RR_Retirement_Chiller_2__Eddy_Inspection2-8-13.pdf

Perfection Probes, Inc.

Eddy Current Inspection of

ROTARY SCREW CHILLER

Make: YORK Model: YS FA FA S5 CSA Serial #: SMBM9214167581 Name: RM-2

Located at:

Railroad Retirement Board 835 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: 2/5/2013 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: 2/5/2013 Model: YS FA FA S5 CSA Job Number: 4558 Serial #: SMBM9214167581

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: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

Total Tubes: 670

Defect Description Depth of Defect # of Tubes % of Bundle I.D. Pit 25 - 49% 3 0.448

TUBE SHEET DIAGRAM

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

I.D. Pit < 25% Thru Wall

< 50% Thru Wall

< 75% Thru Wall

>= 75% Thru Wall

TESTED TUBE DETAILS

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

Row Number

Tube Number

Location of Indication

Division of Deflection

Percent Thru Wall

Defect Description

2 20 BAY 2 0.3 25.0% I.D. Pit 3 9 BAY 3 0.3 25.0% I.D. Pit 4 10 BAY 3 0.2 25.0% I.D. Pit

Perfection Probes

CALIBRATION STANDARD SCREEN DISPLAY

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

Differential

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

X-Axis

SCREEN DISPLAY

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

Typical Tube

Row 3 Tube 9

NOTES: All of the tubes contained up to .2 divisions noise level representing Inside Scaling or Inside Diameter Pitting less than 20% thru wall.

TEST SUMMARY REPORT

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR

Total Tubes: 414

Defect Description Depth of Defect # of Tubes % of Bundle I.D. Pit < 25% 1 0.242 I.D. Pits < 25% 3 0.725 Plugged Tube 2 0.483 Restricted Tube 1 0.242

TUBE SHEET DIAGRAM

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR

Plugged Tube < 25% Thru Wall

Restricted Tube < 50% Thru Wall

I.D. Pit < 75% Thru Wall

I.D. Pits >= 75% Thru Wall

TESTED TUBE DETAILS

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR

Row Number

Tube Number

Location of Indication

Division of Deflection

Percent Thru Wall

Defect Description

2 40 BAY 2 0.2 20.0% I.D. Pit 3 37 BAYS 3, 2 0.2 20.0% I.D. Pits 3 40 ALL BAYS 0.2 20.0% I.D. Pits 4 25 BAY 2 0.2 20.0% I.D. Pits 7 22 TS-1 0.0 0.0% Plugged Tube 8 25 TS-1 0.0 0.0% Plugged Tube 12 25 BAY 3 0.0 0.0% Restricted Tube

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR

Differential

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR

X-Axis

SCREEN DISPLAY

Test Site: Railroad Retirement Board Make: YORK Test Date: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR

Typical Tube

Row 4 Tube 25

3 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.

*** 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: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

CONDENSER

1 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.

3 Tubes Exhibited I.D. Pits 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. See the Test Summary Report page of this bundle for specific recommendations.

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 A Restriction in the tube prevented total probe transit. A tube that was not completely tested should be cleaned thoroughly and re-inspected or, if a leak is suspected, isolated from the system. When a tube is restricted, in a machine where the freon runs through the I.D. of the tube, that tube should be isolated from the system.

*** 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: 2/5/2013 Model: YS FA FA S5 CSA Test Type: Differential/Cross-Axis Serial #: SMBM9214167581

EVAPORATOR