The Tube Inspection Process

The tube inspection process comprises the following steps:

1. Mapping of site and generation of work plan
2. Setup of the inspection parameters
3. Measurement of tubes
4. Establishing reference measurement and setup of inspection thresholds
5. Report generation and results analysis

Step 1 - Mapping of site and generation of work plan

In this stage, a photograph or schematic diagram of the heat exchanger is uploaded to the system in order to create a map of the tube openings. Each of the tube openings is assigned a number. This enables the system to create a graphic representation of the heat exchanger and to keep track of which tubes have already been measured, allowing the technician to work in a systematic manner.

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Step 2 - Setup of Inspection Parameters

Using Dolphin's intuitive user interface, the technician sets the inspection parameters related to the physical attributes of the tubes. These parameters include the tube's length, diameter and wall thickness, as well as the probe adaptor's length and diameter.

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Step 3 - Taking the Measurements

Using Dolphin's compact handheld probe, the technician begins to inspect the tubes in accordance with the site map and work plan. The probe is applied to each tube opening for approximately 10 seconds. It emits an acoustic pulse and then measures the resulting reflections using APR technology. LEDs on the probe indicate when the measurement is complete and the software guides the technician to the next tube to be measured.

Step 4 – Establish Reference Measurement and Set Inspection Thresholds

Once all of the measurements have been taken, the system calculates a reference measurement based on an intelligent average of the measurements, taking into account statistical deviation and the presence of ambient noise. Any measurement beyond that deviation is a potential flaw. In addition, the system enables the heat exchanger owner to determine thresholds for each type of flaw depending on the sensitivity of the given application (e.g., percentage of wall loss, blockages, etc.). Only those measurements that exceed the defined threshold are reported as flaws.

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Step 5 – Generate Report and Analyze Results

This is the stage in which the raw data (i.e., signals) collected by the system is interpreted and presented to the technician for analysis. This entire process is performed automatically by the system software.

Using breakthrough algorithms, our patented PTS software identifies the different signatures of each type of flaw, allowing the system to automatically identify every defect. It pinpoints the location and determines the severity of every problem in an objective and consistent manner. The precision and sophistication of AcousticEye's detection algorithms are field-proven to ensure accurate identification of faults, regardless of the presence of background noise or the distance of the fault down the tube.

The system flags all "suspicious" measurements which may indicate a fault and presents them in an easy-to-read online report for verification. The technician can drill down to obtain additional information on each measurement (including the signal graph) as needed before accepting or rejecting each flagged item.

At the conclusion of this process, the system generates a final report (PDF) containing summary information, including tabular reporting and screenshots of the detected flaws. The final report is typically presented to senior management.

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