MTA-MA-008 - Revision history

Monica Hurley: Revision 0 Reviewed by Colton Smith

2026-03-26T17:38:25Z

Revision 0 Reviewed by Colton Smith

← Older revision		Revision as of 17:38, 26 March 2026
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	{{DISPLAYTITLE:Reduce Heat Exchanger Maintenance Costs through Online Monitoring - MTA-MA-008}}		{{DISPLAYTITLE:Reduce Heat Exchanger Maintenance Costs through Online Monitoring - MTA-MA-008}}
			[[Modernization_Technology_Assessment\| Return to MTA Table]]
	{{MTATemplate\|\|		{{MTATemplate\|\|
	\| Date \|12/15/2020		\| Date \|12/15/2020
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	Continuous On-Line Monitoring (COLM): Heat Exchanger, General Tube Type (EPRI [https://www.epri.com/research/products/3002012774 3002012774])		Continuous On-Line Monitoring (COLM): Heat Exchanger, General Tube Type (EPRI [https://www.epri.com/research/products/3002012774 3002012774])

	~~EPRI Preventive Maintenance Basis Database (PMBD) (EPRI~~ [https://~~www~~.epri.com/~~research/products/3002005428 3002005428~~])		[https://pmbd.epri.com/ EPRI Preventive Maintenance Basis Database (PMBD)]
	\| Industry SME \|		\| Industry SME \|
	EPRI – ~~Kurt Crytzer~~		EPRI – PRR

	~~EPRI – Tim Eckert~~

	~~EPRI – Richard Pepin~~

	Contact: NuclearPlantMod@epri.com		Contact: NuclearPlantMod@epri.com
	\| Previous Implementation \| Please contact EPRI for implementation examples and contacts.		\| Previous Implementation \| Please contact EPRI for implementation examples and contacts.
	\| Implementation Enablers \|		\| Implementation Enablers \|
	* MTA-MA-003 – Implement a Wireless Network Infrastructure Using a Distributed Antenna System (DAS)		* [[MTA-MA-003\| MTA-MA-003]] – Implement a Wireless Network Infrastructure Using a Distributed Antenna System (DAS)
	* MTA-MA-004 – Implement a Wireless Network Infrastructure Using WiFi		* [[MTA-MA-004\| MTA-MA-004]] – Implement a Wireless Network Infrastructure Using WiFi
	~~\| SWEEP Score \|~~
	* Cost – Level 3 – Implementation costs should be less than $1 million.
	* Savings – Level 1 – Savings are less than $1 million per year.
	* Payback – Level 1 – Payback period varies based on extended inspection and maintenance intervals, and pre-COLM plant practices, but annualized benefits are expected to be low relative to the cost of implementation. Thus, payback period may be greater than five years.
	* Licensing Readiness – Level 3 – Elements of this approach have already been implemented at nuclear power plants.
	* Technology readiness – Level 3 – The technology is ready for wide operational deployment. Advanced OLM has already been implemented at fossil facilities and piloted at nuclear facilities.
	* Implementation proficiency – Level 2 – Implementation proficiency is dependent on site-specific experience related to wireless data infrastructure, wireless data transmission for maintenance and monitoring, cyber-security protocols, etc.
	\| Applicability \| All reactor types		\| Applicability \| All reactor types
	All geographic regions		All geographic regions
	\| Keywords \| On-line monitoring; heat exchanger; equipment reliability; condition-based maintenance; quick guides		\| Keywords \| On-line monitoring; heat exchanger; equipment reliability; condition-based maintenance; quick guides
	\| Business Case Analysis Cross-Reference \| Plant Modernization Business Case: Monitoring and Diagnostic Program Development (EPRI [https://www.epri.com/research/products/~~3002018424 3002018424~~]).		\| Business Case Analysis Cross-Reference \| Plant Modernization Business Case: Monitoring and Diagnostics Program Development Update (EPRI [https://www.epri.com/research/products/000000003002020885 3002020885])

			Plant Modernization Business Case – Monitoring and Diagnostic Program Development: Cost-Benefit Analysis of Implementing Online Monitoring (OLM) and a Monitoring and Diagnostic Program Using Advanced Pattern Recognition (APR) Software (EPRI [https://www.epri.com/research/products/000000003002028178 3002028178])
	}}		}}

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	Data acquisition and processing tools have reached the point where Continuous Online Monitoring (COLM) of equipment is possible and cost‑effective. COLM can be used to transition from time‑based to condition‑based maintenance, which reduces maintenance costs by eliminating or reducing premature maintenance activities. COLM also provides valuable insights into equipment health that may help to detect incipient failures before major equipment damage. This MTA specifically applies to the monitoring of heat exchanger components.		Data acquisition and processing tools have reached the point where Continuous Online Monitoring (COLM) of equipment is possible and cost‑effective. COLM can be used to transition from time‑based to condition‑based maintenance, which reduces maintenance costs by eliminating or reducing premature maintenance activities. COLM also provides valuable insights into equipment health that may help to detect incipient failures before major equipment damage. This MTA specifically applies to the monitoring of heat exchanger components.

