Optimized cloud-based non-destructive testing of enhanced non-ferromagnetic heat exchanger piping installed in fluid-cooled climate products

Abstract

The invention discloses an optimized cloud-based non-destructive testing of an enhanced non-ferromagnetic heat exchanger piping installed in a fluid cooled climate product. A test probe inserted into a particular heat exchanger tube is used to generate test data for a non-destructive test of the particular heat exchanger tube. Test data for non-destructive testing of the particular heat exchanger tube is accessed. Determining a structural health assessment of the particular heat exchanger tube using the accessed test data of the non-destructive test of the particular heat exchanger tube compared to calibration data from the test of at least one calibration standard heat exchanger tube, the calibration standard heat exchanger tube is more closely related to the particular heat exchanger tube than a universal tube.

Description

Technical Field

[0001] The present disclosure generally relates to testing and diagnosing for refrigerant systems or heat exchanger tubes. Background Art

[0002] Heat exchanger tubes or tube systems for refrigerant systems, HVAC (heating, ventilation, air conditioning) systems, fluid-cooled chillers (usually water-cooled chillers), and related industrial applications, etc., may have or develop defects that reduce heat exchange capacity, reduce efficiency, or cause system failures. Testing in the factory and on-site testing can reveal defects, but are time-consuming, require technical expertise, and may be prone to delays and errors. There is a need for technical improvements in testing and diagnosing for refrigerant systems or heat exchanger tubes, and the present embodiment is generated in this environment. Summary of the Invention

[0003] The present disclosure includes, but is not limited to, the following examples:

[0004] One embodiment is a method for non-destructive testing of a heat exchanger tube system. The method includes performing machine-controlled testing using a test probe inserted into a specific heat exchanger tube to generate test data for non-destructive testing of the specific heat exchanger tube. The method includes accessing the test data for non-destructive testing of the specific heat exchanger tube. The method includes using the accessed test data for non-destructive testing of the specific heat exchanger tube and comparing it with calibration data to determine a structural health assessment of the specific heat exchanger tube, the calibration data being associated with at least one calibrated standard heat exchanger tube that is more closely related to the specific heat exchanger tube in terms of its structural characteristics compared to a general-purpose tube.

[0005] One embodiment is a tangible, non-transitory computer-readable medium having instructions that, when executed by a processor, cause the processor to perform a method. Test data and calibration data are used for the health assessment of a heat exchanger tube. The method includes receiving test data from a non-destructive test of a particular heat exchanger tube, the test data being generated by performing a machine-controlled test using a test probe inserted into the particular heat exchanger tube. The method includes storing the test data from the non-destructive test of the particular heat exchanger tube in a data store. The method includes receiving calibration data associated with at least one calibration standard heat exchanger tube that is more closely related to the particular heat exchanger tube than a general-purpose tube in terms of its structural characteristics. The method includes storing the calibration data from the test of the at least one calibration standard heat exchanger tube. The method includes enabling access to the test data from the non-destructive test of the particular heat exchanger tube and the calibration data from the test of the at least one calibration standard heat exchanger tube in the data store to enable a structural health assessment of the particular heat exchanger tube based on the test data and the calibration data.

[0006] One embodiment is a system for non-destructive testing of a heat exchanger tube system. The system provides test data and calibration data for use in the health assessment of a heat exchanger tube. The system includes at least one memory and at least one processor coupled to the at least one memory. The at least one processor is arranged to receive test data from a non-destructive test of a particular heat exchanger tube generated using a test probe inserted into the particular heat exchanger tube. The at least one processor is arranged to store the test data from the non-destructive test of the particular heat exchanger tube in a data store. The at least one processor is arranged to store calibration data from a test of at least one calibration standard heat exchanger tube that is more closely related to the particular heat exchanger tube than a general-purpose tube in terms of its structural characteristics. The at least one processor is arranged to enable access to the test data from the non-destructive test of the particular heat exchanger tube and the calibration data from the test of the at least one calibration standard heat exchanger tube in the data store to enable a structural health assessment of the particular heat exchanger tube based on the test data and the calibration data.

[0007] These and other features, aspects, and advantages of the present disclosure will become apparent by reading the following detailed description in conjunction with the accompanying drawings briefly described below. The present disclosure includes any combination of two, three, four, or more of the above-described embodiments, examples, or implementations, as well as any combination of two, three, four, or more features or elements set forth in the present disclosure, regardless of whether such features or elements are explicitly combined in the specific example descriptions herein. The present disclosure is intended to be read as a whole such that any separable feature or element in any one of its aspects, embodiments, examples, or implementations of the disclosed subject matter should be considered combinable as desired unless the context clearly dictates otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The described embodiments and advantages can be best understood by reference to the following description in conjunction with the accompanying drawings. These drawings in no way limit any changes in form and detail that a person skilled in the art may make to the described embodiments without departing from the spirit and scope of the described embodiments.

[0009] Figure 1 An embodiment of a system for non-destructive testing of a heat exchanger tube system and an embodiment of a component of the system are shown.

[0010] Figure 2A Aspects of non-destructive testing of a heat exchanger tube system for an embodiment are shown.

[0011] Figure 2B A process diagram is shown that illustrates the role of test data from non-destructive testing of a specific heat exchanger tube and calibration data from non-destructive testing of (a) calibration standard heat exchanger tube(s) for various embodiments including Figure 2A of.

[0012] Figure 3 A flowchart of a method for non-destructive testing of a heat exchanger tube system in an embodiment is shown.

[0013] Figure 4A An example of spool coil data is shown.

[0014] Figure 4B Examples of array probe data and spool coil data are shown.

[0015] Figure 5A , Figure 5B , Figure 5C and Figure 5D Examples of a heat exchanger tube system and a probe suitable for an embodiment are shown.

[0016] Figure 5A A finned tube system is shown.

[0017] Figure 5B Shows an internally reinforced piping system with defects.

[0018] Figure 5C Shows a spool coil probe.

[0019] Figure 5D Shows an array probe.

[0020] Figure 6A and 6B Shows a sectional view of condenser fins and evaporator fins, which shows the position of the heat exchanger tubes in an example installation.

[0021] Figure 6A Shows a sectional view of condenser fins.

[0022] Figure 6B Shows a sectional view of evaporator fins.

[0023] Figure 6C Shows a perspective view of an example cooler, which shows the condenser fins and evaporator fins, and the heat exchanger tubes are in situ in the device, applicable to the embodiments.

[0024] Figure 6D Shows an end view of an example cooler, which shows the condenser fins and evaporator fins, applicable to the embodiments.

[0025] Figures 7A - 7C Shows an example heat exchanger tube with structural damage.

[0026] Figure 7A Shows an example condenser tube with no wall loss.

[0027] Figure 7B Shows an example evaporator tube with no wall loss.

[0028] Figure 7C Shows an example heat exchanger tube with a defect of zipper crack type and a defect depth of 25% into the tube wall.

[0029] Figure 8 Shows a tool fixing device with a test probe, applicable to various embodiments.

[0030] Figure 9A Shows a flowchart for non-destructive testing of a heat exchanger piping system in an embodiment.

[0031] Figure 9B Shows a further flowchart of a method for some embodiments, characterized by a spool coil and an array probe.

[0032] Figure 9CShows a further flow chart of a method for some embodiments, characterized by a tube array for testing.

[0033] Figure 10 Shows a control circuitry according to some example implementations of the present disclosure. Detailed Description

[0034] Various embodiments of systems, system components, and methods of operating a system for non-destructive testing of a heat exchanger tube system are presented herein. Some embodiments are particularly applicable to heat exchanger tube systems in water-cooled climate products, including condenser tubes and evaporator tubes. The embodiments address technical problems that arise in heat exchangers and their manufacture, monitoring, and repair, as further described in the various examples below. A calibration standard is used in the various embodiments, which may be embodied as a calibration standard heat exchanger tube.

[0035] One embodiment includes a calibration standard for eddy current testing of non-ferromagnetic tubular products used in water-cooled climate products. In one example, the new calibration standard is a calibration standard heat exchanger tube made of the same test object material alloy as other heat exchanger tubes and having a combination of defects (e.g., intentionally induced or other known defects) that enables a technician to characterize many types of defects found in non-ferromagnetic tubular products having enhanced surfaces both internally and externally. The same calibration standard (e.g., a particular calibration standard tube(s)) can be used throughout the life of the main product to monitor the development of any potential defects or general structural integrity. These defects, which can be introduced by etching, mechanically, or otherwise on this special calibration standard, can be specific to a particular product.

