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1 | February 3, 2016 | © 2014 Curtiss-Wright
Nuclear Division
Establishing a Heat
Exchanger Test Plan
Authored and Presented
By:
Edward Plansky
and
Steven Schaefer
Presented to:
FSRUGJANUARY 26, 2016
2 | February 3, 2016 | © Curtiss-Wright
INTRODUCTION
What are some of the determining factors in establishing a HX inspection test plan?
• Criticality of the HX
• Suspected or known leaks
• Limited window of access
• Identical HX has known issues
• HX Program identifies plan %
• Prior history or lack of
• Schedule
• Budget
• License extension
• Regulatory compliance or commitment
3 | February 3, 2016 | © Curtiss-Wright
INTRODUCTION
What are some of the different sample plans?
• All open/accessible tubes or 100% sample
• Identified leakers and the bounding tubes
• All tubes with historical damage, bounding prior plugged tubes and
tubes within potential damage prone areas, usually totaling a
predetermined percentage of tubes
• All tubes with historical damage, bounding prior plugged tubes and
tubes within potential damage prone areas plus a predetermined
percentage of tubes that have not been inspected previously
• If multiple HX’s, like WB’s, then a 100% sample in one or more and
a sample like the 3rd one above in the remaining HX’s. Rotating the
plans until all HX’s have been inspected 100%.
4 | February 3, 2016 | © Curtiss-Wright
Basic 100% Straight Length Sample Plan
A plan of all accessible
tubes was selected.
This is a Spent Fuel
Pool Cooler with U-
Bend tubes. The
sample plan was 100%
of the straight lengths.
The plan was based on
historical vibrational
damage and limited
access to the HX.
5 | February 3, 2016 | © Curtiss-Wright
Basic 100% St. Lgth. & Accessible U-Bend Sample Plan
All accessible tubes were inspected. This was a Residual Heat Removal HX with U-Bend tubes. The sample plan was 100% of the straight lengths plus as many U-Bends as possible. The U-bends were added because of OE at a site with a similar RHR that had vibrational damage in the U-Bends.
The black fill shows the U-Bends that were inspected.
6 | February 3, 2016 | © Curtiss-Wright
Basic 100% Sample Plan – Damage Driven
All accessible tubes
were inspected. This
is a copper alloy
tubed HX with ID
pitting. The sample
plan was 100%
because pitting is a
random damage
mechanism.
7 | February 3, 2016 | © Curtiss-Wright
Varible 100% / >50% Sample Plan – Schedule Driven
This inspection sample plan varies between 100% and >50% depending on LCO window. This is one of four CCW HX’s which have 304 Stainless Steel tubes with no service related damage to date. When schedule allows the sample plan is 100% but when time is limited scope is reduced to include all perimeter tubes and every other row. Then the next inspection the sample can be the perimeter again and the opposite rows. This way tubes with the highest potential for damage (perimeter) are inspected every time and after two inspections 100% coverage is completed on the Safety Related HX.
8 | February 3, 2016 | © Curtiss-Wright
Expanded Sample Plan – Leaker & Damage Driven
If a FWH the with a
drain cooler is
scoped for a sample
of tubes it is very
important to inspect
tubes with the
highest potential for
damage. This would
include perimeter
tubes (filled) and
tubes along the baffle
overlap (half filled) in
the drain cooler.
9 | February 3, 2016 | © Curtiss-Wright
Expanded Sample Plan – Leaker & Damage Driven
A relatively new fossil plant HP FWH with leaks in less than a year. So a sample of the perimeter and cross section to determine the extent and severity of the damage was selected. Once the damage was located that area was expanded to encompass the effected tubes.
10 | February 3, 2016 | © Curtiss-Wright
Expanded Sample Plan – Leaker & Damage Driven
A relatively new fossil
plant IP FWH which
experienced leaks
multiple times from
IGSCC in the de-
superheater zone.
That area is
inspected 100% and
the perimeter and
selected rows in the
Inlet pass were
added to monitor for
possible damage.
11 | February 3, 2016 | © Curtiss-Wright
Selected 15% Sample Plan – Main Condenser
This shows a basic ~15% sample plan consisting of all perimeter tubes, selected tubes across the bundle and potential FM collection areas. Areas can be expanded when things occur like bellows failures or dropped objects.
