Chiller Eddy Current Tube Test Report
Use this Chiller Eddy Current Tube Test Report to document tube-by-tube NDE results, coverage, and plug-or-replace recommendations for condenser and evaporator bundles. It gives maintenance and QA teams a clear record of findings, risk, and sign-off.
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Overview
This Chiller Eddy Current Tube Test Report template is built for documenting non-destructive examination of chiller condenser and evaporator tubes. It captures the inspection identity, the instrument and probe setup, the number of tubes tested versus available, defect indications, and the final recommendation to plug, replace, or monitor specific tubes.
Use it when a chiller is opened for planned maintenance, after a suspected tube leak, or whenever you need a formal record of tube condition and test coverage. The template is especially useful when multiple bundles, tube sheets, or access constraints make it important to show exactly what was inspected and what could not be tested. It also gives you a place to record calibration verification, cleaning status, and environmental conditions that may affect signal quality.
Do not use this as a generic HVAC service sheet or for visual-only checks. If the work is limited to routine cleaning, water treatment checks, or a quick operational walkthrough, a simpler maintenance form is usually enough. This report is intended for eddy current NDE events where the findings may drive corrective action, service risk decisions, or audit-ready documentation. It is also not a substitute for the site’s written procedure, OEM requirements, or the qualifications of the technician performing the test.
Standards & compliance context
- This template supports traceable inspection records commonly expected under quality management practices such as ISO 9001:2015 and site maintenance programs.
- If the inspection is part of a broader plant safety program, align the work with applicable OSHA general industry requirements and local lockout-tagout controls before opening the chiller.
- For facilities with life-safety or fire protection dependencies, coordinate shutdown and access planning with the site’s NFPA-based procedures and the Authority Having Jurisdiction where required.
- Use the report alongside the written eddy current procedure, OEM guidance, and technician qualification records; the form documents the work but does not replace competency requirements.
- If the chiller serves regulated environments such as healthcare or food-related operations, retain the report as part of the facility’s maintenance and sanitation documentation trail.
General regulatory context for orientation only — verify current requirements with counsel or the relevant agency before relying on this template for compliance.
What's inside this template
Inspection Identification
This section establishes exactly which chiller was inspected, when the work occurred, and which procedure governed the test.
- Inspection date and time
- Facility name and location
- Chiller asset ID / equipment tag
- Inspection scope
- Work order / service ticket number
- Inspector / technician name
- Supervisor or client representative
-
Reference standard or procedure used
Enter the governing procedure, OEM guidance, or site-specific NDE procedure used for this test.
Test Equipment and Method
This section proves the inspection was performed with the right instrument, probe, calibration, and setup conditions.
- Eddy current instrument model and serial number
- Probe type and size
-
Calibration / reference standard verified
Confirm the instrument was calibrated and verified against an appropriate reference standard before testing.
- Calibration date
-
Test frequency / setup parameters recorded
Confirm that test frequency, gain, phase, and other setup parameters were documented.
-
Tube cleaning completed before test
Confirm tubes were cleaned sufficiently to allow reliable probe travel and signal interpretation.
- Access limitations or obstructions noted
-
Environmental or operating conditions affecting test
Record any conditions that may affect signal quality, access, or interpretation.
Tube Count and Coverage
This section shows how much of the bundle was actually tested and whether any tubes were left out for a documented reason.
- Condenser tube count inspected
- Condenser tube count available
- Evaporator tube count inspected
- Evaporator tube count available
-
Coverage percentage achieved
Enter the percentage of intended tubes successfully tested.
-
Untested tubes identified and reason
List any tubes not tested and the reason, such as access limitation, blockage, or equipment restriction.
-
Tube sheet or bundle identification method
Describe how tube locations were identified or mapped for traceability.
Defect Findings
This section records the actual indications, their severity, and the service risk they create for the chiller.
-
Any defect indications detected
Mark yes if any relevant indications such as wall loss, pitting, cracking, wear, or tube thinning were found.
- Number of tubes with indications
- Defect type(s) observed
-
Most severe indication location
Identify the tube number, row, bundle, or location of the most significant indication.
-
Severity assessment
Rate the overall severity of the tube findings.
- Leak risk or service impact
-
Photo evidence of representative indications
Attach photos when available to support defect interpretation and location tracking.
Recommendations and Sign-Off
This section turns the findings into a clear disposition and captures acceptance from the responsible party.
- Recommended disposition
- Number of tubes recommended for plugging
- Number of tubes recommended for replacement
-
Corrective action details
Summarize the recommended repair plan, affected tube locations, and any follow-up testing needed.