[0036] The structural quality of non-ferromagnetic tubular products is a far-reaching issue in water-cooled coolers and related industrial heat exchange applications. Customers and manufacturers of such equipment have tried several methods to enhance the quality and usability of the tubular materials used in their machines to meet the lifespan of their products. The example disclosures herein describe improvements to optimize eddy current technology processes.

[0037] Challenges in monitoring the lifespan of tubular products include differences in technology (detection procedures), personal experience, signal interpretation skills, equipment, and calibration standards used when testing the object material. The human factor aspect in non-destructive testing broadens the bandwidth of subjectivity and leaves room for significant differences in test results and response actions. While this particular gap can be addressed to some extent through training, there are other particular gaps that can be targeted for improvement. As mentioned above, one of the key challenges in the art is "differences in the calibration standards used", which provides a target for improvement.

[0038] In some embodiments, calibration standards (e.g., calibration standard heat exchanger tubes) are mainly used to characterize all identified anomalies by using known defects etched into the calibration standards. Each known defect is classified as an acceptable defect or an unacceptable defect based on whether the known defect is understood to have a substantial impact on the performance of the heat exchanger tube. Industrial practitioners may use similar (but not identical) types of alloy materials and several different types of standards to characterize such anomalies and ultimately arrive at different interpretations. This is mainly due to the inability to obtain a material sample identical to the material sample used inside the heat exchanger or the same standards used during the primary baseline tests in the factory.

[0039] Calibration standards may vary significantly based on the original product design (e.g., internal or external surface (such as fins) treatment), the alloy materials used, defect design differences, etc. To eliminate this variation, in the process of the present disclosure, new calibration standards are developed. In various embodiments, the new calibration standards (e.g., (multiple) calibration standard heat exchanger tubes) are more closely related to the specific heat exchanger tubes to be tested and compared in terms of structural characteristics (e.g., tube type, material, surface treatment, and / or specific defects, etc.) compared to general-purpose tubes. For example, a general-purpose tube that may have been used in past tests may be a general material and not of the same type as the specific heat exchanger tube to be tested. The general-purpose tube may not have specific, intentional defects as may be desired in the field or during manufacturing. For example, the calibration standard heat exchanger tube can be made of the same (possibly identical) test object material alloy and surface treatment as the (multiple) specific heat exchanger tubes to be tested and can have a special combination of defects that enables technicians to characterize many types of defects found in non-ferromagnetic tubular products with enhanced surfaces on both the inner and outer sides. This special combination of defects arranged on the heat exchanger tube can include unacceptable wall damage and acceptable surface damage. The same calibration standard can be used throughout the life of the main product to monitor the development of any potential defects or general structural integrity. In some embodiments, the specific defects intentionally and deliberately placed in the (multiple) calibration standard heat exchanger tubes are generated through trial and error and / or possibly by consulting technicians in the art. In some examples, they are based on existing tubes with an acceptable performance level utilized in the field.

[0040] In an embodiment, the calibration standard heat exchanger tube or multiple calibration standard heat exchangers are characterized by: 1. A 1.27” custom combination standard made of the same material as the object test material. 2. A unique combination of 15 defects placed to characterize the identified anomalies. 3. The defects are as follows: a. A 10% inner diameter (“ID”) groove b. Round-bottomed pits at 25% and 50% ID c. 100% through-wall holes d. Flat-bottomed holes at 60% outside diameter (“OD”) e. Flat-bottomed holes at 4% - 20% OD, circumferentially spaced 90 degrees apart f. 10% OD grooves with outer fins removed g. 0% OD wear scars of 180 degrees with only outer fins removed h. 30% OD spiral grooves with a 1.5" pitch and a 400-degree wrap i. Planes at 25% and 50% OD j. Circumferential notches at 20% and 50% OD with a 50-degree wrap k. Axial notches at 20% and 40% OD with a 0.250" axial length 4. The only packaging to protect the lifespan of the calibration standards used during production In some examples, these features are utilized more or less, and it is understood that the values can potentially be adjusted based on, for example, the tube being tested

[0041] Eddy current testing (ECT) is a non-destructive testing (NDT) method that is used to provide information (such as unexpected and / or preventive conditions that affect equipment reliability and operating costs). This form of inspection is critical and is widely performed on non-ferromagnetic tubular material products installed in commercial and industrial water-cooled coolers. In some examples, non-ferromagnetic tubular products are the most critical (or very critical) components in climate control products, rather than compressor technology which is also used in climate control products

[0042] To further understand the situation, the efficiency of the cooler is generally highly related to the type of non-ferromagnetic tubular product, and thus, this information can be considered proprietary to cooler manufacturers. Such products are typically designed with maximum precision and demonstrate high-end traditional engineering achievements

[0043] One of the main purposes of such non-ferromagnetic tubular products is to provide a controlled energy transfer (usually heat transfer) between the working fluids within climate products. The desired transfer rate can be achieved, but this depends on several geometric features of the product as well as the material alloy. Such products are typically designed in a way that maximizes the surface area, which enhances the convective process of heat transfer. Depending on the specific design of the geometric features, the manufacturing process can introduce several non-compliant situations, leading to failures

[0044] In some examples, the raw material for the tubular product is produced using a stretching process, and the final product is generated using a mandrel on the inside and a finned disc assembly on the outside. During the manufacturing process, transportation, and installation, several defects can be introduced into the tubular product, as shown below but not limited to: 1. Metal loss from the tube wall 2. Ferromagnetic dust / fragments / deposits 3. Split / bent fins along the tube OD / ID 4. Small dents, where the tube ID is less than 5% of the nominal ID 5. Large dents, where the tube ID is greater than 5% of the nominal ID 6. Obstruction. Inspection cannot be performed due to a possible bent tube end. 7. Restricted. The probe cannot perform 100% full-length inspection of the tube. 8. Chatter: A phenomenon caused by the tube manufacturing process, characterized by isolated horizontal movement areas. 9. Inaccessible: Indicates that the tube cannot be tested through the tube sheet. 10. Corrosion: Formed by acidic conditions between the tube OD and the shell ID that appear inside the cooler / heat exchanger. 11. Permeability Variation: A phenomenon of similar flaws (foreign objects) that cause false eddy current signals. 12. Micro Inclusion, a microscopic level material void that can develop into other more serious phenomena (such as lap seams). These voids are usually smooth and difficult to characterize. 13. Outside Micro Pitting, pitting marks at the microscopic level on the OD that can develop into more serious phenomena. 14. Inside Micro Pitting, pitting marks at the microscopic level on the ID that can develop into more serious phenomena. 15. (Ferro)magnetic “Writing”—associated with ferromagnetic fragments being forced through the tube ID, leaving traces of ferromagnetic material on the ID tube wall. 16. Lap Seam—a phenomenon that begins with the inclusion appearing in the original metal billet before the inclusion is expelled during extrusion and creates an overlapping layer. If unobstructed, a change from ID to OD will occur. 17. Zipper Crack - A phenomenon that begins with the appearance of an inclusion on the surface of the original metal billet before the inclusion is expelled during extrusion and is formed into a crack when the external force applied during the finning operation acts on the tube OD. If unhindered, a change from OD to ID will occur. 18. Circumferential Crack - Also known as a transverse crack; appears to spread consistently with the eddy current field and is hardly detectable by differential testing, and shows a unique signal characteristic in the X-axis test. 19. Stress Crack - Appears in large numbers over a short span distance and usually penetrates the tube to various depths. 20. Stress Corrosion Crack - A stress crack phenomenon corresponding to corrosion. 21. Longitudinal Crack - Appears to spread along the length of the tube and shows a long and unique signal characteristic in both differential and X-axis tests.

[0045] The importance of product integrity confirmation is usually critical for climate products. For example, any fluid leakage between the refrigeration side and the water side will immediately render the climate machine inoperative. In addition, the material wall thickness of the tubular products discussed here can range between 0.025" and 0.035". Any material loss greater than 12% (0.03") is generally considered unacceptable.

