4/19/2008

Basics Of Exchanger Inspection

Amir Raza
 Attributes Of An Inspector

W Vigilance
W Perseverance

W Thoroughness/ attention to detail

W Commitment

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 Reporting-general requirements

W Always mention date of inspection on the record

format.
W Write your name along with signatures on the
record format.
W Clearly write tag numbers of the equipment
inspected
W Clearly distinguish between tubes plugged before
& after a hydrostatic test.
Note: Always demand work order for any inspection job

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 Fundamentals

TEMA (Tubular Exchangers Manufacturers

Association)
W Shell and tube type exchangers are
designed/fabricated as per TEMA standards and
are mostly R-Class exchangers in ECPL (R-type
represents exchangers designed for petroleum
service)

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 Hydrostatic Test

W Test Temperature
Please refer to exchanger file for safe temperature
limits ( above Critical Exposure Temperature) to
avoid Brittle Fracture.
W Vessel shall be vented prior to water filling.
W For Test pressure >1000 psig, pressurising rate
shall be 750 psig/hour. Pressure to be held for 10
minutes after each step
W Ensure that pressure gauges with valid calibration
are used.
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W Also ensure gauges are not faulty, stuck or
damaged by observing reading on dial and lightly
tapping with finger.
W Range of graduation shall be reasonable in
relation to test pressure.

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 Inspection Items
Take UT of shell

Inspect •Examine internal

gasket surface for corrosion,
surface at cracking or
nozzle & deposition
weld
condition
(with shell)

Inspect gasket
surface

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 Tube Sheet

Examine for
pitting and
cracks, report
depth and area
covered

Record number
of plugged tubes
before and after
test and mention
separately

Maintain a tube
sheet map of all
exchangers and
mark plugged
tubes

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Inspect pass partition gasket
grooves for wear/erosion

Check tube ends

for wear, record

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 Tube sheet flange not integral with shell also
requires checking of gasket surface, also check
condition of tube while entering tube sheet holes
on shell side
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 Check condition
of baffle and its
clearance with
tubes plus any
indication of
cracking adjacent
to/ under baffles

Check sealing
strip condition for
erosion/ corrosion
damage

Check tube for

sagging

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 Corrosion damage in spacers/tie-rods, such visual indications are
also worth recording so that replacement could be planned in time

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 Tubes sagging Tie-rod fasteners
loose

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 Given appropriate hardware UT and ECT can also be done

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 Corrosion Damage

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 Lined Channels are to be
carefully inspected for
damaged of liner and
welded joints

Channel Head s
internal surface is to
be checked for
pitting/corrosion

Partition plate welds to be

inspected and gasket
surfaces to be checked

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 While inspecting reboilers look
for erosion and looseness of
impingement plates as well as
shell adjacent to such plates for
signs of erosion.

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 Nipples, vents and deadlegs are
particularly susceptible to
corrosion, inspect by
radiography and/or ultrasonics.

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 Thank you

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