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Eddy Current Training: Pay Now or Pay Later

Ed Korkowski

The Hidden Cost of Untrained Eddy Current Personnel: Why Proper Training Matters


Eddy current testing (ECT) is a vital part of ensuring the safety and reliability of critical equipment, especially in industries like power generation, aerospace, and petrochemicals. But even the most advanced technology is only as effective as the people using it. When personnel are untrained, the costs can quickly add up—not just in terms of equipment and labor, but also in time lost to rework and inefficiency. Let’s take a closer look at how untrained eddy current personnel can impact your operations.  For this scenario, we will discuss tube testing in a power plant heat exchanger, using human probe handlers.


1. Misidentifying Tubes: A Recipe for Rework

Probe handlers are responsible for inserting the test probe into the correct tube, based on a tubesheet map that assigns each tube with a row and column number. When probe handlers aren’t properly trained or are inattentive, they might place the guide tube over the wrong hole. The result? Misidentification of tubes. The inspection could be performed on the wrong tube, misidentifying the wrong tube to be removed from service if a defect is reported in that tube. This not only impacts the accuracy of the inspection but also leads to rework—requiring more time to correct the mistake and complete the inspection.


2. Slower Probe Changes and Increased Downtime

Changing probes may seem like a simple task, but there’s more to it than meets the eye. An untrained technician might take longer to make the necessary changes, causing inspection delays. And those delays add up. Extended downtime translates to longer inspection times, increased labor costs, and a slower turnaround on critical maintenance schedules. In the end, what could have been a quick task turns into a costly one.


3. Snorkel Adjustment: A Small Misstep with Big Consequences

The snorkel guides the probe as it moves through the tube during testing. When it’s improperly routed, the probe can encounter resistance, requiring more effort from the probe pusher. An untrained operator may respond by increasing the tension on the probe pusher clamshell wheels, which can damage the probe itself. This can lead to prematurely worn-down probe pusher drive wheels and ruined, expensive probes, increasing costs across the board.


4. Safety Violations: A Risk to People and Profits

Safety protocols are in put in place for a reason- to protect workers.  Untrained personnel may not understand the importance of following safety protocols. For example, entering confined spaces without proper authorization is a violation at most sites. These actions not only put personnel at risk but also result in fines or shutdowns, further adding to operational costs.


5. Troubleshooting Gone Wrong: Wasting Time and Resources

When troubleshooting motorized rotating probe coils, an untrained operator might start swapping out parts—motors, probes, cables, and more—without understanding the root cause of the issue. Often, the problem can be as simple as an incorrect instrument setting. Instead of troubleshooting efficiently, untrained staff end up wasting valuable time and resources. In environments that require radiological protection, unnecessary work can also mean unnecessary radiation exposure. This not only impacts the budget but also the health and safety of your team.


6. Tube Plugging: Proper Training is Essential

In addition to probe handling, maintenance personnel who are responsible for inserting tube plugs must also be properly trained to read tubesheet maps. Misidentifying a tube can lead to the installation of plugs in perfectly good tubes, while defective tubes are left in service. This could compromise the effectiveness of your testing and result in additional, unnecessary maintenance.


7. Data Interpretation: The Cost of Misreading Signals

Eddy current data evaluators must have a keen eye for interpreting test results. Untrained personnel may misread signals, leading to incorrect conclusions. This can result in incorrect data being used for decision-making, which could require rework or, in some cases, bring an operation to a standstill. This unplanned downtime can result in significant costs, both in lost productivity and in unanticipated maintenance expenses.


Conclusion: Time and Money Lost to Inexperience

The cost of untrained personnel isn’t always immediately obvious, but it can quickly accumulate. The extended time needed to complete inspections, the increased need for rework, the potential for equipment damage, and the higher risk of safety violations all contribute to a higher operational cost.


Investing in proper training for your eddy current personnel is not just about improving the quality of work; it’s about saving time, reducing costs, and ensuring safety. With the right training, your team can work more efficiently, avoid costly mistakes, and keep operations running smoothly.

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13 minutes ago

Really impressive

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