[0046] One of the most effective ways to identify rejects in non-ferromagnetic tubular products is a non-destructive testing method called eddy current testing. This testing is typically required to be performed in accordance with ASME (American Society of Mechanical Engineers) BPVC (Boiler and Pressure Vessel Code), Section V, Mandatory Appendix II (Eddy Current Examination of Non-Ferromagnetic Heat Exchanger Tubing). The testing of a given tube can be performed after the tube is manufactured, after the tube is installed in a component, after the tube and component are installed in a complete assembly, after the installation of the complete assembly at the customer site, and / or at intervals during the life of the completely installed assembly at the customer site. Typically, in order for the end customer to obtain an acceptable tubular product that passes 100% in the final machine, the testing is performed after the tubular product is installed inside a climate product (a pressure vessel such as an evaporator and condenser) and before the pressure vessel is shipped from the manufacturer. In this way, almost all possibilities of defects caused by the manufacturer, shipping, material handling, installation, pressure vessel assembly, etc. have occurred. On the contrary, if the testing is performed as soon as the end customer receives the final product, the possibility of obtaining a replacement tubular product is minimal and can affect the commissioning plan of the entire project. Moreover, the end customer also cannot retest the container and requalify the container to meet the requirements of ASME BPVC VIII.

[0047] Generally speaking, it is preferred to perform a baseline eddy current test at the site of the manufacturer of the tubular product, then a second baseline eddy current test at the equipment (heat exchanger) manufacturer, and continue to perform this second baseline eddy current test annually at the customer site.

[0048] Unfortunately, the testing is often subjective, and it is common for tests to result in different or incorrect results after multiple tests. The main factors causing this difference are the use of non-standard calibration standards, or just the use of different types of calibration standards made of unknown alloys, which may be close enough but not exactly the same alloy. In addition to the material, the enhancements (tube fins) on water-cooled climate products are also specifically designed and are usually proprietary to the tube manufacturer. There are often significant variations between these enhancement designs, which will prevent the testing technique from achieving optimal results.

[0049] To address such technical obstacles, the solutions described below in various embodiments are aimed at creating a unique calibration standard made of the same material / sample used in the tubular product. The design of this calibration standard should include a specific set of carefully placed defects, which will optimize the process of characterizing anomalies.

[0050] An amount of volume loss of material from the tube wall equal to or more than that of the calibration standard can be a reason for rejection, and various other factors can also be reasons for rejection. The analyst can compare the actual defect signal with Combinations of available response characteristics to determine whether the anomaly is an actual defect.

[0051] The quality and quantity of this combination of available responses may matter. This may vary depending on a) the similarity of the sample to the actual geometry and design. For test data and calibration data, it is recommended to use the same b) frequency channels, c) fill factor (the ratio of the OD of the probe to the ID of the tube), d) coil arrangement, e) number of coils, f) type of defect in the calibration standard as expected in the field or manufacturing process, etc.

[0052] Figure 1 An embodiment of a system for non - destructive testing of a heat exchanger tube system and an embodiment of components of the system are shown. In an embodiment, a tool fixture 112, which may be a tool support or may be a robot, positions a tool 110 that inserts a probe 102 into a particular heat exchanger tube 104 to be tested. Alternatively, the probe can also be operated outside the particular heat exchanger tube 104 for testing. Or, the particular heat exchanger tube can be moved relative to the probe and vice versa. Here, the heat exchanger tube 104 is shown as being mounted to a tube sheet 106 (such as may be found in a heat exchanger), and typically a number of tubes are mounted to the tube sheet (not shown, but see Figures 6A - 6D ).

[0053] Measurement data from the probe 102 moving 108 within the heat exchanger tube 104 is transmitted to a technician system 120, and this measurement data typically comes from the tool 110 pushing and / or pulling the probe 102 via an extendable and retractable instrument cable 114. There, a processor 122, a memory 126, and one or more applications 124 can locally store and / or process the measurement data from the probe 102 and transmit the measurement data or data processed from the measurement data to a cloud storage 138 via a network 140.

[0054] Correspondingly, in various embodiments, measurement data collected from the probe (s) of the calibration standard tube (s) 118 is also transmitted and stored in the cloud storage 138, or can be stored in the technician system 120 or the analyst system 130. For example, the same or another technician or robot fixture can operate the same tool fixture 112, tool 110, and probe 102 or another one of these under controlled conditions to collect measurement data from the probe 102 moving within the relevant calibration standard tube 118 or another probe (preferably the same or close to the same within appropriate tolerances). The calibration standard tube (s) 118 have intentional defects 116 arranged such that the measurement data from probing the calibration standard tube (s) 118 represents these defects and can be used for analysis. More specifically, the measurement data from probing the calibration standard tube 118 with intentional defects 116 is used to compare with the measurement data from the selected heat exchanger tube 104 under test.

[0055]

[0055] The use of cloud storage 138 allows the analyst system 130 to be used remotely or at other locations, which need not be co-located with the technician system 120 and the selected heat exchanger tube 104 under test (but may be in some embodiments). That is, remote analysis is enabled through the use of cloud storage 138. The analyst system 130 with a processor 132, a memory 134, and one or more applications 136 accesses measurement data or processed data from the selected heat exchanger tube 104 under test via a network 140 connected to the cloud storage 138 and the memory therein. This enables remote analysts to compare measurement data with possible defects from probing the selected heat exchanger tube 104 with measurement data with intentional defects 116 from probing the calibration standard tube 118.

[0056]

[0056] In one embodiment, the tool fixture 112 is a tool support and reduces the physical fatigue of the user when holding the tool 110. For example, the tool fixture 112 can be manually positioned by the user (e.g., see Figure 8 ) for properly positioning the tool 110 and the probe 102 to a particular heat exchanger tube 104. In one embodiment, the tool fixture 112 is roboticized and includes, for example, a robotic locator, a robotic arm, etc., and local or integrated robotic control communicable with or part of the technician system 120 for robotic positioning and determining the position of the tool 110 and the probe 102.

[0057]

[0057] In one embodiment, the tool 110 has a machine-controlled pulling speed for the test probe 102. For example, the tool can push the probe 102 into the selected heat exchanger tube 104 by extending the instrument cable 114, to which the probe 102 is attached at its end. The tool can pull the probe 102 through the selected heat exchanger tube 104 by retracting the instrument cable 114, to which the probe 102 is attached at its end. One, the other, or both of these operations can be at a controlled rate, which can be constant or variable in various embodiments, and this can provide precise positioning of the probe 102 and the correlation of test data with the probe position for analysis.

[0058] In one embodiment, more than one probe is used. For example, the probes can be of various types, some of which are more sensitive while some are less sensitive. Probes of the less sensitive type can be used initially, followed by probes of the more sensitive type. Examples of probe types for internal operation of the tube being tested include spool probes (which may have lower sensitivity), array probes (which may have higher sensitivity), etc. Examples of probe types for external operation of the tube being tested include surface probes (which can have variants with higher or lower sensitivity), encircling coils or doughnut-shaped probes (which operate outside the tube (e.g., encircling the tube) and can have variants with higher or lower sensitivity), etc. It is contemplated that one type of surface probe can operate inside the tube while another can operate outside the tube, and various combinations of these probes can also be used. It is contemplated that one probe can employ a transmitter outside the tube in a sensor inside the tube, and one probe can employ a transmitter inside the tube and a sensor outside the tube. In accordance with the teachings herein, various other probes and probe types can be employed singly, multiply, and in different ways.

[0059] Figure 2A Aspects of non-destructive testing of a heat exchanger tube system for an embodiment are shown. Data collection 202 assisted or performed by a technician 210 (possibly a lower-level or less experienced technician (e.g., a Level I technician)) can be completed on-site 226 while testing one or more selected heat exchanger tubes. Analysis 206 assisted or performed by another technician 212 (possibly a higher-level or more experienced technician (e.g., a Level IIA or Level III technician)) can be completed off-site 228 (e.g., at a location remote from the heat exchanger tube(s) being tested). Communication between the system and the associated processes (e.g., involving data transfer) can be performed via storage 204 (possibly cloud storage) and network communication 220 from data collection 202 to storage 204 and network communication 222 from storage 204 to analysis 206. There can also be a communication path 224 between technician 210 (lower-level technician (e.g., a Level I technician)) and technician 212 (higher-level technician (e.g., a Level IIA or Level III technician)) for, e.g., notification, alert, question-and-answer, indication, reporting, etc. Other communication paths and processes can also be utilized.

[0060] Figure 2B A process diagram is shown that shows for including Figure 2AThe role of test data 242 from non-destructive testing of specific heat exchanger tubes and calibration data 254 from non-destructive testing of (one or more) calibration standard heat exchanger tubes in various embodiments. An entity 240 (which may include a technician, tools, probes, and / or robots, a test system, etc.) collected test data 242 for a specific heat exchanger tube. An entity 246 (which may include the same or another technician, tools, probes, and / or robots, a test or calibration system, etc.) collected calibration data 254 for one or more specific calibration standard heat exchanger tubes. The test data 242 and the calibration data 254 are stored in a storage 244 which, in various embodiments, may be cloud storage, (one or more) local storage, or distributed storage and is accessible in the storage 244. An entity 248 (which in some further embodiments may include an analyst, a system, or AI) performs a comparison and analysis process 250 on the test data 242 and the calibration data 254 as accessed through the storage 244. Thereby, the entity 248 (which in some further embodiments may include the same or another analyst, a system, or AI) performs a structural health assessment 252 on the (one or more) specific heat exchanger tubes.

