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Maintenance ENG

Maus Italia has risen to a position of world / eade.rship thanks to the tireless work of many collaborators and the belief of an Italian clientele which is exceptionally active on the international market in the subsequent years. An irresistible desire of innovation push our company in Inserting new products, more.and more Innovatory In the field of manufacture and maintenance of the heat exchangers.

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Nasir Abbas
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686 views92 pages

Maintenance ENG

Maus Italia has risen to a position of world / eade.rship thanks to the tireless work of many collaborators and the belief of an Italian clientele which is exceptionally active on the international market in the subsequent years. An irresistible desire of innovation push our company in Inserting new products, more.and more Innovatory In the field of manufacture and maintenance of the heat exchangers.

Uploaded by

Nasir Abbas
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF or read online on Scribd
a) © MAUS ITALIA Maintenance Tools, equipments and machines On-shore 7 Off-shore tube bundle heat-exchangers maintenance Tube testing and plugging Tube bundle extraction and transporting Tube bundle cleaning Retubing Franco: Founder @yaus since 1961 tthe end of the nineteen fies Mr. Franco Agostino was afforded the opportunity to lear the art of making tube ‘expanders by an old German manufacture, Mr. Albert Oto. From that time, and thanks to the determination and perseverance of these men, Mi. Agostino was able to start up the small Italian factory that a few years later became Maus Italia, Today Maus italia has risen fo a position of world leadership thanks to the tireless work of many collaborators and the belief of an Maan clientele which fs exceptionally active in the interational marketplace, ‘Active on the international market in the subsequent years, «an irresistible desire of innovation push our company in inserting new products, mare and more innovatory in the field of manufacture and maintenance ofthe heat exchangers. This ast ones the subject ofthis brochure, up-to-dated at 2010, that Maus tala 's presenting withthe attempt of giving ‘a contribution of cleamess and competence, which are values that have always marked us all over the worid. ©maéus Index ITAUA 1 Tube testing and tube plugging Pneumatic pressure tube testing ycrostatc pressure tube testing Tube plugs and High pressure tube plugs Bp > seat extn and omnia Symbols ‘Aerial tube bundle extractors ‘vil tube bundle extractors (of-shor) ‘Self propelied tube bunale extractors ‘Self propelled tube bundle extractors (off-shore) Truck mounted tube buncle extractor Tube bundle transportar Praia, High Pressure interna cleaning robot ne High Press intemaeemel manual ering pump Det NORSKE VERITAS - ‘Mechanical internal cleaning (straight tubes only) LITY MANAGEMENT SYSTEM CERTIFICATE Pages nn Tum to page nn PB ene D> Retubing M.A.U,S, ITALIA di F. Agostino & C. Sas $5 Pon T0208 gids Cranes = Ba Bundle saw machine emerson on ‘Single internal tube incising/cutting ee Note peated tbe cuting Hydraulically operated stubs pulier Hydraulically operated continuous tube pullers es ‘Manual too! for tube extraction wonw.dnvit- worw.sincertit MA-10 MA-T11 MAT MA-12 MAR 14 MA-20 MAR 22 MA. 26 MA-28 MA-32 MA-34 MA-38 MA-40 MA-48 ‘MA-60 MAR 54 MA-58 MA-60 MA. 64 MA-76 MA-78 MA. 84 MA-88 Maintenance Tools, equipments and machines for On-shore / Off-shore tube bundle heat-exchangers maintenance Inthe next pages we have tried to show by sketches main maintenance