Tubular Heat Exchanger: Inspection, Maintenance and Repair / Edition 1

by Carl F Andreone P.E., Stanley Yokell

Overview

Today's cost-conscious process and manufacturing industries require the life of tubular heat exchangers to be extended. That's why engineers and technicians will welcome this guide, packed with inspection checklists and tips for cost containment that reduce the need for new equipment.

Advice on evaluating heat exchangers and on inspection strategies for both operating and out-of-service equipment will help prevent the need for costly reapairs. Additional benefits include tips on tube plugging, retubing, shell-side repairs and alterations, maintenance, repair, and alteration of closures, channels, bonnets, and tubesheets.

Product Details

ISBN-13:	9780070017788
Publisher:	McGraw-Hill Companies, The
Publication date:	09/19/1997
Pages:	536
Product dimensions:	6.30(w) x 9.29(h) x 1.65(d)

Table of Contents

	Preface	ix
Chapter 1.	General Information	1
	Introduction	1
	Inspector's Qualifications	5
	Roles of Code Authorized Inspectors and Non-Code Inspectors	6
	Preinspection Conferences	8
	Inspection Tools and Instruments	8
	Inspection Reports and Data Collection	11
	Inspection Records as a Maintenance Tool	13
	References	16
Supplement 1.1	African, Asian, European, Near Eastern, and North American Nondestructive Testing Societies and Related Organizations	16
Chapter 2.	Inspecting in the Heat Exchanger Factory	21
	Introduction	21
	Inspection Briefs	21
	Safety Precautions for Entering Closed Spaces	31
	Safety When Inspecting in the Factory	31
	Inspecting Factory Repairs, Retubing, or Alterations	32
	Inspection Checklists	35
	Pressure Testing	54
	References	55
Supplement 2.1	Inspection Checklist for Factory Inspection of Heat Exchangers	56
Supplement 2.2	Checklist for Initial Inspection of Exchangers to Be Factory-Altered, Repaired, or Retubed	65
Chapter 3.	Evaluating Heat Exchanger Factories and Repair Shops	71
	Introduction	71
	Manufacture-to-Order Factories (Job Shops)	73
	The Wonderful Heat Exchanger Manufacturing Company, Inc. (WHEMCO): An Imaginary Intermediate-Sized Factory	74
	Large Exchanger Factories	93
	Feedwater Heater Manufacturers	95
	Field Service Organizations and Erectors of Exchangers Too Large to Ship	97
	Production-Line Heat Exchanger Factories	98
	Surveying Manufacture-to-Order Factories (Job Shops)	100
	Assessing Field Construction, Repair, and Alteration Organizations	111
	Evaluating Production-Line Exchanger Factories	114
	References	114
Supplement 3.1	Survey Form for Evaluating Custom Heat Exchanger Manufacturing and Repair Shops	115
Chapter 4.	Maintenance Inspection and Inspecting Out-of-Service, Mothballed, and Used Exchangers	129
	Introduction	129
	Safety Precautions When Inspecting Shutdown Exchangers	130
	Planning for Maintenance Inspections	132
	Inspection before Maintenance	136
	Inspection during Performance of Maintenance Work	143
	Inspection on Completion of Maintenance	143
	Recording and Documenting Maintenance Work	144
	Assessing and Inspecting Mothballed and Used Exchangers	145
Chapter 5.	Test and Nondestructive Examinations	149
	Introduction	149
	Guidelines to ASME Code, Section V, "Nondestructive Examination"	150
	Visual Inspection (VT)	151
	Radiographic Examination (RT)	153
	Ultrasonic Examination (UT)	154
	Liquid Penetrant Examination (PT)	156
	Magnetic Particle Examination (MT)	157
	Eddy-Current Examination (ET)	158
	Leak Testing	161
	Pressure Testing	166
	Destructive Sampling and Trepanning	175
	Interpreting Test and Examination Results	176
	Records of Inspections and Tests	177
	Precautions for Hydrostatic and Pneumatic Testing	177
	References	178
Chapter 6.	Inspection Codes	179
	Introduction	179
	Jurisdictional Requirements	182
	Guide to the National Board Inspection Code (NBIC)	183
	The API Inspection Code (API 510)	204
	How the National Board and API Codes Apply the ASME Code Rules	207
	References	208
Chapter 7.	Exchanger Cleaning	209
	Introduction	209
	Off- versus On-Line Mechanical Cleaning	210
	Hydraulic and Chemical Cleaning	218
	Deciding on Contract Cleaning Organization or Plant Maintenance Force	222
	References	224
Chapter 8.	Record Keeping; Preparing for Repairs and Alterations	225
	Introduction	225
	Organizing Inspection and Maintenance Records	225
	Deciding Whether to Use In-Plant Maintenance Force or to Contract a Repair or Alteration Organization	236
	Materials Documentation	238
	Documentation of Procedures	239
	Scheduling	240
	Reference	246
Chapter 9.	Maintaining Tubesheets, Bonnets, Channels and Covers	247
	Introduction	247
	Flange Design Basics: Bolting and Unbolting Closures	247
	Opening and Closing Quick-Opening and Nonbolted Closures	263
	Repairing Corroded or Damaged Gasket Surfaces	265
	Field Remachining Warped Flanges	267
	Correcting Excessive Deflection in Flat Covers	268
	Strategies for Dealing with Chronically Leaking Gasketed Flanged Closures	269
	Opening and Resealing Diaphragm Closures	276
	How to Correct Pass-Partition Bending	278
	Removing and Replacing Feedwater Heater Pass-Partition Covers	279
	Restoring Damaged Feedwater Heater Pass Partitions	279
	Replacing Channels and Covers	280
	Repairing Eroded and Wormholed Tubesheets	280
	References	281
Chapter 10.	Plugging, Ferruling and Sleeving	283
	Introduction	283
	Failures in Tubes and Tube-to-Tubesheet Joints	284
	Locating Tube Failure Positions	306
	Finding Tube-to-Tubesheet Joint Leaks	311
	Plugging Heat Exchanger Tubes	312
	Ferrules and Sleeves	348
	Heat and Erosion Shields	350
	References	352
Chapter 11.	Shell-Side Repairs and Alterations	353
	Introduction	353
	Shell-Side Failures and Their Causes	353
	Procedures and Practices for Repairing and Altering Heat Exchangers	369
	References	381
Chapter 12.	Retubing and Rebundling	383
	Introduction	383
	General Considerations	383
	General Retubing Techniques and Procedures	394
	Parts Replacements, Repairs, Reassembly, and Testing	407
	In-Place Retubing	428
	Shop Retubing	432
	Retubing Closed Feedwater Heaters	438
	A Typical Repair of a Three Zone Closed Feedwater Heater	440
	Rebundling	440
	References	447
Chapter 13.	Feedwater Heater Autopsies	449
	Introduction	449
	Why Conduct an Autopsy?	450
	Who Should Participate in Feedwater Heater Autopsies and Why	450
	Documents to Gather in Preparation for the Autopsy	454
	Scheduling Autopsies	457
	Space Requirements, Facilities, and Tools	457
	Disassembly Procedures	460
	What to Look for When Conducting Autopsies	466
	Recording Observations	474
	Reports	474
	Reference	474
	Glossary	475
	Index	501