[0061] Figure 3 A flowchart of a method for non-destructive testing of a heat exchanger tube system in an embodiment is shown. Actions as performed in or by various groups of personnel 302, 304, 306, 308 are shown, and these groups of personnel may belong to a parent company, may be independent, and may operate in cooperation with the parent company. It should be understood that in a process consistent with the teachings herein, further embodiments with various groups of personnel, their various devices, and various associations can be readily extended. In performing Figure 3 the various operations shown, various embodiments of calibration standards, (one or more) calibration standard tubes, or calibration standard heat exchanger tubes can be used, and various embodiments of the processes, methods, and systems described herein can be used, as further discussed below.

[0062] Actions 310, 312, 314 may be performed by or through a group of sales, order management, and engineering personnel 302 which may be associated with a parent company. In action 310, an order is received. The order may be for a heat exchanger tube, components including the heat exchanger tube, a heat exchanger system (e.g., refrigerant, HVAC, water-cooled chiller, industrial installation), etc.

[0063] In action 312, the order for construction is scheduled. This may be an order for constructing or installing (e.g., in manufacturing or at a customer site) a heat exchanger tube, components, an entire system, or a subsystem, etc.

[0064] In operation 314, a job file is created for a specific tubular product under each pressure vessel order. The format and content of the job file are readily understandable from the context of the order for construction in operation 312. The process proceeds to operation 316.

[0065] In various embodiments, operations 316, 326, 328, 332, 334 may be performed by or through a team 306 of NDT (non-destructive testing) analysts, which may be independent and operate in cooperation with the parent company. For example, the team 306 of analysts may be external to manufacturing and may be external to the installation site. Alternatively, in some embodiments, the team 306 of analysts may be in-house. In operation 316, a setup file is created and saved in the server for each order. The process proceeds to operation 318.

[0066] Operations 318, 320, 322, 324, 330 may be performed by or through a team 304 of operators, which may be associated with the parent company. In operation 318, the order readiness is tracked.

[0067] In operation 320, a test is performed and the data is saved in the server. The test and the resulting data may use the embodiments of the processes, methods, components, systems, and / or devices described herein. See Figures 1 - 2A and Figures 4A - 9B .

[0068] In operation 322, it is determined whether there is clean data. If the answer is "no", the process returns to operation 320 to perform subsequent tests and save the data. If the answer is "yes", the process proceeds to operation 324.

[0069] In operation 324, the analysts are alerted to perform an analysis. The process proceeds to operation 326.

[0070] In operation 326, the data in the server is analyzed. The type of the analysis and the data, as well as the location and storage of the data, may use the embodiments of the processes, methods, components, systems, and / or devices described herein. See Figures 1 - 2A and Figures 4A - 9B . The process proceeds in parallel to operation 328 and operation 332.

[0071] In operation 328, the test result from operation 326 is determined to be passed or failed. If the test result is "passed", the process proceeds to operation 330 to transport the product. If the test result is "failed", the process proceeds to operation 334.

[0072] In action 330, in response to "pass", transport the product. In action 334, in response to "non - conforming", the analyst's company personnel group 306 will provide the operations personnel group 304 with a list of defective tubes or rework instructions, and meanwhile the process goes to action 320 (see above). The list of defective tubes and rework instructions can be based on data and analysis using the (multiple) embodiments of the processes, methods, (multiple) components, (multiple) systems, and / or devices described herein, see Figures 1 - 2A and Figures 4A - 9B 。

[0073] In action 332, following action 326, compare the data and the analyzed data with the baseline data in the server. More specifically, compare the data obtained from testing the (multiple) tubes with the baseline data from the (multiple) test tubes, where the baseline data of the (multiple) test tubes is, for example, testing various calibration standard heat exchanger tubes in the (multiple) embodiments, or testing against previously saved production test data obtained from testing the (multiple) tubes, etc. This can use the (multiple) embodiments of the processes, methods, (multiple) components, (multiple) systems, and / or devices described herein, see Figures 1 - 2A and Figures 4A - 9B 。The process proceeds to action 338.

[0074] Actions 336, 338, 340 can be performed by or through the customer service personnel group 308, which can be associated with the parent company. In action 338, either plug or monitor the defective tubes. This action 338 is based on the analysis and comparison from actions 326 and 332, and can be understood as involving the transfer of relevant data from the analyst's company personnel group 306 to the customer service personnel group 308, thus using the (multiple) embodiments of the processes, methods, (multiple) components, (multiple) systems, and / or devices described herein, see Figures 1 - 2A and Figures 4A - 9B 。

[0075] In addition, the customer service personnel group 308 can perform action 336, perform an annual test (continuous monitoring), which also leads to action 338, to plug or monitor the defective tubes.

[0076] The process ends at action 340. It should be understood that the above actions and processes can be ongoing, continuous or intermittent throughout the entire life of the (multiple) specific tubes, (multiple) heat exchanger tubes, and / or (multiple) heat exchanger systems.

[0077] Figure 4AExamples of bobbin coil data are shown. Such data is illustrated as a graphical form (e.g., a waveform, a two-dimensional XY plot, etc.), and it is understood that the data can be stored, rendered, visualized, analyzed, etc. in various other forms (such as tabulated, 3D rendered and operable for viewing, virtual reality rendering, etc.).

[0078] The bobbin data 402 is shown in a two-dimensional format (e.g., signal probe versus probe position for a number of specified frequencies). These may be channels for bobbin data from a bobbin probe that is inserted into a tube (e.g., a heat exchanger tube) and moved through a range of positions within the tube.

[0079] The bobbin coil data 404 is shown in a two-dimensional format (eg, an XY cross-sectional frequency response at a particular bobbin coil probe location within the pipe, as indicated by the cursor position in the lower data trace at the potential defect location).

[0080] Figure 4B Examples of array probe data and bobbin coil data are shown. Such data is illustrated in graphical form (e.g., waveforms, plots, maps, two-dimensional projections of three-dimensional views, etc.), and it is understood that the data can be stored, rendered, visualized, analyzed, etc. in various other forms (such as tabulated, 3D rendered and operable for viewing, virtual reality rendering, etc.).

[0081] The bobbin coil data or array probe data 422 is shown in a two-dimensional format, for example, the signal amplitude for two specified frequencies is relative to the probe position. The bobbin coil data or array probe data 424 is shown in a two-dimensional format, for example, as the signal frequency response of the lobe in the XY format cross section at a specific probe position, which is indicated in the form of an amplitude relative to the probe position diagram as described below. The bobbin coil data or array probe data 426 is shown in an XY diagram, and the signal amplitude or intensity can be shaded or color-coded on the diagram. The bobbin coil data or array probe data 428 is shown at the top as a two-dimensional lobe, and the bottom is a two-dimensional projection of a three-dimensional rendering, where potential defects are shown or indicated as signal peaks, which can also be shaded or color-coded on the diagram, etc. As can be seen, the resolution of the test data results is expected to vary based on the selected probe, and therefore the probe should be consistent between the use of the tested tube and the use of the calibration standard.

[0082] Figure 5A , Figure 5B , Figure 5C and Figure 5D Examples of heat exchanger tubing and probes suitable for use with embodiments are shown. Further embodiments are not limited to these examples and may be readily devised while remaining consistent with the teachings herein.

[0083] Figure 5A The finned tube system 506 is shown. The fins 502 may be located inside the finned tube system 506 in some embodiments, or outside the finned tube system 506 in some embodiments. The fins 504 may be different from the fins 502, and the fins 504 may be located inside the finned tube system 506 in some embodiments, or outside the finned tube system 506 in some embodiments. It should be understood that in some embodiments, a damaged fin may be considered an unacceptable defect, or in some embodiments, if the wall thickness is not affected, a damaged fin may be considered not a defect or an acceptable defect.

[0084] Figure 5B An internally reinforced tube system with a defect 512 is shown. The view shown is the surface of the tube system 510 with the defect 512, which is shown as a displacement or deformation of the surface features. It can be understood that the defect 512 is detectable by analyzing data from a probe, as described in various embodiments herein.

