ATA-2022

CHE RETUBING REPORT

COLD INTERPASS HEAT EXCHANGER:
SPECIFICATIONS:
NO OF TUBES : 344
MOC OF TUBES : MILD STEEL (BS-3059)
TOTAL HEIGHT : 14588 mm
MOC OF SHELL : MILD STEEL (SA516 GRADE 70)
SHELL ID : 1980 mm
SHELL OD : 2000 mm
SHELL THICKNESS : 10 mm
TUBE ID : 43.48 mm
TUBE OD : 50.8 mm
TUBE LENGTH : 10973 mm
TUBE THICKNESS : 3.66 mm
TOP TUBESHEET THICKNESS : 40 mm
BOTTOM TUBESHEET THICKNESS : 45 mm
TUBESHEET TUBE BORE ID : 51.35 mm
TUBESHEET TUBE PROJECTION LENGTH :6 mm
NO OF BAFFLES :4
DISTANCE BETWEEN BAFFLES : 2200 mm (Approx.)
BAFFLE THICKNESS : 10 mm
BAFFLE TUBE BORE ID : 51.6 mm
NO OF EXPANSION JOINT :1
NO OF SEALING STRIPS :4
FLOW PATTERN : COUNTER FLOW
TUBE PITCH TYPE : TRIANGULAR
TUBE PITCH LENGTH : 76 mm
DESIGN CALCULATION:
Tube side Gas Inlet temperature = 82 Deg.C
Tube side Gas outlet temperature = 315 Deg.C
Shell side Gas Inlet temperature = 465 Deg.C
Shell side Gas Outlet temperature = 286 Deg.C
Heat Transfer Area = 535 m2
Specific Heat of Sulphur Dioxide = 1.24 KJ/Kg
Specific Heat of Sulphur Trioxide= 0.63 KJ/Kg
Specific Heat of Oxygen = 0.92 KJ/Kg
Specific Heat of Nitrogen = 1.04 KJ/Kg
Gases leaving from 3rd BED = 31785.94 Nm3/Hr
HEAT DUTY OF SHELL SIDE(Q) = M*Cp*ΔT
= 8126473.984 KJ/Hr
= 2257353 KW
LMTD:
ΔT1 = 204
ΔT2 = 150
LMTD = (ΔT1 - ΔT2) / ln (ΔT1/ ΔT2)
= 175.895
Q = U*A* LMTD
2257353 = U * 535 *175.895
U = 23.98 W/m2K
Overall Heat Transfer co-efficient,U = 23.98 W/m2K
CHE CROSS SECTIONAL VIEW:
CHE TUBESHEET CROSS SECTIONAL VIEW:
CHE BOTTOM CROSS SECTIONAL VIEW:
CONTRACT : OXFORD ENGINEERING
Job started from 19-03-2022
• Scaffolding erected for Top dish end and shell side ‘4’ baffle areas upto 20-03-2022
• Insulation removed for Top dish end on 21-03-2022
• Top dish end cutted and removed by 50T crane on 22-03-2022
Top Dish End :

Date : 22-03-2022
 ❖ On 23-03-2022 Scaffolding alteration for shell side ‘4’number of baffle spotted area
window cutting purpose.
❖ On 23-03-2022 Baffle Spotted area insulation removed upto 17:00 Hrs
BAFFLE SPOTTED AREA:

Date: 23-03-2022

❖ On 24-03-2022 1st and 2nd Baffle Window cut down

❖ On 24-03-2022 3rd and 4th Baffle spotted area insulation removed.
❖ On 24-03-2022 Shell Bottom Manhole cut-down and inside accumulated sludge
cleaning done upto 17:00 Hrs
SHELL SIDE BOTTOM MANHOLE INSIDE VIEW

Date: 24-02-2022
4th BAFFLE INSIDE VIEW:
Date: 24-03-2022
3rd BAFFLE INSIDE VIEW:

Date:24-03-2022
 ❖ On 25-02-2022 3rd and 4th Baffle window cut down
❖ On 25-02-2022 All baffles and Shell Bottom manhole inside accumulated sludge
cleaned.
❖ On 25-02-2022 Tubes cutting work started from bottom to 4th Baffle inside tubes (22
number of 2m lengthy tubes cut down.)
2nd BAFFLE INSIDE VIEW:

Date:25-02-2022

1st BAFFLE INSIDE VIEW:

Date:25-02-2022
 Date: 25-03-2022

AFTER CLEANING BAFFLES AND BOTTOM MANHOLE INSIDE VIEW:

