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Improve Performance

Performance, Drive Profitability


Profitability, Lead Innovation
Innovation, Conserve Energy

AcousticEye Introduction
NDT System for Tube Integrity Inspection
} Non-traversing
} FAST
} Extremely accurate
} Easy to operate
} Self Analyzing
} Generates Reports
} Clean and Green
First developed and tested at Israel Aircraft for
complicated Aeronautic Hydraulic Systems

The Problem
Recognized Global
Industrial Problem
Tubes in the Heat Exchangers Become
Defective and Hinder Efficiency and Operation
Not all tubes are inspected for integrity due to:
Time limitations, Materials, Tube Configurations

o
o
o
o

Loss of 0.25% of GNP


Environment Harming
Decrease in Performance
Energy Waste

Tube Inspection
A Major Concern
in All Industries
} Faults commonly found in tubes
}Pitting (Picaduras)
}Erosion
}Wall perforations
}Blockages
}Bulges
(Protuberancias)
P t b
i )

NDT Alternatives
Limitations of Current Inspection Technologies
} Require physical traversal of the entire length of the
tube with a probe
probe.
} No bent tubes (U-tubes)
} Time Consuming
} Dependent on wall material
} Limited to average diameter tubes
Do not apply
pp y to narrow or wide diameter tubes
} Require highly skilled certified personnel to interpret
the results

NDT Technologies
g
Comparison
p
Eddy
Current

Xray

Ultrasonic ThermalEmission Pressure


Gauge

Acoustic
Emission

NO

NO

NO

NO

YES

NO

YES

NoAccessRequired

NO

NO

NO

NO

NO

NO

YES

Costeffective

NO

NO

NO

NO

YES

NO

YES

YES

YES

YES

YES

NO

YES

YES

NO

NO

NO

NO

YES

YES

YES

NO
YES
NO
YES
NO

NO
NO
NO
YES
NO

NO
YES
NO
YES
NO

NO
YES
NO
NO
NO

NO
YES
NO
NO
NO

NO
YES
NO
NO
NO

YES
YES
YES
YES
YES

NO

NO

NO

NO

YES

NO

YES

NO

NO

NO

YES

YES

YES

YES
6

NonTraversing

PinpointsDefectlocation
Embeddable
Rapid testingtime
testing time
Noradiationemitted
Automated
Detectscorrosion\erosion
Findblockagesandpartial
blocks
Notaffectedbytubewall
material
Notaffectedbypresenceof
supportsheets

The AcousticEye Product


Hardware & Software

The AcousticEye Upper Hand


Rapid
p Single
g Point Inspection
p
of Inaccessible Tubes
} Non-traversing
p
less than 10 seconds p
per inspected
p
tube
} FAST Inspection
} Any tube configuration (narrow, fin tubes, y & t joints, 90 turns)
p
interpretation
p
of data,, minimal expertise
p
required
q
} Automatic independent
for operation
p
inspects
p
all tubes:
} Non-material dependent
graphite, stainless, copper,
brass etc.

Working Method
}Tube Inspection in 5 easy steps
1.

2.
3.

4.

5.

Map out the site and the work plan


0 This can be done by taking a simple digital photo of the
exchanger and entering into system
Set up the parameters of the inspection details
Set your inspection thresholds
these can be determined and revised
before and after testing
Take the measurements
a. Conduct calibration measurement
there are several calibration methods
b. Point and Shoot tubes
Generate Report

AcousticEye
y Core Technology
gy
Pulse Reflectometry (PR) based on measurements of one
dimensional acoustic waves propagating in tubes:
Schematically:
Loudspeaker

Microphone

Object

Excitation pulse:
Reflections:

Any change in the cross sectional area in the tubular system creates a reflection
reflection.
All reflections propagate back and the proprietary algorithms enable self-analysis.

Each defect has its own signature


As a result the APR gives:
Exact location, type and size of the defect
ONLY inner diameter defects are detected

What can we
learn from reflections?
} Reflections are created whenever
a change in the cross section is
encountered:
o C
Constrictions:
t i ti
a reduction
d ti iin
cross section due to a partial
blockage
g or a connector to a
narrower tube

Schematically:
Impinging pulse

Reflection from
a constriction

o Expansions: erosion or
connection
ti to
t a wider
id
tube

o Effective changes in cross section


due to openings into the atmosphere such as holes and cracks

Reflection from
an expansion

Reflection from
a leak

More Typically
} Well have a local
blockage:

or

(deposits, dents, welding material)

degradation:
(pitting)

Impinging pulse

Reflection from a
Local blockage

Reflection from a
Local degradation

Some Actual Measurements


From the Lab
A Hole

Tube Wall Degradation


0.03

0.03

Reflection from Scoring

0.02

Relative Units

Reference
meaasurement
Reference
Measurement
0.01

0.01
0

-0.01

-0.01

-0.02
1.2

1.25

1.3

1.35

1.4

1.45

1.5

1.55

1.6

1.65

Reference measurement

-0.02

Reflection caused by a hole

-0.03
1.8

1.7

2.2

[m]

2.4

[m]
4
3

Partial Blockage

Relative Units

Relative Units

0.02

Reflection from Constriction

Reference measurement

1
0
-1
-2
2
-3
1

1.2

1.4

1.6

[m]

