RR_Retirement_Chiller_1_Eddy_Inspection_2-8-13.pdf

Perfection Probes, Inc.

Eddy Current Inspection of

ROTARY SCREW CHILLER

Make: YORK Model: YS FA FA S5 CSA Serial #: SMBM9214167541 Name: RM-1

Located at:

Railroad Retirement Board 844 N. Rush Chicago, IL 60611

Submitted To:

Kim O'Connor Air Comfort Corporation 2550 Braga Drive Broadview, IL 60155-3943

Customer P.O. #:

189854

Inspection Date: 2/4/2013 Job Number: 4558

Technicians:

Tom Powers

Reviewed By:

Paul H. Christensen President SNT-TC-1A Level III

Table Of Contents

Inspection Technique 3 Definition of Terms and Abbreviations 4 Test Data 5

CONDENSER

Test Summary and Support Sheet Distances 6 Tube Sheet Diagram 7 Tested Tube Details Report 8 Calibration & Screen Displays 9

EVAPORATOR

Test Summary and Support Sheet Distances 12 Tube Sheet Diagram 13 Tested Tube Details Report 14 Calibration & Screen Displays 15

Recommendations 18

INSPECTION TECHNIQUE

SCOPE AND PURPOSE:

To establish guidelines which provide quality control in accordance with Perfection Probes 4 channel Eddy Current Procedure IDET-104.

INSPECTOR QUALIFICATIONS:

Technicians performing the inspections and providing technical data shall be certified Level II or higher in accordance with ASNT Recommended Practices, SNT-TC-1A.

TEST EQUIPMENT:

Perfection Probes utilizes the Zetec, Inc. MIZ 27, the most advanced Eddy Current System in the industry for in-site tubing inspection, coupled with custom probes designed to maximize test sensitivity.

TEST TECHNIQUE:

The Eddy Current inspection unit consists of a sophisticated electronic test instrument, storage monitor, strip chart recorder and probes. The most important element is the technician performing the inspection. The inspection is actually a comparison test between calibration tubes with known discontinuities and tubes in the machine being tested. Set-up and calibration of equipment, its proper use and the interpretation of indications rely on integrity, quality training and experience.

The equipment is a balanced bridge circuit in which coils located in the probe act as one arm of the bridge. The instrument is balanced in a good portion of a tube standard. The coils in the probe set up a magnetic field that creates electrical disturbances in the tube wall called Eddy Currents. When a probe encounters a discontinuity, the Eddy Current Field is forced to change shape. This distortion creates an electrical signal that unbalances the bridge circuit and is presented as a visual pattern on the monitor. The direction, size and shape of the deflection permit interpretation of the discontinuity.

DEFINITION OF TERMS AND ABBREVIATIONS

Corrosion Metal loss generally associated with a chemical deterioration of the tube wall.

Eddy Current Small circular eletrical currents induced in a conductive material by an alternating magnetice field.

Erosion Metal loss associated with turbulent flow characteristics. Generally at a tube end.

I.D. Inside diameter.

M.L. Metal loss.

M.L. @ Support Metal loss at support.

O.D. Outside Diameter.

O.D.M.L. > 1" Outside diameter metal loss greater than one inch in longitudinal length.

O.D.M.L. <= 1" Outside diameter metal loss less than or equal to one inch in longitudinal length.

P.S.C. Possible stress crack.

P.S.F. Possible split fin.

P.Z.C. Possible zipper crack.

T.W.H. Through the wall hole.

TS-1 Tube sheet 1. The tube sheet at the inspection end of the machine.

TS-2 Tube sheet 1. The tube sheet at the opposite end of the machine.

TEST DATA

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Job Number: 4558 Serial #: SMBM9214167541

CONDENSER

Test End: Right Facing Controls Tube Count: 670 Test Type: Differential/Cross-Axis Tube Supports: 3 Tube Type: Skip Fin/I.E. Tube O.D.: 0.75" Tube Material: Copper Tube Length: 145" U-Bend: No Tube Wall: 0.028"

EVAPORATOR

Test End: Right Facing Controls Tube Count: 414 Test Type: Differential/Cross-Axis Tube Supports: 3 Tube Type: Skip Fin/I.E. Tube O.D.: 0.75" Tube Material: Copper Tube Length: 145" U-Bend: No Tube Wall: 0.028"

NOTES: All of the tubes contained up to .3 divisions noise level due to scale and/or Inside Diameter Pits less than or equal to 15% deep. Perfection Probes, Inc. recommends a more thorough tube cleaning prior to the next Eddy Current Examination

