Heat exchanger inspection checklist pipewelder1999 industrial 3 oct 03 05. Heat exchanger inspection checklist heat exchanger inspection checklist james10 mechanical op 2 oct 03 19. Heat exchanger, condenser and boiler inspection methodology. This is a handson tech teaching tech workshop on greatly increasing your abilities at finding failure using the inspector camera. Any change is an indication of a heat exchanger leak. Hvac courses understanding your heat exchanger the. Author of the heat exchanger experts residential furnace inspection manual, ellis is considered one of the foremost experts when it comes to finding cracked heat exchangers. Hydrostatic test for heat exchanger floating head aes.
This is a draft and must be edited based on your po requirements. Aa, bg, c, d, hp, hr, lc, and tv series heat exchangers. Heat exchanger inspection techniques and corrosion mechanisms 1. Sodium bicarbonate salt solutions, on the other hand, are non. A smoke bomb test a smoke generator is placed in the heat exchanger, then the outside of the heat exchanger is visually accessed to watch for smoke passing through the crack. When opening and assembling the heat exchanger observe the following. About hedh multimedia heat exchanger design handbook. Boost training and consulting certified training course.
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. 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. A drain that is plugged or slow to drain allows condensate to build up in the secondary heat exchanger and collector box. Exchanger inspection 101 visual inspection of shell and tube heat exchangers. Induceddraft furnace heat exchanger inspection procedure. If you know the scope, steps and activities, schedule, resources and cost plan can be developed easily and monitored. Heat exchanger design handbook mechanical engineering. Warranty and service contact information is also included. This contractortalk forum entry is a compilation of a number of heat exchanger tests that can be used to identify a cracked fire box or if a heat exchanger has holes.
Eddy current inspection is often used to detect corrosion, erosion, cracking and other changes in non ferromagnetic tubing. It is designed to fit in your toolbox or glove compartment of your vehicle. Eddy current inspection is often used to detect corrosion, erosion, cracking and other changes in tubing. 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. Its why were known as a top rated national heat exchanger training company. In our many years of work with heat exchangers, weve seen nearly everything. If the plate at fault is punched 1234, the unit may be rapidly put back on line by removing an adjacent plate with the same punching. The objective of this book is to provide engineers with sufficient information to make better logical choices in designing and operating the system. Tubular heat exchanger inspection, maintenance, and repair. Heat exchanger equipment field manual sciencedirect. Sonomatic provides a range of inspection and integrity services for heat exchangers and tubing. Conventional inspection techniques of heat exchanger tubes, such as ultrasonic and eddy current, examine one local area at a time and therefore a scan of the entire tube is required.
Heat exchanger inspection planning inspectioneering. 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. Heat exchangers such as shell and tube exchangers, singlephase exchangers, multiphase exchangers, multicomponent condenser exchangers, reboiler exchangers, fixed tube sheet exchangers, ubundle exchangers and floating head pull through bundle type heat exchangers can be tested. Heat exchanger inspection techniques and corrosion mechanisms powerpoint presentation. The term heat exchanger applies to all equipment used to transfer heat between two streams. Heat exchanger inspection techniques and corrosion mechanisms. Because there are several hundred of tubes in a heat exchanger bundle, and conventional inspection is slow, only a small fraction of the tubes is inspected. Tubular heat exchanger inspection, maintenance, and repair will be your most valuable costcutting field manual. 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. 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.
Heat transfer will be reduce d only to a minor extent. So what to do if your expecting a crack, or you have evidence that there is a crack in the heat exchanger. Maintenance and cleaning may only be done with a shutdown heat exchanger. Bg series heat exchangers ctv series heat exchangers 2. Repeat this sequence to arrive at the required q distance. Free furnace heat exchanger inspections harster heating. As the solution is sprayed into the burner flame, visual inspection of the heat exchanger surface below the burner port level is needed. Attached is the official carrier bryant payne 90% furnace heat exchanger inspection procedure. Ellis prach has workid in the business for over 40 years. The prach family has earned their expert title after decades of experience, and literally writing the book on heat exchanger inspection and repair. 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. Due to the custom nature of all xchanger heat exchangers, this manual discusses the characteristics and procedures that are common to all exchangers.
Heat exchangers and condensers are designed to sustain 100% separation between the products in the tube tube side and the products in the vessel shell side. The inspector infrared video inspection camera allows you to clearly see the holes, cracks, rust, or corrosion damage inside any furnace. Which heat exchanger inspection method is usually included in a by the standards inspection of a conventional gas furnace. In the focus on finding failure advanced class for heat exchanger inspection training, each technician will learn how to increase their ability to be truly focused on finding failure to incredible levels. Two of the most common defects that are generally inspected for are.
The planning process starts by finding out what data is needed from the 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. This approach means inspection of the shell can take place without the need to remove the tube bundle. If a solution of sodium chloride table salt is used, corrosion of the heat exchanger can be accelerated. Like with most equipment, inspection planning is essential for the successful inspection and maintenance of heat exchanger tubulars. Comprehensive and unique source integrates the material usually distributed among a half a dozen sources. Inspection procedure for shell and tube heat exchangers printed. The piston will travel forward and the pressure plate will travel in the same direction. Searching documents and internet sources the following is what i found on heat exchanger inspection methods and sources. 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. Chapter 5 heat exchangers faculty of engineering and.
