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. 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. 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. The advanced heat exchanger tube inspection using mfl magnetic flux leakage, offers traceable and archiveable records. Apr has been used successfully in assessing tube cleanliness at various stages of the process, which is valuable information for operators, since cleanliness has a direct effect on heat exchanger efficiency. 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. Description general the tube and fin heat exchanger consists of copper tubes and aluminium or copper fins. Heat exchanger inspection planning inspectioneering. In the case of fixed tube sheet units, allow room on both ends of the unit to remove the heads for inspection and tube cleaning.
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. 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 the housing. May 01, 2017 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. Testex provides scheduled and emergency inspection services for all types of tubular heat exchangers including air cooler fins and fans. Heat exchanger inspection techniques and corrosion mechanisms powerpoint presentation. Understanding id eddycurrent inspection of heat exchanger tubing. Depending on the application, heat exchangers come in all kinds of shapes, dimensions and materials. 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. A plate heat exchanger, phe, is a compact heat exchanger where thin corrugated plates some 0. The heat exchanger shall be operated by persons who have studied the instructions in this manual and have knowledge of the process. Nde technologies for the examination of heat exchangers and boiler tubes principles, advantages and limitations.
As requested by incon inspection consultants acting for client a, innospection has carried out an iris internal rotational inspection system ultrasonic tube inspection, on the heat exchanger tube bundle identified as 123. Due to the custom nature of all xchanger heat exchangers, this manual discusses the characteristics and procedures that are common to all exchangers. Plate heat exchanger 2 operation and maintenance manual. Cracks this large are very dangerous and can lead to carbon monoxide safety 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. 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. Induceddraft furnace heat exchanger inspection procedure. This report introduces the concept of a riskbased design margin selection process as a quantitative aid in separating the individual components that comprise the uncertainty in heat exchanger design. Furnace heat exchanger focus on finding failure class the.
Inspection of the entire length of heat exchanger tubes however brings along a few extra challenges. This api standard covers the inspection practices for fired boilers and process heaters furnaces used in petroleum refineries and petrochemical plants. This approach means inspection of the shell can take place without the need to remove the tube bundle. Heat exchangers 73 individual thermal resistances of the system. Below is a gas furnace inspection checklist that you can use to ensure that your furnace is working at its best. Piping long radius elbows should be used in place of standard elbows wherever possible, because of. Heat exchanger inspection checklist qc, inspection. When heat exchanger handles steam and other fluid of high temperature, it has hazard of burns. Lmats offers the latest advanced heat exchanger tube testing and inspection using mfl magnetic flux leakage to assess the integrity of your heat exchange tubes thus maximising production and the life of your heat exchangers.
Since 1979, he has consulted on a variety of problems with process and power generation heat exchanger problems. The term heat exchanger applies to all equipment used to transfer heat between two streams. The figure shows the test data from a heat exchanger tube bundle mockup at the electric power research institute. Nde technologies for the examination of heat exchangers. We deliver effective nonintrusive inspection nii for heat exchanger vessels and apply this approach widely to the shell side. The tubes are zigzag mounted to achieve a maximum transfer effect between the medium inside. Would that mean my heat exchanger is bad or is there a pan that is leaking. Pass pure water through the heat exchanger for 510 minutes. Heat exchanger inspection pdf free download as pdf file. Allowance should be made for the clearance required to remove the tube bundle. Aa, bg, c, d, hp, hr, lc, and tv series heat exchangers. This rp addresses vessel components, inspection planning processes, inspection intervals, methods of inspection and. The heat exchanger should be located in a clean, open area, where it is easily accessible for inspection, service and repair.
It is safe to say that it would be rare to find someone in this industry that does not believe in having a plate heat exchanger maintenance strategy. Pheonwj platform personnel found 93 leaking tubes locations in the fin fan coolers gascooling heat exchanger. It is designed to fit in your toolbox or glove compartment of your vehicle. Please check for updates on the european medicines agencys website. Maintaining a plate heat exchanger and its related cost is not just a good idea it is a necessity for any successful business strategy concerned with its continued manufacturing productivity. Heat exchanger inspection system, hx inspection equipment.