	A heat exchanger transfers heat between fluids. To function properly and to ensure efficient heat transfer, heat exchanger components require routine inspection and maintenance (e.g., removing fouling and deposits). Properly implementing heat exchanger COLM could allow for the extension of existing maintenance intervals. Multiple sensors and wireless gauge readers can be used to support heat exchanger COLM, including temperature, pressure, flow, and level sensors that may already be monitored by a site. Plants can also consider implementing vibration sensors to detect failure mechanisms, although experience has shown that these sensors are less useful for pinpointing the root cause. Additionally, humidity sensors can be used on air‑water heat exchangers. In addition to these sensors, water pH, turbidity, total suspended solids, oxidation‑reduction potential, radiation, acoustic and chloride monitors can be used for monitoring the heat exchanger water loop.		A heat exchanger transfers heat between fluids. To function properly and to ensure efficient heat transfer, heat exchanger components require routine inspection and maintenance (e.g., removing fouling and deposits). Properly implementing [https://www.epri.com/research/products/3002012774 heat exchanger COLM] could allow for the extension of existing maintenance intervals. Multiple sensors and wireless gauge readers can be used to support [https://www.epri.com/research/products/3002012774 heat exchanger COLM], including temperature, pressure, flow, and level sensors that may already be monitored by a site. Plants can also consider implementing vibration sensors to detect failure mechanisms, although experience has shown that these sensors are less useful for pinpointing the root cause. Additionally, humidity sensors can be used on air‑water heat exchangers. In addition to these sensors, water pH, turbidity, total suspended solids, oxidation‑reduction potential, radiation, acoustic and chloride monitors can be used for monitoring the heat exchanger water loop.

	For the purpose of this MTA, the boundary of a heat exchanger is defined as follows, consistent with the EPRI Preventative Maintenance Basis Database (PMBD):		For the purpose of this MTA, the boundary of a heat exchanger is defined as follows, consistent with the EPRI [https://pmbd.epri.com/ Preventative Maintenance Basis Database (PMBD)]:

	Includes:		Includes:
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	Sensors can vary in implementation difficulty and costs.		Sensors can vary in implementation difficulty and costs.

			==SWEEP Score==
			{\| class="wikitable" style="vertical-align:bottom;"
			\|-
			! Category
			! style="text-align:center; vertical-align:middle;" \| Level
			! Description
			\|-
			\| Cost
			\| style="text-align:center; vertical-align:middle;" \| 3
			\| style="color:#242424;" \| Implementation costs should be less than $1 million.
			\|-
			\| Savings
			\| style="text-align:center; vertical-align:middle;" \| 1
			\| style="color:#242424;" \| Savings are less than $1 million per year.
			\|-
			\| Payback
			\| style="text-align:center; vertical-align:middle;" \| 1
			\| style="color:#242424;" \| Payback period varies based on extended inspection and maintenance intervals, and pre-COLM plant practices, but annualized benefits are expected to be low relative to the cost of implementation. Thus, payback period may be greater than five years.
			\|-
			\| Technical Readiness
			\| style="text-align:center; vertical-align:middle;" \| 3
			\| style="color:#242424;" \| The technology is ready for wide operational deployment. Advanced OLM has already been implemented at fossil facilities and piloted at nuclear facilities.
			\|-
			\| Licensing Readiness
			\| style="text-align:center; vertical-align:middle;" \| 3
			\| style="color:#242424;" \| Elements of this approach have already been implemented at nuclear power plants.
			\|-
			\| Implementation Proficiency
			\| style="text-align:center; vertical-align:middle;" \| 2
			\| style="color:#242424;" \| Implementation proficiency is dependent on site-specific experience related to wireless data infrastructure, wireless data transmission for maintenance and monitoring, cyber-security protocols, etc.
			\|}

Jacob Sommer: 1 revision imported

2026-03-05T01:37:54Z

1 revision imported

← Older revision	Revision as of 01:37, 5 March 2026
(No difference)

10.142.237.162 at 19:54, 3 March 2026

2026-03-03T19:54:07Z

New page

{{DISPLAYTITLE:Reduce Heat Exchanger Maintenance Costs through Online Monitoring - MTA-MA-008}}
{{MTATemplate||
| Date |12/15/2020
| Functional Area Where Benefits Will Be Realized | Maintenance Engineering
| Reference Implementation Guidance |
Continuous On-Line Monitoring (COLM): Heat Exchanger, General Tube Type (EPRI [https://www.epri.com/research/products/3002012774 3002012774])