[0085] Figure 5C The bobbin coil probe 518 is shown. This example bobbin coil probe has a plurality of probe coils 522, 524 and an instrument cable 520. The instrument cable 520 may have a dual function of signal communication with the probe coils 522, 524 and mechanical communication with the probe coils 522, 524 for the movement and positioning of the bobbin coil probe 518 (e.g., inside a tube). The plurality of probe coils 522, 524 may support multi-frequency signaling. Probes of various sizes may be available for tubes of different inner diameters, or for tubes with or without deposits or a range of deposits and their thicknesses, which may affect probe movement and / or signal coupling.

[0086] Figure 5D The array probe 530 is shown. This example of the array probe has a plurality of probe coils 532, 534 and may also have an instrument cable (not shown but easily understood). The plurality of probe coils 532, 534 may support multi-frequency signaling. One or more of the probe coils 532, 534 may be array coils, which, compared to and in contrast to the bobbin coil probe 518, support highly directional signaling and / or signaling with a greater number of channels.

[0087] Figure 6A and 6B A tube sheet diagram of a condenser tube sheet and an evaporator tube sheet is shown, which shows the position of the heat exchanger tubes in an example installation. The tube sheet may also be referred to as a tube plate (see Figure 1 ), and vice versa. In some examples, these tube sheet diagrams may be provided on a display or other medium.

[0088] Figure 6A A fin diagram of a condenser fin is shown. In a heat exchanger system, the condenser tubes are located in the condenser of the heat exchanger (see also Figure 6C and Figure 6D ). The fin diagram is a representation of the position or orientation of the heat exchanger tubes of the condenser and can be represented in various formats of data to allow tracking of the heat exchanger tubes during installation, testing, repair (e.g., plugging), replacement, etc. For example, one of the tubes 602 is indicated as okay or "passed", one of the tubes 604 is indicated as defective but currently does not require repair, multiple tubes 606 are indicated as defective and require repair, and one of the tubes 608 is indicated as recently replaced or alternatively needs to be replaced (e.g., replace with a new tube).

[0089] Figure 6B A fin diagram of an evaporator fin is shown. In a heat exchanger system, the evaporator tubes are located in the evaporator of the heat exchanger (see also Figure 6C and Figure 6D ). The fin diagram is a representation of the position or orientation of the heat exchanger tubes of the evaporator and can be represented in various formats of data to allow tracking of the heat exchanger tubes during installation, testing, repair (e.g., plugging), replacement, etc. For example, one of the tubes 620 is indicated as okay or "passed", multiple tubes 622 are indicated as defective and require repair, and one of the tubes 624 is indicated as recently replaced or alternatively needs to be replaced (e.g., replace with a new tube).

[0090] Figure 6C A perspective view of an exemplary cooler is shown, which shows the condenser fin 640 and the evaporator fin 642, and the heat exchanger tubes are in situ in the device, suitable for the embodiment. The heat exchanger tubes for the condenser are within the condenser chamber 644, and the condenser chamber 644 has the condenser fin 640 as an end plate (the heat exchanger tubes are not shown, but see Figure 6A ). The heat exchanger tubes for the evaporator are within the evaporator chamber 646, and the evaporator chamber 646 has the evaporator fin 642 as an end plate (the heat exchanger tubes are not shown, but see Figure 6B ).

[0091] Figure 6D An end view of the exemplary cooler is shown (see Figure 6C) This end view shows the condenser fin 680 and the evaporator fin 684, applicable to the embodiment. To test the heat exchanger tubes (e.g., heat exchangers or their sub-assemblies) in-situ in the device, before transportation, or in-situ in the device after installation at the customer site (e.g., complete cooler installation), a suitable probe is inserted into the hole 682 of the condenser fin 680 or the hole 686 of the evaporator fin 684, and into the selected heat exchanger tube located on the other side of the condenser fin 680 or the evaporator fin 684 inside the condenser or the evaporator. Thus, according to the embodiment, there is no need to remove the heat exchanger tubes from the heat exchanger for such tests.

[0092] Figures 7A - 7C An example heat exchanger tube with structural damage is shown.

[0093] Figure 7A An example condenser tube 702 with no loss in the tube wall is shown. The damaged area 704 shows bent, crushed, or otherwise damaged fins on the outside of the condenser tube 702, which may occur through physical contact or impact with an object. In this example, the cross-sectional longitudinal view (the lower part of the figure) shows that the thickness of the tube wall 708 has no loss, even in the damaged areas 710, 712 where the fins are bent, crushed, or even removed. In various embodiments, the rendered test data 706 obtained by probing the example condenser tube 702 (see also Figure 4A and Figure 4B ) is analyzed to determine the health assessment of the condenser tube 702. For example, by comparing the signal data from a probe with that from a calibrated standard heat exchanger tube, the signal data from a specific probe can be analyzed to determine that the tube wall of the selected condenser tube 702 has no loss, and the health assessment is that the condenser tube 702 has some damage but does not require repair or replacement.

[0094] Figure 7B An example evaporator tube with no loss in the tube wall is shown. The damaged area 724 shows fins bent or displaced along a line segment, which may occur through scraping contact with an object. In this example, the cross-sectional transverse view (the lower part of the figure) shows that the thickness of the tube wall 720 has no loss, even in the damaged area 722 of the displaced fins. In this example, by comparing the signal data from a probe with that from a calibrated standard heat exchanger tube, the signal data from a specific probe can be analyzed to determine that the tube wall of the selected condenser tube has no loss, and the health assessment is that the condenser tube has some damage but does not require repair or replacement.

[0095] Figure 7C An example heat exchanger tube 730 with a defect type of zipper crack and a defect depth of 25% into the tube wall is shown. The external view on the left side of the figure shows a diagonal damaged area 732, which may look likeFigure 7B is similar to the damaged area 724 in. However, in this example, the cross-sectional side view (right side of the figure) shows that the tube wall 734 has losses in the form of zipper cracks 736 that are not visible from the outside. In this example, the signal data from a particular probe can be analyzed by comparing it with the signal data from a probe of a calibrated standard heat exchanger tube to determine the presence of losses in the tube wall of the selected condenser tube, and the health assessment is that the condenser tube is damaged and does indeed require repair or replacement.

[0096] Figure 8 A tool fixture with a test probe 802 is shown, suitable for various embodiments. In various embodiments, the tool fixture can be an ergonomic fixture that both positions the tool with the test probe and reduces user fatigue that may occur when the user holds the tool by hand. In this embodiment, the tool fixture has brackets or clamps 828, 832 that can be fastened to other fixed, movable, or adjustable devices, and has a slide rail 810 onto which a suitable tool 806 with a test probe 802 can be mounted. The vertical beams 824, 830 have brackets or clamps 828, 832 and support the horizontal beams 814, 812, which can be telescoped or slid for adjustment. The cross beams 818, 820 increase the support force and rigidity of the tool fixture. The tool 806 is mounted to the slide rail 810 through a tool mount 808 and can be moved and positioned along the slide rail 810. The horizontal beams 814, 812 can be moved in and out. In some embodiments, the vertical beams 824, 830 are telescoping or slidable for height adjustment of the tool fixture. In some embodiments, the device to which the brackets or clamps 828, 834 are attached can be adjusted in height. Thus, when the probe 802 is inserted and moved within the selected tube for testing, the tool fixture allows adjustment of the positioning of the tool 806 in the X, Y, and Z axes and the support of the tool 806. For example, the tool fixture can be attached to a wheeled variable height (e.g., electric or hydraulic lift) cart, platform, or lift, then moved into position, and then the tool fixture is adjusted into position, after which the tool fixture is manually adjusted to align the tool 806 and the probe 802 in situ (e.g., in a component, device, or field installation) with the selected heat exchanger tube.

[0097] Figure 9A A flowchart of a method for non-destructive testing of a heat exchanger tube system in an embodiment is shown. The method can be practiced using embodiments of the devices, components, systems, and processes described herein and their variations. Embodiments can use one or more calibrated standard heat exchanger tubes, can use cloud storage, and / or can use one or more remote analysts.

[0098] In operation 902, a test probe is used in the (multiple) specific heat exchanger tubes to generate and store test data. The generation and storage of the test data do not need to be at the same location or at the same time.

[0099] In operation 904, a test probe is used in the (multiple) calibration standard heat exchanger tubes to generate and store calibration data. This can be done before, during, or after operation 902 and the generation and storage of the test data. The generation and storage of the calibration data do not need to be at the same location or at the same time.