operations performed on heat echangers tube bundles. ‘The purpose is to summarize for our qualified customers a complete range of machines and tools for the maintenance of tube bundles of heat exchangers both on-site and in the workshop. The machines designed and manufactured by us are the result of decades of experience with hundreds of clients on five continents. ‘The three main plant maintenance operations are depicted here briefly ‘The testing, extraction, transporting and water cleaning of the tube bundles in off-shore and on-shore petrochemical installations. ‘After washing, it could be necessary the partial or total retubing of the tube bundle. The operations, detailed here following, briefly explain the use of our tools, equipments and machines, matched to the different phases of the retubing ‘operation: cut, extraction, tube-sheet refurbishment, tube bundle assembling, expansion, facing, welding, ° Tube testing & Plugging ¢ Retubing and reparing on site On-shore : 122 bundle extraction and transporting Testing # Bugging / patting mags Ao ig Paes Fd expanders 8 Aerial bundle extractor Tube bundle extraction and transporting Tube bundle extraction and transporting & Tube bundle cleaning iy ee amie leaning Py F i a-S 7 ls} Ouus Tube bundle heat-exchangers TEA melt J, Gb i Sr tenn Tube bundle cleaning H ° Tube cutting Retubing = ° tube suing ° Tube sheet refurbishment ¢ Tube bundle assembling ° Tube rolling ¢ Tube to tube sheet * Tube facing _TIG orbital welding Tube cutting sa A Tube pulling Refurbishment Tube bundle assembling of the tube-sheet Holetoo! Tube pilot Drilling - Reaming - Grooving \ Tube to tube sheet TIG orbital welding Tubweld semi-automatic equipment Automatic welding machine (MUN.70 MWH-80 Tubwold-Top-S/ Basl-S iva Sis Tube bundle heat- Partly oll maintenance o D. oO iAUA Bundle saw machine =] = iT Single internal tube] 4a \ SB Ising/eutting Kaw. | * ‘Stub puller » A = lee tube puller pom re oN Tube rolling Be Spmiautomatic pnouinatic tobe rolling rolling machine Srcieer tube rolling Minirol Macro! Mastero! Fey , 4 Eas] i] Tube facing Semiautomatic electric or pneumatic tube facing Automatic facing machine 4 Tube testing. and tube plugging In order to solve the problem of pnoumaticaly testing the leakage inthe tube and inthe junctions between tube and tube sheet in heat exchangers when assembled, operative or in uso, Maus faa proposes the guns ofthe @ series and P series which ae fast, efficient, easy to use and to handle. ‘After having verified the possibilty of intervention on site, it is possible to plug some defective tubes with standard plugs ‘model F/785, made by a ring and a tapered pin, or by high- tech plugs model Pop a plug. Pneumatic pressure tube testing Provides a fast and effective method for pneumatically testing hheat exchanger tubes and tube to tubestest joints for leaks. ‘Three ditfarent type G-series are proposed: G-150, G-450 and 6-650. Hydrostatic pressure tube testing P--series potable type, compat and inpendent for hycrostal tests the heat PSR-2300 » PSR-7800. Tube plugs and high pressure tube plugs ‘Tube plug mode! F/785 in carbon steel, brass, stainless steel or aluminium and high pressure plugs modet Pop @ plug. Quick (3:10 tubes per min) Efficient Pneumatic pressure tube testing Simple to use Manageable testing heat exchanger tubes and tube to tubesheet joins for leaks, Three different type are proposed: G-150, @-450 and G-650. Guns G-SerIeS provides « 1281 and ettective method for pneumatically G-150 - Individual near end tube testing {tis used to test single stralght, U-shaped 1. 