EPRI Preventive Maintenance Basis Database (PMBD) (EPRI [https://www.epri.com/research/products/3002005428 3002005428])
| Industry SME |
EPRI – Kurt Crytzer

EPRI – Tim Eckert

EPRI – Richard Pepin

Contact: NuclearPlantMod@epri.com
| Previous Implementation | Please contact EPRI for implementation examples and contacts.
| Implementation Enablers |
* MTA-MA-003 – Implement a Wireless Network Infrastructure Using a Distributed Antenna System (DAS)
* MTA-MA-004 – Implement a Wireless Network Infrastructure Using WiFi
| SWEEP Score |
* Cost – Level 3 – Implementation costs should be less than $1 million.
* Savings – Level 1 – Savings are less than $1 million per year.
* Payback – Level 1 – Payback period varies based on extended inspection and maintenance intervals, and pre-COLM plant practices, but annualized benefits are expected to be low relative to the cost of implementation. Thus, payback period may be greater than five years.
* Licensing Readiness – Level 3 – Elements of this approach have already been implemented at nuclear power plants.
* Technology readiness – Level 3 – The technology is ready for wide operational deployment. Advanced OLM has already been implemented at fossil facilities and piloted at nuclear facilities.
* Implementation proficiency – Level 2 – Implementation proficiency is dependent on site-specific experience related to wireless data infrastructure, wireless data transmission for maintenance and monitoring, cyber-security protocols, etc.
| Applicability | All reactor types
All geographic regions
| Keywords | On-line monitoring; heat exchanger; equipment reliability; condition-based maintenance; quick guides
| Business Case Analysis Cross-Reference | Plant Modernization Business Case: Monitoring and Diagnostic Program Development (EPRI [https://www.epri.com/research/products/3002018424 3002018424]).
}}

==Description==
Data acquisition and processing tools have reached the point where Continuous Online Monitoring (COLM) of equipment is possible and cost‑effective. COLM can be used to transition from time‑based to condition‑based maintenance, which reduces maintenance costs by eliminating or reducing premature maintenance activities. COLM also provides valuable insights into equipment health that may help to detect incipient failures before major equipment damage. This MTA specifically applies to the monitoring of heat exchanger components.

A heat exchanger transfers heat between fluids. To function properly and to ensure efficient heat transfer, heat exchanger components require routine inspection and maintenance (e.g., removing fouling and deposits). Properly implementing heat exchanger COLM could allow for the extension of existing maintenance intervals. Multiple sensors and wireless gauge readers can be used to support heat exchanger COLM, including temperature, pressure, flow, and level sensors that may already be monitored by a site. Plants can also consider implementing vibration sensors to detect failure mechanisms, although experience has shown that these sensors are less useful for pinpointing the root cause. Additionally, humidity sensors can be used on air‑water heat exchangers. In addition to these sensors, water pH, turbidity, total suspended solids, oxidation‑reduction potential, radiation, acoustic and chloride monitors can be used for monitoring the heat exchanger water loop.

For the purpose of this MTA, the boundary of a heat exchanger is defined as follows, consistent with the EPRI Preventative Maintenance Basis Database (PMBD):

Includes:
* Heat exchanger nozzle to nozzle
* Shell
* Supports
* Tubes

Excludes:
* Control systems and devices (e.g., temperature and pressure control valves, safety relief valves, external vents and drains, insulation)

Consistent with the EPRI COLM guideline for tube‑type heat exchangers, Main Steam Reheaters (MSRs) and Feedwater heaters are also not within the scope of this MQG.

==Benefits==
===Benefits Estimate===
Level 1 – Savings for one unit implementing heat exchanger COLM are expected to be less than $1 million per year from extending maintenance intervals.

===Benefits Description===
* Potential labor savings for extending PM task intervals by transitioning to condition‑based maintenance; for example, manual reading of gauges by operators could be replaced by wireless gauge readers.
* Improved visibility to heat exchanger condition through more frequent data collection and real‑time monitoring, allowing earlier detection of adverse conditions and reducing equipment forced outages and corrective maintenance (CM) costs.
* Reduction in maintenance‑induced failures due to less frequent maintenance.

==Costs and Schedule==
===Cost===
Level 3 – Implementation costs associated with sensors should be less than $1 million (up to 23 sensors per heat exchanger). These costs include the sensors, installation, and software and can be shared site‑ or fleet‑wide if other components implement OLM.

===Schedule===
Six months to two years, which includes planning and implementing new sensors.

===Scope Context===
Per unit, with multiple heat exchangers per unit. A unit is expected to have at least five heat exchangers that are suitable for COLM.

==Risks==
IT risks associated with integrating with existing plant network, data storage, and analysis software. Addressing IT concerns at the requirements phase of the project (e.g., how the sensor data will be gathered and used) will mitigate this risk.

Sensors can vary in implementation difficulty and costs.