‘The Handbook of In-Service Inspection Tube cracking, Can seriously reduce the Cracking of baffles ‘can be indicative of vibration: induced fatigue which may Nozzles and Internal erosion Requires wal thickness) fittings, around nozzle-to-shell_ nozzle compensation fitting, calculation to code requirements. Calculate remaining life based on Erosion of baffle plate {impingement guards). of heat exchanger insp varying views on both conditionsjexcess fluid velocity. Nozzle flange-face There are TEMA (Section 7) i requirements on flange-face alignment, Fig. 16.11 (Continued) inspections of heat exchangers. Thi envelope considerations and proce Pressure envelope considerations Inspection findings which co pressure envelope situation does, however, Some designs are such exchanger have a greater chance of ‘hock 4 Sheooarson Fig. 16.12 Shot! and tube exchangers ~ inspection points48 Fig, 16:13 Shell and tube exchangers ~ further inspection points “The Handbook of In-Service Inspection Heat exchangers 475 jickness required to ‘shell corrosion common and is caused by either localized CUI bined crosion/corrosion on the inside. Common i show some useful points Sealing and corrosion of tubes ‘ivuling is caused by poor process conditions, Fxvessive temperatures ‘und process transients make the situation worse, Unless it is sufficiently76 ‘The Handbook of In-Service Inspection Heat exchangers an \ge design is normally an electrochemical corrosion mechanism, made worse le existence of a tight crevice. Some specific features are * ‘Stainless Stee! anges are susceptible o sitoss corrosion cracking ‘C), They show as fine ‘hairike’ branched cracks running radially lange-face flatness heck this with a steel straight edge. Any visible bowing indicates serious distortion, Nozzle flange distortion mainly caused during manufacturing (or repair) rather than by ice conditions (except in high-temperature heaters using super- steam which can suffer twisting). These tolerances (see Fig, are important — they can transfer any ‘out of design’ static load nozzle-to-shell welds, causing failure.478 ‘The Handbook of In-Service Inspection Heat exchangers ara Tube cleaning \ ‘* Weak citric acid solution or hot 2% NaOH solution can remove scale General corrosion characteristics '* Ti forms a good corrosion-resistant passive surface film which can easily withstand fluid velocities up to 20mjs. '* Tian suffer from crevice corrosion > 130°C. d '* Tis cathodic to most other heat exchanger materials. Fatigue limit Approximately 50% UTS (in air or seawater), Erosion resistance ‘* Negligible erosion in clean seawater at velocities <20m/s or water containing sand and grit at < 2m/s. ) Typical Ti tube corrosion/erosion rates ed Service Corrosionjerosion rato C9 Clean water 1 10- ?mmiyear Sulphuric acid 10% @ 25°C 0. 25mmjyear ay Nitric acid 10% @ 100°C 0.03mmiyear ‘sae of abe pola Chiorine-saturated water @ 100°C 0.07mm/year I 2.3 Toeed unt tiooope: Te al Sodium chloride solution 10% @ 100°C Nil Hydrochloric acid 10% @ 35°C 0.76 mmiyear Fig. 16.16 Titanium heat exchanger tubes ~ useful data ipered or threaded. Special tools are 7 Fig, 16.17 Heat exchanger tube defects and sampling Horescope inspection of tube internal surface yy is to use a special remaining life years or more) shutdowa insp nee d NDT techniques Although most inspection techniques on heat exchangers are visual, several specialized NDT techniques are used for specific tasks.480 The Handbook of In-Service Inspection Heat exchangers 481 Borescope examination of Insige face of tbe shat 80° borescope head from tbeshest pS regi in these areas, Fewer problems occur near of the tube length, Panoramic vow for Cracking at seal welds inlernal cracking a tubes orligament areas Tube ‘ring’ test. Under site condilons Fig. 16.19 Heat exchanger visual/NDT inspection496 ‘The Handbook of In-Service Inspection “Transportable pressure equipment (TPE) 497 measuring the volume of water Table 17.2 Typical rejection criteria for welded TPR cylinders pressure, and then agai In the non-water-ja comparing the volume of rejected back out when the pressure is released. Me a calibrated glass burette. Figure 17.4 sh ‘Ropar or render Rejection imits* unserviceable Alleylinders with Render such a defect unserviceable ‘When the depth of Render unserviceable Dent Render ss unserviceable of the dent ‘than 15 tn depth A sharp impression When the depth of where metal has been the cut or gouge removed or Render unserviceable Cylinders are subject to a volumetric expansion test during construc- tion and in-service. '* The objective: to check the ductility of the material and the way in which it interfaces with the design of the cylinder. '» The principle: water is used to pressurize the cylinder (at normal test pressure). The volume of water used allows the percentage volumetric expansion under pressure and the accompanying permanent plastic deformation to be calculated '* Acceptance criteria: for in-service testing a ‘rule-of-thumb’ accep- tance level (from BS 5430) is: — for non-corroded cylinders permanent expansion should not ‘exceed 5% of the total volumetric expansion; — for corroded cylinders, permanent expansion should not exceed 2% of the total volumetric expansion, Render unserviceable Render unserviceable Fig. 17.3 TPR (cylinders) ~ the volumetric expansion test