Work Instruction

Title: BAC 1st Stage Intercooler Reference: MMEC-WI-1004

110-ES-102/202
Revision: 1

Effective date: October 2012

Total pages: 11

Revision date: September 2015

Custodian: Signature Date

Head of Static Maintenance Jayagopu Rajagopal

Approved by:

Maintenance Manager Steven Siccard

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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Content
Page

1. Application ………………………………………………….. 3

2. Purpose …………………………………………………….. 3

3. Definitions …………………………………………………… 3

4. General Safety Awareness & PPE ……………………….. 3

5. Environmental Aspects …………………………………….. 4

6. Tools & Equipment Required …………………………….. 4

7. Permit to Work Procedure (PTW) ………………………... 4

8. Maintenance Procedures …………………………………. 4

8.1 General advice and dangers

8.2 Cleaning of Exchangers
8.3 Chemical cleaning
8.4 Mechanical cleaning
8.5 External inspection
8.6 Checking the tube joint leaks
8.7 Plugging the leaking tubes
8.8 Hydro test procedure for the exchanger
8.9 Reassembling shell and tube exchanger

9. Record Keeping …………………………………………. 11

10. Development Team ……………………………………….. 11

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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1. Application
This Procedure applies to the following equipments.
110-ES-102 Air cooler BAC-1
110-ES-202 Air cooler BAC-1

2. Purpose
The purpose of this procedure is to provide a safe, practical and consistent method of
carrying out the Maintenance in Exchanger which is critical part of the plant operation.
This procedure is intended to provide a source of reference for Maintenance crew.

3. Definition
MSDS - Material Safety Data Sheet
PPE - Personal Protective Equipments
PTW - Permit to Work
SHERQ – Safety department

4. General Safety Awareness & PPE

4.1. Observe all the Hazards in the Work Area

4.2. Check all the Lifting Gears are having Current Color Code and in good condition

4.3. Check all the Hand Tools are in the Good Condition

4.4. Complete all PTW Procedures before Starting the Work

4.5. Be aware the Location of Fire Fighting Equipments

4.6. Check the MSDS for the Chemicals/Liquids Going to use

4.7. Use all the Personnel Protective Equipments as specified on PTW and SMP

Personal Protective Equipment for this Task

1 PPE PPE PPE

Coverall √ Safety Hat √ Rubber Gloves

Leather Gloves √ Wool Socks √ Safety Shoes √
Safety Glasses √ Face Shield √ PVC Raincoat
Canvas Cap Gum Boots
Ear Plugs √ Safety Harness √ O2 Monitor √
Emergency shower Isolation Locks √ CO Monitor
Dust mask √ LEL detector

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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5. Environmental Aspects

Disposal of Waste Materials Like used Oil/Grease, Waste Rags; used Gaskets
are to be according to the Waste Disposal Policy/Rules from the ORYX GTL
SHERQ Department.

6. Tools & Materials Required

6.1. Lifting tackles with the Current Colour Code and in good condition.

6.2. Hand Tools in Good Condition

6.3. Spanners for providing the blinds as per the blind list.

6.4. Spanners for opening and closing the Channel covers.

6.5. Some basic tools needed for inspection are pointed scraper, Steel measuring tape,
Steel rule, Wire brush, Flashlight, Magnifying glass, Inspection mirror.

6.6. Scaffolding requirement for opening Channel cover, Test ring providing, blinding and
Deblinding and repair works.

6.7. 250 Ton Crane required for Removing and boxing up the bundle with puller

6.8. Hydraulic troque wrench

6.9. Tools required for tube repair – Tube cutter, Reamers & wall thickness reducers,
back out punches, Hydro test pump and measuring instruments.

7. Permit to Work Procedures

7.1. Check the Work Order in SAP

7.2. Complete the Cold Work Permit procedure

7.3. Check the necessary Process Isolation is completed from Operation Side

7.4. If required use Electrical Isolation Permit / Lock out & Tag out procedure for
downstream Rotary Equipments.

7.5. Follow Hot work Permit procedure, if Hot Work arise

7.6. If required use valve Interlocking procedure for all block valves.

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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8. Maintenance Procedures
8.1. General Advice / Dangers

8.1.1. Make sure the Unit is NOT under Pressure, Temperature and is empty before
starting the Work

8.1.2. Cool the heat exchanger before starting the work; If possible, allow the heat
exchanger to stand and cool overnight.

8.1.3. Ensure the proper purging or flushing is carried out on the equipment

8.1.4. Once again crosscheck all the PTW Procedures are carried out and positive
isolations on the equipment

8.1.5. Blinding should be done as per the production department blind list.

8.2. External Inspection

8.2.1. Inspect all the equipment and connected piping supports and saddles,
supporting structures, foundations, associated platforms and access ladders,
appurtenances, exchanger support-to-equipment welds, skirt-to-equipment
welds, and gusset-to-shell welds for irregularities.

