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HEAT EXCHANGERS & PROCESS COOLERS

The following images & videos were captured using various sizes of small diameter flexible video scopes and borescopes. Maverick uses inspection systems such as these flexible probes to access areas of interest through small openings and gather data in equipment internals and small piping. Video inspections on both the tube and shell sides of heat exchangers & process coolers include observations such as  cleanliness, general conditions,  corrosion, and erosion. These powerful imaging tools are often enhanced by measuring capabilities.

Video Scope Equipment for Small Tubes

Remote Video Inspection (RVI) is the use of camera systems to image the internals of structures, equipment, and components that are otherwise inaccessible due to physical configurations, safety concerns, or other limitations. Maverick has a proven video inspection service track record including rapid response emergency services, working with our clients to plan RVI requirements for turnarounds, assisting in the development of predictive maintenance execution plans, and sourcing out or developing unique inspection technology.


Video Gallery


EXCHANGER TUBE CLEANING DAMAGE

This video shows the aftermath of high pressure cleaning in a heat exchanger tube. An investigation found that the damage was the result of the incorrect use of a high-pressure cleaning tool. It was determined that surface wear and damage on the exchanger tube wall was created from the rotating tip of the 40,000 psi cleaning tool staying in one place too long. This inattention caused metal loss which created a small hole. The water streaming into the tube is from the pressurized shell side of the exchanger.

LUBE OIL COOLER BANK - FLOW TURBULATORS EXPOSED

Prior to start up after construction of the oil cooler, a robotic pan and tilt camera was used to verify that the turbulators were installed flush to the tube sheet.
The video shows the cooler bank flow turbulators protruding.

HEAT EXCHANGER SHELL SIDE EXPOSURE

A tube was extracted from the front tube sheet of the exchanger so a small diameter video scope camera could be inserted to determine the cleanliness and general condition of the tubes' outside diameters. The camera inspected to the first baffle from the 3/4" opening tube sheet access. A light accumulation of deposits was noted.

HEAT EXCHANGER TUBES BEFORE CLEANING

These random tubes were part of an internal inspection to determine the condition prior to mechanical cleaning to remove the hard deposits. The tubes were re-inspected after the cleaning to verify removal of the deposits. A flexible video scope was used to carry out this work on the heat exchanger.

CLUSTER PITTING INSIDE EXCHANGER TUBE

Cluster pitting was detected inside this exchanger tube after high pressure cleaning.

INTERNAL CORROSION OF HEAT EXCHANGER TUBE

A small diameter video scope was used to capture internal corrosion inside this heat exchanger tube.

SPIRAL TUBE EXCHANGER

This quick video shows the external condition of the shell side of the exchanger. Small particles of wood from the cooling tower are evident.

EXCHANGER TUBE BUNDLE WITH EXTERNAL CORROSION

Corrosion is clearly seen here on the bottom portion of the tube bundle on the tubes' outside diameters. This exchanger is in the vertical position, and liquids had settled before the exchanger was taken out of service. Flushing had not been carried out prior to the inspection.

CONDENSER TUBE FAILURE

Prior to the client cleaning these condenser tubes, Maverick used a small diameter video scope to observe general conditions.

FINFAN COOLER TUBE WITH CORROSION

Corrosion and wall loss of the tube's internal diameter is clearly shown here after high pressure cleaning.

HEAT EXCHANGER TUBE FAILURE

A ruptured exchanger tube was discovered after hydro testing on the product side. It would appear as though the tube failed from possible thinning of the tube wall from the product when in operation.

HEAT EXCHANGER RUPTURED TUBE

The process side of the exchanger shows all areas including the baffle with significant material loss.
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