Rev. :0 CLEANING AND HYDROTESTING ROS: 70 DATE: AUG. 2001 OF TRIM COOLERS Page: 10f 4. 1.0 INTRODUCTION 2.0 3.0 34 A trim cooler is a heat exchanger used for cooling a process fluid by transferring heat to cooling water. Cleaning and testing of trim coolers are highly important in a refinery due to > The leaking of these exchangers during service can cause the danger of ingress of hydrocarbon (normally gases) to cooling water and subsequent release to atmosphere, which has potential to cause fire or explosion. > Trim coolers are prone to corrosion failure due to the presence of corrosive fluid on shell side and from cooling water side. > The deposition and plugging of tubes in cooling water side can cause under deposit corrosion and impair heat transfer. > Leaks of exchanger during service usually result in reduction in plant load or may even lead to unplanned shutdown The essential requirements/procedures to be followed for cleaning and hydrotesting of trim coolers during planned shutdowns are described in the following paragraphs. Trim Cooler - Types and construction details Trim coolers are generally used for cooling a process fluid by transfer of heat to cooling water. Both condensers (where the medium being cooled changes its phase from vapour to liquid) and coolers (when there is no phase change) come under the category of trim cooler for the purpose of this ROS. The procedures described below are applicable for all exchangers when one side is hydrocarbon and the other side is cooling water with the exception of lube oil coolers. There can be different types of construction for a trim cooler: i. Shell and tube exchanger with conventional floating head ji, Shell and tube exchanger with lantern ring arrangement for floating head. ii, Shell and tube exchanger with fixed tube sheet iv. Double pipe exchangers. In general the trim coolers are designed with cooling water on tube side and hydrocarbon on shell side. Cause of Deterioration General Deterioration may be expected on all surfaces of exchangers in contact with hydrocarbon, chemicals or water. The form of attack may be electrochemical, chemical or mechanical or a combination of the three. The attack may be further GM (Tap) AAS 7 ond RC se DIRECTOR (REFINERIES) tans)32 33 4.0 5.0 REV. :0 CLEANING AND HYDROTESTING - ROS: 70 DATE : AUG. 2001 CE coor, L. Bage : 2of 4 influenced by certain accelerating factors such as temperature, stress, fatigue, impingement, high velocity of flow etc. Corrosion Corrosion may occur on any portion of an exchanger. The severity of the attack is influenced by the concentration and nature of the corrosive agents in the fluid as. well as by the corrosion resistance of the construction materials. Corrosion from hydrocarbon side of an exchanger is predominantly due to compounds of sulphur and hydrogen chloride, Under low temperature these compounds can form acidic solution with water and can corrode the shell side. Inside of tubes is subjected to numerous corrosion phenomena, which are created by particular characteristics or the environmental influence of water. The types of attack that may be experienced are erosion corrosion, galvanic corrosion, impingement attack, de-zincification, deposit or cellular attack and stress corrosion. Mechanical Deterioration The following types of mechanical deterioration such as cracking of shell, channel, shell cover etc., loosening of tubes, buckling of tubes and vibration of tubes can occur in heat exchangers, Cleaning The tube bundle of all trim coolers (except fixed tube sheet exchangers) are to be taken out and thoroughly cleaned by hydroblasting during every planned shutdown. (Fixed tube sheet exchangers are to be cleaned by hydroblasting with the bundle in position). While bundle pulling and dismantling the tag number of the exchanger shall be clearly written on all components of the exchanger. Both inside and outside of tubes have to be thoroughly cleaned. Special care shall be taken to rotate the bundle and externally hydroblast all the sides. Exchangers shell, channel, channel cover, shell cover and floating head are also to be hydroblasted. All tubes shall be cleared of deposits/ plugging The tube bundles shall be inspected and the clearance of cleaning shall be given by an officer of the owner department. The same shall be recorded in a log book. Inspection / Hydrotesting General inspection of the shell, channel, shell cover, floating head and tube bundle is to be carried out by Inspection Section when the exchanger is dismantled for cleaning. Thickness survey of the exchanger is to be carried out based on rate of deterioration and remaining corrosion allowance. Insulation (if any) shall be removed for inspection and thickness survey of shell. Premature failure of tubes shall be investigated and cause of failure is to be established. fomereny AT | ewok ALO EDT measles | DIRECTOR (REFINERIES) l qa6.0 61 62 63 REV. :0 CLEANING AND HYDROTESTING ROS: 70 DATE: AUG. 2001 OF TRIM COOLERS Page : 3of 4 The following requirements are to be ensured by Maintenance Department while hydrotesting exchangers i. Allthe trim coolers (floating head type) are to be tested with test ring. ii, Only calibrated pressure gauges shall be used for hydrotest. The range of pressure gauge shall be such that the test pressure falls within 30 to 70% of the range. iii, Proper venting of entrapped air is to be ensured. It is desirable to provide pressure gauge connection at top and carry out water filing/pressurisation from bottom. iv. Raw water/cooling water only should be used for hydrotesting, Inspection/ Hydrotesting : Initial Shell Test Initial shell test shall be performed with the channel cover open and the test ring mounted on the other side. For fixed tube sheet both end covers shall be kept open. If any leak is observed during pressurising the same shall be rectified by re- rolling / plugging of tubes etc. Plug material shall be same as that of tube material Once the pressure is holding Inspection shall witness the test. Pressure shall be held for a minimum duration of half an hour. All tubes and roll joints shall be closely examined for leakage. Gasket of tube sheet with shell also is to be checked for leakage during first test. Shell weld joints, nozzles and bleeders are also to be checked during the test. When tube side test pressure is higher than the shell side test pressure, initial shell side pressure test shall be preferably carried out at a higher test pressure based on the shell design parameters, subject to a maximum of tube side test pressure Second Test (Tube Test) The tube side of the exchanger is pressurised to the test pressure after fixing the floating head and channel cover. The pressure shall be held for minimum half an hour and inspection should be done to check the leakages through floating head, channel gasket and for tube leak, roll leak ete. Third test (Final Shell Test) This test shall be carried out after fixing shell cover and applying pressure on shell side, Pressure shall be held for minimum half an hour and gaskets joints of shell cover, tube sheet with shell are to be checked for leakage. Tube side drain nozzle shall be kept open during this test. All the above tests, shall be witnessed by inspection and final clearance shall be recorded in a log book maintained by the Owner department GM (T&D) A em) HC DIRECTOR (REFINERIES) i — rf 4,7.0 8.0 Rev. :0 CLEANING AND HYDROTESTING ROS: 70 DATE: AUG. 2001 OF TRIM COOLERS Page : 4ot 4 Note: 1) Fixed tube sheet exchangers shall be tested in the following sequence a) Shell test with channel covers open b) Tube test 2) Double pipe exchangers also will have only two test viz. shell test and tube test. Other conditions regarding test duration and repair of tubes remains same as above ~ Records and Documentation Inspection Section shall maintain records of inspection and testing of exchangers. It should also contain information regarding number of tubes plugged, replacementretubing of exchangers etc. Test ring and spare bundle status to be kept updated by Maintenance Department. Owner department shall maintain a log book and all the clearances like cleaning and each stage of pressure testing shall be recorded during the planned shutdown Other General Requirements > Spare bundle are to be kept for all identified trim coolers. > Immediately after hydrotesting, the exchanger shall be dried by air blowing Owner department shall ensure that the exchanger shalll be dried by air blowing after hydrotest [om (rap) ALES cM orf W.-C fewer) ont > (eecroe (REFINERIES) Efe