

15
 HTesTex Headquarters
• TesTex Service Locations
TesTex Service Locations: Headquarters:
Pittsburgh, PA Buenos Aires, Argentina TesTex, Inc.
Atlanta, GA Mumbai, India Pittsburgh, PA USA
Houston, TX Baroda, India Tel: 412-798-8990
South Bend, IN Kolkata, India Fax: 412-798-8995
Philadelphia, PA North Killingholme, UK Website: [Link]
New Orleans, LA Lyon, France
email: info@[Link]
Bakersfield, CA Moncton, Canada
Lacombe, Canada
Princes Town, Trinidad