Document No.

GP 32-48
Applicability Group
Date 26 December 2005

Guidance on Practice for

In Service Inspection and Testing of Heat
Exchangers

GP 32-48

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ENGINEERING TECHNICAL PRACTICES
26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

Foreword

This is the first issue of Engineering Technical Practice (ETP) BP GP 32-48.

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Copyright © 2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organisation. None of the information
contained in this document shall be disclosed outside the recipient’s own organisation
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

Table of Contents
Page
1. Scope........................................................................................................................................4
2. Normative references ...............................................................................................................4
3. Symbols and abbreviations.......................................................................................................5
4. Site Technical Practices, inspection plans, procedures, and checklists ...................................5
4.1. Site Technical Practices ................................................................................................5
4.2. Inspection plans and procedures...................................................................................5
4.3. Inspection checklist .......................................................................................................6
4.4. Pressure vessel components ........................................................................................6
4.5. Shell-and-tube (TEMA type) - Bundles..........................................................................7
4.6. Double pipe exchangers................................................................................................8
4.7. Air fin coolers.................................................................................................................9
4.8. Plate exchangers.........................................................................................................10
5. NDE techniques for heat exchanger tubes .............................................................................10
5.1. General........................................................................................................................10
5.2. Overview of tube NDE techniques...............................................................................10
6. Inspection frequency...............................................................................................................11
7. Modification and repair ...........................................................................................................12
Bibliography .....................................................................................................................................13

List of Tables

Table 1 - Inspection checklist components ........................................................................................6

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

1. Scope

a. This Guidance on Practice (GP) provides specific guidance for service inspection and
testing recommendations for heat exchangers.
b. This GP should be read and interpreted in conjunction with GP 32-30 and GP 32-40.
c. This GP applies to:
1. Shell-and-tube heat exchangers.
2. Process waste heat boilers.
3. Condensers.
4. Coolers.
5. Plate exchangers.
6. Air cooled exchangers.
d. This GP is applicable to:
1. Refineries.
2. Chemical plants.
3. Onshore and offshore oil and gas production facilities.
4. All types of duty.
e. It is not practical to provide detailed guidance on every available design of heat exchanger,
but principles of inspection of most common designs are generally applicable to other
designs.
f. This GP covers the most common types of heat exchanger (i.e., those covered by
GIS 26-XX series):
1. Shell-and-tube exchangers, TEMA type.
2. Double pipe exchangers.
3. Air fin coolers.
4. Plate exchangers.
g. Outside the scope are heat exchangers associated with air conditioning equipment.

2. Normative references

The following normative documents contain requirements that, through reference in this text,

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constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.

BP
GN 32-009 Risk Based Inspection of Shell-and-tube Heat Exchanger Bundles.
GP 32-30 Guidance on Practice for In Service Inspection and Testing of
Equipment - Management Principles.
GP 32-40 Guidance on Practice for In Service Inspection and Testing of
Equipment - Common Requirements.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

GP 32-41 Guidance on Practice for In Service Inspections of Unfired Pressure

Vessels.

American Petroleum Institute (API)

API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair
and Alteration.
API RP 572 Inspection of Pressure Vessels (Towers, Drums, Reactors, Heat
Exchangers and Condensers).
API RP 932-B Design, Materials, Fabrication, Operations and Inspection Guidelines for
Corrosion Control in Hydro-processing Reactor Effluent Air Cooler
(REAC) Systems.

3. Symbols and abbreviations

For the purpose of this GP, the following symbols and abbreviations apply:

ET Eddy current testing

IA Inspection Authority

ID Inside diameter

IRIS Internal rotary inspection system

MFL Magnetic flux leakage testing

NDE Non destructive examination

OD Outside diameter

RFT Remote field testing

TEMA Tubular Exchanger Manufacturers’ Association

4. Site Technical Practices, inspection plans, procedures, and checklists

4.1. Site Technical Practices

a. This GP shall be adopted, modified, or supplemented by Sites into a Site Technical
Practice (STP).
b. The STP shall be approved by the Site Engineering Authority and form the basis for the

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4.2.
a.
development of equipment specific inspection plans and procedures.

Inspection plans and procedures

Site equipment specific inspection plans, procedures for heat exchangers shall:
1. Be developed for relevant design types.
2. Be approved by Site IA.
3. Include reference to heat exchanger components up to and including associated piping
flange connections.
4. Consider potential damage mechanisms including corrosion, erosion, environmental
cracking, fatigue cracking, etc.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

b. Normative references, bibliography, and requirements of this GP shall be used to develop

inspection plans and procedures.