8.2.2. Inspect the condition of the Insulation. Remove the external insulation for visual
inspection as required.

8.2.3. Inspect for bulging of the exchanger surfaces where insulation has been
removed. When bulging is noted, the insulation must be removed and the visual
inspection extended.

8.2.4. Inspect the condition of the shell, heads and nozzles for deviations or defects.
(Example would be discolouring caused by excessive heat or excessive
corrosion under-insulation).

8.2.5. Ascertain the extent of moisture ingress through the insulation, and possible
deterioration of the external shell surface. (Corrosion and scale build-up in lower
sections).

8.2.6. Inspect the cleanliness of the Sliding saddle and check whether any thing
obstructing the movement of the exchanger.

8.2.7. Thorough inspection must be conducted on the nozzles, with special emphasis
on the gasket sealing faces of the flanges, and nozzle-to-shell welds.

8.2.8. Check the condition of the foundation and anchor bolts.

8.2.9. Inspect the condition of the fire proofing cement.

8.2.10.Check the condition of the earthing lugs two numbers.

8.2.11.Check and clean the tell tale holes in the nozzle reinforcing pads.

8.3. Chemical cleaning

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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8.3.1. Obtain the chemical cleaning procedure and schematic diagram from production
department.

8.3.2. Establish all the Temporary connections and arrangements for cleaning system.

8.3.3. Clean the exchanger to dilute chemicals used as per the chemical vendor
recommendations after desirable level cleaning and dismantle all the chemical
cleaning arrangement.

8.4. Dismantling of Heat exchanger

Before disassembly. the user must ensure that the unit has been
completely shut down and depressurized, vented, drained, and
neutralized and/or purged of hazardous material.

8.4.1. Remove the bolting between the shell and Channel Head Cover by using
Hydraullic Torque wrench after making proper markings

Use letters and numbers by punching and mark the

exchanger identification numbers on all parts such as Shell,
tube sheet and Channel cover.

8.4.2. Take care while removing the Channel head Cover. Remove all the bolts after
supporting the channel cover by crane properly.

8.4.3. Remove the Channel Head Cover from the Shell and Tube Sheet.

8.4.4. Remove the Gland ring and packing

8.4.5. Assemble a bundle support skid which is long enough to hold the entire bundle.
Place the skid upto snug under the fixed tube sheet axis, so that the bundle will
slide along the inside corners of the skid beams.

8.4.6. Jack the Tube bundle from the shell by means of jack bolt or by Hydraulic jack.

8.4.7. Fix the tube bundle pulling package with the tube bundle and pull out the
exchanger bundle by properly supporting it.

8.4.8. Extreme care should be taken to avoid any damages to the tubes baffles.

8.4.9. After pulling out lower the tube bundle in a desirable place.

8.4.10.Check the gasket seating surface in the Shell and tube bundle for any damages.

8.4.11.Check the bundle for any damages in tube surfaces, deposit in the surface of
tubes, scaling, external pittings, damage to the baffles ,tie rods and Long baffle.

8.4.12.Clean the external side of the tubes by hydro jetting if required.

Be sure that all the Lifting Tackles are having current color code

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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and meets the required SWL.

Support arrangements for removing tube bundle from shell in horizontal position.

8.7. Mechanical cleaning

8.7.1. If the tubes are not completely blocked they can be cleaned with a nylon brush
together with frequent washes with hot or cold water. Alternatively a low-
pressure water or steam jet can be used.

8.7.2. Rods or drills must not be used in an attempt to remove scale as this invariably
causes broken tubes. If a tube is completely blocked it is best to leave it rather
than to risk breaking through the tube wall and that tube to be plugged.

8.7.3. Cleaning by brushing, low-pressure water or steam jet can then be carried out.

When cleaning a tube bundle, tubes should not be hammered on

with any metallic tool and, in case it is necessary to use
scrapers, care should be exercised that the scraper is not sharp
enough to cut the metal of the tubes.

8.8. Reassembling Shell and Tube Heat exchanger

8.8.1. Check that gaskets and gasket seating surfaces in the shell and shell seating
side of the tube sheet should be thoroughly cleaned and should be free of
scratches and other defects. Gaskets should be properly positioned

8.8.2. It is required that when a heat exchanger is dismantled for any cause, it be
reassembled with new gaskets (SS304L Metal jacketed with graphite filler) This
will tend to prevent future leaks and/or damage to the gasket seating surfaces of
the heat exchanger.

8.8.3. Any damage at a gasket joint should be rectified and not permitted to persist as
it may result in Leakage.

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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8.8.4. Fix back the bundle with proper care into the shell as the way it was taken out.

8.8.5. When fixing back the exchanger make sure that match marking is coincide with
the earlier marking.

8.8.6. Check the tube sheet alignment and level of the bundle when inserting the
exchanger inside the bundle.

8.8.7. Position the gland ring over the floating head of tube bundle and fix the gland
packing

8.9. Hydro test Procedure for the Exchanger

Inspect all the nozzles, flanges, supports and exposed parts in the exchanger, then test
the exchanger as follows:

8.9.1. The exchanger shell side lines should be blinded before to be tested as close as
possible.

8.9.2. Isolate the Instruments and relief valve connections as per the requirement.

The process side should be completely free from working fluid

before commencing the test.

