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There are two major types of eddy current tests performed in petrochemical
plants. These can be broadly categorized as surface testing and tubing
testing. Surface testing techniques use portable and battery powered eddy
current systems. The major applications are the detection of surface cracks,
clad overlay measurement and wear measurements. Tube testing is done
with multifrequency eddy current equipment and is used for testing heat
exchanger tubes.
Principle
The eddy current method is based on the principle of measuring changes in
the impedance of an electromagnetic coil as it is scanned over a surface of
conductive material (Cecco, 1992). The test is performed by an
electromagnetic coil that is placed over a conductive material (Figure 1). An
alternating current in the coil produces a magnetic field that is induced in the
material. To counter the coil's primary magnetic field, eddy currents are
produced in the material. Eddy currents produce a secondary magnetic field
H'B to oppose the coil's primary magnetic field HB. When the coil is scanned
over a discontinuity, the secondary magnetic field is distorted, thereby
changing the loading on the coil. Changes in coil loading directly affect the
coil impedance. These changes in coil impedance may be related to the
discontinuity.
Depth of Penetration
Discontinuity detection is limited to the penetration depth of eddy currents.
Penetration depth is inversely proportional to the square root of conductivity,
frequency and permeability. For most applications, the penetration depth in
nonferromagnetic material is limited to approximately 5 mm (0.2 in.). In the
case of ferromagnetic materials, such as carbon steel, the penetration depth
is extremely shallow because of high permeability. Testing of ferromagnetic
material is therefore limited to surface discontinuities only.
Instruments
Surface eddy current testing is normally performed with portable eddy
current systems. These systems are usually single or dual frequency.
Surface eddy current instruments normally cost between $6,000 and
$10,000.
Surface eddy current testing is performed using probes that include pencil
probes, spot probes and cross axis probes. Eddy current testing of tubing is
done using bobbin probes.
Tube Testing
There are three basic eddy current test techniques for testing tubes.
Selection of the techniques depends on the tube material. Birring (2001)
provides detailed information on eddy current testing techniques for tube
testing.
Surface Testing
Surface eddy current testing is used for the detection of surface cracks in
both nonferromagnetic and ferromagnetic materials. The method is very
sensitive in detecting tight cracks. Calibration is performed on electrical
discharge machined notches as shown in Figure 2. In addition to detection,
the method can accurately measure crack depth in nonferromagnetic
materials. These materials include stainless steels and high temperature
nickel chromium alloys. When sizing cracks, the eddy current test frequency
is selected so that the depth of penetration is greater than the expected
crack depth. Some common probes used for surface eddy current testing
are spot probes, X-point probes and pencil probes.
Both surface eddy current testing and liquid penetrant testing are surface
test techniques used for the detection of surface breaking cracks. Eddy
current testing has advantages over liquid penetrant testing in certain
applications:
Vessels
Two major applications of eddy current testing in vessels are crack
detection and clad thickness measurement.
(a) (b) (c) (d)
Figure 1 - The eddy current principle: (a) eddy current coil in air
- the coil produces a magnetic field HA and the coil impedance is
Zair ; (b) eddy current coil over a conductive material - eddy
currents are produces in the material that opposes the magnetic
field of the coil, the coil's magnetic field changes from H A to HB
and the impedance of the coil changes from Zair to ZB along the
liftoff line; (c) eddy current coil over a crack - eddy currents are
distorted by the crack, which changes the magnetic field of the
eddy currents from H'B to H'C , thereby changing the loading on
the coil; (d) the coil impedance changes to Zcrack.
(a)
(b)