Heat exchanger inspection techniques and corrosion mechanisms powerpoint presentation. Sampling is a way to evaluate a small portion of a population to infer useful information about. Heat exchanger, condenser and boiler inspection methodology ndt welding. Process materials shall be on the tube side of the exchanger. Heat exchanger tube inspection is vital for refining and petrochemicals. The excess condensate in the heat exchanger or collector box reduces the amount of air moving through the heat exchangers. Understanding id eddycurrent inspection of heat exchanger. Just a little video i shot with my inspector camerachecking out an armstrong heat exchangerenjoy.
Process fluid assignments to shell side or tube side. The inspection of heat exchangers is the one area of equipment inspection where i firmly advocate the use of a check list to make sure you got everything. Remove the furnace blower assembly, the fan limit and other electrical components to prevent damage. Allowance should be made for the clearance required to remove the tube bundle. We follow through with that by offering free heat exchanger inspections. The term heat exchanger applies to all equipment used to transfer heat between two streams. Heat exchangers jordan university of science and technology. Please note that all heat exchangers will eventually fail, even if they have been properly. Disassemble the furnace until you can visually inspect all heat exchanger exterior surfaces.
Do not use water or smoking agents to check for leaks. A leaking tube can impact production, the environment and most importantly, lives. Preassemble the heat exchanger and after placing the tightening units on the diagonal nuts, apply oil pressure. A heat exchanger is a device that is used to transfer thermal energy enthalpy between two or more fluids, between a solid surface and a fluid, or between solid particulates and a fluid. Exchanger inspection 101 visual inspection of shell and tube heat exchangers. Sampling 500 tubes 10% from a tube heat exchanger that contains 5000 tubes contains more useful information than sampling 10 tubes 10% from a 100 tube heat exchanger. Design of heat exchangers4 constraints imposed on design of heat exchangers include the following. Induceddraft furnace heat exchanger inspection procedure 1 this procedure is intended for use by qualified individuals trained and experienced in the servicing of this type of. Heat exchangers are pieces of process equipment built and designed for maximum efficiency of heat transfer between two different machines or mediums. Free furnace heat exchanger inspections harster heating. Guide for source inspection and quality surveillance of. Piping long radius elbows should be used in place of standard elbows wherever possible, because of their. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users.
Searching documents and internet sources the following is what i found on heat exchanger inspection methods and sources. Gwa also provides consulting services for pipeline inspection, heat exchanger tube inspection, anchor rod inspection, and other challenging guided. If there is a gap between pressure plate and fixed nut, turn the nut by hand. There are a variety of methods of inspecting or testing heat exchangers. We deliver effective nonintrusive inspection nii for heat exchanger vessels and apply this approach widely to the shell side. The heat transfer cylinder is 4 inches 102 mm in diameter by 120 inches 3048 mm long.
Combining each of these resistances in series gives. Inspection and test plan reference document acceptance criteria verifying document 1. Setting shell side and tube side pressure drop design limits. Sonomatic provides a range of inspection and integrity services for heat exchangers and tubing. The visible defects heat inspection system enables the technician to better evaluate the integrity of a heat exchanger by visually enhancing a crack if it exists. The water spray test is another alternative inspection method. A drain that is plugged or slow to drain allows condensate to build up in the secondary heat exchanger and collector box. Welcome to the most trusted and comprehensive heat exchanger inspection directory on the internet. Heat exchangers 73 individual thermal resistances of the system. Craftsmen in stainless allegheny bradford corporation. Spray the exterior of the heat exchanger with a watersoap solution 1 gallon water 1 tablespoon soap using a garden sprayer. Heat exchanger inspection techniques and corrosion mechanisms.
Since 1979, he has consulted on a variety of problems with process and power generation heat exchanger problems. Installation location the heat exchanger should be located in a clean, open area, with sufficient clearance at the head of the heat exchanger to remove the tube bundle. This procedure applies to the pressure containing parts of the exchanger alone with supporting structures. The heat exchanger should be located in a clean, open area, where it is easily accessible for inspection, service and repair. Heat exchanger inspection checklist qc, inspection. If you want to make sure your heat exchanger is in good shape even if youre not quite sure what a heat exchanger is or what it does you at least know who to call. In such a case a secondary accident caused by leak from the heat exchanger is forecast e. Heat exchangers suffer problems within the tubes that make up the majority of the useful area within the exchanger unit. All dealers and service contractors should use this procedure to properly troubleshoot and inspect 90% furnace heat exchangers. Though it is unlikely for an induced draft furnace to leak flue products from the heat exchanger to the circulated airstream, this guideline outlines a new test procedure to enhance the existing threestep methodology to make it more applicable, reliable and repeatable for the inspection of induced draft furnace heat exchangers. This procedure and the 90% furnace heat exchanger inspection certificate will be posted in hvacpartners under the postsale support service area. This article describes the use of advanced tubing inspection ndt methods for boiler and heat exchanger equipment in the petrochemical industry to supplement major turnaround inspections. The accessories in the kit allow the technician to inspect clamshellserpentine designs by applying penetrant on.