BOTTOM MANHOLE:
4th BAFFLE:

3rd BAFFLE:

2nd BAFFLE:
1st BAFFLE:

Date: 25-03-2022

BOTTOM TUBESHEET TO 4th BAFFLE AREA TUBES CUTTING WORK:

Date:25-03-2022
CUTTED TUBES:
HARD SCALE FORMED ON TUBE INNER SURFACE

HARD SCALE FORMED ON TUBE OUTER SURFACE

Date: 25-03-2022
 ❖ On 26-03-2022, 49 Tubes (2m Lengthy tubes) removed, so far 77 tubes removed. (from bottom to 4th Baffle
segment)
❖ On 26-03-2022, Top Tubesheet area grinding work being done.
❖ On 27-03-2022, 200 Tubes (2m Lengthy tubes) removed, so far 277 tubes removed. (from bottom to 4th Baffle
segment)
❖ On 27-03-2022, Top Tubesheet area grinding work being done.
❖ On 28-03-2022, 67 tubes (2m Lengthy tubes) removed, so far 344 tubes removed. (from bottom to 4th Baffle
segment)
❖ On 28-03-2022, Top Tubesheet area grinding work being done.
BOTTOM TO 4TH BAFFLE TUBES REMOVED SEGMENT VIEW:

❖ On 28-03-2022, 30 Tubes (2m Lengthy tubes) removed, so far 30 tubes removed. (From Top to 4th Baffle
segment)
❖ On 29-03-2022, 37 Tubes (2m Lengthy tubes) removed, so far 67 tubes removed. (From Top to 4th Baffle
segment)
❖ On 29-03-2022, Top Tubesheet area grinding work being done.
❖ On 30-03-2022, 277 Tubes (2m Lengthy tubes) removed, so far 344 tubes removed. (From Top to 4th Baffle
segment)
TOP TUBESHEET TO 4TH BAFFLE SEGMENT TUBES REMOVED SEGMENT VIEW:

Date: 29-03-2022
 ❖ On 30-03-2022, 154 Tubes (2m Lengthy tubes) removed, so far 154 tubes removed. (From 4th Baffle to 3rd
Baffle segment)
❖ On 30-03-2022, Bottom Tubesheet Area grinding work being done.
1ST BAFFLE TO 2ND BAFFLE SEGMENT TUBES REMOVED SEGMENT VIEW:

Date: 31-03-2022
❖ On 30-03-2022, 114 Tubes (2m Lengthy tubes) removed, so far 114 tubes removed. (From 1st Baffle to 2nd
Baffle segment)
❖ On 31-03-2022, 230 Tubes (2m Lengthy tubes) removed, so far 344 tubes removed. (From 1st Baffle to 2nd
Baffle segment)
❖ On 31-03-2022, 344 Tubes (2m Lengthy tubes) removed, so far 344 tubes removed. (From 2nd Baffle to 3rd
Baffle segment)
❖ On 01-04-2022, 344 Tubes (2m Lengthy tubes) removed, so far 344 tubes removed. (From 3rd Baffle to 4th
Baffle segment)
❖ On 01-04-2022, Bottom Tubesheet Grinding being done.
❖ On 02-04-2022, Top and Bottom Tubesheet Grinding being done.
❖ On 03-04-2022, Top and Bottom Tubesheet Grinding being done.
❖ On 04-04-2022, Top and Bottom Tubesheet Grinding being done and all baffle plates cleaning done.
❖ On 05-04-2022, Top and Bottom Tubesheet Grinding completed.

BOTTOM TUBESHEET GRINDING AND POLISHING:

 Date:05-02-2022

TOP TUBESHEET GRINDING AND POLISHING:

Date:05-02-2022
ALL BAFFLE PLATES CLEANING:

SEALING STRIPS -TO

AVOID BYPASS OF GASES
BETWEEN BAFFLE PLATES

Date: 04-04-2022
 Date:04-04-2022
❖ On 05-04-2022, Bottom Tubesheet Chamfering completed
❖ On 06-04-2022, Top Tubesheet Chamfering completed
TOP AND BOTTOM TUBESHEET CHAMFERING:
 CHAMFERING/
V-SHAPED
GROOVE

Date:06-04-2022
❖ On 07-04-2022, Bottom Tubesheet Internal Diameter(51.35mm) of Bore checked by Bore Dial Gauge by
inspection Department.
❖ On 08-04-2022, Top Tubesheet Internal Diameter(51.35mm) of Bore checked by Bore Dial Gauge by
inspection Department.
❖ On 08-04-2022, After getting clearance from Inspection Department, Tubes insertion started by manual
lifting.
❖ 10 metres height Scaffolding Erected from top dish for tube lifting purpose.
❖ Total scaffolding height erected from Bottom end to top 24 metres.