2 tubes, or tubes with only one end open the kits composed of a ar gun anda tube plugging gun (in case of tubes open at both ends). They have been conceived to preumatealy test the leakage ofthe smalest hole. They weight 1 Kg (2.2 Lb) approx.as they 2 are made in aluminum: they make possible to test tubes with ID trom: G-150 :7,1 mm to 31,3 mm (0,280" to 1,230") G-1504 :31,4mm to 64,3 mm 0,231" to 2,531"). After making the gaskets ofboth guns expand simultaneously and aftr the preseure has stabilzeg inside the tube, every smal leakage iseasly detected, Conosived to test an entire tube when it can be accessed only from one end. tis supplied with a connection and fixed test length; itis available in lengths from 610 mm 0 1830 mm (rom 210 6 feet). The test length can be assembled up to a lenath of 7820 mm (24 Fi) It weight 1K (2.2 Lb) approx. as itis made in aluminium: tis very easy to handle. ‘Tubes with ID from 12,2 mm to 31,2 mm (rom 0,480 9 1,230") canbe tested. ‘Aer insertng the entire test length and expanding the two gaskets at the ends and after the pressure has stabilized inside the tube, the slightest leakage will be easly detected. o y ---49 ---------- G-650- Roll joint testing ------------ This gun's refered to as a vacuum ‘gun as it has been conceived to test the joint between the tube le din ia Mar Oring {and the tube-sheet creating @ ae | wot; cot | oor; mete | coe See tee || 714114 028 0.46 4s¢-6508 | csc-6808, 2,07 0.790] asc-6708 This gun weight 1 kg (2.2 Lb) 7.24126 | 0.29 GSC-6509 Spproxasitismeden aluminum, 5/6" | 2" " cc) ow eo sang | O8C-2510 2502 0.98] GSC.8710 Weer as) toad andirakes AT +150 oe ible to test tubes “ ‘ aschownie Tab, Anyleckage can | 3/4” || 107 S121 1042047) 0) SC-S5I1 | asc. gpin 29.01. 115| 080-6712 ‘easily detected after having ease) ee — ‘expanded the gasket, createdand 7/8 ||140+21,3 0.55 + 0.84 GSC-6514 | GsC-6614'31,05 1.240] GSC-6714 Suoettaecummbe "elas aralaarcaae|| | escareleaeene sum cal cseare 080 + 1.09 8¢-6518| a8c-6618 39,37 1.550] G8C-6718 092+ 121 8¢-6520| a8c-6620 42,55 1.875] G8C-6720 1.17 146|/ | @8C-6824] asc-6624'54,74'2.155] asc-724 40,4 1.30 + 1.59 8c-2525| asc-6626 57,91 2.200] G8C-6728 i 26, 1424.71 8¢-6525| 48-6626 61,34 2.475] 680-6728 Ep feeasaoa 107. 106] °° scaste|ascese 70 zo:s|ascore | (2178 | 408+ 56,1 | 1922221 280-6596] a8¢-696.74,04'2.915] @8C-6795 \ (2172 55,1 +625 '217 +246 80-6540 | a8c-6640 80 393.165] @SC-6740 F785 itz plugs ‘Tube piug composed of ring and tapered pin in carbon steel (CS), brass (8), stainiess steel (SS) or aluminium (AL). Hydrostatic pressure tube testing Pump P-Series pum, Rarely eet eee alow thetydrostati tests in single tubes of heat exchangers. They are designed to supply high pressure water utilizing 1,72 - 8,62 Bar (25 - 125 ps) compressed air to drive the pump. The system is supplied with AUTO SQUAT cyfinders kit for fi TIGHT GRIP TEST PLUGS in the tubes. GRIPTIGHT plug Hydrostatic pump tubes. * Self lubricating air over water intensifier A *Loctabl miu to bax ayaa + Water supply connection * Regulator to contro! inlet air supply | phi * High pressure bleed valve * High pressure outlet barre oye Pop a plug PSR-2300 PSR-7800 Maximum Outlet pressure High pressure tube plugs een cae ee) Pop a plug is undoubtedly an innovative proposal which Flow Rate at 85% Rated Output Lymin 0,8 (0.22) enables the tubes in the heat exchangers to be plugged, ae fone stot Poremoved op to prouuts of S00 Bar ASCO es) wiht a — Sa Bareroved tbo prose (4500 05) wih ‘Height mm * 267 (10.172) It fs made up of three Approximate Shipping Weight Kg Lb 19/42) ce mechani! part: aa threaded adapter. Baseaingeng ca tapered pin 2} The threaded adapter is fixed to the hydraulic pump and is then ingerted inthe tube ata minimum. ‘each of 1.3/4" (about 