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PM Task Report 1/12/2011

Component Type: Heat Exchanger - Main Condenser


Task Name: Waterbox Inspection
Criticality Critical Minor
Duty Cycle High Low High Low High Low High Low
Service Conditions Severe Mild Severe Mild
CHS CLS CHM CLM MHS MLS MHM MLM
2Y NA 2Y NA NA NA NA NA
Task Objective
The task is essential for predictively identifying precursors to catastrophic or more expensive failures
involving corrosion and fouling. The interval is determined by the need to maintain continuous condition
assessment and prediction capability, and is influenced by many common, but random, mechanisms
which are not efficiently screened by a time directed task; only in the mildest conditions could the
interval be extended.

Task Content
Waterbox Inspection should include the following:
Inspect for evidence of erosion, corrosion, and cracks.
Inspect for presence of fouling.
Inspect the cathodic protection system for damage to anodes and supports; ensure proper settings and
operation of impressed and sacrificial systems.
Perform a borescope examination on a representative sample of tubes.
Inspect o-rings for evidence of damage and deterioration.
Verify tube plugging map.
Determine the degree and type of fouling to adjust the cleaning interval.
Inspect waterbox and tube sheet liners and coatings.
If installed, inspect tube sleeve condition for evidence of wear, looseness, and damage
Perform leak testing to look for evidence of tube leaks.

Principle Failure Location And Causes:


The Waterbox Inspection is focused on detecting the extent of tube erosion, corrosion, fouling, scaling,
and tube defects and cracking, and also on the detection of corrosion at the tube sheet and rolled tube
joints. The task is essential for predictively identifying precursors to catastrophic or more expensive
failures. The Waterbox Inspection will include leak testing (a pressure test), primarily to detect defects
in tube joints.

On-line leak detection (trace gas injection) is more likely to detect tubing cracking and tube defects than
to detect defects in tube joints.

Progression Of Degradation In Time:

EPRI PM Basis Database - PM Program Report Page 1 of 2


PM Task Report 1/12/2011

Component Type: Heat Exchanger - Main Condenser


Task Name: Waterbox Inspection
Criticality Critical Minor
Duty Cycle High Low High Low High Low High Low
Service Conditions Severe Mild Severe Mild
CHS CLS CHM CLM MHS MLS MHM MLM
2Y NA 2Y NA NA NA NA NA
The corrosion and fouling processes of various kinds are all quite common in the industry and
sometimes represent chronic conditions, or otherwise initiate randomly, often progressing rapidly.
Although the deterioration is often erratic, the task does provide predictive information that can be used
to adjust the cleaning interval.

Support For The Task Interval And Relation To Other Tasks:


The Waterbox Inspection is recommended to be performed at each refueling outage. There is not much
scope for changing this interval except in the mildest conditions where plant history has repeatedly
shown that degradation only slight at the suggested interval.

EPRI PM Basis Database - PM Program Report Page 2 of 2