Reformer tube inspection

Comprehensive reformer tube inspection – inside and out. FOERSTER combines eddy current and laser technologies to detect cracks, creep, and other damage mechanisms throughout the full wall thickness of centrifugally cast reformer tubes. Our automated LEO-Scan and LEO-iScan systems deliver precise, repeatable results that form the basis for reliable remaining life assessments.

Reformer tubes are exposed to extreme thermal and mechanical stress, making regular inspection essential for safe, efficient, and long-term operation.

With LEO-Scan, FOERSTER performs external tube inspections on both reformers and MIDREX® direct reduction units. Using proprietary eddy current and multi-laser technology, the system detects cracks, wall defects, and creep with full wall penetration up to 23,5 mm – across all alloys, without couplant or cleaning. Even large-diameter up-flow MIDREX® tubes can be inspected within a minute, with precise, repeatable results.

The complementary LEO-iScan enables internal inspection from flange to catalyst grid. Eight synchronized lasers and eddy current probes provide a 360° view of the tube’s inner surface, ideal during catalyst changeovers and for detecting early creep initiation.

All data are recorded and can be evaluated with our TubeLife software to generate a FOERSTER-adapted, API 579–based Remaining Life Assessment (RLA) – a separate service available exclusively for LEO-Scan measurements. This provides a reliable basis for predictive maintenance and long-term asset stability.

External tube inspection

LEO-Scan inspects reformer and MIDREX® tubes from the outside using FOERSTER’s eddy current and multi-laser technology. The probes penetrate wall thicknesses up to 23,5 mm, detecting cracks and creep even in tight furnace layouts – without cleaning, fully repeatable and proven for all alloys.

Internal tube inspection

LEO-iScan combines eight high-precision lasers and eddy current probes for internal tube inspection from the flange to the catalyst grid. This method reveals creep initiation and dimensional changes in 360°, providing reliable data during catalyst replacement.

Remaining Life Assessment

FOERSTER’s TubeLife software integrates inspection data, strain values, and crack information to calculate the remaining service life of reformer tubes. Based on FOERSTER adopted API 579 standards, it supports sound maintenance planning and long-term asset integrity.