In recent years all 4 WB’s were inspected 100% in both Units for the 1st time since retube in 1988.
12 | February 3, 2016 | © Curtiss-Wright
Selected 15% Sample Plan – Main Condenser
This shows a basic
~15% sample plan of
all perimeter tubes,
selected tubes across
the bundle and
potential FM collection
areas. Areas can be
expanded when things
occur like bellows
failures or dropped
objects.
In recent years all 4
WB’s were inspected
100% in both Units for
the 1st time since
original install in 1973.
13 | February 3, 2016 | © Curtiss-Wright
Selected 10% Sample Plan – Main Condenser – Multi BWG
This shows how sometimes the sample plan needs to be divided into two separate plans. One plan for thicker wall perimeter tubes (dark tubes) and another plan for thinner wall main body tubes (red tubes).
14 | February 3, 2016 | © Curtiss-Wright
Selected 10% Sample Plan – Main Condenser
This shows the
combined sample plans
for approximately 10%
of the total tubes.
Again, the highest
damage potential being
the perimeter, bounding
prior plugs and
selected rows for
randomly occurring
damage.
15 | February 3, 2016 | © Curtiss-Wright
Selected 10%+ Sample Plan – Main Condenser
This shows how the original sample plan was expanded as time permitted to included tubes that had not been previously inspected. This way over time 100% of the tubes will be inspected without leaving out high potential tubes.
16 | February 3, 2016 | © Curtiss-Wright
Tools for Assisting in Sample Selection – Tubesheet Maps
OEM Tubesheets
maps can also be
helpful in identifying
features of the HX like
cross over U-Tubes
and blanks where tie
rods attach to the
tubesheet and tube
supports holding them
in place.
17 | February 3, 2016 | © Curtiss-Wright
Tools for Assisting in Sample Selection – Internals Drawing
As built drawings
can be used to
identify the internal
structures like tube
supports and
baffles as well as
identify the cut-out
patterns. They
also show inlets
and outlets which
are areas with
higher potential for
damage.
18 | February 3, 2016 | © Curtiss-Wright
Tools for Assisting in Sample Selection – Externals Drawing
As built drawings
can be used to
identify the shell
inlets and outlets
which are areas
with higher
potential for
damage.
19 | February 3, 2016 | © Curtiss-Wright
Tools for Assisting in Sample Selection – Plan Views
This shows a side view of the HP & LP steam boxes of a main condenser.
The tubes directly under the turbine discharges are prone to steam erosion &
vibrational damage and should get extra attention.
20 | February 3, 2016 | © Curtiss-Wright
SUMMARY
What are some of the determining factors in establishing a HX inspection test plan?
• Criticality of the HX
• Suspected or known leaks
• Limited window of access
• Identical HX has known issues
• HX Program identifies plan %
• Prior history or lack of
• Schedule
• Budget
• License extension
• Regulatory compliance or commitment
21 | February 3, 2016 | © Curtiss-Wright
SUMMARY
What are some of the different sample plans?
• All open/accessible tubes or 100% sample
• Identified leakers and the bounding tubes
• All tubes with historical damage, bounding prior plugged tubes and
tubes within potential damage prone areas, usually totaling a
predetermined percentage of tubes
• All tubes with historical damage, bounding prior plugged tubes and
tubes within potential damage prone areas plus a predetermined
percentage of tubes that have not been inspected previously
• If multiple HX’s, like WB’s, then a 100% sample in one or more and
a sample like the 3rd one above in the remaining HX’s. Rotating the
plans until all HX’s have been inspected 100%.
22 | February 3, 2016 | © Curtiss-Wright
For More Information
Darren HoweManager, AnatecET Level III QDA
AnatecPhone: 949-271-7520Mobile: 949-300-2173
Edward PlanskyManager, Mid-West Office
ET Level III QDAAnatec
Phone: 920-657-1350Mobile: 920-374-0093
Nuclear Division
23 | February 3, 2016 | © Curtiss-Wright
http://www.curtisswright.com/
Steven Schaefer
Manager, BOP Services
ET Level III QDA, ASNT Level III ET
Anatec
Mobile: 860-885-4695
Nuclear Division