January 16-19, 2017

Austin, Texas

Objectives

Relationship of Tube Deposits to Lost Efficiency

Prerequisites for Cleaning

Types and Methodologies Of Cleaning

Results of Cleaning and Increased Efficiency

Safety and Human Performance

Selecting a Vendor

Conclusion

Develop an understanding of choosing a cleaning method that offers the desired results.

Understand the types of cleaning in order to make an educated choice as to which system best suits the component.

Using the cleaning results to better determine a maintenance strategy that offers optimum efficiency and is rewarded with financial gains to the facility.

Learning what parameters are associated with each method:◦ Water use

◦ Waste water disposal

◦ Water containment

◦ ALARA

◦ Contamination

How does safety play a part in the cleaning methods?◦ Low Risk

◦ Medium Risk

◦ High Risk

Utilizing human performance standards to optimize quality, reduce risk and finish safely.

Knowledge of what questions to ask when selecting a vendor for cleaning activities.

The proper performance of shell and tube type heat exchangers within a process can affect the cost of the final product, or even the production rate. Heat exchangers are prone to fouling and its nature depends on the fluids flowing within and over the tubes and the reduction in heat transfer that results has an impact on product cost. To reduce this impact; heat exchanger performance should be monitored and the heat exchanger cleaned at intervals that are determined from economic criteria.

The concept, although analyzed in great detail, is very simple. Scale or fouling of tubes reduces efficient thermal transfer, causing increased costs of energy production, strain on related equipment and ultimately loss of revenue.

THE GROUP OF “C’s”

Contact

Communication

Consideration

Conditions

Commitment

Communication is a main key to success!.

Always make time to provide answers. The next persons activity might depend on it.

Make it personal. Live talk or face to face always adds value.

Establish a main point of contact early.

Categorize any specific areas of concentration.

Set aside time for update with work groups.

Build a team that is committed.

Dependable Equipment with back-up units available

Berms to protect against leaks or equipment failure

What is required to draw clarified water from operations? Lay of the land

How to handle, discharge and dispose of the effluent water?

Filter systems and storage allow for maximum use of the clarified water.

Have the current known conditions been evaluated?

Is there a possibility that conditions will change?

Are we prepared for a change in condition?

Do we have a secondary or contingent plan for unexpected changes?

Rotary Style Brush

Propelled Projectile

High Pressure Water Lance

Recommended for removing soft deposits (mud, algae, etc.) in straight, ferrous and nonferrous tubes. Tube cleaning brushes are manufactured from the highest quality components to strict engineering tolerances and built to deliver the results. Brush should be equal to or 1/16" (1.6mm) smaller than tube I.D. Available for tube sizes 1/4"-1" (6.4-25.4mm) I.D.

Metal Brush Meant for medium type scale.

More aggressive than nylon. Used when cleaning requires more than mud or silt deposits.

Swivel Scrapper Designed to navigate through “U”

tubes with parameters on the minimum radius. Propelled through each tube with high velocity and gpm of water.

Metal Scrappers

This spring-loaded tube cleaner is effective on all types of deposits, including micro/macro fouling,organic type scales, corrosion and pitting by-products, and all types of obstructions. It can also be usedwith thin wall metal inserts and coatings on tube sheets orinlet ends.

Water jetting (hydrolazing) is an environmentally-safe method used to handle cleaning, cutting and surface preparation problems in a variety of industrial applications. This versatile technology has been proven effective for use with many type of materials. Water jetting is environmentally friendly in that it does not produce hazardous water products. In addition, water jetting uses small amounts of water, which can be recycled. Water jetting also reduces the release of contaminants, thereby creating a safer environment for equipment operators.

Flex Lance

Rigid Lance

Hand Lance (Shot Gunning)

Pipe Cleaning (RHD)

Understanding nozzles and how they work is a key step to a successful cleaning. Knowing the proper use of each nozzle will ensure that you always select the right one for each job. It’s important to note that it may take multiple nozzles at times to achieve the correct end result.

There should be no guessing when selecting a nozzle for cleaning operations. Nozzles are designed for specific cleaning applications. If they are not used for their intended purposes, then they won’t be as effective.

Determining factors from cleaning:◦ Was the desired cleanliness achieved?