45 mn) ; tmust however be in the tube sheet area to guarantee safe 89 10-11 1243 1415 1647 1819 de wa ‘owe ‘ova ‘swo swo . mo. G-series eee srtone (eplecentrorat eae, =| i | Lei (cil {cai pats cha ci HR™| ~ | ~ 0028 | ooxs | ons7 | 0040 ; 0048 eeeenceatere _ {78 | 0030 | 0037 0040 | 0O47/ 0050 0053 | 0055 tapered pn i pulled by the ‘Cran Cot '3/4” | 0043 ; 0047 | 0053 ; 0056 ; 0062 | 0085 : 0068 threaded adapter, and passes GS#+ cod. i through the sealg ng wich (0065 | 0072 | 0075 expands and presses with its s wings agains ho side part of the tube thus quarantcing the requested seaing 109 | or10 | o112 on15 | o122 | 0126 ‘ors ‘After reaching the puting 0118 | 0122 0128 | o194 | of97 | 0140 | 0148 rotenig rat | 0137 0140! o17 | 0150 | 0159! o156 esaciclcatit tee eat 0149 | 0147 | 0159 | 0158 | 0162 | 0165 ! 0168 BOOS (0168 ; 0173 | 0178 ; 0183 ; 0167 | 0190 | 0193 % 189 | or98 | 0209 ; a20e | 0212 | 0215 | 0218 ca1e | 0223 | 0208 | o2a2 | 0287 | 0240 | 0243 Tube bundle extraction and transporting ‘After having carried out al the operations forseen in the testing, ‘phase and having excluded any possibilty of partial reparation On site, or itis simply necessary to wash the bundle, its necessary to remove it from the shell For this purpose Maus Italia has developed a complete series: Cf tube bundle pullers which fal into two categories, AERIAL and SELF-PROPELLED, which are available for ON-SHORE and OFF-SHORE operations ,on request, with special preparation for operation in dangerous classified areas, ‘The AERIAL type, designed for use with the help of a ee Neem crereme nts eee ne eeeacan Saas ‘The SELF-PROPELLED type has the ‘advantage of not needing a crane but clearly has a more determined and ; limited range of use. Let's examine them in detail Mef express + Mammut (on-shore) “The quick hooking aerial tube bundle puller is produced in various sizes for tube bundles up to {95 T (143300 Lb) and lengths up to 12,5.m (41 1). ‘This madel works Welln combination with the absolutely ‘new Mammut tube bundle transporter, suitable for pic transport to the work bench for washing on workshop. Mef express NAVY (off-shore) &) 2 ‘Aerial bundle extractor, suitable for ocean platforms and FPSO installations. This isa special version of the Mef espress, designed and manufactured for meeting the specific needs of safety and off-shore maneuverability. Specific construction solutions are assessed case by case depending on the motor drive and limitations, (of weight and size). (One of these IMIVY solutions envisages the separated Van Motor drive unit including one converted diesel engine (Explasion-proof), assembled on a ‘self-propelied trolley. Mef mobil (on-shore) Solf-positioning remote controlled bundle puller for extraction, hoisting and movement of tube bundles. “This tube bundle puller has been designed for cases of dificult access.It is completely self-sufficient, as is presented as a global solution in petrochemical plants for the extraction and transportation of tube bundles. Mef mobil NAY (off-shore) Solf-positioning remote controlled bundle puller for extraction, hoisting and movernent of bundles on platforms and FPSO. This special version of the Mef mobi is available in different sizes and also designed taking into consideration the possibilty of maneuvering on board. Ithas two parts (lke the Mef Aerial NI), one operative and the other for ‘control, consisting of the hydraulic unit powered by an ‘explosion-proof version of the diesel motor, installed on. a self-propelled trolley. ‘Mef truck, thanks to the original project of = the telescopic rotating column, allows the quick puliing/insertng of the bundle. L] ‘Once the truck is