4.3. Inspection checklist

Inspection checklists, if used, should include exchanger components in Table 1.

Table 1 - Inspection checklist components

Shell-and-tube Air fin cooler

Shell and nozzles Headers and coverplates
Shell cover (bonnet) Tubesheets
Channel and nozzles Nozzles
Channel cover Tube fins
Floating head cover, backing ring, studs Tubes
Tubesheets Plugs and plugsheets
Tubes Louvres
Bundle trim (e.g., baffles, impingement plates, Fan blades, hubs, and guards
tie rods, spacers, etc) Plenum chamber
Anodes Foundations and supports
Insulation Platforms, ladders, and stairways
Painting and lining Nameplate
Foundations and supports
Nameplate
Earthing/grounding
Platforms, ladders, and stairways

4.4. Pressure vessel components

a. In certain countries, pressure containing parts, such as shell, bonnet, channel, headers, and
tubes, are considered pressure vessels and are subject to statutory control and survey by
external inspection authorities, especially in steam duty.
b. Principles of pressure vessel inspection described in GP 32-41, API 510, and API RP 572
shall be applied to these components.
c. Some designs of exchanger, such as fixed tubesheets, cannot be dismantled, and internal
access is limited via nozzles. In these cases inspection procedures shall specify other
means to facilitate thorough examination of shell, usually involving remote visual and
NDE.
d. The following damage and deterioration types are particularly relevant to exchanger shells
and channels and shall additionally be addressed, as applicable:
1. Corrosion or mechanical damage to gasket faces.

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3.
4.
Deformation of shell and channel flanges.
Damage to internal protective coatings or metallic linings.
Inadequate remaining sacrificial anode material to provide protection over the next
service period.
5. Deformation and fatigue cracking of division plates.
6. Circumferential grooving of shell internal at baffle locations.
7. Scoring of shell caused by bundle pulling.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

4.5. Shell-and-tube (TEMA type) - Bundles

4.5.1. Preparatory
Shell-and-tube TEMA type exchanger bundles are difficult to inspect because of limited
visibility on both sides. To make accurate assessment of exchanger condition, inspector shall
know:
1. Design and operating conditions on both sides.
2. Process streams and their corrosivity on both sides.
3. Materials of construction.
4. Most likely damage modes and locations.
5. Full details of exchanger inspection, operational, and maintenance history.

4.5.2. Bundle inspection

a. Degree of fouling on each side of bundle shall be recorded, ideally by photography.
b. Bundle cleaning
1. Bundle cleaning shall be sufficiently thorough to permit detailed inspection.
2. Inspection of dirty bundles shall be avoided.
c. Tube damage
1. Tube with unacceptable damage shall preferably be renewed.
2. Tube plugging may be performed if renewal is not feasible.
d. Corrosion of baffles, tie rods, and spacers shall be recorded.
e. Enlargement of baffle holes shall be checked.
f. Tubesheets shall be visually checked (both sides if possible) for corrosion, erosion,
distortion, and mechanical damage.
g. Brass tubesheets shall be examined for dezincification.
h. Tube ends shall be visually checked for thinning, impingement erosion, and cracking.
i. Ferrules
1. Ferrules shall be removed as necessary to permit thorough inspection.
2. Damaged ferrules shall be renewed.
j. Locations of plugged tubes shall be checked against previous inspection report.
k. Tube end welds

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1. Tube end welds shall be visually examined for preferential corrosion and cracking.
2. NDE crack detection shall also be considered.
l. Tube internal surfaces
1. Tube internal surfaces may require internal inspection with appropriate NDE or
remote visual techniques, especially if tubeside stream is corrosive.
2. Refer to clause 5 and GN 32-009 for details.
3. Tube inside diameters (ID) may be recorded at representative locations at both ends to
monitor tube end thinning.
m. Tube external surfaces

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

1. Tube external surfaces shall be visually inspected over full bundle length and from
top to bottom by rotation of bundle, if practical.
2. Light hammer testing of steel and copper alloy tubes may be appropriate but not
recommended for thin wall tubes in corrosion resistant alloys.
3. General roughening, pitting, and grooving at back of tubesheets and at baffle
locations shall be recorded.
4. Outside diameter (OD) measurements shall be taken at representative worst areas.
5. Unintended tube expansion beyond back of tubesheets shall be noted.
6. Particular attention shall be paid to erosion of tubes adjacent to shell inlet nozzles and
impingement plates.
n. Tube extraction
1. If inspection and bundle history leave doubt about ability to operate for another run
without leakage, tube extraction shall be considered, if possible.
2. Tubes shall be selected for extraction based on results of visual inspection and NDE,
ensuring adequate coverage of bundle cross section.