◦ Is the equipment running at optimum performance?

◦ What effects did the cleaning have on chemistry?

◦ Did start-up meet the desired criteria?

◦ Did the schedule hit the mark?

◦ Are there any improvements for the next evolution?

◦ Was the final cost in-line with the estimated budget?

◦ Were there any safety impacts for discussion?

“Thank you to everyone involved to make these results happen,” continued Sharrett. “This type of knowledge, understanding and analysis will provide excellent Chemistry health during this cycle while also supporting asset preservation and long-term operations.”

Duke Energy/McGuire Nuclear Station (Oct. 4, 2016)

Lower Sodium is Healthy! The Chemistry control working group consists of several departments, including Operations, Engineering, Chemistry, Maintenance, Work Control and General Office (Chemistry) as well as contractors. This team has helped improve secondary chemistry over the past two refueling outages by taking actions to lower secondary system sodium and iron. Several activities have been accomplished by the team such as dimple plugging condenser tubes, hydro-lasing feed water heaters and initiating procedure changes to incorporate heater flushing. Results of these actions have helped to tremendously lower contaminants within the secondary system and improve system health along with saving costs by increasing service time on secondary demineralizers. Sodium in our water systems causes corrosion and is detrimental to the steam generators. Iron corrosion reduces efficiencies in our feed water heaters, condensate heat exchangers and steam generators. Please congratulate this team of nuclear PROS!

No Job is successful unless it is done safely!

#1 Priority = SAFETY

Pre-Job Brief

Procedure Use & Adherence

Take-A-Minute

Component Verification

STAR

Focus

Questioning Attitude

Right Tool for the Job

Place Keeping

Housekeeping

High-pressure water cleaning is normally performed using jet streams that can have a velocity greater than that of a 45-caliber bullet, and do as much damage. Therefore, extreme caution and strict compliance with procedures must be used to prevent the jet stream from striking the operator, other employees or delicate equipment. No portion of the body must ever be placed in front of the water jet. These jets of water can easily puncture and tear the skin or penetrate deeper causing infection or serious internal damage.

As with any type of industry, the first step to be taken prior to water blasting is to perform a thorough Job Hazard Analysis (JHA). This step is critical to preventing workplace injuries and should not become routine. The JHA forms the basis of the project safety mindset and should be conducted with participation of affected employees. Once it has been completed, it should be discussed in detail with each employee working on the project prior to beginning the operation.

In summary, the hazards associated with this industry are numerous. With proper employee education, along with thorough JHAs, providing the correct personal protective equipment, extensive training, creating a safety-conscious culture, these hazards can be mitigated, if not eliminated.

While researching suppliers, make sure that you obtain evidence of any supplier’s expertise such as customer testimonials. You should also verify that any potential provider of cleaning can further reduce your maintenance costs by combining services such as camera inspection and 3D modelling to perform internal visual inspections in conjunction with cleaning cycles. Always consider a vendor that “thinks outside the box”. What do they bring to the table? Can they adapt to changing conditions?

Step#1 – Define your objectives and goals.

Step#2 – Investigate the vendor candidates.

Step#3 – Prepare an RFQ for the scope.

Step#4 – Due diligence; compare apples to apples.

Step#5 – Do a test project if possible.

Step#6 - Make your selection.

TOP THREE MISTAKES: #1 Solely looking at the vendor offering and price and not

looking at “the vendor”.

#2 Making a biased decision based on relationships or communication advantages. Could jeopardize the project and credibility.

#3 Not comparing “apples to apples”

“It’s not hard to make decisions when you know what your values are.” Roy Disney

Shell and tube heat exchangers are a vital part of the process in which they are installed and their condition can significantly affect additional equipment and increase the cost of goods sold. Thus, to improve the performance of those heat exchanges prone to fouling problems, data should be acquired and analyzed. The costs of fouling must also be quantified and the cleaning criteria monitored. The optimum time to clean is when this criterion achieves its minimum value. Further, the cleaning method selected should be one that is not only able to handle effectively the type of fouling experienced with that heat exchanger, but also result in minimum annual maintenance and downtime costs.

WELCOME AMBER MOLITOR

PALO VERDE