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| 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. |
| 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. |
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Click
on image to enlarge Condenser Map |
| One of the greatest advantage
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-4200 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. |
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| 1. |
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. |
| 2. |
Find tubes with holes/leaks
that don’t show up on hydro
checks due to clogging and thermal
expansion issues |
| 3. |
Reduce/eliminate back
pressure due to in-leakage and increase
megawattage of the overall system. |
| 4. |
Know exactly what condition
the condenser tubes are in so that
you can forecast condenser tube remaining
life, tube replacement, shield installations,
etc. |
| 5. |
Justify a tube replacement
by performing a full or random tube
inspection. |
| 6. |
Eliminate the possibility
of condenser tube leaks when electricity
demand is high. |
| 7. |
Reduce/eliminate cost
for additional water treatment chemicals,
polishers, and make-up water. |
| 8. |
Reduce damage to other
plant equipment (for example, Corrosion
Cells and Hydrogen Damage in the Boiler)
that can stem from leaking condenser
tubes. |
| 9. |
Increase reliability. |
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