4.5.3. Pressure testing

4.5.3.1. General
a. The preferred fluid for pressure testing is normally potable water.
b. If heat exchangers contain austenitic stainless steels, chloride ion content of hydrotest
water should normally not exceed 50 ppm.

4.5.3.2. Shell test

4.5.3.3. Tube test

4.5.3.4. Reverse shell test (straight bundles)

4.5.3.5. Differential pressure testing

Pressures shall be gradually increased and decreased on each side of exchanger to ensure that
maximum tubesheet differential pressure is not exceeded.

4.5.3.6. Pressure testing

a. Test pressures shall be maintained for at least:
1. 30 min for shell test and tube test.

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2. 15 min for reverse shell test.
b. If unexpected tube leak occurs, every effort shall be made to determine cause.
c. Tube plugging shall follow approved procedures.

4.6. Double pipe exchangers

a. Principles and practices of inspection and testing double pipe exchangers are essentially
same as TEMA type shell-and-tube designs.
b. Exchanger shall be prepared and cleaned to permit thorough inspection of pressure
containing parts.
c. Inner elements shall be withdrawn and cleaned, if practical.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

d. Shell and elements (whether single or multiple tubes, plain or finned) shall be examined to
detect degree and extent of corrosion, erosion, or other defects.

4.7. Air fin coolers

4.7.1. General
a. Principles of inspection and testing of air fin coolers are similar to those for shell-and-tube
designs, with one important difference: tube failure results in loss of containment. This
means that air coolers in hazardous duty tend to be of higher criticality than equivalent
shell-and-tube exchangers.
b. The inspection procedures for air fin coolers vary with design type:
1. Low pressure bolted cover plate designs.
2. Medium pressure threaded plugsheet and tubesheet designs.
3. High pressure fully welded designs.

4.7.2. External inspection

External inspection can usually be performed while air cooler is in operation, as follows:
a. Ladders, walkways, platforms, and stairways shall be inspected for:
1. Corroded, damaged, or missing structural parts.
2. Loose or missing bolting.
3. Corroded floor plates.
b. Foundations and supports shall be inspected for:
1. Spalling, cracking, or settlement of concrete.
2. Anchor bolt corrosion or looseness.
3. Corrosion, distortion, and cracking of steel supports and welds.
4. Freedom of movement for thermal expansion or contraction.
c. Louvres and associated drive or positioning mechanisms shall be inspected for damage or
malfunction.
d. Tubes shall be inspected for corrosion, sagging, and distortion.
e. Fins on top rows of tubes shall be inspected as far as possible for corrosion and mechanical
damage.
f. Fan guards shall be inspected for corrosion and break-up.
g. Plenum plates shall be inspected for corrosion or other deterioration.

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4.7.3. Internal off stream inspection
a.

b.
Sufficient plugs or cover plates shall be removed to permit representative thorough
inspection.
Partial plug removal shall be performed on regular pattern to cover full width and height of
bundles in representative manner.
c. Tubes shall be adequately cleaned for inspection.
d. Tube ends and tubesheets shall be visually inspected for corrosion, erosion, and cracking
of tube to tubesheet welds.
e. Header boxes, cover plates, and nozzles shall be visually inspected for internal corrosion
and erosion, as far as access permits.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

f. Ultrasonic wall thickness checks on header box plates and nozzles shall be recorded.
g. Tube internal surfaces shall be inspected as appropriate for anticipated damage
mechanisms.
h. Tube fins shall be inspected for corrosion and fouling.
i. Fan blades and hubs shall be inspected for corrosion or mechanical damage.
j. Plugs and plugsheets shall be inspected for thread damage.
k. Gaskets shall not be reused.
l. Air coolers in hydro-processing reactor effluent duty shall be inspected in accordance with
API RP 932-B.

