American Exchanger Services saves utility Hundreds of Thousands of dollars. AMEX Services performs Tube Sleeving Operation at Nuclear Facility to bring Heat Exchangers back online in record time.

AMEX Services reacts quickly to service request and saves utility large downtime cost.

In May of 2002 - two fuel pool cooling water heat exchangers were tested for leaks and it was determined that the tubes had small cracks on the shell side of the tubesheet and that these leaks were sever enough to cause the utility to shut down the entire unit. This shutdown effected over 600 MW of power in the system. This was a major problem in that the options of purchasing a complete new unit would take up to a year to deliver and install and the option to retube would take up to 15 weeks with the majority of the time exhausted with the tube delivery. This extensive downtime was unacceptable to the utility and other actions were necessary to bring these units back into an operable condition.

The utility called American Exchanger Services (AMEX Services) on a Saturday to discuss the situation and AMEX Services was on site the same day to support the utility in analyzing the situation suggesting alternatives to seal the leaks as well as providing them with budget cost for the various alternatives. After two days, the solution of installing specially machined sleeves into the tubesheet and into the tube was selected. Immediately AMEX Services determined the sleeve material and length needed for the operation and the utility purchased the sleeve material. AMEX Services immediately began to machine the sleeve material when it arrived to the exacting requirements for he job. Because of the necessity for cleanliness in the tubesheet and tube end to assure a good bond, AMEX Services geared up with 6 technicians to prepare the tubes for the sleeves. This preparation was a 24-hour per day operation with 2-12 hour shifts. In addition the sleeve machining was also a 24-hour per day operation to complete over 4,000 sleeves.

Once a partial quantity of the sleeves was machined, they were delivered to the plant for installation. The first unit received sleeves that were rolled into the tubesheet and then the opposite end was carefully rolled into the tube outside the tubesheet. To assure a sound joint, a sealant was also applied. After completion of the sleeving on the first unit, the exchanger was closed up and given a hydrostatic test to check integrity of the newly installed sleeves. The test result was that 100% of the sleeves held up and the unit was ready for operation. With this first unit complete and ready for operation within 8 days of being brought out of service, the second unit was prepared for sleeves in the same way. With the experience gained on the first unit, the sleeves on the second unit were installed in a 24-hour period and the second unit was ready for testing. Again the second exchanger passed the hydrotest with flying colors. With the successful completion of the sleeve installation, the exchangers were ready for service.

Because of this immediate call to AMEX Services and their commitment to customer service, these exchanges were repaired to an operable condition and the plant was able to be brought back on line for the summer peak load time. This will allow the utility to consider alternatives and plan ahead to permanently rebuild or replace the heat exchangers during a normal outage.

Amex Services is a full service company ready to serve your needs.

For Additional Information Contact:

Joe Bruno
VP Sales

American Exchanger Services
1950 Innovation Way
Hartford, WI 53207

Phone: (414) 529-0067
FAX     (262) 670-6645

e-mail : sales@amexservices.com
website: www.amexservices.com