Condensate that forms on the outside of the fins can be drained though this coupling to a drain leg or trap. Pdhonline course m371 2 pdh shell and tube heat exchangers. Discharge the fluid with water and monitor the situation through the glass tube. Chapter 5 heat exchangers faculty of engineering and. Heat exchangers jordan university of science and technology. Individual heat transfer equipment is named as per its function. The inspection approach is different for equipments after it is put to use as compared to the equipments which is being fabricated. Asme section viii, division 2 fatigue analysis of pressure. 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. However, the term is commonly used to equipment in which two process. Heat exchangers suffer problems within the tubes that make up the majority of the useful area within the exchanger unit. You should check your heat exchanger for possible cracks which if not repaired, can result in the emission of toxic gases.
Furnace heat exchanger is the number one business to business supplier of inspector cameras, manuals, and training classes for hvac professionals. References material safety data sheets msds are electronically stored and can be. Compilation of community procedures on inspections and exchange of information. The inspection was conducted at the clients site, located in. Introduction gas furnaces have earned a reputation for safe, reliable performance.
This includes knowledge of precautions regarding media type, pressures, temperatures in the heat exchanger as well as specific precautions required by the process. Purpose establish inspection guidelines to ensure mechanical integrity and continued reliable operation of shell and tube heat exchangers. The heat exchanger experts manual will prove to be invaluable for seasoned technicians, novice technicians and everyone in between. Steps have been taken in designing these furnaces to prevent flue products from leaking into the home environment. 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. Heat exchanger safety inspection cracked heat exchanger. Setting shell side and tube side pressure drop design limits. Pdf risk based inspection of gascooling heat exchanger. The third party inspection for shell and tube heat exchanger article provides a sample procedure for heat exchanger inspection and heat exchanger tsting.
In this way the singlesided access for weld inspection was realized xray endoscope. Heat exchanger tube inspection is vital for refining and petrochemicals. Tube tech can complete shell side cleaning of heat exchangers and ensures all debris is cleared completely. The first type of a heat exchanger is called the recuperative type, in which heat are exchanged on either side of a dividing wall by fluids. This standard applies to heaters, condensers, coolers, and reboilers. Manual we wrote the book on heat exchanger repairs.
Risk based inspection of gascooling heat exchanger. Furthermore, dont touch it until complete cooldown to the normal temperature after the shutdown. Pdf the demands for rapid changes in power generation is increasing. This procedure applies to the pressure containing parts of the exchanger alone with supporting structures. Combining each of these resistances in series gives. Guidelines for the mechanical design, material selection, fabrication, inspection, testing and preparation. Inspection procedure for shell and tube heat exchangers. Typically, a heat exchanger is used with two process streams. 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.
A more expert inspection is needed to assure your system is. A plate heat exchanger maintenance and inspection schedule is dependent on many factors including environment time, temperature and concentrations, frequency of use, and, in some cases, a mandate from a regulatory agency. After analysis had been performed, the crack in the tube strongly indicate that stress corrosion cracking was occurred by chloride. Plate heat exchanger maintenance periodic maintenance is. Plate heat exchanger hereinafter phe performs heat exchanging by transferring heat between hot and cold fluids flowing alternately through heat transfer plates, which are thin metal sheets having fine corrugated patterns. Apr 20, 2015 heat exchanger tubular inspection planning. Welcome to the most trusted and comprehensive heat exchanger inspection directory on the internet. However, in those situations where a heat exchanger has. An improved inspection system for rt inspection of metal tubetotube sheet joints of heat exchangers was developed based on a unit combining a rod anode xray tube and a new digital detector array arranged in tiles around this rod anode. Heat exchanger tubes made of carbon steel, stainless steel, titanium alloys, copper and copper alloys and other metals require nondestructive testing ndt solutions that can meet astm e2, e570, e426 and en 1089310 inspection standards, as well as other standards.
For inservice inspection you may have to check with nbic, for fabrication inspection refer to the following from asme, tema, api 660, api 572, these would help you in preparing your own check list. Warranty and service contact information is also included. A leaking tube can impact production, the environment and most importantly, lives. After visual inspection of the phe, the unit is disassem ess. Heat exchangers are devices that regulate efficient heat transfer from one fluid to another. Harsters first concern is you and your familys safety.
