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MATRIX probe Progress Report 2008. By Jay Zimmerman Independent Electronic Inspection (IEI) Presented at the 10 th 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”.

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matrix probe progress report 2008

MATRIX probeProgress 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

“Good ideas are not adopted automatically. They must be driven into practice by courageous patience”.

Hyman Rickover

what is matrix
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
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
How does MATRIX work?

0 degrees

360 degrees

TUBE AXIS

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

= Receive coil “A”

= Optional Transmit Coil

TRANSMIT/RECEIVE BENEFITS = NOISE REDUCTION AND IMPROVED SENSITIVITY

= Receive coil “B”

successful field deployment may 2008
Successful field deploymentMay 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 20081
Successful field deploymentMay 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
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
100% circ notch, 45 degree extent

Data presented courtesy of The Young Group

indication at tubesheet
indication at tubesheet

Data presented courtesy of The Young Group

indication at tubesheet1
indication at tubesheet

Data presented courtesy of The Young Group

indication at tubesheet2
indication at tubesheet

Data presented courtesy of The Young Group

indication in free span
Indication in free span

Data presented courtesy of The Young Group

indication at tubesheet3
indication at tubesheet

Data presented courtesy of the Young Group

indication at tubesheet4
indication at tubesheet

Data presented courtesy of the Young Group

indication at tubesheet5
indication at tubesheet

Data presented courtesy of the Young Group

indication at tubesheet6
indication at tubesheet

Data presented courtesy of the Young Group

matrix strengths and limitations
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
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
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
Rare helical undulations wreaked havoc on MATRIX data because coils were parallel to the “waves”

Flaw clearly detected, but distorted by horizontal noise = DQ

matrix goals in hvac
MATRIX goals in HVAC
  • Replace Tri-tip probe as the industry standard
    • 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
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

what are other uses of matrix
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
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
MATRIX probe TSP suppression(no mix required)

T/R ABSOLUTE CHANNELS

T/R DIFF CHANNELS

UP TO 25:1 SUPPRESSION

odscc under tsp
ODSCC under TSP

ABSOLUTE TSP RESPONSE IS OFF SCREEN

AXIAL ODSCC AT SUPPRESSED TSP

circ crack at expansion
Circ crack at expansion

CIRC INDICATION AT EXPANSION (suppressed)

mixed mode cracks rpc response
Mixed mode cracks, RPC response

ID axial at expansion (behind circ)

OD circ at expansion

OD circ

ID axial

same 2 cracks matrix response
Same 2 cracks, MATRIX response

MATRIX = 40”/sec

RPC = 0.4”/sec

100 X FASTER

matrix response to under rolled expansion
MATRIX response to under-rolled expansion

Low frequency MATRIX signal shows under-roll condition

TUBESHEET

EXPANSION AREA

very large od indication
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
What’s next for MATRIX?
  • Revisit the transmit/receive (T/R) version of MATRIX first attempted in 2004
    • 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
Opinion
  • MATRIX should be used in tandem with bobbin on a universal basis in BOP
    • 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
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
    • Access to another 100+ years combined EC exp.
    • Onsite access to machines, lab equipment, etc.