8.9.3. Fix the test ring with temporary gasket in the tube sheet side and provide all the
studs. The studs should be tightened with proper torque value. Do not make
over tightening.

If Bundle was not pulled for gasket renewal means during the
removal of head cover tube bundle should be firmly fixed by
suitable arrangement with shell to avoid the slackness of the
bundle to shell gasket.

8.9.4. Then connect the lower side branch to the water supply with valves, pumping
arrangements.

Hydro test shall be carried out with fresh water having chloride
content less than 200 PPM .The PH value should be kept between
6 to 8.

8.9.5. Fill the shell with water through the lower service side branch allowing the
displaced air to be vented through the upper service side branch.

8.9.6. Pressurize the unit on service side to the test pressure given on the nameplate
of the exchanger or check the data sheet of the Equipment or as per the
Inspection department recommendation.

Be attentive while hydro testing to prevent over pressurizing

and damage to the exchanger.

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
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8.10. Checking the Tubes and Tube Joint Leaks

8.10.1. Pressurize the exchanger on shell side as detailed in the hydro testing
procedure.

8.10.2. Identify leaks between the tubes, tube to tube sheet joints and shell weld joints.

8.10.3. If any defects or leaks were found mark the location to carry out the repair work.

8.10.4. Clean the tube sheets for further inspection if required by the Inspection
department.

8.11. Repairing the Leaking Tubes

8.11.1. Providing that the heat exchanger has sufficient over-capacity and only a small
percentage of the total tubes are broken, the leaking tubes may be plugged
rather than replaced.

8.11.2. Clean the tubes by Water Jet, followed by air blowing and ensure all the tubes
were dry.

8.11.3. Clean the Tube sheet by buffing. Ensure that is no sign of corrosion, scales etc
on the tubesheet

8.11.4. Clean the tube hole with the Wire Brush and if necessary use emery paper.

8.11.5. Obtain Welding procedure specification before carrying out the job.

8.11.6. Defective tube shall be ruptured away from the tube sheet before plugging.

8.11.7. Plugs shall be checked for UT to identify the sub surface defects.

8.11.8. Check the data sheet to get the Plug details like Material, dimension of the Plug
and type of plugging method.

8.11.9. Make sure that both the tube hole and surface of the plug are dry and free from
dirt and dust.

8.11.10. Tubes and tube sheet shall be thoroughly cleaned by emery paper and
subsequently cleaned with TCE before welding.

8.11.11. Insert the Plug into the Tube Hole and press the Plug inside by means of
mechanical method like slight hammer blows.

8.11.12. Check the Projection of the plug from the Tube Sheet. This dimension is to be
confirmed by Equipment vendors manual. In general 2/3 portion of the plug
should be inside the tube and 1/3 portion should be left outside.

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
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8.11.13. Make the welding between plug and tube sheet as specified in the welding
procedure specification.

Preheating of the tubesheet before welding should be as per

the Welding procedure specification sheet

T Tarpaulins to cover the welding activity especially while working in

the Higher elevation to avoid welding porosity

8.11.14. Ensure that adjacent weld joints are not falling under Heat affected zone.

8.11.15. After making the repair work, Rehydrotest the exchanger to verify the condition
of the exchanger.

8.12. Fixing the Channel head

8.12.1. Remove the Test ring from the Bundle and secure and preserve the test ring
properly.

8.12.2. Check that gaskets and gasket seating surfaces, partition grooves in the tube
sheet and it should be thoroughly cleaned and should be free of scratches and
other defects.

8.12.3. Any damage at a gasket joint should be rectified and not permitted to persist as
it may result in Leakage.

8.12.4. Position the Gaskets in the tube sheet properly. (Cam profile with graphite 4
Thk.)

8.12.5. Then fix the channel head cover with the shell and Tube Sheet by using the new
gasket ensure the correct seating of the gasket in the Groove and with correct
match mark.

Position the studs at nozzles before positioning the head cover.

8.12.6. Tighten the Channel covers with the Tube Sheet by using Hydraulic torque
wrench after making necessary repair work.

8.12.7. Follow the steps for the Hydro test on the Tube bundle, after fixing the Channel
head cover to determine the Leakage and gasket tightness of the Channel cover
with the Tube Sheet.

8.12.8. Follow the steps for the Hydro test on the Shell side, after fixing the Channel
head cover to determine the Leakage between the shell and tube sheet.

8.12.9. Deblinding the lines as per the blind provided.

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BAC 1st Stage Intercooler Reference: MMEC-WI-1004
110-ES-102/202 Revision: 1
Page: 11 of 11

8.12.10. Clean the area and close work order in the SAP.

9. Record Keeping

Record all the abnormalities, results of inspection and repair action details to
be updated in the history sheet.

10. Development Team

Leader of the Development Team : Vishwanadha Raju
Member of the development Team : Mohandas.S

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