[0100] In operation 906, the test data and the calibration data or data processed from them are accessed. The access can be through cloud storage. By comparison, a structural health assessment of the (multiple) specific heat exchanger tubes is determined. The determination of the structural health assessment can be performed by a remote analyst. In some examples, the process includes using software, a processor, or other devices to perform the health assessment. In these examples, the health assessment can be displayed on a screen (not shown). In some examples, the display shows various coils that pass or fail the assessment, which may include similar to Figure 6A and / or Figure 6B such a display.

[0101] In a variant, the system detects damage to the tube (such as a crushed tube, a bent tube, a wall deflection, etc.) that prevents the probe from traveling, and assesses the tube as defective.

[0102] Figure 9B A further flowchart of a method for some embodiments is shown, which features a spool coil and an array probe. In various embodiments, the method can be practiced using the method depicted in Figure 9A within the method or as a variant of the method. The method can be practiced using embodiments of the devices, components, systems, and processes described herein and their variants. Embodiments can use the (multiple) calibration standard heat exchanger tubes, can use cloud storage, and / or can use the (multiple) remote analysts. Variants of the method can be practiced using a first probe type (for preliminary test data) and a second more sensitive probe type (for secondary test data).

[0103] In operation 908, a spool coil probe is used to generate preliminary test data for the (multiple) specific heat exchanger tubes.

[0104] In operation 910, spool coil preliminary test data is used to determine if there are possible defects in the specific heat exchanger tube(s). This can be accomplished using operations 902, 904, 906. Alternatively, this can be a variant of operations 902, 906. If the determination in operation 910 is "no", the process branches to operation 911, "pass". If the determination in operation 910 is "yes", the process branches to operation 912.

[0105] In operation 912, an array probe is used to generate secondary test data.

[0106] In operation 914, a structural health assessment is performed on the specific heat exchanger tube(s) using the secondary test data or the secondary test data and the preliminary test data. This can be accomplished using operations 902, 904, 906. Alternatively, this can be a variant of operations 902, 906.

[0107] Figure 9C A further flowchart of a method for some embodiments is shown, featuring an array of tubes for testing. The method can be practiced using various probes, tubes, tube arrangements, and / or tube components, systems, users, etc. and their variants as disclosed herein in the embodiments. The method can be practiced as part of the various methods described herein in the embodiments or differently from these methods.

[0108] The method has a start 920, proceeding to operation 922. Additionally, it can proceed from a determination operation 930 to operation 922, as further described below. In operation 922, a tube is selected from the array of tubes for testing. That is, there is an array of tubes, which can be embodied as an arrangement of tubes, a tube component, a part having tubes, a subsystem or system having tubes, etc., and can be located at a manufacturer site, a test site, a customer installation site, etc. To begin testing, one of the tubes is selected.

[0109] In operation 924, a tool with a probe is positioned on the selected tube. Various tools and various probes can be suitable. The positioning can be done manually, or through a support structure for the tool, or through a device (such as a robotic locator). Positioning the tool with the probe on the selected tube positions the probe to the appropriate location to begin testing the tube using the probe.

[0110] In operation 926, the selected tube is tested using the tool with the probe. For example, the operation of the properly positioned tool moves the probe within the tube, which generates test data.

[0111] In operation 928, test data from operation 926 is stored in association with the selected tube. For example, there may be a database that has an entry for test data for each tested selected tube, and the database maintains the association and storage of the test data.

[0112] In determination operation 930, it is determined whether the testing, e.g., of the array of tubes, has been performed. If the answer is "no", the testing is not complete and the next tube should be selected for testing, and the process branches back from operation 930 to operation 922 to select another tube in the array of tubes for testing. If the answer is "yes", the testing is complete, and the process proceeds to end 932. In various embodiments, the test data may be analyzed after this.

[0113] Figure 10 A control circuitry 1000 according to some examples of the present disclosure is shown, which may be a device. In some examples, the control circuitry 1000 includes some or all of the technology system 120 and / or the analysis system 130, or any other similar device described in the present disclosure. In some examples, multiple components include the control circuitry. For example, the technician system 120 may include the control circuitry 1000, the analysis system 130 may include another separate control circuitry 1000, and the cloud storage 138 may also include its own control circuitry. In fact, in some examples, the control circuitry 1000 may include one or more of each of several components, such as, for example, a processor 1002 connected to a memory 1004. A processor is generally any piece of computer hardware capable of processing information, such as, for example, data, computer programs, and / or other suitable electronic information. The processor includes one or more electronic circuits, some of which may be encapsulated as an integrated circuit or multiple interconnected integrated circuits (integrated circuits are sometimes more commonly referred to as "chips"). Depending on the particular example, the processor 1002 may be several processors, a multi-core processor, or some other type of processor.

[0114] The processor 1002 may be configured to execute a computer program, such as computer-readable program code 1006, which may be stored on-board the processor or stored in the memory 1004 in some other manner. In some examples, the processor may be embodied as one or more ASICs, FPGAs, etc., or otherwise include one or more ASICs, FPGAs, etc. Thus, while the processor may be capable of executing a computer program to perform one or more functions, the processors of various examples may be capable of performing one or more functions without the assistance of a computer program.

[0115] Memory 1004 is generally any piece of computer hardware capable of temporarily and / or permanently storing information such as, for example, data, computer-readable program code 1006 or other computer programs, and / or other suitable information. The memory may include: volatile memory (such as random access memory (RAM)) and / or non-volatile memory (such as a hard disk drive, flash memory, etc.). In various instances, the memory may be referred to as a computer-readable storage medium, which is a non-transitory device capable of storing information. In some examples, the computer-readable storage medium is non-transitory and has computer-readable program code stored therein, which, upon execution by processor 1002, causes control circuitry 1000 to perform the various operations described herein, some of which operations may in turn cause the climate control system to perform various operations.

[0116] In addition to memory 1004, processor 1002 may also be connected to one or more peripheral devices (such as network adapter 1008), for example, for connection to a communication bus as described above, one or more input / output (I / O) devices (e.g., (multiple) input devices 1010, (multiple) output devices 1012), etc. A network adapter is a hardware component configured to connect control circuitry 1000 to a computer network to enable the control circuitry to send and / or receive information via the computer network. The I / O devices may include one or more input devices capable of receiving data or instructions for the control circuitry, and / or one or more output devices capable of providing output from the control circuitry. Examples of suitable input devices include a keyboard, keypad, etc., and examples of suitable output devices include display devices (such as one or more light-emitting diodes (LEDs), LED displays, liquid crystal displays (LCDs), etc.).

[0117] The following clauses are illustrative of embodiments applicable to various combinations.

[0118] Clause 1. A method for non-destructive testing of a heat exchanger tube system, comprising: performing a machine-controlled test using a test probe inserted into a specific heat exchanger tube to generate test data for non-destructive testing of the specific heat exchanger tube; accessing the test data for non-destructive testing of the specific heat exchanger tube; and using the accessed test data for non-destructive testing of the specific heat exchanger tube in comparison with calibration data associated with at least one calibration standard heat exchanger tube, the at least one calibration standard heat exchanger tube being more closely related to the specific heat exchanger tube in terms of its structural characteristics than a general-purpose tube.

[0119] Clause 2. The method of any clause set forth herein further comprises: using cloud-based storage for test data of non-destructive testing of the particular heat exchanger tube and calibration data associated with the at least one calibration standard heat exchanger tube, wherein accessing comprises accessing the cloud-based storage.

[0120] Clause 3. The method of any clause set forth herein, wherein machine-controlled testing using the test probe comprises using a robot to position and operate a tool comprising the test probe.

[0121] Clause 4. The method of any clause set forth herein, wherein machine-controlled testing using the test probe comprises using a machine-controlled draw speed for the test probe.

[0122] Clause 5. The method of any clause set forth herein, wherein using the test probe comprises: using a tool mounted in an ergonomic fixture configured to reduce user fatigue and position the test probe; and the tool having a mechanized, controlled draw speed for the test probe for the machine-controlled testing.

[0123] Clause 6. The method of any clause set forth herein, wherein generating the test data using the test probe comprises: using a probe of a first probe type inserted into the particular heat exchanger tube to generate preliminary test data; and in response to a preliminary determination that the preliminary test data indicates a possible defect in the particular heat exchanger tube, using a probe of a second, higher-sensitivity probe type inserted into the particular heat exchanger tube to generate secondary test data.

[0124] Clause 7. The method of any clause set forth herein, wherein test data of non-destructive testing of the particular heat exchanger tube is generated and a structural health assessment of the particular heat exchanger tube is determined prior to delivery or installation of the particular heat exchanger tube.

