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American Effiencincy Services

American Efficiency Services, LLC (AES) was founded in 2001 to provide quality, satisfaction-guaranteed helium leak detection services to the power generation marketplace.

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Overview

American Efficiency Services, LLC (AES) was founded in 2001 to provide quality, satisfaction-guaranteed helium leak detection services to the power generation marketplace. Two of the three founding partners had years of prior experience in the field, and knew helium leak detection to be the most accurate and comprehensive method to find leaks in systems under positive and negative pressure. AES has grown in sales, staff and scope each year since its founding and now has offices in Maryland, Missouri, Florida and Texas to serve customers across the nation – and the world – 24 hours a day/7 days a week.

The company developed a reporting system for inspection findings that is comprehensive, aids plant personnel in repairs, and provides a record of potential patterns of failure for maintenance. AES provides customers with definitive leak tags, clear close-up pictures of leak locations, and a final written report that one plant manager said was “almost too good”.

Building upon their initial success, AES next began inspecting systems used in Ethanol, Pharmaceutical, Food Processing, and Petrochemical plants. Additional areas of expertise and services include Condenser Tube Cleaning and Industrial Evaluation and Consulting.

​AES believes a company is only as good as its’ employees, and takes great pride in it’s’ workforce. New hires begin an intensive program that requires a study of the use of all AES equipment, systems and how they work, how components fit into the picture, system weak points, and AES inspections methodology. The final piece of training focuses on communicating with plant personnel and report writing. Employees are tested on their knowledge in these areas in class as well as practically on-site. Only when personnel have passed all tests and consistently demonstrate knowledge of system operations can they be considered for a Project Manager position. All employees participate in ongoing safety training and drug testing.

Attention to detail, listening to the needs of plant operators, and answering multiple emergency calls have won the trust of companies across North and South America, and the world. A knowledge of systems developed through inspections in hundreds of plants, plus detailed and comprehensive reports have made AES the company to call when you want a “complete inspection”.


Products & Services
Eddy Current Testing

Most people are not familiar with Eddy Current or Eddy Current Testing but ECT has become a star in the field of non-destructive testing. Eddy Current Testing is the use of electromagnetic testing to find leaks and identify surface and sub-surface flaws in conductive materials. It is also used to examine non-ferrous tubing in condensers and heat exchangers.

Eddy-Current Testing is great for checking pipe’s surface area, checking for faults inside pipes, remote testing of carbon steel pipes, eddy current weld inspection, and clad thickness. Outside of our industry, the most common use of Eddy Current is in metal detectors. Eddy Current Flaw Detector is very good for inspecting metallic parts.

If you’re looking to get a quote for Eddy Current Testing, please click the button below.  If you want to learn everything there is to know about Eddy Current Testing Services, continue reading! We break down the advantages and disadvantages of Eddy Current Testing as compared to non-destructive testing, so you can be fully informed about what awaits you with this service and what you can expect. To get a quote for eddy current tester price call us on (877) 816-9081.

Eddy Current Inspection

History, Applications, and Pros and Cons

eddy current testing equipmentTo best understand the use of Eddy Current Testing and determine if this is the right service for you is to understand how eddy current Testing began and what its most common uses are today.

The eddy current system goes back to the mid-1800s and is fairly simple to understand in terms of its structure and process. A comprehensive breakdown is provided to compare and determine if an eddy current inspection is a right application for you and your company, dependant on your needs.

American Efficiency Services is always available to provide recommendations and insights on any concerns or questions you may have so you always end up with the best solution for your specific project. Our eddy Current Testing Of Condenser Tubes find defects before they become disasters. Eddy current testing of chillers is one of the best tubing inspection methods or eddy current tube because the probes are uniquely shaped to test chiller tubes.

Eddy Current Testing Services

The History; and Where it all Started

Eddy Current Testing by American Efficiency ServicesEddy Current Testing also known as ECT and not to be confused with Electroconvulsive therapy, is testing that started or derived from electromagnetism. François Arago is credited with observing eddy currents in 1824 but it was in 1855 when French physicist Léon Foucault was actually credited with the discovery.

There was very little use for Eddy Current Systems or development in the field of Eddy Current until WWII. A German professor named Friedrich Förster started to look at Eddy-Currents for industrial use. Friedrich started developing coils, testing conductivity and measured out ferrous materials, all to more accurately detect flaws in conductive materials.

Friedrich would ultimately go on to found the Foerster Group and continue development of ECT and other non-destructive testing techniques. The Foerster Group developed practical instruments used to carry out ECT testing for the masses and today it is a widely used and accepted technique for Eddy Current NDT.

Eddy Current Testing Equipment

How the apply to Today’s Eddy Current Testing Equipment

American Efficiency Services employee checking eddy currentsThe most basic form of the Eddy Current Testing principal uses a single coil that is excited using alternating electrical currents. When the wire is excited, it produces an electromagnetic field around the coil. The electromagnetic field oscillates (spins) at the same frequency that ran through the coil. Introducing the coil to conductive material will create currents that are opposed to the ones in the coil and these currents are Eddy Current. This will often be referred to as the Eddy-Current Coil.

ECT uses Eddy Currents to produce an electromagnetic field using coils and detection instruments. When everything is normal and a conductive material is introduced to the magnetic field (normally rings) they stay circling around the coil like a stream, creating the Eddy Current System.

If the conductive material has faults, breaks, or cracks, these streams start to jump off the typical Eddy-current magnetic field and causes the voltage that you are measuring change. These variants can be measured for fault detection in conductive materials allowing us to detect faults even if the eye cannot see them.