- Inspector signature
- Client or supervisor acknowledgment
How to use this template
- 1. Enter the inspection identification details, including the chiller asset tag, location, date, work order number, and the reference procedure used for the test.
- 2. Record the eddy current instrument, probe, calibration standard, setup parameters, and any access or environmental limitations before testing begins.
- 3. Document the condenser and evaporator tube counts available and inspected, then calculate coverage and list any untested tubes with the reason they were skipped.
- 4. Record each defect indication with its location, type, severity, and representative photo evidence so the findings can be traced back to the tube map or bundle ID.
- 5. Assign the disposition, specify how many tubes should be plugged or replaced, and note any corrective action details required before return to service.
- 6. Obtain inspector and client or supervisor sign-off after the findings are reviewed and the final action plan is accepted.
Best practices
- Verify the calibration or reference standard immediately before the walk-through and record the verification in the report, not from memory later.
- Clean tube surfaces and note the cleaning method before testing, because scale, sludge, and debris can mask or distort eddy current indications.
- Record untested tubes separately with the exact reason, such as blocked access, damaged tube sheet, or unsafe conditions, so coverage is not overstated.
- Tie every indication to a specific tube location or bundle reference so the maintenance team can find it without re-testing the entire chiller.
- Use a severity scale that matches your procedure and distinguish confirmed defects from ambiguous signals or areas affected by poor access.
- Photograph representative indications at the time of inspection and label the image with the chiller ID, tube location, and date.
- Keep plug and replace recommendations aligned with the observed condition and service impact; do not recommend replacement for every minor indication.
- Have the supervisor or client representative review the final disposition before the chiller is returned to service.
What this template typically catches
Issues teams running this template most often surface in practice:
Common use cases
Frequently asked questions
What does this Chiller Eddy Current Tube Test Report template cover?
It captures the core record for an eddy current NDE of chiller condenser and evaporator tubes: inspection identification, test equipment and method, tube counts and coverage, defect findings, and final recommendations. The template is built to show what was tested, what was found, and what action was taken. It is useful when you need a defensible maintenance record for a specific chiller asset, not a general HVAC service log.
When should I use this report instead of a routine maintenance checklist?
Use it when a chiller tube inspection is being performed as a formal non-destructive examination, especially after performance loss, suspected leakage, water-side fouling, or during planned outage work. A routine checklist is fine for basic service tasks, but it usually does not capture calibration data, tube coverage, defect severity, or disposition decisions. This template is meant for inspection events that may drive plug, repair, or replacement actions.
Who should complete the report?
A qualified eddy current technician or inspector should complete the technical sections, with review by a supervisor, maintenance lead, or client representative as needed. The person entering the findings should understand probe setup, reference standards, and how to distinguish a true indication from noise or access limitations. Final sign-off should come from someone authorized to accept the findings and corrective action plan.
How often should chiller tube eddy current testing be performed?
The cadence depends on the chiller’s service history, water quality, operating environment, and prior defect trends. Many facilities schedule it during planned shutdowns or at intervals set by their maintenance program, risk profile, or OEM guidance. This template helps you document each event consistently so you can compare results over time and spot deterioration trends.
Does this template support OSHA, ASME, or other compliance needs?
It supports documentation expected under general industry safety and quality programs, but it is not a substitute for the governing procedure or site-specific requirements. Eddy current testing itself is typically governed by internal procedures, OEM guidance, and applicable NDE or quality standards, while the work environment may also involve OSHA, ANSI, or NFPA controls. The report helps preserve traceability, but the inspection must still be performed by qualified personnel under the correct program.
What are the most common mistakes when filling out this report?
The biggest issues are incomplete tube counts, missing calibration details, vague defect descriptions, and recommendations that do not match the severity of the indication. Another common problem is failing to note untested tubes and why they were inaccessible, which can make the coverage percentage misleading. Good reports clearly separate confirmed indications from suspected issues and show how the final disposition was reached.
Can I customize the template for different chiller types or tube materials?
Yes. You can adapt the scope to condenser-only, evaporator-only, or full-bundle testing, and add fields for tube material, pass count, or bundle map references if your procedure requires them. If your site tracks specific defect modes such as pitting, wall loss, or support plate wear, those can be added to the defect findings section without changing the overall structure.
How does this compare with ad hoc notes or a service ticket?
Ad hoc notes and service tickets often miss the technical details needed to defend a maintenance decision later. This template forces a structured record of instrument setup, coverage, findings, and corrective action so the inspection can be reviewed, audited, or trended. It is especially useful when multiple technicians, vendors, or shifts are involved and you need a consistent handoff.
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