[0125] Clause 8. The method of any clause set forth herein, wherein: generating test data of non-destructive inspection of the particular heat exchanger tube using the test probe is performed in-situ, wherein the particular heat exchanger tube is installed in a component at a first location or in a refrigerant system at a second location; and determination of the structural health assessment of the particular heat exchanger tube is performed by a remote analyst, wherein the remote analyst is not on-site where the particular heat exchanger tube is installed in the component or in the refrigerant system.

[0126] Clause 9. The method of any of the clauses listed herein further includes: arranging a plurality of defects on at least one heat exchanger tube to form the at least one calibrated standard heat exchanger tube; and inserting the same or related test probes into the at least one calibrated standard heat exchanger tube to perform the same or related tests, generating calibration data associated with the at least one calibrated standard heat exchanger tube.

[0127] Clause 10. A tangible, non-transitory computer-readable medium having instructions that, when executed by a processor, cause the processor to perform a method, wherein test data and calibration data are being used for the health assessment of a heat exchanger tube, the method including: receiving test data from a non-destructive test of a specific heat exchanger tube, the test data being generated by performing a machine-controlled test using a test probe inserted into the specific heat exchanger tube; storing the test data from the non-destructive test of the specific heat exchanger tube in a data store; receiving calibration data associated with at least one calibrated standard heat exchanger tube, the calibrated standard heat exchanger tube being more closely related to the specific heat exchanger tube in terms of its structural characteristics than a general-purpose tube; storing the calibration data from the related non-destructive tests of the at least one calibrated standard heat exchanger tube; and enabling access to the test data from the non-destructive test of the specific heat exchanger tube and the calibration data from the tests of the at least one calibrated standard heat exchanger tube in the data store to enable a structural health assessment of the specific heat exchanger tube based on the test data and the calibration data.

[0128] Clause 11. The tangible, non-transitory computer-readable medium of any of the clauses listed herein, wherein: the data store includes cloud-based storage; and wherein the method further includes performing a structural health assessment of the specific heat exchanger tube based on the test data from the specific heat exchanger tube and off-site calibration data.

[0129] Clause 12. The tangible, non-transitory computer-readable medium of any of the clauses listed herein, wherein the method further includes: guiding a robot to position and operate a tool including the test probe for the machine-controlled test.

[0130] Clause 13. The tangible, non-transitory computer-readable medium of any of the clauses listed herein, wherein the test data from the non-destructive test of the specific heat exchanger tube includes preliminary test data using a probe of a first probe type and secondary test data using a probe of a second, more sensitive probe type.

[0131] Clause 14. The tangible, non-transitory computer-readable medium of any of the clauses listed herein, wherein the calibration data from the related non-destructive tests of the at least one calibrated standard heat exchanger tube represents a plurality of defects of the at least one calibrated standard heat exchanger tube.

[0132] Clause 15. A system for non-destructive testing of a heat exchanger tube system, wherein the system is configured to provide test data and calibration data for use in a health assessment of a heat exchanger tube. The system includes: at least one memory; and at least one processor coupled to the at least one memory and configured to: receive test data from a non-destructive test of a particular heat exchanger tube using a test probe inserted into the particular heat exchanger tube; store the test data from the non-destructive test of the particular heat exchanger tube in a data store; store calibration data associated with at least one calibration standard heat exchanger tube, the calibration standard heat exchanger tube being more closely related to the particular heat exchanger tube in terms of its structural characteristics than a general-purpose tube; and support access to the test data from the non-destructive test of the particular heat exchanger tube in the data store and the calibration data from tests of the at least one calibration standard heat exchanger tube to enable a structural health assessment of the particular heat exchanger tube based on the test data and the calibration data.

[0133] Clause 16. The system for non-destructive testing of a heat exchanger tube according to any one of the clauses listed herein, wherein at least the data store includes cloud-based storage.

[0134] Clause 17. The system for non-destructive testing of a heat exchanger tube system according to any one of the clauses listed herein, further comprising: a robot for positioning and operating a tool including the test probe for a test controlled by the machine.

[0135] Clause 18. The system for non-destructive testing of a heat exchanger tube system according to any one of the clauses listed herein, further comprising: a tool including at least one test probe and having a machine-controlled pulling speed for the at least one test probe.

[0136] Clause 19. The system for non-destructive testing of a heat exchanger tube system according to any one of the clauses listed herein, wherein the test data from the non-destructive test of the particular heat exchanger tube includes preliminary test data using a probe of a first probe type and secondary test data using a probe of a second, more sensitive probe type.

[0137] Clause 20. The system for non-destructive testing of a heat exchanger tube system according to any one of the clauses listed herein, wherein a plurality of defects of the at least one calibration standard heat exchanger tube are represented in the calibration data.

[0138] Detailed illustrative embodiments are disclosed herein. However, the specific functional details disclosed herein are merely representative for the purpose of describing embodiments. However, the embodiments may be embodied in many alternative forms and should not be construed as limited to the embodiments set forth herein.

[0139] It should be understood that although the terms first, second, etc. may be used herein to describe various steps or calculations, these steps or calculations should not be limited by these terms. These terms are only used to distinguish one step or calculation from another. For example, without departing from the scope of the present disclosure, the first calculation may be referred to as the second calculation, and similarly, the second step may be referred to as the first step. As used herein, the term "and / or" or the symbol " / " includes any and all combinations of one or more of the associated listed items.

[0140] As used herein, the singular forms "a / an" and "the" are also intended to include the plural forms unless the context clearly dictates otherwise. It will be further understood that when used herein, the terms "comprises", "comprising", "includes" and / or "including" specify the presence of the stated features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof. Thus, the terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting.

[0141] It should also be noted that in some alternative implementations, the labeled functions / actions may not occur in the order labeled in the figures. For example, depending on the functions / actions involved, two figures shown in succession may actually be executed substantially simultaneously, or the figures may sometimes be executed in the reverse order.

[0142] In view of the above embodiments, it should be understood that these embodiments may employ various computer-implemented operations that involve data stored in a computer system. These operations are those that require physical manipulation of physical quantities. Usually, although not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. In addition, the manipulations performed are commonly referred to by terms such as generating, identifying, determining, or comparing. Any operations forming part of the embodiments described herein are useful machine operations. The embodiments also relate to devices or apparatuses for performing these operations. The apparatus may be specially constructed for the required purposes, or the apparatus may be a general-purpose computer selectively activated or configured by a computer program stored in the computer. In particular, various general-purpose machines may also be used with computer programs written in accordance with the teachings herein, or it may be more convenient to construct a more specialized apparatus to perform the required operations.

[0143] Modules, applications, layers, agents, or other entities operable by a method can be implemented as hardware, firmware, or a processor executing software, or a combination thereof. It should be understood that, in parts of this disclosure where software-based embodiments are disclosed, the software can be embodied in a physical machine, such as a controller. For example, the controller can include a first module and a second module. The controller can be configured to perform various actions (e.g., of a method, application, layer, or agent).

[0144] Embodiments can also be embodied as computer-readable code on a tangible non-transitory computer-readable medium. A computer-readable medium is any data storage device that can store data, which can thereafter be read by a computer system. Examples of computer-readable media include hard disk drives, network attached storage (NAS), read-only memory, random access memory, CD-ROMs, CD-Rs, CD-RWs, magnetic tapes, and other optical and non-optical data storage devices. The computer-readable media can also be distributed over network-coupled computer systems such that the computer-readable code is stored and executed in a distributed fashion. The embodiments described herein can be practiced with various computer system configurations, including handheld devices, tablet computers, microprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, and the like. Embodiments can also be practiced in a distributed computing environment where tasks are performed by remote processing devices via a wired or wireless network link.

[0145] Although method operations are described in a particular order, it should be understood that other operations can be performed between the described operations, the described operations can be adjusted such that they occur at slightly different times, or the described operations can be distributed in a system that allows the processing operations to occur at various intervals associated with the processing.

[0146] In various embodiments, one or more parts of the methods and mechanisms described herein can form part of a cloud computing environment. In such embodiments, resources can be provided as services over the Internet according to one or more various models. Such models can include Infrastructure as a Service (IaaS), Platform as a Service (PaaS), and Software as a Service (SaaS). In IaaS, computer infrastructure is delivered as a service. In this case, the computing devices are typically owned and operated by the service provider. In the PaaS model, the software tools and infrastructure used by developers to develop software solutions can be provided as a service and hosted by the service provider. SaaS typically includes the service provider licensing software as a service on demand. The service provider can host the software, or can also deploy the software to the customer for a given period of time. Various combinations of the above models are possible and conceivable.