positioned, itis easy and quick to lift the extractor and to proceed with the extraction. This system is particularly advised for the ‘maintenance companies which operate continuosly inthe petrochemical plant field Mammut bundle transporter This specially designed machine provides a brilliant solution to the problem of moving tube bundles inside installations from LE = ‘the point where they are extracted to the washing area or the workshop insie the installation, eliminating the Use of trucks and mobile cranes and speeding up considerably the loading | {and unloading operations carried out just a few centimeters from {ground level in complete safety. Aerial bundle ctors (on-shore) Quick hookin: Mef expre tubs bundle puller ‘ef express tube bundle pulie isthe quick hooking version ofthe already existing ‘Mef model. Ithas been entirely designed and manufactured by Maus ltl for Gael” Bathe maintenance of heat exchangers tube bundies in petroichemical plants. The Ae E hydraulic hooking ofthe tube plate makes it possible fo quickly inset and a = ill out the tube bundles when the refineries are at shutdown with a ‘consequent work time reduction “The great soliciy and sturdness ofthe structure as well as the innovative improvements make this machine extremely reliable ‘Met express pulle is proposed in different standard dimensions ‘according to the weight, the length and clameter of the tube bundles. A Portable Console enables the remote control of al the operations with ‘consequent reduction inthe personnel and increase inthe final safety margins. In the diesel version a console with wireless remote control is available. It's supplied with diesel or pneumatic motorization. ‘The Mof express tube bundle puller, which already ‘ives good performance in the basic version is supplied on request with a series of very interesting optional features ilustrted in the next page. re cae Easy to operate Tested solidity Performing and reliable (lifting test) = OMS) os Affordable prices Bundle extractors can be supplied with Diesel engines or air motors. Motors executions suitable for hazzardous classified working area are available on request (complete with Atex conformity declaration. Customized executions tnost pect eouremetis fornia customer Surin a ncescay spec ra : suiting ln docs / Srawings calcuations) ia Bundle dimensions 1300 65 TubeshestOD. Drm] 1900 Length mm 6500 6500 7500 | 6500 7500 | 6500 7500 10000 7500 10000 | 10000 12500 aie Maxiitting capacity () +] 1015 | 1825) | 22033) | 95625) | 35625 | 450675) | 051075) * ef mnanaiere 1300 1600 1700 2000 2000 2200* 2500* 5 6575 6575, 6578, 100 75 —~100_, 100125 width Tm | 1600 200 7080 7300 2300 2300 3000 Height Hm | 2000 2500 2600 2200 000 900 3650 Length Loom 7800 8100 9100 | 8100 9100 | 8100 3100 11600 9100 11600 | 11600 14100 Height (moto) Hm om | 2150 2280 2250 2250 2280 Weight xo | 4950 | e200 e400 | e800 e700 | aso asoo | 10aco | 12000 1400 | 16000 1500 *% Pulling max speed mina] 2.5 25 25 20 20 20 15 Puling force = 3800mm (138) on request! Front view of . the bundle | Sup, hydraulic extraction with Motor group | trolley and heat bundle support Hydraulic unit exchani trolley and changer lectric system Blocking system hydraulic vice Tengih mm & Diameter D mm « Max iting capacty } T Lb Performances 50 (110200) 266) Self propelled bundle extractors (on-shore) __ ‘The main operations are shown below in sequence. proach Approximate i to about 0,5mi 2 4hydraulic feet to stabilize the puller Servo-assisted positionin. 3 and hoistin ie 2 Y max= m (165”) Zmax = 1500mm (59”) Servo-assisted positionin # up to X max = Zoom ey 5 Shell blocking Trolley feedin. 