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| Preface | |
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| General Information | |
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| Introduction | |
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| Inspector's Qualifications | |
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| Roles of Code Authorized Inspectors and Non-Code Inspectors | |
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| Preinspection Conferences | |
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| Inspection Tools and Instruments | |
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| Inspection Reports and Data Collection | |
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| Inspection Records as a Maintenance Tool | |
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| References | |
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| African, Asian, European, Near Eastern, and North American Nondestructive Testing Societies and Related Organizations | |
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| Inspecting in the Heat Exchanger Factory | |
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| Introduction | |
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| Inspection Briefs | |
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| Safety Precautions for Entering Closed Spaces | |
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| Safety When Inspecting in the Factory | |
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| Inspecting Factory Repairs, Retubing, or Alterations | |
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| Inspection Checklists | |
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| Pressure Testing | |
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| References | |
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| Inspection Checklist for Factory Inspection of Heat Exchangers | |
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| Checklist for Initial Inspection of Exchangers to Be Factory-Altered, Repaired, or Retubed | |
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| Evaluating Heat Exchanger Factories and Repair Shops | |
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| Introduction | |
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| Manufacture-to-Order Factories (Job Shops) | |
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| The Wonderful Heat Exchanger Manufacturing Company, Inc. (WHEMCO): An Imaginary Intermediate-Sized Factory | |
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| Large Exchanger Factories | |
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| Feedwater Heater Manufacturers | |
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| Field Service Organizations and Erectors of Exchangers Too Large to Ship | |
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| Production-Line Heat Exchanger Factories | |
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| Surveying Manufacture-to-Order Factories (Job Shops) | |
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| Assessing Field Construction, Repair, and Alteration Organizations | |
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| Evaluating Production-Line Exchanger Factories | |
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| References | |
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| Survey Form for Evaluating Custom Heat Exchanger Manufacturing and Repair Shops | |
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| Maintenance Inspection and Inspecting Out-of-Service, Mothballed, and Used Exchangers | |
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| Introduction | |
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| Safety Precautions When Inspecting Shutdown Exchangers | |
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| Planning for Maintenance Inspections | |
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| Inspection before Maintenance | |
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| Inspection during Performance of Maintenance Work | |
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| Inspection on Completion of Maintenance | |
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| Recording and Documenting Maintenance Work | |
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| Assessing and Inspecting Mothballed and Used Exchangers | |
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| Test and Nondestructive Examinations | |
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| Introduction | |
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| Guidelines to ASME Code, Section V, "Nondestructive Examination" | |
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| Visual Inspection (VT) | |
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| Radiographic Examination (RT) | |
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| Ultrasonic Examination (UT) | |
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| Liquid Penetrant Examination (PT) | |
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| Magnetic Particle Examination (MT) | |
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| Eddy-Current Examination (ET) | |
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| Leak Testing | |
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| Pressure Testing | |
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| Destructive Sampling and Trepanning | |
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| Interpreting Test and Examination Results | |
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| Records of Inspections and Tests | |
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| Precautions for Hydrostatic and Pneumatic Testing | |
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| References | |
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| Inspection Codes | |
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| Introduction | |
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| Jurisdictional Requirements | |
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| Guide to the National Board Inspection Code (NBIC) | |
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| The API Inspection Code (API 510) | |
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| How the National Board and API Codes Apply the ASME Code Rules | |
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| References | |
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| Exchanger Cleaning | |
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| Introduction | |
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| Off- versus On-Line Mechanical Cleaning | |
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| Hydraulic and Chemical Cleaning | |
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| Deciding on Contract Cleaning Organization or Plant Maintenance Force | |
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| References | |
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| Record Keeping; Preparing for Repairs and Alterations | |
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| Introduction | |
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| Organizing Inspection and Maintenance Records | |
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| Deciding Whether to Use In-Plant Maintenance Force or to Contract a Repair or Alteration Organization | |
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| Materials Documentation | |
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| Documentation of Procedures | |
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| Scheduling | |
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| Reference | |
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| Maintaining Tubesheets, Bonnets, Channels and Covers | |
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| Introduction | |
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| Flange Design Basics: Bolting and Unbolting Closures | |
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| Opening and Closing Quick-Opening and Nonbolted Closures | |
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| Repairing Corroded or Damaged Gasket Surfaces | |
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| Field Remachining Warped Flanges | |
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| Correcting Excessive Deflection in Flat Covers | |
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| Strategies for Dealing with Chronically Leaking Gasketed Flanged Closures | |
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| Opening and Resealing Diaphragm Closures | |
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| How to Correct Pass-Partition Bending | |
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| Removing and Replacing Feedwater Heater Pass-Partition Covers | |
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| Restoring Damaged Feedwater Heater Pass Partitions | |
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| Replacing Channels and Covers | |
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| Repairing Eroded and Wormholed Tubesheets | |
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| References | |
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| Plugging, Ferruling and Sleeving | |
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| Introduction | |
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| Failures in Tubes and Tube-to-Tubesheet Joints | |
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| Locating Tube Failure Positions | |
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| Finding Tube-to-Tubesheet Joint Leaks | |
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| Plugging Heat Exchanger Tubes | |
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| Ferrules and Sleeves | |
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| Heat and Erosion Shields | |
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| References | |
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| Shell-Side Repairs and Alterations | |
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| Introduction | |
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| Shell-Side Failures and Their Causes | |
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| Procedures and Practices for Repairing and Altering Heat Exchangers | |
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| References | |
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| Retubing and Rebundling | |
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| Introduction | |
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| General Considerations | |
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| General Retubing Techniques and Procedures | |
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| Parts Replacements, Repairs, Reassembly, and Testing | |
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| In-Place Retubing | |
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| Shop Retubing | |
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| Retubing Closed Feedwater Heaters | |
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| A Typical Repair of a Three Zone Closed Feedwater Heater | |
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| Rebundling | |
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| References | |
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| Feedwater Heater Autopsies | |
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| Introduction | |
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| Why Conduct an Autopsy? | |
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| Who Should Participate in Feedwater Heater Autopsies and Why | |
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| Documents to Gather in Preparation for the Autopsy | |
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| Scheduling Autopsies | |
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| Space Requirements, Facilities, and Tools | |
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| Disassembly Procedures | |
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| What to Look for When Conducting Autopsies | |
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| Recording Observations | |
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| Reports | |
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| Reference | |
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| Glossary | |
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| Index | |