Eddy Current Testing
Tier 1 Integrity delivers advanced electromagnetic inspection services for heat exchangers, condensers, air coolers, boilers, piping systems, tanks, and critical process equipment. Our dedicated Electromagnetic Testing Division combines industry-leading equipment, experienced Level II and Level III personnel, and proven inspection methodologies to identify corrosion, erosion, cracking, wear, and other degradation mechanisms before they become reliability threats.
Heat Exchanger & Condenser Programs
Comprehensive tube inspection programs for shell-and-tube exchangers, condensers, chillers, and reboilers. Our data analysts evaluate tube integrity, identify active damage mechanisms, and provide condition assessments that support repair, plugging, replacement, and run-repair-replace decisions. Electromagnetic testing is an excellent partner in the development and implementation of risk-based inspection (RBI) programs. Whether supporting a major turnaround, capital project, or routine mechanical integrity program, we provide actionable data that drives informed maintenance decisions and maximizes asset reliability. All tubing applications are available with array technologies.
Tubing Inspection Methods
Eddy Current Testing (ECT)
Eddy Current Testing is one of the most effective and widely used electromagnetic inspection methods for evaluating non-ferromagnetic heat exchanger and condenser tubing. The technique uses electromagnetic induction to identify changes in material properties and detect discontinuities that may compromise equipment reliability. ECT provides rapid inspection speeds while delivering highly sensitive detection of pitting, corrosion, erosion, wear, cross-axial cracking, and mechanical damage throughout the tube length. Because testing can be performed from a single tube end, large tube bundles can be inspected efficiently during outages and routine maintenance. Tier 1 Integrity uses advanced multi-frequency techniques and specialized probe technologies to improve defect characterization and separate competing signals from support structures, deposits, and geometric influences.
Typical Applications
- Shell-and-Tube Heat Exchangers
- Surface Condensers
- Chillers
- Reboilers
- Feedwater Heaters
- Thin-Walled Ferritic Alloy Tubing
Detectable Damage Mechanisms
- Internal Pitting
- External Pitting
- General Wall Loss
- Erosion
- Tube Support Bulging
- Tube Support Fretting and Wear
- Stress Corrosion Cracking
- Circumferential Cracking with array applications
Remote Field Testing (RFT)
Remote Field Testing is specifically designed for the inspection of ferromagnetic tubing, where conventional eddy current methods have limited effectiveness. The technique uses low-frequency electromagnetic fields that travel through the tube wall, providing balanced sensitivity to both internal and external defects. RFT has become the industry standard for carbon steel heat exchanger tubing because it allows inspectors to evaluate wall loss on either side of the tube while maintaining high inspection productivity. Tier 1 Integrity performs RFT inspections using advanced digital acquisition systems and experienced analysts capable of identifying corrosion patterns, erosion damage, and localized metal loss that may threaten equipment reliability.
Typical Applications
- Carbon Steel Heat Exchangers
- Boiler Tubes
- Heavy-Walled Ferritic Alloy Tubing
- Process Heat Transfer Equipment
Detectable Damage Mechanisms
- Internal Corrosion
- External Corrosion
- General Wall Thinning
- Tube End Erosion
- Localized Wall Loss
- Tube Support Fretting
Near Field Testing (NFT)
Near Field Testing is an electromagnetic inspection method developed specifically for carbon steel tubing with external aluminum finning. NFT combines the speed of electromagnetic testing with enhanced sensitivity to localized defects, making it particularly valuable for air-cooled heat exchangers and fin-fan applications. NFT inspections can often be completed significantly faster than alternative techniques, reducing outage duration and lowering inspection costs while providing reliable identification of corrosion-related damage.
Typical Applications
- Fin-Fan Coolers
- Air-Cooled Heat Exchangers
- Carbon Steel Tubing
Detectable Damage Mechanisms
- Internal Corrosion
- Localized Wall Loss
- Isolated Internal Pitting
- Erosion Detection and Sizing
Internal Rotary Inspection System (IRIS)
The Internal Rotary Inspection System is a water-based ultrasonic tube inspection method that provides highly accurate quantitative measurements of tube wall thickness. Unlike electromagnetic techniques that primarily detect and characterize indications, IRIS directly measures remaining wall thickness, making it an excellent verification and fitness-for-service tool. IRIS is frequently used alongside ECT, RFT, and NFT inspections to validate findings and support engineering decisions regarding repair, replacement, and continued operation.
Typical Applications
- Heat Exchangers
- Condensers
- Chillers
- Reboilers
- Critical Service Equipment
Detectable Damage Mechanisms
- Internal Corrosion
- External Corrosion
- Generalized Erosion
- Localized Pitting
- General Wall Thinning
Surface & Through-Insulation Methods
Surface Eddy Current Testing (SECT)
Surface Eddy Current Testing is a highly sensitive inspection technique used to identify surface-breaking and near-surface discontinuities in conductive materials. The method provides excellent sensitivity to cracking and is frequently used where magnetic particle testing or dye penetrant testing may be impractical. Because surface preparation requirements are often minimal, inspections can frequently be completed without removing coatings or disrupting operations.
Typical Applications
- Weld Inspections
- Structural Components
- Machined Surfaces
- Pressure Boundary Components
- Aircraft and Aerospace Components
- Paint Thickness Measurement
Detectable Damage Mechanisms
- Fatigue Cracking
- Stress Corrosion Cracking
- H2S Induced Cracking
- Heat-Affected Zone Cracking
- Surface-Breaking Defects
- Grinding Cracks
Pulsed Eddy Current (PEC)
Pulsed Eddy Current provides a powerful solution for inspecting carbon steel assets through insulation, coatings, weather jackets, and fireproofing. The technology uses low-frequency electromagnetic pulses to measure remaining wall thickness and identify corrosion without requiring extensive insulation removal. PEC is commonly used as a screening tool to identify areas of concern across large asset populations. By rapidly locating areas with elevated corrosion risk, PEC helps focus follow-up inspections and significantly reduces inspection costs.
Typical Applications
- Corrosion Under Insulation (CUI)
- Corrosion Under Fireproofing (CUF)
- Process Piping
- Pressure Vessels
- Storage Tanks
- Structural Steel
- Offshore Assets
Detectable Damage Mechanisms
- General Wall Loss
- Atmospheric Corrosion
- External Metal Loss
Tube Mapping, Analytics & Integrity Reporting
Inspection data only creates value when it can be translated into actionable maintenance decisions. Tier 1 Integrity delivers comprehensive reporting packages designed to support reliability engineers, inspectors, and mechanical integrity programs. Our reports provide detailed visualization of asset condition through tube maps, corrosion trend analysis, and defect summaries with repair recommendations. We work closely with our clients to ensure inspection findings can be incorporated directly into turnaround planning, RBI programs, and long-term asset management strategies. Our data analysts deliver final inspection reports the same day as testing whenever possible, supporting rapid decision-making, efficient repair planning, and reduced outage durations.
Reporting Deliverables
- Color-Coded Tube Sheet Diagrams
- Defect Distribution Analysis
- Corrosion Trending Analysis to aid Remaining Life Assessments
- Plug Mapping per Customer Request
- 3-D Diagrams of Heat Exchanger Defect Locations
- Data Analysis Screen Captures
- Visual Representation of Quantifiable Flaws
Have a tubing or surface EC scope?
Our dedicated eddy current team is ready to plan and execute.