Work Instruction

Title: MAC 1st Stage Intercooler Reference: MMEC-WI-1003

110-ES-101/201
Revision: 1

Effective date: October 2012

Total pages: 15

Revision date: September 2015

Custodian: Signature Date

Head of Static Maintenance Jayagopu Rajagopal

Approved by:

Maintenance Manager Steven Siccard

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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 …………………………………. 5

9. Record Keeping …………………………………………. 14

10. Development Team ……………………………………….. 15

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1. Application
This Procedure applies to the following equipments.
110-ES-101 Air cooler MAC-1
110-ES-201 Air cooler MAC-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, Health, Environment, Risk and Quality
JHA - Job Hazard Analysis

4. General Safety Awareness & PPE

4.1. Observe all the Hazards in the Work Area

4.2. Maintenance job for heat exchanger must always be carried out by personnel trained
and authorized for this purpose
4.3. Ensure that flushing and purging procedure have been completed until the
exchanger free of hazardous product (toxic/poisonous chemical, hot liquid/gases)
before performing maintenance activity.
4.4. Ensure that temperature of both side exchanger decrease sufficiently until below 40
deg C
4.5. Ensure that both side exchanger have been depressurized and drain properly

4.6. Check all the Lifting Gears are having Current Color Code, sufficient SWL for the job
and in good condition

4.7. Be aware the Location of Fire Fighting Equipments

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

4.9. Use all the Personnel Protective Equipments as specified on PTW and JHA

Personal Protective Equipment for this Task

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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5. Environmental Aspects
Disposal of Waste Materials Like used Oil/Grease, Waste Rags, used Gaskets, used
gloves must be according to the Waste Disposal Policy/Rules from the ORYX GTL
SHERQ Department.

6. Tools & Materials Required

6.1. Crane, lifting tackles with the Current Colour Code and in good condition.

6.2. Hand Tools in Good Condition

6.3. Spanners for opening and closing the Channel covers, pipe flanges, etc.

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

6.5. Scaffolding requirement for required maintenance job

6.6. Tube Bundle puller machine

6.7. Bundle Trolley 50 Tons, provided by ORYX

6.8. Hydraulic torque wrench

6.9. Welding machine, grinding machine for plug welding, repair broken welding joint

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

6.11. Spare part for maintenance activity: equipment and piping gasket, tube plug,
welding material. Consumables: cotton rags, grease, emery paper, penetrant oil

6.12. Circulation pump, hoses and solvent for chemical cleaning

6.13. High pressure jet machine and hoses for hydraulic cleaning

7. Permit to Work Procedures

7.1. Obtain the Work Order from the maintenance planner

7.2. Complete the Work Permit procedure and complete necessary supporting document
related to maintenance activity

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 locking procedure for all block valves.

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8. Maintenance Procedure
8.1. Exchanger Inspection
Inspection must be preferably carried out by authorised inspectors. Furthermore,
users/operators must always mind certain matters, such as leakage and the
performance of the heat exchanger. Experience with inspection is necessary to
inspect the heat exchanger properly.

An authorised inspector has been qualified by a certain authority or government.

These authorities have set up different guidelines which operators may be required
to observe when using heat exchanger.

8.1.1 External Inspection

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.

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

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.

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).

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).

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

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. Check the condition of the foundation and anchor bolts.

9. Inspect the condition of the fire proofing cement.

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

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

8.1.2 Internal Inspection

1. Check the condition of internal shell for any corrosion, erosion, and deposits,
welding seam condition and welding joint condition connected to external pipe

2. Check the condition of baffle plate, stiffener plate, and sliding plate for any
corrosion, erosion, deformation, damage or crack.

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3. Check the condition of tubes, and tube sheet for any damages or crack

4. The shell side and outside of the tube can be visually inspected. The inside of the
tubes can be checked by means of borescope or eddy current.

5. Tracing tube or tube joint leakage can be done by hydrotest. Furthermore we can
carry out by the means of eddy current, ultrasound or borescope.

