POWER PLANT HEAT EXCHANGER CONDITION ASSESSMENT
Seven sessions totaling 2 days
The text material will serve as a guide and will minimize the need for note taking. 
This seminar is presented on a slide and physical specimen assisted lecture/discussion basis.
Half of the seminar is devoted to identifying heat exchanger failure mechanisms and the other half is devoted to examination techniques. Eddy current testing (ET) is the principle examination technique discussed. ET's capabilities and limitations are identified. The role of the Analyst is emphasized.
The intent of the seminar is to provide the participants with the necessary background information that is required to identify and evaluate heat exchanger condition. This information includes a review of feedwater heater and steam surface condenser design and operation.
The Course Director is Mr. Robert J. Bell, President of Heat Exchanger Systems, Inc., a consulting engineering and non-destructive testing firm in Boston, Massachusetts. He specializes in the analysis and specification of steam surface condensers and associated systems. Mr. Bell's experience includes performance testing, performance monitoring, corrosion failure analysis, vendor surveillance, materials selection, consultation on operation and maintenance, condenser retubing and troubleshooting. For additional information: Mr. Bell
SESSION 1 - Operating and Design Features of Steam Surface Condensers and Feedwater Heaters: An overview of alternate designs and design features pertinent to inspection practices. Also included is overview of principles of operations. Includes subjects such as steam flow, high velocity zones and the detrimental affects of abnormal operation.
SESSION 2 - Condenser Tube Problems: An overview of the most frequent tube problems both on the steamside, (impingement attack, flow induced vibration, condensate corrosion and stress corrosion cracking) and on the waterside, (galvanic corrosion, dealloying, pitting, and sulfide attack) is presented. Proper design, operation and maintenance methods are also identified.
SESSION 3 - Feedwater Heater Failure Causes: An overview of the most frequent tube failure causes such as impingement erosion is presented. The relationship between feedwater design, feedwater heater normal and abnormal modes of operation and other component failures such as impingement plates are discussed.
SESSION 4 - Visual Examination: Visual examination techniques and key components to be examined are identified. Surface preparation, lighting, level of detection and recording methods and equipment are identified.
SESSION 5 - Principles of Eddy Current Testing Non-Ferromagnetic Tubes: Included is an explanation of how the technique works and an overview of signal analysis, various modes of operation, test frequencies and test sensitivity are discussed. The alternate equipment and probe designs are identified. The advantages and limitation of the technique are discussed.
SESSION 6- Electromagnetic Examination of Slightly Ferritic (i.e. monel) and Highly Ferritic (i.e. ferritic stainless steel and carbon steel), Tubing: The following techniques are presented and their advantage and limitation are discussed:
- Saturation Eddy Current Testing
- Partial Saturation Eddy Current Testing
- Flux Leakage Testing
- Remote Field Eddy Current Testing
SESSION 7 - Condition Assessment Techniques: The three level approach is described below:
Level I Assessment
- Records Review/Interviews
- Historical Data Comparison
Level II Assessment
- Visual Examination
- Direct
- Remote
- Magnetic Particle Testing
- Electromagnetic Examination
- Eddy Current Testing
- Flux leakage Testing
- Partial Saturation Eddy Current Testing
- Remote Field Eddy Current Testing
- Ultrasonic Testing
- Tubes
- Shells, Waterboxes and Channels
Level III Assessment
- Failure Analysis
- Corrosion Monitoring
The advantages and limitations of each technique are discussed. Eddy Current Testing will be demonstrated using tube samples removed from power plant heat exchangers.
Eddy current testing is as much an art as it is a science. Erroneous results are often obtained because of the examiner's lack of knowledge of power plant heat exchanger failure mechanisms and because of the use of poorly qualified technicians. Techniques for assuring accurate eddy current testing are identified.
This course is intended for those engineers and support staff concerned with specification, operation, maintenance and repair of steam surface condensers. The program should be of special value to personnel who are required to evaluate the condition and operation of existing equipment, make "repair or replace" decisions, and resolve operating problems.
Advantages to your company include:
- Up to 30 of your engineers, operations and maintenance personnel participate interactively in this course
- Opportunity to request modifications to the standard program
- Customization of this course for your plant
The fee for this course will be determined based on the number of participants and the course location. To receive a quotation or to arrange for this in-plant course, please contact Joyce Kelly at (781) 337-9400 or send email to: joyce@heatexsys.com.
Please contact Robert J. Bell at (781) 337-9400 regarding any technical questions/information pertaining to this course