HEAT EXCHANGERS

During the CNC 2022 TAR, twenty-nine (29) exchangers were opened, cleaned,
inspected and in instances where repairs were deemed necessary, the affected
exchangers were serviced accordingly. Each exchanger was also subjected to tests
such as Eddy Current Testing (ECT) and Hydro or Leak Testing etc. to ensure that all
exchangers were in suitable condition before reassembly and handback to
Operations. Additionally, the 105-C and 172-C were replaced/upgraded, in which
both the bundle and shell were replaced entirely. The 172-C was upgraded to a
welded channel to tube sheet arrangement similar to N2000 and the 105-C was
replaced in kind with the addition of two nozzles for level transmitters to be mounted
for monitoring purposes.

WO# PE# Equipment Description WO# Description

st
1 Stage Air Compressor Open and inspect intercooler -
235752 101JCA
Intercooler Bundle to be removed
2nd Stage Air Compressor Open and inspect intercooler -
268077 101JCB
Intercooler Bundle to be removed
4th Stage Air Compressor Open and inspect intercooler -
235755 101JCD
Intercooler Bundle to be removed
247195 101JTG 1st Stage Gland Condenser Open and inspect tube side
247196 102JTG 2nd Stage Gland Condenser Open and inspect tube side
HTS Effluent BFW Preheater /
235758 103C1 Open and inspect tube side
Steam Generator
HTS Effluent BFW Preheater /
235832 103C2 Open and inspect tube side
Steam Generator
Open and inspect tube side -
235833 103JTC Combined Surface Condenser
Anodes to be replaced
247197 103JTG 3rd Stage Gland Condenser Open and inspect tube side
Replacement of heat exchanger
263521 105C CO2 Stripper Reboiler
bundle
LTS Effluent / LP BFW
235834 106C Open and inspect tube side
Exchanger
248851 110C Lean Solution Cooler Open, inspect and repair
CO2 Stripper Ejector Steam Open and inspect tube side -
248680 111C
Generator Flange machining required
Methanator Feed/ Effluent To wash and conduct internal
263523 114C
Exchanger inspection (He test)
248852 115C Methanator Effluent Cooler Open, inspect and repair
Ammonia Converter Effluent
247192 123C1 Cooler / 2nd Boiler Feed Water Open and inspect tube side
Preheater

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 subsequently plugged. All turbulators were reinstalled, however only partial
lengths were able to be re-inserted into the tubes due to restrictions during
installation. The exchanger was reassembled and placed back into service
without issue.

5. CO2 Reboiler, 105C – The 105C exchanger was replaced in kind during the
turnaround. All piping flanged joints were reassembled and torqued, and the
exchanger was reinsulated. This exchanger is fit for service and should be
inspected at the next recommended inspection interval or TAR for acquisition
of base line in-service data.

6. LTS Effluent/LP BFW Exchanger, 106C – In addition to the pre-planned

maintenance activities and NDE, a blue impression test was performed on the
eastern channel cover to identify areas of none contact on the gasket seating
area. This channel head cover was taken to a machine shop to conduct flange
run out checks, the results of which were deemed acceptable. On site run out
checks were conducted on the eastern channel flange face, and it was
determined that machining works were required. The flange machine works
were completed with a final depth of 7.64mm achieved and the channel cover
bolt surface was machined from an as found depth of 8.58mm to a final depth
of 10.64mm. The blue impression test was repeated and deemed acceptable.
It should be noted that issues were noted with the first machining contractor
while conducting works on the channel flange, however this was rectified by a
second machine shop and the desired gasket crush was obtained. The
exchanger was reassembled and no issues noted.

7. CO2 Stripper Ejector Steam Generator, 111C – Additional to the planned

maintenance works on the 111C, a blue impression test was performed on the
western channel cover to determine if sufficient contact on the gasket seating
area was present. The channel head cover was then collected by a machine

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Proman TAR Executive Report – CNC 2022 TAR