4.7.4. Pressure testing

a. Air coolers opened for inspection shall be tightness tested as minimum requirement.
b. Full strength test shall be applied if repairs to pressure containing components have been
made (including cutting out of tubes) or if results of inspections leave doubt as to cooler
integrity.

4.8. Plate exchangers

a. Plates and platens shall be examined for corrosion, erosion, cracking or other defects.
b. Gasket locations where crevice corrosion may have developed shall receive particular
attention.
c. Tie bolts shall be checked for possible deformation and cracking.
d. Reassembly and pressure testing shall follow Vendor procedures.

5. NDE techniques for heat exchanger tubes

5.1. General
a. Tube end inserts shall require removal for full length coverage of tubes.
b. Some NDE probes do not travel around U bends.
c. Calibration tubes in appropriate material are required.
d. Providing the NDE contractor with information about likely type of defect increases the
success rate of inspection.
e. Most techniques are highly operator dependent.
f. If using real time data analysis, detection of severe defects (e.g., loss of more than 50%

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wall) should be immediately brought to attention of turnaround (TAR) inspection and
maintenance team.
g. Radiography can only be used on outer rows of tubes where there is room to insert film.

5.2. Overview of tube NDE techniques

a. Remote field (RFT), eddy current (ET-T) and magnetic flux leakage (MFL) techniques are
much faster and less costly than internal rotary inspection system (IRIS), typically by
factor of 5. These three former techniques provide indication of damage but do not require
as high level of cleanliness as more quantitative techniques (e.g., IRIS).
b. RFT
1. Can be applied to ferrous tubes.

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Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

2. Can detect but not discriminate between volumetric ID or OD flaws.

3. Is relatively insensitive to small localised defects, defects within tubesheet thickness
or baffles, or at support plates.
c. ET
1. Is qualitative or quantitative inspection technique used primarily on non ferrous
materials.
2. Can detect and quantify general or localised defects (e.g., pits or cracks) and general
wall loss. Fine pits can be missed.
3. Can discriminate between ID and OD flaws.
d. MFL
1. Is a semi-quantitative inspection technique, typically used as screening method for
ferrous materials.
2. Can detect holes 1 mm (0,04 in) in diameter and general 5% wall thickness loss.
3. Can be insensitive to axially orientated flaws and gradual wall loss.
e. IRIS
1. IRIS techniques provide indication of actual wall thickness, but cleanliness
requirements are greater than other NDE.
2. IRIS is commonly used for defect verification in ferrous and non ferrous tubing
materials.
3. Hydroblast pressures up to 1 380 bar (20 000 psi) may be required, but this has not
been reported causing tube damage.
4. No-go gauge to IRIS probe dimensions assists cleaning contractor.
5. IRIS crews and cleaning crews need to work together such that IRIS testing is not
performed until cleanliness requirements have been met.
6. IRIS can be accurate for thickness measurement, as well as detecting internal and
external pits greater than approximately 1,5 mm (0,06 in) in diameter. Fine pitting,
pinholes, and cracks are not likely to be detected. Another limitation is minimum
measurable thickness.
7. Some site experience indicates IRIS is more effective for Monel tubes than either ET
or MFL.
f. In some cases, specialised use of conventional ultrasonic testing (UT) in tubular fixtures
may be advantageous (e.g., near tubesheet and baffle damage).
g. Radiography

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2.
3.
Radiography is useful supplemental technique, even though its scope of application is
limited to small percentage of tubes (i.e., outer rows where film insertion is possible).
Radiography can reliably detect general wall thickness and localised pitting.
Radiography can inspect outer rows of U bends that may not be inspectable by
internal probes.

6. Inspection frequency

Inspection frequencies shall comply with the principles in:

a. GP 32-30.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

b. Other normative references listed in this GP.

c. GN 32-009, as applicable.

7. Modification and repair

a. Authorisation for design of repair, welding procedures, heat treatments, and materials shall
be:
1. Obtained from appropriate TA.
2. Subject to approval of IA.
b. Modifications shall not be performed unless they:
1. Are authorised by relevant TA.
2. Comply with site management of change (MOC) procedure.

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26 December 2005 GP 32-48
Guidance on Practice for In Service Inspection and Testing of Heat Exchangers

Bibliography

BP
[1] RD 32-010 Guide to Compact Heat Exchangers.

[2] GP 06-29 Guidance on Practice for Corrosion Protection During Hydrotesting.

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