6 Fastehing to Yebolts Pull with cable joo onus Trolley re-approach with cabie lease 7 Hooking up for extraction and support Pulling and support wi independent 8 hydraulically controlled trolleys End of pulling 9 Shell release 10 Lowering of bundle 17 Release of 4 hydraulic feet 12 ___ Towards the maintenance area oases bl Self propelled bundle extractors (off-shore) Mef mobil navy contoied orextecton. hosing and movement of tube bundles Re eee Minoan eb eos ce ne RL loa Bele sepa gerry et ae enn one Pace Pesca ea eae weer one aren epee tay mene tim Ar Fes eesea aero teneer e epson este ee nO Sar aston trae \\X\J application, the dimensional details of the Mef NY Sten aa cnt oe eae ns in charge of the project in a spint of the closest collaboration. E LL LEM. ev eorene | Performing and reliable Fe, yy Customized design oma SSD ~Serpostionng armen supplied Motors executions sabe forhazzardousclassiied fer tila ose rate cto oe Ws Alec caer oct Customized executions Maus ($0 9001 cortifed) can suppl also cusiorzed bundle pullers to meet special requiments rom the customer (Submitting al necessary docs / drawings / calculations). } . ae =i SS = e NY ~ Hydraulic control 1 ee itt. = BY Lom ‘ xed fo i _— oy [ i i ‘ i QW Blockir item “enue Po = = e 9 ‘ i y ! Main carriage Ga Advanced 7 i design Crawler trucks fj ~ Truck mounted tube bundle puller Completely indipendent tube bundle puller assembled on the truck ‘Mef truck, thanks to the original project of the telescopic rotating column, allows the quick. pulling/insering of the bundle, ‘Once the truck is positioned, itis easy and ‘Quick to lft the extractor and to proceed with the extraction This system is particularly advised for the maintenance companies which ‘operate continuosty in the. petrochemical plant field Quick pulling Performing and reliable Self propelled completely independent 2Ft —— Up to 7000 mm 22.97 Ft =~ 600 mm Main features ‘Met truck positioning Hydraulic stabilizers Olzodynamic stricture with 6 telescopic indipendent arms Rotating telescopic column Complete iting system assembled on tivust bearing and having ait stroke ‘of 6400mm (2 F600 + 7000 mm (2523 1.90" column rotation is permiting the positioning ofthe extractor on the sare ‘x8 of the bundle (working positon) Extractor frame The extractor rama is assembled on the iting fork and itis longitudinally mouved by two double effect hydraulle cylinders. Pulling/pushing Manual trolleys ‘They grant a safe support during the ‘extraction/nsertion ofthe bundle. Pulling/pushing trolley Bundle extraction on both truck sides thanks to the frame design and especialy {hanks to the main cariage (compiete ‘with anchoring plate on both sides) design with capacty of puling/pushing on both sides Controt Proportional remote control Control on working operations by racio remote control wireless system. Manual commands Emergency push buttons command, Truck mounted tube bundle puller Technical features Smax 4000.m™ for max lifting capacity () 20 T / 44000 Lb — p 2Max 1800 mm enn Max 70,8" = 3985 mm 13.0 Ft "Bundles dimensions and max TubeshestOD. «Dm ~——*| 1600 708 Length mm | 7500 | 246 Maxiting capacity (} = T =| 20 | 44000 Mef truck is supplied with: ‘Overall dimensions 5 ared weight 1800 VOLVO FM13:960 8x4 % Truck wieth Tom * | 00 | 82 - % Height Hom | gms | 130 iss % Length Lo nm om | t0sg0 | 957 Seeman) Weight "ow | 2900 | 72500 aoe D198 13 tre inline 6 cyinder Sa nan turbo charged So 1800 inlreooircesel f__workang copackies___=_ Max power HK Ledge Smax mm | 4000 | 13.2 1360 HP (270KW) aie Pundit. (minima Hutte mm | 50/6050 ' 72550 ‘at 1400-1800 rpm Pulling max speed minin Pmin] «2 | BE or Pulling/pushing fore

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