Air Cooler Maintenance

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

Prepared by Carlo Leoni [Stationary Section Adviser]-30August 2006

IBN-ZAHR Inlet

MECHANICAL MAINTENANCE PROCEDURE “AIR COOLER” Heat Exchanger 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

Condensate Outlet

3

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE “AIR COOLER” Heat Exchanger Tube Assembly and Plug Detail Inlet Stationary Header

Fin Tubes Gasket

Plug

Grooves for expansion

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

Do Not Start The Job Without a Safety Plan 6

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

“AIR COOLER” Heat Exchanger 1. Leakage from Header Plugs 1.1. On Line leak elimination [Temporary solution]

Drill blind hole and thread the leaking Plug on situ Screw in the threaded stud

This is a Maintenance Innovation made by IZ Special device Leak

Inlet Header

Assembly the special cap device with gasket and screw it in until the leak stops Replace gasket & Plug 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 Blind Stationary Header Inlet & Outlet

PG

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 PG

Stationary Header

Insert Expander tool, expand the tube up to the established torque Remove expander tool

Reinstall new gasket and plug Fill the system by water Raise the pressure Re-check leaks from outside [No more leak]

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 Blind Stationary Header Inlet & Outlet

PG

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

Drain water, remove PG & pump

Plug

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 C

C 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 body with gasket

Steam

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 PP PLANT

MTBE PLANT

Non 1.

110-E09 A-B

2. 110-E15 A-B-C-D

13. 130-E15 I-L-M-N 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