Near Drum Imaging - GENISYS

 

GENISYS is the latest technology for the inspection of boiler tubes for near drum corrosion. This system is often used as a complement to Hi-Tech Testing Service’s typical boiler inspection program. The system can be used in the mud drum or steam drum without the need to flood tubes. GENISYS is an internally developed and proprietary HI-Tech system.

Our technicians are proficient in the operation and maintenance of these units. GENISYS has proven to be reliable and accurate system.

In optimum conditions where the tube outside diameter is 2” (in the swaged area) and the tubes are clean with no deposits, scale or ID pitting, the GENISYS system is capable of scanning up to 100 or more tubes per hour, which makes this system the fastest on the market today. The presence of dirt, scale, chemical deposits, inside pitting, etc. will slow the scanning process depending on how severe the problems are. This system is capable of scanning tubes with OD ranges from 2” to 3”. However, larger than 2 inch outside diameter tubes will slow the scanning process exponentially as the diameter increases.

Data Acquisition / Analysis

Generating section tubes are typically scanned for acquisition of thickness measurements every 0.032 inch circumferentially and every 0.032 inch axially. The tube scan commences at ¼ inch to ½ inch from the outside diameter (O.D.) of the drum and progresses outward two (2) inches past the drum O.D. This area represents the most prevalent area for near drum corrosion to occur.

Upon completion of the scan the technician analyzes the scanned data. The measurement representing the thinnest reading for each tube is saved to file along with the Ultrasonic waveform. As saved data these files may be reviewed with ‘’B’’ and/or ‘’C’’ scan representations of the tube thickness.

A color enhanced tube sheet map is generated at the completion of the inspection. This field report is reviewed with the customer’s designated representative prior to departing the project. An interim report may be generated at any time during the inspection depicting the thickness measurements of tubes scanned up to that point. The color enhancement of this report may be used to assess general tube thinning throughout a section of localized areas of wear.

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A formal written report is generated after the completion of each project. This report details all tubes inspected, noted areas of thinning, along with ‘’B’’ and ‘’C’’ scans representative of prevalent thinning noted.