IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
"AIR COOLER" Heat Exchanger
MAINTENANCE
Prepared by Carlo Leoni
[Stationary Section Adviser]-30August 2006
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
Inlet General Assembly view
Floating Header
Tubes
Stationary Header
Plug
Outlet Fan
Conveyor
Scaffold Electric motor
Structure
2
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
Vapor Inlet
Tube Bundle Details
Stationary Header Floating Header
Fin Tubes
Plug
3
Condensate Outlet
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
Tube Assembly and Plug Detail
Inlet
Stationary Header
Fin Tubes
Gasket
Grooves for expansion
Plug
4
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
Maintenance Activity Cases Summary
1. Leakage from Header Plugs
1.1. On Line leak elimination [Temporary solution]
2. Leakage from Tubes
2.1. Leak elimination from expanded area
2.2. Leak elimination from broken tube
2.3. On line Leak elimination from broken tube
[Temporary solution, Bottom & Top row only]
5
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
"AIR COOLER" Heat Exchanger
MAINTENANCE
Do Not Start The Job Without a Safety Plan
6
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
1. Leakage from Header Plugs Drill blind hole and thread
the leaking Plug on situ
1.1. On Line leak elimination [Temporary solution]
Screw in the threaded stud
This is a Maintenance Assembly the special cap
Innovation made by IZ device with gasket and
Inlet Header
screw it in until the leak
stops
Special device
Replace gasket & Plug
Leak later in Shutdown
Fin Tubes
Leaking Plug
Additional Gasket
7
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
Shutdown, isolate & drain the equipment
PG Blind Stationary Header Inlet & Outlet
Stationary Header
Install Pressure Gauge
Connect water pump
Fill system by water
Raise the pressure
Leak
Locate leaks from outside
Discharge water
Open Plugs at leak position
Remove gasket
See continuation
Fin Tube
Plug
8
Water Pump
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
Insert Expander tool, expand the tube up
to the established torque
PG
Stationary Header Remove expander tool
Reinstall new gasket and plug
Fill the system by water
Raise the pressure
Re-check leaks from outside
Leak [No more leak]
Discharge water
Remove PG & water pump
Remove In-Out Blinds and
tight flange bolts
Fin Tube
Plug
9
Water Pump
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 2.2. Leak elimination from broken Tube
Shutdown, isolate & drain the equipment
PG Blind Stationary Header Inlet & Outlet
Stationary Header
Install Pressure Gauge
Connect water pump
Fill system by water
Raise the pressure
Leak Locate leaks from outside
Drain water
Open Plugs at leak position both
sides And remove gasket
Plug the leaking tube [both sides]
Reinstall gasket & plugs [Both sides]
Fill in water again
Raise pressure & check sealing
Fin Tube
Plug Drain water, remove PG & pump
Remove in-out blinds, tight bolts
10
Water Pump Remove field blinds
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
2.3. On line Leak elimination from broken tube : [Temporary solution]
[Bottom & Top row only]
B
Leak See continuation
Special Device
Section “B-B” Section “C-C”
Drain Valve
11
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
2.3. On line Leak elimination: from broken tube : [Temporary solution]
[Bottom & Top row only]
Stop the fan set only
Erect scaffold below fan
Remove fins at leaking
area
Install the upper half
Steam
body with gasket
Install the lower half body
with the drain open
Tight the body bolts
Install packing and gland
at left side and tight bolts
Condensate Leak
Install packing and gland
at right side and tight
bolts
Close the drain
DEVICE INSTALLATION METHOD 12
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
“AIR COOLER” Heat Exchanger
Handover & Final House Keeping By Maintenance
▪ Remove tools and equipment ❑ Remove scaffold before El. Fan start-up
▪ Clean and wash the area ❑ Close Work permit
13
IBN-ZAHR MECHANICAL MAINTENANCE PROCEDURE
List of Air Coolers
Installed in IBN-ZAHR
MTBE PLANT PP PLANT
Non
1. 110-E09 A-B 13. 130-E15 I-L-M-N
2. 110-E15 A-B-C-D
14. 130-E15 O-P
3. 110-E15 E-F-G-H
4. 110-E15 I-J-K-L 15. 130-E19 A-B
5. 110-E15 M-N-O-P 16. 140-E03 A-B
6. 110-E19 A-B
17. 140-E06 A-B
7. 120-E03 A-B
8. 120-E06 A-B 18. 220-E29 A-B
9. 200-E29 A-B 19. 220-E30 A-B-C-D-E-F
10. 130-E09 A-B
20. 740-E01
11. 130E15 A-B-C-D
12. 130-E15 E-F-G-H 21. 740-E02
13. 130-E15 I-L-M-N 22. 770-E03 A-B-C-D
The End 14