Date Tubes Inserted Cumulative Tubes Inserted

08-04-2022 1 1
09-04-2022 33 34
10-04-2022 68 102
11-04-2022 56 158
12-04-2022 81 239
13-04-2022 81 320
14-04-2022 24 344
TOP VIEW OF TUBES AFTER INSERTION:
 6mm Tube
projection

Date: 14-04-2022
❖ On 14-04-2022, 6mm tube projection checked for Top and Bottom Tubesheet as per OEM Drawing by
inspection department and then clearance given for TIG Welding.
❖ On 14-04-2022, Bottom Tubesheet 138 Tubes, so far 138 Tubes TIG welding completed.
❖ On 15-04-2022, Bottom Tubesheet 94 Tubes, so far 232 Tubes TIG welding completed.
❖ On 16-04-2022, Bottom Tubesheet 112 Tubes, so far 344 Tubes TIG welding completed.
❖ On 17-04-2022, Top Tubesheet 150 Tubes, so far 150 Tubes TIG welding completed.
❖ On 18-04-2022, Top Tubesheet 160 Tubes, so far 310 Tubes TIG welding completed.
❖ On 19-04-2022, Top Tubesheet 34 Tubes, so far 344 Tubes TIG welding completed.

TIG WELDING:
TOP TUBESHEET AREA TIG WELDED TUBES:

Date:18-04-2022
Dye Penetrant Test:

Date: 19-04-2022
❖ On 19-04-2022, Dye Penetrant Test Checked for TIG Welded Tubes by inspection department and then
clearance given for Flaring.
❖ On 20-04-2022, Doom welding and flaring Done for top and bottom tubes.
❖ On 21-04-2022, All cut open baffle area windows welded back.
NEW TUBES INSIDE VIEW:
NEWLY INSTALLED ATA-2022 CHE TUBE INLET DUCT CATCH POT :

STIFFNER PLATE
OBSERVATIONS AFTER ATA-2022:
DATA OF CHE TUBE PRESSURE DROP AFTER ATA-2021
DESIGN DP : 230 mmwc
PRESSURE DROP
DATE (mmwc) LOAD(RPM)
18-07-2021 700 6700
22-07-2021 720 6500
26-07-2021 750 6900
15-08-2021 815 6900
19-07-2021 830 6900
25-08-2021 870 6900
13-09-2021 890 6900
26-09-2021 890 6900
03-10-2021 900 6900
10-10-2021 930 6500
18-10-2021 950 6800
24-10-2021 930 6500
21-11-2021 950 6500
12-12-2021 1050 6900
21-12-2021 1120 6500

DATA OF CHE TUBE PRESSURE DROP AFTER ATA-2022

DESIGN DP : 230 mmwc
DATE PRESSURE DROP (mmwc) LOAD(RPM)
08-05-2022 110 6900
15-05-2022 100 6900

FOR ACTUAL BEFORE ATA-2022

Tube side Gas Inlet temperature = 75 Deg.C
Tube side Gas outlet temperature = 277 Deg.C
Shell side Gas Inlet temperature = 462 Deg.C
Shell side Gas Outlet temperature = 316 Deg.C
Heat Transfer Area = 535 m2
Gases leaving from 3rd BED = 31785.94 Nm3/Hr
HEAT DUTY OF SHELL SIDE(Q) = M*Cp*ΔT
= 8126473.984 KJ/Hr
= 2257353 KW
LMTD:
ΔT1 = 310
ΔT2 = 200
LMTD = (ΔT1 - ΔT2) / ln (ΔT1/ ΔT2)
= 251
Q = U*A* LMTD
2257353 = U * 535 *251
U = 16.81 W/m2K
Overall Heat Transfer co-efficient, U =16.81 W/m2K
FOR ACTUAL AFTER ATA-2022
Tube side Gas Inlet temperature = 70 Deg.C
Tube side Gas outlet temperature = 265 Deg.C
Shell side Gas Inlet temperature = 465 Deg.C
Shell side Gas Outlet temperature = 380 Deg.C
Heat Transfer Area = 535 m2
Gases leaving from 3rd BED = 31785.94 Nm3/Hr
HEAT DUTY OF SHELL SIDE(Q) = M*Cp*ΔT
= 8126473.984 KJ/Hr
= 2257353 KW
LMTD:
ΔT1 = 239
ΔT2 = 185
LMTD = (ΔT1 - ΔT2) / ln (ΔT1/ ΔT2)
= 210
Q = U*A* LMTD
2257353 = U * 535 *210
U = 20.00 W/m2K
Overall Heat Transfer co-efficient, U =20.00 W/m2K
FOR DESIGN