Noting down and storing maintenance data is important for future

maintenance of heat exchanger. This can be done in accordance with the
procedure current at the factory where the heat exchanger has been
installed

8.1.3 Studying Log Books

Take a look at the operational log books for the certain heat exchanger is
important. The data will describe the way the heat exchanger has functioned
during the past time. Check weather the device has been exposed to high
pressure or temperatures. Study the causes and the effect of any deviations.
these may have caused damage.

8.2 Exchanger Cleaning

Cleaning can be done mechanically, chemically or hydraulically. Mechanical and
chemical cleaning can take place on line and off line. Which cleaning method is
selected depends on the type of heat exchanger and the process.

Types of pollution and recommended cleaning method

8.1.3 Chemical Cleaning

1. Obtain the chemical cleaning procedure and schematic diagram from production
department.

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

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.

4. Chemical cleaning method

 Rinsing with water
 Washing with solvent
 Washing with soap or agent
 Washing with acid
 Washing with an alkaline solution
 Bacteriological treatment
 Combination of first six method

5. In the case that chemical cleaning will lead to heavy pollution, special precaution
must be taken. Solvent cleaning and removed deposits must be contained in special
bucket. Serious pollution in effluent treatment may occur if those contaminants
released to common trench or storm water path.

8.2.2 Hydraulic Cleaning

1. Cleaning by high pressure jet must be done by trained and authorised personnel

2. Separate PTW for HP cleaning shall be received from production and all
precaution that mentioned must be followed strictly.

3. All the equipment, hoses, connection, gun must have been ensured in good
condition.

4. Abrasives, chemical solvent or hot water may be used to improve cleaning

performance.

5. All removed deposits and used chemical which may be hazardous must be
contained in special bucket or container.

8.2.3 Mechanical Cleaning

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.

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.

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

8.4. Dismantling of Heat exchanger

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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 inlet and outlet pipe elbow on water side by using crane
8.4.2.
Remove the flexible joint of inlet and outlet line on water side
8.4.3.
Remove the gland packing ring on the floating head side.
8.4.4.
Remove the gland packing/o-ring on the floating head side
8.4.5.
Remove the channel head cover on fixed head side
8.4.6.
Start to pull out the bundle according removal step by step mentioned in the
manual book
Bundle Removal Step Drawing
Step 1A.

Step 1B.

Step 2.

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Step 3.

Step 4.

Step 5A.

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Step 5B.

8.4.7. Take care while removing the Channel head Cover. Remove all the bolts after
supporting the channel cover by crane properly.
8.4.8. Remove the Channel Head Cover from the Shell and Tube Sheet.
8.4.9. Remove the Gland ring and packing

8.4.10.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.

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

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

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

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

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

8.4.16.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.

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

Be sure that all the Lifting Tackles are having current color code
and meets the required SWL.

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

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.

8.7. Reassembling Shell and Tube Heat exchanger

8.7.1. 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

8.7.2. 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.

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

8.7.4. Fix back the bundle with proper care into the shell as the way it was taken out.

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

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

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

8.8. Hydro test Procedure for the Exchanger

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

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

8.8.2. 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.

8.8.3. 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.

8.8.4. 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.

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

8.8.6. 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.

8.9. Checking the Tubes and Tube Joint Leaks

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

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

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

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

8.10. Repairing the Leaking Tubes

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8.10.1. 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.

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

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

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

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

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

The Outer rows of tubes may not have the acces to plug it at
floating head side,such a codition the floating head required to
cut for plugging .

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

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

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

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

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

8.10.12. 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.

8.10.13. 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

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

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

8.11. Fixing the Channel head

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

8.11.2. 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.

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

8.11.4. Position the Gaskets in the tube sheet properly. (Cam profile,graphited)

8.11.5. 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.

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

8.11.7. 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.

8.11.8. 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.

8.11.9. Deblinding the lines as per the blind provided.

8.11.10. 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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