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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 l.jpg

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


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

Hyman Rickover


What is matrix l.jpg
What is MATRIX? driven into practice by courageous patience”.

  • 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


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What does MATRIX offer? driven into practice by courageous patience”.

  • 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)


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How does MATRIX work? driven into practice by courageous patience”.

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”


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Successful field deployment driven into practice by courageous patience”.May 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)


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Successful field deployment driven into practice by courageous patience”.May 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


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Clean expansion signal driven into practice by courageous patience”.

Suppressed expansion signals

12’ long tubes with no supports

Tube sheet thickness = 2”

Data presented courtesy of The Young Group


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100% circ notch, 45 degree extent driven into practice by courageous patience”.

Data presented courtesy of The Young Group


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indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of The Young Group


Indication at tubesheet11 l.jpg
indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of The Young Group


Indication at tubesheet12 l.jpg
indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of The Young Group


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Indication in free span driven into practice by courageous patience”.

Data presented courtesy of The Young Group


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Speaking of indications…. driven into practice by courageous patience”.


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Negative indication driven into practice by courageous patience”.


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Negative indication driven into practice by courageous patience”.


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Negative and/or positive indication driven into practice by courageous patience”.


Positive indication l.jpg
Positive indication driven into practice by courageous patience”.


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indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of the Young Group


Indication at tubesheet20 l.jpg
indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of the Young Group


Indication at tubesheet21 l.jpg
indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of the Young Group


Indication at tubesheet22 l.jpg
indication at tubesheet driven into practice by courageous patience”.

Data presented courtesy of the Young Group


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MATRIX strengths and limitations driven into practice by courageous patience”.

  • “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


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Copper Air Conditioner tubing with enhanced fins (OD and ID) driven into practice by courageous patience”.

Coils must be somewhat perpendicular to internal fins

Not parallel


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Lesson learned in 2004; driven into practice by courageous patience”.helical undulations in tubing

Barely visible in RPC data shown here


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

Flaw clearly detected, but distorted by horizontal noise = DQ



Figgedabadit l.jpg
Figgedabadit will be problems


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MATRIX goals in HVAC will be problems

  • 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


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How does MATRIX suppress fins? will be problems

TUBE AXIS

Each circuit (green and gold) sees the same number of fins at any moment in time allowing for common mode cancellation






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MATRIX response to tiny pin hole will be problems(.039” diameter 100% thru wall)


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Bobbin response to tiny pin hole will be problems(.039” diameter 100% thru wall)






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Tube obstruction will be problems(efforts to remove in progress)



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Same flaw with window open will be problems



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Both flaws with AC3 probe transition(first pull)


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Both flaws with AC3 probe transition(second pull)

.

DEAD SPOT


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MATRIX probe has no dead spot transition

OVERLAP ZONE


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What are other uses of MATRIX? transition

  • 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)


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MATRIX probe radial dent suppression transition(no mix required)

T/R ABSOLUTE CHANNELS

T/R DIFF CHANNELS

UP TO 25:1 SUPPRESSION


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MATRIX probe TSP suppression transition(no mix required)

T/R ABSOLUTE CHANNELS

T/R DIFF CHANNELS

UP TO 25:1 SUPPRESSION


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ODSCC under TSP transition

ABSOLUTE TSP RESPONSE IS OFF SCREEN

AXIAL ODSCC AT SUPPRESSED TSP


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Circ crack at expansion transition

CIRC INDICATION AT EXPANSION (suppressed)


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Mixed mode cracks, RPC response transition

ID axial at expansion (behind circ)

OD circ at expansion

OD circ

ID axial


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Same 2 cracks, MATRIX response transition

MATRIX = 40”/sec

RPC = 0.4”/sec

100 X FASTER


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MATRIX response to under-rolled expansion transition

Low frequency MATRIX signal shows under-roll condition

TUBESHEET

EXPANSION AREA


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Very large OD indication transition

THAT’S JUST PLAIN COOL!

Actually a 600’ tall lava extrusion, Mt. St. Helens, summer 2006 (USGS photo)


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What’s next for MATRIX? transition

  • 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!!!!


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Opinion transition

  • 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


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Who is IEI? transition

  • 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.


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www.best-test.com transition


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