Overall Heat Transfer co-efficient, U = 23.98 W/m2K

FOR ACTUAL BEFORE ATA-2022

Overall Heat Transfer co-efficient, U =16.81 W/m2K

FOR ACTUAL AFTER ATA-2022

Overall Heat Transfer co-efficient, U =20.00 W/m2K

COMPARSION OF ABSORBED ACID TEMPERATURE FOR IAT AND FAT BEFORE

AND AFTER ATA-2022:
BEFORE ATA AFTER ATA
DESIGN ACTUAL ACTUAL
ACID IAT FAT IAT FAT IAT FAT
INLET TEMP(DEG.C) 82 82 77 77 77 77
OUTLET TEMP(DEG.C) 118 96 107 83 115 95
FLOW(M3/HR) 193 96 167 130 192 101

COMPARSION OF FAT GAS INLET PRESSURE BEFORE AND AFTER ATA-2022:

PARAMETER LOAD DESIGN BEFORE ATA AFTER ATA

PRESSURE DROP(MMWC) 6900 480 660
6900 460 650

From the above table concludes,

DUE TO LESS PRESSURE DROP IN CHE TUBE SIDE AND 1ST BED COMPARED TO
BEFORE ATA, HIGH GAS INLET PRESSURE GOES TO FAT SO ABSORBED ACID
TEMPERATURE ΔT OF BOTH TOWERS IS RAISED SIGNIFICANTLY, SO NIL SO3
SLIPS TO STACK AND STACK VISIBILITY IS LESS COMPARED TO BEFORE ATA.

ΔT of IAT Before ATA = 30

ΔT of IAT After ATA = 38
ΔT of FAT Before ATA = 6
ΔT of FAT After ATA = 18
BENEFITS OF CHE TUBES RETUBING:
❖ CHE TUBE SIDE PRESSURE DROP IS LOW SO GAS INLET PRESSURE OF
FAT IS HIGH COMPERED TO PREVIOUS YEAR THEN GAS-LIQUID
CONTACT IS GOOD, SO NIL SO3 SLIPS , CURRENTLY STACK VISIBILITY IS
LOW.
❖ IAT GAS OVERLOADING IS REDUCED DUE TO CHE TUBE SIDE PRESSURE
DROP IS LOW, THEN HERE ALSO GAS-LIQUID CONTACT IS GOOD AND
IAT TOP SHELL AREA GAS OUTLET PRESSURE IS LOW DUE TO CHE TUBE
SIDE PRESSURE DROP IS LOW SO FURTHER GAS LEAK IS NOT POSSIBLE
AT THAT AREA.
❖ CAUSTIC CONSUMPTION ALSO REDUCED.
❖ PLANT PRODUCTION ALSO IMPROVED.
❖ NO BACK PRESSURE AFFECTS THE BLOWER DISCHARGE AIR PRESSURE.
❖ BY-PRODUCT STEAM GENERATION ALSO IMPROVED.
WAYS TO PREVENT FURTHER CHE TUBES RETUBING:
❖ AT TEMPERATURES BELOW 205 DEG.C, SUPERSATURATED STATE
OCCURS SO TO AVOID HOT SHUTDOWN NOT TO REACH ABOVE THE
SUPERSATURATED STATE OF SO3 GASES AT SHELL SIDE.(i.e., not to reach
the temperature of CHE shell outlet below 205 deg.C)
❖ MAINTAIN ACIDITY AND MOISTURE OF DRY AIR INLET TO THE SYSTEM
UNDER SPECIFIED LIMIT.
❖ RAW SULPHUR HYDROCARBON CONTENT UNDER SPECIFIED LIMIT TO
BE BUY.
❖ IAT CANDLE INSPECTION AND WASHING TO BE MANDATORLY DONE
EVERY ATA.
❖ IAT SADDLES WASHING AND TROUGH INSPECTION TO BE MANDATORLY
DONE EVERY ATA.
❖ EVERY ATA CHE SHELL BOTTOM MANHOLE INSIDE BOTTOM
TUBESHEET AREA ACCUMULATED SLUDGE TO BE CLEANED UPTO
POSSIBLE LIMIT TO PREVENT TUBE LEAK.