TUV INDIA – EXPERTISE FOR YOUR SUCCESS

1
 Why shutdown required ?

 To ensure safe and reliable operation

 Periodic maintenance
 Integrity check of equipment

Some refinery cases :

Explosion in FCCU Reactor video

Explosion due to ruptured elbow video

2
3
4
5
 Working of crude distillation unit

6
 7

FIN FAN COOLER INSPECTION

To ensure safe and reliable operation
 1. EXTERNAL INSPECTION :

 Tube fins condition to be checked visually for any mechanical damage or deformation

 Check for surface corrosion on nozzles, header box, drain and vents.

 Check if paint is damaged.

 Identify any leaky point.

 Check for earthing strip connection, support and frame

 Check for PG /TG condition.

8
 2. INTERNAL INSPECTION

 In case of plug type header box, about 10% of plugs shall be opened in M&I shutdown. Plug marking to

be done.

 The tube bore shall be inspected by using fibro scope / narrow beam light source.

 If the tubes are found badly fouled, all the plugs shall be opened and thorough cleaning of the tubes shall

be done.

PRECLEANING INSPECTION :

 Take photos of all components in as it is condition.

 Note down the area of heavy deposition , their appearance, color and if required collect sample.

9
10
Hydro jet cleaning of tubes
 POST CLEANING INSPECTION:

 Tube plug thread to be checked for damage,

 Tube sheet internal thread for plug to be checked for any possible damage or erosion.

 Header box internal inspection to done through plug holes, any sign of corrosion erosion pitting shall be

checked.

 Tube choking to be checked,

 Tube end thinning shall be checked.

 Inlet outlet nozzles shall be check for any abnormality.

 All flanges gasket seating face and serration to be checked.

11
 Plug thread visual inspection Plug opening process

12
 Wall thickness measurement

 Header box (top, bottom and both side plate) thickness to be measured.

 Inlet/outlet nozzles thickness to be measured.

 Drain and vent thickness to be measured.

 Inlet /outlet piping bends thickness to be measured.

 If thickness loss observed is more than corrosion allowance, then remaining life

shall be calculated as per API 510.

13
 Tube inspection method and NDT
 Tube integrity to be ensured by RFET / IRIS.

 In case of repair/ alteration, approved procedure to be used and applicable codes and standard to be

followed (API 661, API 510, API RP 571, ASME SEC IX)

 DPT as per ASME SEC VIII DIV -1 APP-8

14
 Hydro test of fin fan cooler :
 All new gasket of plug should be used.

 Hydro test to be conducted as per approved procedure.

 Two PG required at top and bottom

 Calibration to be checked for both PG.

 PG range should be of 1.5 to 4 times of test pressure.

 Pressure holding time should be of 30 minutes.

 In case of pressure drop, leak location to be identified.

 Tube plugs at both end to be checked for any leak.

 If plug leak observed, then pressure to be reduced to 0, and tightness to be checked of plug.

 In case of internal thread of header box damaged then plug to be seal welded.

15
 Retubing of fin fan cooler video

16
 Inspection record :

 Observations in brief,

 Thickness and gauging record of all components including data readings prior to commissioning.

 In case of Repair / replacement jobs to be carried out :

 WPS/PQR/ITP

 Radiographic and other NDE results

 Procedure for stress relieving

 Electrode / filler wire specifications

 Material specification

 Stages of NDT required.

 Pressure test records.

17
 Record of material replacement
 Document record :
The data report should include the following information:

 Manufacturers Serial Number

 GA drawing

 Owner-Users Identification Number

 Pressure vessel dimensional data (width, height, diameter, etc.)

 Material of construction

 Original wall thickness data for pressure vessel and dished heads

 Original code of construction including NDE method

18
19
20