E-10203A & B

Inspection: Visual & NDT

 Post cleaning visual inspection including
SS covers, shell & SS tube bundle and
nozzles
 ECT ~23% = ~753nos
Tube SS31254L – 25.4mm OD x 1.63mm
thick x 7315mm x 3274 nos
 Replace all RCP for both E10203A & B
 Hydrotest fixed shell to 15.24 barg
 Hydrotest tube side 14.07 barg

Notes & Past Findings:

New Exchanger installed in 2018 – Material
change
Old equipment tube leaks and cracks found.

General Preparation Notes:

1. Drop covers . Cleaning of shell, covers, attachments including gasket surface. Baseline cleaning: brushing and water spraying.
To employ other methods if cleaning does not meet requirements. Ref: WI 70934 for more guides.
2. All brushes must be of similar material as the base metal. E.g. CS use CS, SS use SS.
3. Inspection & NDT requirements: To have access to location of interest, including provision of platforms & scaffold, removal of
insulation, done sufficiently and preferably within eye level view and lighting (ASME V: not more than 24 inches visual distance,
access between 30 degrees to 150 degrees relative to the surface with adequate lighting of 1000 lux), without blockages
4. All VI cleanliness including tube bundle external requirements: Dry surface, able to visually determine the condition of bare metal
and detect presence of defects/discontinuities without blockages
5. Tube cleaning requirement: Tube internal and gasket surface. Visually no scales, dirt, sludges & fouling. Tube internal shall be
checked with dummy probe test (min 92% fill factor). To submit dummy probe report (with indication of “no go” locations if any)
and visual report by QC before calling for inspection. Baseline Hydrojetting of <15000psi. To employ other methods if cleaning
does not meet requirements. Ref: WI 70934 for more guides.
6. Tube testing: Provide shade and lighting. Electrical supply is required. Water filling is required for IRIS.
7. All tube plugging requires puncturing before plugging. 1st Choice: Perma plugs, 2nd Choice Taper plugs. Puncture tubes @ 12 & 6
O’ clock for horizontal tubes and near top and bottom for vertical tubes
8. Hydrotest: Slow water filling & bleeding, & hand pumping. For expansion bellow on shell, install shipping bolts before HT and
remove after test. Step increase/release for above 10barg pressure. Hydrotest: Use Demin Water. Blow dry after HT.
E-10203A & B
Inspection: Visual & NDT
Tube testing:
 First three tubes along the side peripheral
 First two tubes from top and bottom on entire top
and bottom most section
 Two vertical columns of tubes at the center.
 First tube on both sides of the partition section
 Estimated:
ECT ~23%= ~753nos
Tube SS31254 – 25.4mm OD x 1.63mm thick x
7315 mm L x 3274 nos