However, mutlistream heat exchangers are sometimes used with energy extensive processes, such as lng processing, to reduce capital cost. Double pipe heat exchanger inspection and test plan. Because of this, heat exchangers were created to capture and reuse heat that would otherwise be lost to the environment. The inspector infrared video inspection camera allows you to clearly see the holes, cracks, rust, or corrosion damage inside any furnace. The authors have presented more than 100 short intensive courses on shellandtube heat exchangers, closed feed water heaters, and tubular exchanger inspection, maintenance, and repair in the united states, canada, and europe. The owner of a plate heat exchanger need not wait for these visible signs of disrepair and failure before scheduling maintenance for a unit. There are many areas on a heat exchanger that you can not get to for visual inspections while the heat exchanger is in the furnace. Purpose establish inspection guidelines to ensure mechanical integrity and continued reliable operation of shell and tube heat exchangers. Any crack or hole that is big enough to affect combustion will be easily visible to the naked eye. In most industrial processes, the loss of heat is very wasteful and inefficient. All welding shall be of gtaw tig or gmaw mig types.
Heat exchanger inspection certificate must also be attached to or held with the secondary heat exchanger part or furnace. Introduction gas furnaces have earned a reputation for safe, reliable performance. Heat exchanger inspection checklist heat exchanger inspection checklist james10 mechanical op 2 oct 03 19. Reason for heat exchangers a heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another hot and cold fluid. The optimum thermal design of a shell and tube heat exchanger involves the consideration of many interacting design parameters which can be summarized as follows. The methods presented include remote field eddy current, magnetic flux leakage, internal rotary inspection system iris and eddy current. Understanding id eddycurrent inspection of heat exchanger tubing eddycurrent testing can be a useful tool when it is planned for a specific purpose, and the manufacturer, fabricator and owneroperator communicate effectively. Acoustic noise control during operation flow turbulence control during operation pumping power requirements spatial dimensions requirements availability of materials and standards availability of know and how technology. This double pipe heat exchanger inspection and test plan article provides you with a sample double pipe heat exchanger itp. The heat exchanger inspection article provides you with information about the inspection of the heat exchanger and heat exchanger testing during the manufacturing phase, as well as inservice inspection in operating units.
When pressure drop rises and exceeds original design or when loss of heat transfer occurs and the unit does not cool or heat as designed or specified, maintenance may be required. Gwa sells mss guided wave testing system lrut inspection eqipment to ndt service providers worldwide and supports them with training of personnel, data analysis, supply of accessories, and onsite training of challenging inspection situations. Inspection of the entire length of heat exchanger tubes however brings along a few extra challenges. The 4 x 120 is a unique concentric heat exchanger designed for heating and cooling moderately viscous products. Inspection and test plan for shell and tube heat exchanger before manufacturing materials during manufacturing. The piston will travel forward and the pressure plate will travel in the same direction. R sekulib university of kentucky introduction a heat exchanger is a device that is used for transfer of thermal energy enthalpy between two or more fluids, between a solid surface and a fluid, or between solid particulates and a. Guide for source inspection and quality surveillance of fixed equipment.
This is a draft itp and must be editied based on your purchase order specifications. Induceddraft furnace heat exchanger inspection procedure. However, in those situations where a heat exchanger has. Inspection procedure for shell and tube heat exchangers. A broad range of heat exchanger inspection resources are compiled in this industrial portal which provides information on manufacturers, distributors and service companies in the. References material safety data sheets msds are electronically stored and can be. Inspection of the drain system, trap, and associated tubing should also be performed.
On standard heat exchangers, there is a 34 or 1 inch female npt drain coupling either on the bottom of the front cover or the bottom of. Along the length of the tubes tube tube sheet joints can be visually inspected and standard ndt techniques, like penetrant testing or magnetic testing can be utilized. The heatingcooling medium shall be on the shell side of the exchanger. Furnace heat exchangers joints are not hermetically sealed, so a small amount of leakage is normal. Guide to furnace heat exchanger inspection, testing, leaks how to inspect and test furnace heat exchangers for leaks photographs show clues indicating leaky, dangerous furnace heat exchangers furnace heat exchanger leak testing, a complete list of methods used to find or test for leaks in a furnace heat exchange what is the allowable amount of gas fired heat exchanger leakage. Heat exchanger design john richard thome 1er mars 2008 john richard thome ltcm sgm epfl heat transfer heat exchanger design 1er mars 2008 1 41. Its the worlds first and leading heat exchanger video inspection camera, with an infrared, highresolution camera mounted on a 37inch wand that is attached to its very own display monitor. All 316 stainless steel construction with high efficiency 0. Common example the classic example of a heat exchanger is found in an internal combustion engine in which a circulating fluid known. Steps have been taken in designing these furnaces to prevent flue products from leaking into the home environment. Typically, a heat exchanger is used with two process streams. Any crack or hole that is big enough to affect eye.