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Tubular Heat Exchanger Operation and Repair - Carl F. Andreone

Tubular Heat Exchanger Operation and Repair

Hardcover Published: 19th September 1997
ISBN: 9780070017788
Number Of Pages: 512

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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.

Prefacep. ix
General Informationp. 1
Introductionp. 1
Inspector's Qualificationsp. 5
Roles of Code Authorized Inspectors and Non-Code Inspectorsp. 6
Preinspection Conferencesp. 8
Inspection Tools and Instrumentsp. 8
Inspection Reports and Data Collectionp. 11
Inspection Records as a Maintenance Toolp. 13
Referencesp. 16
African, Asian, European, Near Eastern, and North American Nondestructive Testing Societies and Related Organizationsp. 16
Inspecting in the Heat Exchanger Factoryp. 21
Introductionp. 21
Inspection Briefsp. 21
Safety Precautions for Entering Closed Spacesp. 31
Safety When Inspecting in the Factoryp. 31
Inspecting Factory Repairs, Retubing, or Alterationsp. 32
Inspection Checklistsp. 35
Pressure Testingp. 54
Referencesp. 55
Inspection Checklist for Factory Inspection of Heat Exchangersp. 56
Checklist for Initial Inspection of Exchangers to Be Factory-Altered, Repaired, or Retubedp. 65
Evaluating Heat Exchanger Factories and Repair Shopsp. 71
Introductionp. 71
Manufacture-to-Order Factories (Job Shops)p. 73
The Wonderful Heat Exchanger Manufacturing Company, Inc. (WHEMCO): An Imaginary Intermediate-Sized Factoryp. 74
Large Exchanger Factoriesp. 93
Feedwater Heater Manufacturersp. 95
Field Service Organizations and Erectors of Exchangers Too Large to Shipp. 97
Production-Line Heat Exchanger Factoriesp. 98
Surveying Manufacture-to-Order Factories (Job Shops)p. 100
Assessing Field Construction, Repair, and Alteration Organizationsp. 111
Evaluating Production-Line Exchanger Factoriesp. 114
Referencesp. 114
Survey Form for Evaluating Custom Heat Exchanger Manufacturing and Repair Shopsp. 115
Maintenance Inspection and Inspecting Out-of-Service, Mothballed, and Used Exchangersp. 129
Introductionp. 129
Safety Precautions When Inspecting Shutdown Exchangersp. 130
Planning for Maintenance Inspectionsp. 132
Inspection before Maintenancep. 136
Inspection during Performance of Maintenance Workp. 143
Inspection on Completion of Maintenancep. 143
Recording and Documenting Maintenance Workp. 144
Assessing and Inspecting Mothballed and Used Exchangersp. 145
Test and Nondestructive Examinationsp. 149
Introductionp. 149
Guidelines to ASME Code, Section V, "Nondestructive Examination"p. 150
Visual Inspection (VT)p. 151
Radiographic Examination (RT)p. 153
Ultrasonic Examination (UT)p. 154
Liquid Penetrant Examination (PT)p. 156
Magnetic Particle Examination (MT)p. 157
Eddy-Current Examination (ET)p. 158
Leak Testingp. 161
Pressure Testingp. 166
Destructive Sampling and Trepanningp. 175
Interpreting Test and Examination Resultsp. 176
Records of Inspections and Testsp. 177
Precautions for Hydrostatic and Pneumatic Testingp. 177
Referencesp. 178
Inspection Codesp. 179
Introductionp. 179
Jurisdictional Requirementsp. 182
Guide to the National Board Inspection Code (NBIC)p. 183
The API Inspection Code (API 510)p. 204
How the National Board and API Codes Apply the ASME Code Rulesp. 207
Referencesp. 208
Exchanger Cleaningp. 209
Introductionp. 209
Off- versus On-Line Mechanical Cleaningp. 210
Hydraulic and Chemical Cleaningp. 218
Deciding on Contract Cleaning Organization or Plant Maintenance Forcep. 222
Referencesp. 224
Record Keeping; Preparing for Repairs and Alterationsp. 225
Introductionp. 225
Organizing Inspection and Maintenance Recordsp. 225
Deciding Whether to Use In-Plant Maintenance Force or to Contract a Repair or Alteration Organizationp. 236
Materials Documentationp. 238
Documentation of Proceduresp. 239
Schedulingp. 240
Referencep. 246
Maintaining Tubesheets, Bonnets, Channels and Coversp. 247
Introductionp. 247
Flange Design Basics: Bolting and Unbolting Closuresp. 247
Opening and Closing Quick-Opening and Nonbolted Closuresp. 263
Repairing Corroded or Damaged Gasket Surfacesp. 265
Field Remachining Warped Flangesp. 267
Correcting Excessive Deflection in Flat Coversp. 268
Strategies for Dealing with Chronically Leaking Gasketed Flanged Closuresp. 269
Opening and Resealing Diaphragm Closuresp. 276
How to Correct Pass-Partition Bendingp. 278
Removing and Replacing Feedwater Heater Pass-Partition Coversp. 279
Restoring Damaged Feedwater Heater Pass Partitionsp. 279
Replacing Channels and Coversp. 280
Repairing Eroded and Wormholed Tubesheetsp. 280
Referencesp. 281
Plugging, Ferruling and Sleevingp. 283
Introductionp. 283
Failures in Tubes and Tube-to-Tubesheet Jointsp. 284
Locating Tube Failure Positionsp. 306
Finding Tube-to-Tubesheet Joint Leaksp. 311
Plugging Heat Exchanger Tubesp. 312
Ferrules and Sleevesp. 348
Heat and Erosion Shieldsp. 350
Referencesp. 352
Shell-Side Repairs and Alterationsp. 353
Introductionp. 353
Shell-Side Failures and Their Causesp. 353
Procedures and Practices for Repairing and Altering Heat Exchangersp. 369
Referencesp. 381
Retubing and Rebundlingp. 383
Introductionp. 383
General Considerationsp. 383
General Retubing Techniques and Proceduresp. 394
Parts Replacements, Repairs, Reassembly, and Testingp. 407
In-Place Retubingp. 428
Shop Retubingp. 432
Retubing Closed Feedwater Heatersp. 438
A Typical Repair of a Three Zone Closed Feedwater Heaterp. 440
Rebundlingp. 440
Referencesp. 447
Feedwater Heater Autopsiesp. 449
Introductionp. 449
Why Conduct an Autopsy?p. 450
Who Should Participate in Feedwater Heater Autopsies and Whyp. 450
Documents to Gather in Preparation for the Autopsyp. 454
Scheduling Autopsiesp. 457
Space Requirements, Facilities, and Toolsp. 457
Disassembly Proceduresp. 460
What to Look for When Conducting Autopsiesp. 466
Recording Observationsp. 474
Reportsp. 474
Referencep. 474
Glossaryp. 475
Indexp. 501
Table of Contents provided by Syndetics. All Rights Reserved.

ISBN: 9780070017788
ISBN-10: 0070017786
Audience: General
Format: Hardcover
Language: English
Number Of Pages: 512
Published: 19th September 1997
Country of Publication: US
Dimensions (cm): 23.6 x 16.0  x 4.19
Weight (kg): 0.89