TEST SUMMARY REPORT

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

Total Tubes: 670

Defect Description Depth of Defect # of Tubes % of Bundle I.D. Pit 25 - 49% 4 0.597 Plugged Tube 2 0.299 Restricted @ Tube Sheet Two 1 0.149 Smaller Diameter Probe Used 4 0.597

TUBE SHEET DIAGRAM

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

Plugged Tube < 25% Thru Wall

Restricted @ Tube Sheet Two < 50% Thru Wall

I.D. Pit < 75% Thru Wall

Smaller Diameter Probe Used >= 75% Thru Wall

TESTED TUBE DETAILS

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

Row Number

Tube Number

Location of Indication

Division of Deflection

Percent Thru Wall

Defect Description

1 10 TS-1 0.0 0.0% Plugged Tube 10 10 TS-1 0.0 0.0% Plugged Tube 12 1 BAY 4 0.0 0.0% Smaller Diameter Probe Used 12 4 BAY 4 0.0 0.0% Smaller Diameter Probe Used 13 1 BAY 4 0.0 0.0% Smaller Diameter Probe Used 13 2 BAY 4 0.0 0.0% Smaller Diameter Probe Used 16 31 BAY 4 0.2 40.0% I.D. Pit 17 18 BAY 1 0.2 40.0% I.D. Pit 18 21 BAY 1 0.3 25.0% I.D. Pit 18 30 TS-2 0.0 0.0% Restricted @ Tube Sheet Two 19 2 BAY 4 0.3 25.0% I.D. Pit

Perfection Probes

CALIBRATION STANDARD SCREEN DISPLAY

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

Differential

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

X-Axis

SCREEN DISPLAY

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

Typical Tube

Row 17 Tube 18

NOTES: All of the tubes contained up to .2 divisions noise level.

TEST SUMMARY REPORT

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR

Total Tubes: 414

Defect Description Depth of Defect # of Tubes % of Bundle Plugged Tube 1 0.242

TUBE SHEET DIAGRAM

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR

Plugged Tube < 25% Thru Wall

< 50% Thru Wall

< 75% Thru Wall

>= 75% Thru Wall

TESTED TUBE DETAILS

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR

Row Number

Tube Number

Location of Indication

Division of Deflection

Percent Thru Wall

Defect Description

8 32 TS-1 0.0 0.0% Plugged Tube

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR

Differential

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR

X-Axis

SCREEN DISPLAY

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR

Typical Tube

4 Tubes Exhibited I.D. Pit I.D. Metal Loss less than fifty percent of the tube wall require no immediate corrective action. These tubes should be monitored by subsequent examinations. The frequency of subsequent examinations should increase with the age of the machine. Tubes containing I.D. Metal Loss greater than fifty percent of the tube wall should be isolated from the system. A review of the chemical treatment program should be conducted.

2 Tubes Exhibited Plugged Tube These tubes were plugged prior to inspection and need to be considered when calculating percentage of isolated tubes.

1 Tubes Exhibited Restricted @ Tube Sheet Two Tubes that are restricted at tube sheet two are generally restricted due to baffle plates or head configuration. The tube was completely inspected except for the area under the tube sheet where the tube is expanded. If the bundle is not suspect of leaking this area is not of immediate concern. Prior to a succeeding inspection the baffle or head responsible for the restriction should be removed.

4 Tubes Exhibited Smaller Diameter Probe Used This tube(s) contained either a dent or scale/debris on the tube inside diameter that prevented the appropriate diameter probe from negotiating the entire length of the tube. This tube(s) was inspected utilizing a smaller diameter probe. Using a smaller diameter probe reduces test resolution and possibly test sensitivity. If this is the only defect listed in the Tested Tube Details for this tube no corrective action is required at this time. If there is another defect listed in the Tested Tube Details for this tube please refer to the Recommendations for that particular defect before determining the disposition of this tube.

*** NOTE ***

These recommendations are based on thirty two years of experience in the Eddy Current field.

Currently there are no codes or specifications which dictate corrective action. Therefore, responsibility for determining appropriate corrective action rests solely with the owner/operator.

Please review the notes on the test summary report for this bundle for any further observations/recommendations.

RECOMMENDATIONS

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

CONDENSER

1 Tubes Exhibited Plugged Tube These tubes were plugged prior to inspection and need to be considered when calculating percentage of isolated tubes.

*** NOTE ***

These recommendations are based on thirty two years of experience in the Eddy Current field.

Currently there are no codes or specifications which dictate corrective action. Therefore, responsibility for determining appropriate corrective action rests solely with the owner/operator.

Please review the notes on the test summary report for this bundle for any further observations/recommendations.

RECOMMENDATIONS

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/4/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167541

EVAPORATOR