Installation, operation and maintenance instructions for tube and fin heat exchanger for heating, cooling and heat recovering. Api 660 shellandtube heat exchangers inspectioneering. Heat exchanger inspection checklist heat exchanger inspection checklist james10 mechanical op 2 oct 03 19. Though this procedure has been effective for testing heat exchangers in natural draft furnaces, its effectiveness for testing heat exchangers on induced draft furnaces that maintain a significant negative pressure within the heat exchanger has been questioned. The methods presented include remote field eddy current, magnetic flux leakage, internal rotary inspection system iris and eddy current. The inspector camera is not just an excellent furnace heat exchanger inspection device, it also perfectly addresses the need for an inspection tool to check out evaporator coils or inaccessible blowers, condensate pans without having to. There are a variety of methods of inspecting or testing heat exchangers. Heat exchangers on food duties should be cleaned every day, a suggested method is. 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. Heat exchanger inspection pdf furnace carbon monoxide.
The water leak from condensate could indeed destroy a heat exchanger. Clean out for inspection access as well as possibility to add an additional heating source max. 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. For secondary heat exchangers with failure dates of june 15, 2009 or later, a copy of the 90% furnace secondary heat exchanger inspection certificate included in this bulletin must be faxed to warranty administration at 860 998. Heat exchanger inspection techniques and corrosion mechanisms. Sonomatic provides a range of inspection and integrity services for heat exchangers and tubing.
Fatigue essentials workflow to meet the asme fatigue requirements under asme section viii, division 2 the work flow process for a fatigue analysis starts with a description of the load and their cycles. Free furnace heat exchanger inspections harster heating. In addition, it provides a technique to help the designer determine a reasonable, costeffective margin to apply to the heat exchanger. Process fluid assignments to shell side or tube side. Xray endoscopy for inspection of tube to tube sheet welds. Non destructive testing ndt for heater exchanger tubing. Exchanger inspection 101 visual inspection of shell and tube heat exchangers. 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. Oct 08, 2009 just a little video i shot with my inspector camerachecking out an armstrong heat exchanger enjoy. Just a little video i shot with my inspector camerachecking out an armstrong heat exchangerenjoy. Installation, operation and maintenance instructions for. 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 heat exchanger inspection industry. And test of vessel and heat exchangers project standards and specifications page 2 of 20 rev. Can detect largearea discontinuities such as steam erosion and.
However, mutlistream heat exchangers are sometimes used with energy extensive processes, such as lng processing, to reduce capital cost. Tube tech also offers the unique bladespec inspection system which is one of the slimmest inspection cameras in the world. Compilation of community procedures on inspections and. Third party inspection for shell and tube heat exchanger. The planning process starts by finding out what data is needed from the inspection.
Api standards for heat transfer equipments enggcyclopedia. It shows the photo of mss heat exchanger probe used for inspection of heat exchanger tube. This document forms part of the compilation of community procedures on inspections and exchange of information. Though it is unlikely for an induceddraft furnace to leak flue products from the heat exchanger to the circulated airstream, a new test procedure has been developed that enhances the existing threestep methodology to make it more applicable, reliable and repeatable for the inspection of induceddraft. The inspector infrared video inspection camera allows you to clearly see the holes, cracks, rust, or corrosion damage inside any furnace. Heat exchangers are being used to heat up, cool down, evaporate or condensate process flows. Gas furnace inspection checklist prevent fire hazards 1. Dec 22, 2015 this comfortmaker furnace was inspected during a no heat call and the technician found a cracked heat exchanger. The fin tube heat exchanger inspection article provides you with information about aircooled heat exchanger inspection and testing in the manufacturing shop, as well as in operational plants. With this in hand, the rainflow counting method can be constructed within fatigue essentials. We follow through with that by offering free heat exchanger inspections. Unlike most other ndt companies, heat exchanger inspection is a testex specialty. Like with most equipment, inspection planning is essential for the successful inspection and maintenance of heat exchanger tubulars. Api 660, shellandtube heat exchangers, is a standard developed and released by the american petroleum institute api that covers specific requirements for the mechanical design, material selection, fabrication, inspection, testing, and shipping of shellandtube heat exchangers for the petroleum and petrochemical industries.
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