[0147] Various units, circuits, or other components may be described or claimed as "configured to" or "configurable to" perform one or more tasks. In this context, the phrase "configured to" or "configurable to" is used to mean structure by indicating that the unit / circuit / component includes the structure (e.g., circuitry) that performs one or more tasks during operation. Thus, even when the specified unit / circuit / component is not currently operational (e.g., not powered on), the unit / circuit / component can be said to be configured to perform the task, or configurable to perform the task. Units / circuits / components that are used with the "configured to" or "configurable to" language include hardware (e.g., circuitry, memory storing program instructions executable to implement the operations, etc.). Reciting that a unit / circuit / component is "configured to" perform one or more tasks or "configurable to" perform one or more tasks is expressly intended not to invoke 35 U.S.C. 112, paragraph 6, for that unit / circuit / component. Additionally, "configured to" or "configurable to" can include a general structure (e.g., general circuitry) that is manipulated by software and / or firmware (such as an FPGA or a general-purpose processor executing software) so as to operate in a manner capable of performing the (one or more) tasks being discussed. "Configured to" can also include adapting a manufacturing process (e.g., a semiconductor manufacturing facility) to fabricate a device (e.g., an integrated circuit) adapted to implement or perform one or more tasks. "Configurable to" is expressly intended not to apply to a blank medium, an unprogrammed processor, or an unprogrammed general-purpose computer or unprogrammed programmable logic device, programmable gate array, or other unprogrammed device, unless accompanied by a programmed medium that gives the unprogrammed device the ability to be configured to perform the (one or more) disclosed functions.

[0148] For purposes of explanation, the foregoing specification has been described with reference to specific embodiments. However, the above illustrative discussion is not intended to be exhaustive or to limit the invention to the exact forms disclosed. Many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to best explain the principles of the embodiments and their practical application, to thereby enable others skilled in the art to best utilize the embodiments and various modifications as are suited to the particular use contemplated. Accordingly, the embodiments of the present disclosure should be considered illustrative rather than restrictive, and the invention is not limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.

Claims

1. A method for non-destructive testing of a heat exchanger piping system, comprising: performing a machine-controlled test using a test probe inserted into a particular heat exchanger tube to generate test data for a non-destructive test of the particular heat exchanger tube; accessing test data of non-destructive testing of the particular heat exchanger tube; as well as A structural health assessment of the specific heat exchanger tube is determined by comparing accessed test data from a non-destructive test of the specific heat exchanger tube with calibration data associated with at least one calibration standard heat exchanger tube that is more closely related in its structural properties to the specific heat exchanger tube than to a generic tube.

2. The method for non-destructive testing of heat exchanger piping according to claim 1, further comprising: Cloud-based storage is used for the test data for the non-destructive testing of the particular heat exchanger tube and the calibration data associated with the at least one calibration standard heat exchanger tube, wherein accessing includes accessing the cloud-based storage.

3. The method for non-destructive testing of heat exchanger piping according to claim 1, wherein the machine-controlled testing using the test probe comprises: A robot is used to position and manipulate a tool including the test probe.

4. The method for non-destructive testing of heat exchanger piping according to claim 1, wherein the machine-controlled testing using the test probe comprises: A machine controlled pull speed was used for the test probe.

5. The method for non-destructive testing of heat exchanger piping according to claim 1, wherein using the test probe comprises: using a tool mounted in an ergonomic fixture configured to reduce user fatigue and position the test probe; as well as The tool has a mechanized, controlled pull speed for the test probe for the machine controlled testing.

6. The method for non-destructive testing of heat exchanger piping according to claim 1, wherein generating the test data using the test probe comprises: generating preliminary test data using a probe of a first probe type inserted into the particular heat exchanger tube; as well as In response to a preliminary determination that the preliminary test data indicates a possible defect in the particular heat exchanger tube, secondary test data is generated using a probe of a second, more sensitive probe type inserted into the particular heat exchanger tube.

7. The method for non-destructive testing of heat exchanger tubing as claimed in claim 1, wherein test data for non-destructive testing of the specific heat exchanger tube is generated and a structural health assessment of the specific heat exchanger tube is determined before the specific heat exchanger tube is delivered or installed.

8. The method for non-destructive testing of heat exchanger piping according to claim 1, wherein: Generating test data for nondestructive testing of the particular heat exchanger tube using the test probe is performed in situ where the particular heat exchanger tube is installed in a component at a first location or installed in a refrigerant system at a second location; as well as Determining a structural health assessment for the particular heat exchanger tube is performed by a remote analyst who is not on-site at a location where the particular heat exchanger tube is installed in a component or in a refrigerant system.

9. The method for non-destructive testing of heat exchanger piping according to claim 1, further comprising: placing a plurality of defects including unacceptable wall damage and acceptable surface damage on at least one heat exchanger tube to form the at least one calibration standard heat exchanger tube; as well as Inserting the same or related test probe into the at least one calibration standard heat exchanger tube, performing the same or related test, and generating the calibration data associated with the at least one calibration standard heat exchanger tube.

10. A tangible, non-transitory computer readable medium having instructions thereon which, when executed by a processor, cause the processor to perform a method wherein test data and calibration data are used for health assessment of a heat exchanger tube, the method comprising: receiving test data for a non-destructive test of a particular heat exchanger tube, the test data being generated by a machine-controlled test using a test probe inserted into the particular heat exchanger tube; storing in a data store test data of the non-destructive test of the particular heat exchanger tube; receiving calibration data associated with at least one calibration standard heat exchanger tube that is more closely related to the particular heat exchanger tube in terms of its structural characteristics than to a generic tube; storing calibration data from testing of the at least one calibration standard heat exchanger tube; and Accessing test data from the non-destructive testing of the particular heat exchanger tube and calibration data from testing of the at least one calibration standard heat exchanger tube in the data store is supported to enable a structural health assessment of the particular heat exchanger tube based on the test data and the calibration data.

11. The tangible, non-transitory computer readable medium of claim 10, wherein: The data storage comprises cloud-based storage; and Wherein, the method further comprises performing the structural health assessment on the specific heat exchanger tube based on test data and off-site calibration data from the specific heat exchanger tube.

12. The tangible, non-transitory computer readable medium of claim 10, wherein the method further comprises: A robot is guided to position and manipulate a tool including the test probe for testing of the machine control.

13. The tangible, non-transitory computer readable medium of claim 10, wherein the test data for the non-destructive testing of the particular heat exchanger tube comprises preliminary test data using a probe of a first probe type and secondary test data using a probe of a second, more sensitive probe type.

14. The tangible, non-transitory computer readable medium of claim 10, wherein calibration data from the associated non-destructive testing of the at least one calibration standard heat exchanger tube indicates a plurality of defects of the at least one calibration standard heat exchanger tube.

15. A system for non-destructive testing of heat exchanger tubing, wherein the system is used to provide test data and calibration data for use in health assessment of heat exchanger tubes, the system comprising: at least one memory; as well as at least one processor coupled to the at least one memory and arranged to: receiving test data of a non-destructive test of a particular heat exchanger tube, the test data generated using a test probe inserted into the particular heat exchanger tube; storing in a data store test data of the non-destructive test of the particular heat exchanger tube; storing calibration data associated with at least one calibration standard heat exchanger tube that is more closely related to the particular heat exchanger tube in terms of its structural characteristics than to a generic tube; and Accessing test data from the non-destructive test of the particular heat exchanger tube and calibration data from the test of the at least one calibration standard heat exchanger tube in the data store is enabled to enable a structural health assessment of the particular heat exchanger tube based on the test data and the calibration data.

16. The system for non-destructive testing of heat exchanger piping of claim 15, wherein at least the data storage comprises cloud-based storage.

17. The system for non-destructive testing of heat exchanger piping according to claim 15, further comprising: A robot is provided for positioning and manipulating a tool including the test probe for testing of the machine control.

18. The system for non-destructive testing of heat exchanger piping according to claim 15, further comprising: A tool includes at least one test probe and has a machine-controlled pull speed for the at least one test probe.

19. The system for nondestructive testing of heat exchanger tubing of claim 15, wherein the test data for nondestructive testing of the specific heat exchanger tube includes preliminary test data using a probe of a first probe type and secondary test data using a probe of a second, more sensitive probe type.

20. The system for non-destructive testing of heat exchanger tubing as claimed in claim 15, wherein a plurality of defects of said at least one calibration standard heat exchanger tube are represented by said calibration data.

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