To break everything down simpler, the Eddy Current coil produce a voltage that will be at a higher and different level than when introduced to Eddy-Currents. When Eddy-Currents are introduced the voltage steadies and will remain at the same level.

 A fault or break stops the Eddy-Current’s oscillation and the voltage will spike back to the original levels before the Eddy-currents were introduced. The conductive material will not upset or change the spinning of Eddy-Currents but faults, cracks, and corrosion will so when the voltage jumps it typically means there is a fault in the material being tested.

Eddy Current NDT

The Benefits of Eddy Current Testing Services Compared to Other Non-Destructive Testing

  1. In favorable conditions, Eddy Current Testing can test fault in pipes up to 0.5 millimeters. With the proper equipment, the right type of conductive material, and properly trained professional, this test is extremely accurate at pinpointing even the smallest of faults.
  2. It can detect through coated materials. While other types of testing can be hindered or simply not work through paint, protective coatings, rust, and other materials, Eddy Current Testing is still accurate on coated materials up to 5 millimeters thick.
  3. No need to the clean surface area. Along the same lines as coated material, soils, uneven coatings, and rust will not affect the testing and therefore do not need to be cleaned for an accurate test.
  4. Testing is mobile and lightweight. Unlike other NDTs, Eddy Current testing equipment is relatively small and portable. A proper Eddy-Current testing company will have no problem coming to job sites, businesses, or even homes with the equipment and can test smaller areas compared to other non-destructive testing options.
  5. Testing through layers is no problem. Most Eddy Current testing companies claim accurate testing through ten layers. We have found that we can still get accurate testing through 14 different layers without any interference due to the uniqueness of Eddy-Currents.
  6. For those looking for commercial testing, Eddy Current Testing can be automated using uniform parts. The testing is very quick and accurate. If you want to ensure quality production of conductive parts, this test can be streamlined with incredible accuracy.
  7. Lastly, this test provides accurate conductivity measurements. Eddy current instrument that is dedicated to conductivity testing use Eddy-Current. If you are not sure the material of the piping or metal in your wall you can have an eddy current test ran. The test will give you a conductivity reading and accurately tell you the materials in your wall.

The Disadvantages of an Eddy Current Detector Compared to Other Non-Destructive Testing

  1. Eddy-Current testing can only be done on conductive materials. If there is no electrical current that flows through the material then Eddy-Currents are not present and without Eddy-Currents, testing is not possible.
  2. It will not detect flaws parallel with the surface. During testing, the flaws must interrupt the Eddy-current waves to register through testing tools. Eddy-Currents run parallel with the surface so any flaw that runs parallel on the surface will not interfere with the currents and therefore, will not register on the detection tools.
  3. Magnetic Permutations cause testing complications. Ferromagnetic material or any small changes in permeability can have effects on Eddy-currents. While testing is not impossible under such conditions, it makes it very difficult so the testing of welds and other ferromagnetic material are less accurate.
  4. Eddy-Current Testing is best suited for small areas with simple geometries. Large spaces are not the best area for this type of testing. While it is not impossible to do, it requires large expensive equipment and is less accurate than when done on a smaller scale.
  5. Also, different geometries make Eddy-Current Testing difficult. A trained professional with an Eddy Current testing company will be needed to differentiate flaws from deflecting signals caused by different geometries.
  6. There is no real permanent record of testing. During automation of Eddy-Current tests, a print out might be available but only during automation testing. Manual testing will not have any record or lasting reports from the testing, so eddy current testing equiment will always need to be considered.
  7. Lastly, Eddy Current testing requires training and certifications. It is not something an unskilled person will be able to immediately pick up. Professionals are needed to read the testing material, differentiate from deflecting signals and faults, and be able to interpret data correctly on the fly and on-site. An Eddy Current testing company is always needed who are specialized in this area.
Condenser Retubing Services

American Efficiency Services has assembled a team of condenser experts with decades of combined experience specializing in a wide range of retubing services and capabilities. Our unique approach employs seamless processes that effectively manage all aspects of condenser design, operation, and maintenance.

The AES retubing team is comprised of individuals experienced in providing full-scope, turnkey condenser and heat exchanger retubings, utilizing innovative and proprietary equipment and tooling, products, and services. Retubing projects consist of many layers of work tasks and activities, sequenced in accordance with our proven approaches ensuring that complex projects are performed safely, and delivered with quality workmanship, on time and within budget.

With experience in the retubing of all combinations and types of tube and tube sheet materials, including titanium and Sea-Cure®, you can be assured AES has working knowledge of the characteristics, idiosyncrasies, and inherent challenges that accompany every retubing project. This experience also gives us a unique perspective in developing technical approaches tailored to fit each plant’s design.

Whether you are looking for expert technical advice and state-of-the-art tooling and equipment or a full scope, turnkey retubing contractor, AES has the knowledge to assist with:

  • Project Planning & Procedure Development
  • Tube Joint Strength Testing
  • Uplift and Vibration Analyses
  • Sample Tube Removal
  • Tube/Tube Sheet Plugging
  • Tube Sleeving
  • Tube Procurement
  • Coating Tube Sheets & Waterboxes
  • Interference Removal/Reinstallation
  • Waterbox/Waterbox Cover Removal/Reinstallation
  • Tube Sheet Replacement
  • Tube Removal/Tube Installation
  • Tube Sheet Serrating
  • Tube Expansion
  • Tube Staking
  • Tube-to-Tube Sheet Welding
  • Design & Installation of Cathodic Protection Systems
  • Tube Sheet Stress Analysis
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