Within the Power Generation Industry, TesTex offers an Ultra High Speed Condenser Tube Inspection Service. This service (& system) inspects an average of (8) tubes per minute with one inspection system (assuming 30’ long tubes). Tubes up to 70’ long, feedwater heater tubes, and various types of heat exchanger tubes can also be inspected using the Ultra High Speed system. You may hear other NDT companies questioning the speed of our inspection, even saying that we miss flaws inspecting at this speed, but our system has proven itself time and time again to identify the same flaws as slower Eddy Current methods. Numerous tubes have been cut out of condensers to verify the accuracy of our service & system.
The system is based on Eddy Current technology. Probes are propelled into each tube using compressed air; the probes are then retracted using a cable reel system. Each set of data is discreetly numbered and sent to a data cell to correspond with a location on a digital tube sheet map. ECTViewer application showing wall loss near the tube sheet
Unlike other inspection companies, TesTex always has at least one Level II ET inspector on site during an inspection. TesTex conducts its own in house training programs specifically geared to tubing inspection, and certifies personnel as per ASNT SNT-TC-1A guidelines. The data analysis is performed in real time, while on site, to provide instant results. THIS IS CRITICAL. When a questionable signal or a flaw indication occurs, the tube can be retested to ensure an accurate analysis of the tube. At the completion of tube testing, and while still on site, a PC generated full color tube sheet map is printed out and given to the client as part of the preliminary field report. This detailed preliminary field report is always provided on site.
Other inspection companies list a preliminary report as an option for an additional price. If you do not select this option with other vendors, they will do the analysis back in their offices, and there is no chance for questionable signals to be rechecked. TesTex and it’s clients feel that the optimum place to do the data analysis is on site during the inspection. It has also been conveyed to us from some of our clients (who did not select the preliminary report option from the other inspection companies) that they did not receive any test results or inspection reports until four to six weeks after the inspection was completed; some have even said that it took months to get any data at all. PLEASE NOTE: TESTEX IS A COMPANY THAT SPECIALIZES IN TUBING INSPECTIONS; WE ARE NOT A COMPANY THAT SPECIALIZES IN TUBE CLEANING WHILE DOING A MINIMAL AMOUNT OF EDDY CURRENT TESTING. If you need turn-key cleaning and inspection services, TesTex has an array of dependable tube cleaning companies around the nation that we can sub-contract for you.
Why perform a full or partial condenser tube inspection?	Click on image to enlarge Condenser Map
One of the greatest advantages of this service is the detailed full color tubesheet map that is provided immediately after completion of tube testing and while on-site. This allows for immediate plugging for a quick return to service with increased reliability. This map also immediately highlights problem areas that need attention. Some causes of these problem areas include ammonia grooving, steam erosion, steam impingement, inlet end erosion, concentrated areas of internal pitting, steam pit erosion in Titanium tubing, under deposit crevice corrosion, etc.
Because of this technology, 100% inspections can be performed on a condenser with tens of thousands of tubes within a few days. This system is designed for use on very large condensers and heat exchangers but can also be used to inspect smaller tube quantities in emergency situations when a prompt return to service is critical.
TesTex introduced this service in late 2000. This service is proving to be of great value to the power generation sector. For example, on a condenser with 10,000 tubes, we can complete a 100% inspection in (2) days with two stations running on day shifts. This service is being very well received because of reduced shutdown times and the acceptance of the damage a leaking condenser can cause to other plant equipment (for example, Corrosion Cells and Hydrogen Damage in the Boiler).
When percentage inspections are all that is required by clients, TesTex also provides manual Eddy Current testing using our TesTex TX-4400 Multifrequency Multichannel ECT System. This is a fully digital system. Once again, TesTex will always have at least one Level II ET inspector on site during the inspection and the data analysis will be done while on site. In addition to the Eddy Current inspections, TesTex also offers IRIS Ultrasonic Inspections and Video Borescoping Services for condensers. TesTex can also provide tube cleaning and tube cut-out and plugging services when requested by a client.
Why perform a 100% or partial condenser tube inspection? Find the trouble tubes before they find you. This system will very quickly detect and quantify flaws in tubing made of brass, copper-nickel, stainless steel, copper, titanium, AL6XN, Aluminum Brass, etc. Find tubes with holes/leaks that don’t show up on hydro checks due to clogging and thermal expansion issues Reduce/eliminate back pressure due to in-leakage and increase megawattage of the overall system. Know exactly what condition the condenser tubes are in so that you can forecast condenser tube remaining life, tube replacement, shield installations, etc. Justify a tube replacement by performing a full or random tube inspection. Eliminate the possibility of condenser tube leaks when electricity demand is high. Reduce/eliminate cost for additional water treatment chemicals, polishers, and make-up water. Reduce damage to other plant equipment (for example, Corrosion Cells and Hydrogen Damage in the Boiler) that can stem from leaking condenser tubes. Increase reliability.

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