He has owned and operated his own successful heating business and tours the nation regularly delivering seminars. Jun 06, 2016 heat exchanger, condenser and boiler inspection methodology ndt welding. Heat exchanger inspection checklist qc, inspection. Heat exchanger experts residential furnace inspection.
Weve seen so much in fact, we wrote the book on heat exchanger repair. Inside very rusty chambers of an old carrier package unit using a dct410 dewalt wireless snake inspection camera. American gas association aga laboratories under sam number 63092 986. Mar 19, 2007 a smoke bomb test a smoke generator is placed in the heat exchanger, then the outside of the heat exchanger is visually accessed to watch for smoke passing through the crack.
Apr, 2016 heat exchanger inspection with eddy current. In some cases, an oldfashioned visual inspection makes the most sense, either by removing the blower or the high limit or both and using a mirror or borescope to inspect. Non destructive testing ndt for heater exchanger tubing. We recommend that a warning notice is attached to the exchanger to remind personnel that the tie bolts need adjustment before the unit can be put back into service. For a good example of a hazardous heat exchanger, check out the photo below showing a large rust hole in the heat exchanger of this highefficiency furnace that was only ten years old. A more expert inspection is needed to assure your system is. 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. The wintergreen test oil of wintergreen is sprayed into the combustion chamber with the blower operating, then see if the smell is present at the supply. Heat exchanger inspection system, hx inspection equipment. Apr 20, 2015 heat exchanger tubular inspection planning. Heat exchangers and steam generators, which are used in power plants, have thousands of tubes that must be prevented from leaking.
Heat exchanger inspection training the inspector camera. It describes most of the available tests and has images of some of the testing tools and methods of how to check for a cracked heat exchanger. Heat exchangers suffer problems within the tubes that make up the majority of the useful area within the exchanger unit. Sample activities for heat exchanger cleaning and inspection work activities and work steps are very useful information. Gwa also provides consulting services for pipeline inspection, heat exchanger tube inspection, anchor rod inspection, and other challenging guided. The excess condensate in the heat exchanger or collector box reduces the amount of air moving through the heat exchangers. There are a variety of methods of inspecting or testing heat exchangers. Heat exchanger, condenser and boiler inspection methodology ndt welding.
If there is a gap between pressure plate and fixed nut, turn the nut by hand. Heat exchanger equipment field manual provides an indispensable means for the determination of possible failures and for the recognition of the optimization potential of the respective heat exchanger. Would that mean my heat exchanger is bad or is there a pan that is leaking. Invest in your commitment to food plant safety by including cct 4. Inspection of the entire length of heat exchanger tubes however brings along a few extra challenges. Tube inspection is a vital tool for the refining and petrochemical industries. The heat exchanger experts manual will prove to be invaluable for seasoned technicians, novice technicians and everyone in between. Preassemble the heat exchanger and after placing the tightening units on the diagonal nuts, apply oil pressure. Cover the plate pack with black plastic to exclude any sun light. Material list refer to brembana drawing 21626928 rev 4 for part numbers w. Also check for tube od wear where the pass through baffles. Completely revised and updated to reflect current advances in heat exchanger technology, heat exchanger design handbook, second edition includes enhanced figures and thermal effectiveness charts, tables, new chapter, and additional topicsall while keeping the qualities that made the first edition a centerpiece of information for practicing engineers, research, engineers, academicians. Inspection procedure for shell and tube heat exchangers. Boost training and consulting certified training course ask for this course register now.
However, mutlistream heat exchangers are sometimes used with energy extensive processes, such as lng processing, to reduce capital cost. The water leak from condensate could indeed destroy a heat exchanger. Improper or inadequate furnace heat exchanger inspection techniques can result in the misdiagnosis of a heat exchanger failure when a failure has not occurred or is not imminent. Manual we wrote the book on heat exchanger repairs. Heat exchangers jordan university of science and technology. Refrigeration service engineers societys service application manual sam titled residential gas furnace heat exchanger testing douglas dewerth, p. 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. 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.
Typically, a heat exchanger is used with two process streams. We follow through with that by offering free heat exchanger inspections. If this punching arrangement is other than above, you will have to remove and. How to check a heat exchanger for a leak diy furnace. May 20, 2014 heat exchanger inspection techniques and corrosion mechanisms 1. Verify proper location of impingement plate and for tube od erosion in the vicinity of inlet nozzles. We deliver effective nonintrusive inspection nii for heat exchanger vessels and apply this approach widely to the shell side. Hewitt, a group of leading authorities in the fields of heat transfer and fluid flow began to discuss the possibility of producing a handbook dealing with all aspects of heat exchanger design and operations including. You can purchase the manual, our inspection mirrors, and other hee products and gear. When you do find a cracked exchanger it should be quoted for repair and the furnace turned off. Harsters first concern is you and your familys safety. Heat exchanger inspection techniques and corrosion mechanisms 2. The heat exchanger experts now tour the nation annually, providing hvac technicians everywhere the opportunity to develop their skills, and offer a wider array of services to their homeowner clients. Inspection of the drain system, trap, and associated tubing should also be performed.
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