1.8

2.2

2.6

2.8

Our Approach to Signal Analysis


} Comparative analysis:
} compare measurements
t to
t a calibration
lib ti measurement:
t either
ith
taken on a good tube or calculated statistically
} We look for deviations between the two
} Once they are above a certain threshold they have to be identified
} As we saw above:
} different faults present different signatures

Pricing Model
Can you afford the AcousticEye System?
How can you afford not to use this innovative NDT tool?
} Make Money
} Earn Quick ROI
} Save Time
} Increase Capacity
} Be Green
} Work on a High Efficiency Quotient

Applications
Wherever there are tubes there are applications
Added Value:
narrow tubes
tubes, fin fans
fans,
spiral tubes, u-tubes

o Tube Manufacturers QC for tubes


o Manufacturers:
M
f t
Heat
H t Exchangers,
E h
Boilers,
B il
Chillers,
Chill
R
Reactors
t
- in process QC, service of warranty
o Plant
Pl t Scheduled
S h d l d Maintenance
M i t
and
dE
Emergencies
i
Power Plants, Fuel processing, Petrochemicals, Chemicals,
Food and Beverage,
Be erage Air conditioning (HVAC)
(HVAC), P
Pulp
lp and Paper
o Evaluation of Cleaning before and after cleaning

Case Study #1
} Finding a 1 mm diameter hole at 30.9 feet

the inspected tubes


1 mm diameter hole at 30.9 feet

Case Study #1
} Finding a 1 mm diameter hole at 30.9 feet

Signature of a 1mm hole

Defect

Calibration tube

Impinging pulse
End of tube

Z
Zooming
i iin on th
the signal
i
l ffrom
the defect

Signals from two tubes


defective tube (brown line)
good tube (green line)

Case Study #2
Assembly Process QA
Finding a defective weld

Finding a Defective Weld

Finding a Defective Weld


} Finding a defective weld at 29.7 feet

Impinging pulse

End of tube

Finding a Defective Weld


} Good weld on tubes 5,6 and 7. Bad weld on tube 8

tubes 5,6 and 7

Tube 8
Signature of a 1mm hole

In Assembly Management
Main advantages from a manufacturer point of view
1. Evaluating the weld integrity during assembly process
2. Avoid expensive tear-down and reworking after assembly
3. Reduce scrap materials and increased productivity
4. Objective evaluation based on a computational model
and not a subjective operator evaluation
5. Create a documented proof data base of each and every tube, weld
or sub-assembly
6. Much less expensive than traditional NDT

Case Study #3
} Graphite Condenser at a Chemical Plant - Difficult to inspect by the
traditional NDT methods

A hole detected in the bottom left tube

Case Study #4 chemical plant

} Some chemical processes use reactors


} Thousands of tubes filled with catalyst pellets
} Operated at high temperatures and pressures
} One mode of failure: creep (metallurgical term)
} The net result is a bulge in the tubing:

} Conventional NDT methods cant detect this!!

Test run on bulges:


} Three bulges were created for us artificially by a heat exchanger
manufacturer Ohmstead
} The reflection from each different bulge is distinct, despite the very
small differences between them (2.2%, 2.4% and 2.9%):

Reactor measurements
} Further measurements were carried out on an actual reactor
} Multiple blockages were found precluding the use of traversing
technologies
} Small
S ll b
bulges
l
were also
l ffound
d

More reactor measurements

} Expansions:

Case Study #5
Geothermal Power Plant
Fin Fan Tubes Severe Blockages
IIsobutane
b t
fill d h
filled
heatt exchangers
h
60 ft long, 1 diameter, 42 tubes each

More photos

Example of a hole
Example measurement demonstrating a massive hole near the end of
the tube (D210)

Many Partial Blocks


Example measurement demonstrating many partial blocks (D21)

Case Study #6 HVAC


}

Dual System for Air Conditioning


Eddy
y Current gave
g
distorted readings,
g ,
which the technicians had difficulties
interpreting.

AcousticEye found the hole in seconds


Condenser

Steamer

Case Study #7
Power Plant
Israel Electric Company Emergency Maintenance
Indications of seawater leak into the steam

Inspection Results
o

of the condenser was


emptied from midnight to 6am
Zone6

o Vapor side was left in


operation
o Turbine was running and of
th condenser
the
d
was operational
ti
l
o An entire zone that had been
plugged temporarily was opened
up for inspection
o AcousticEye found 6 defective
tubes
o As a result- power production
increased by 15%

Case Study #8
Evaluation of Cleaning
Before Cleaning

After Cleaning

No fault
(clean
tube)

Many/Massive partial
blockages

Full
blockage

We would be happy to demonstrate

THANK YOU

AcousticEye 4 Harehev St. Tel Aviv Israel 972 36888876 info@acousticeye.com


USA: Stroud Systems Inc
Inc. 600 N.
N Shepherd Rd Houston
Houston, TX Tel: (713) 8613270 customerservice@stroudsystems.com
customerservice@stroudsystems com
Intertest Inc. 303 State Route 94 Columbia, NJ Tel: (908) 4968008 pekearney@intertest.com
Inspection Technologies Inc. 2701-A N Towne Ave Pomona, CA Tel: (800) 5451450 sales@inspectiontechnologies.net
Canada: Quality NDE, 164 St. Jeqan Baptiste, Mercier, QC J6R2C2 Tel: +1450 691 9090 qndeltd@qualitynde.com
Benelux: HPFM B.V. 2a-b Molenlei, Akersloot 1921CZ the Netherlands Tel: +31 725 354 081 info.acousticeye@hpfm.nl

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