Inspection 4 Industry LLC Home yl4l Academy Dia you find this article useful? Click on below Like button! Home I4| ACADEMY 41 Academy Courses ‘Aramco API Classroom APLCPO Hours APLSIFE Training APLS10 Training APLSTO Training APLESS Training APLST1 Training -APL580 Training [ASME Training Course ASME DC Training ‘Quality Control Training ‘CWLEndorsement Training Mi Academy Contact GENERAL ARTICLES ‘Third Party Inspection Vendor Inspection Factory Acceptance Test Inspection and Test Plan ‘Commodity Inspection MdGeneral Articles y4Fix Equipment wRotary Equipment yE & | Equipment Heat Exchanger Inspection ‘Tne Heat Exchanger Inspection article provides you with information ‘about the Inspection ofthe heat exchanger and heat exchanger testing uring the manufectuing phase, as well as in-service inspection In ‘operating units. You may want to review shell and tubs heat exchanger Inspection procedure and related inspection and test plan. Shell and Tube Heat Exchanger Inspection in Manufacturing Shop “Tne construction code for shell and tube heat exchangers is ASME Code Section Vill, and it covers the minimum requirements for design, ‘materials, fabrication, inspection, testing, and preparation for inal oliver ‘Alter the 2003 addenda of ASME Code Section Vill is 1, the design of the shell and tube neat exchanger needs to be done based on Subsection In UHX part. The design based on TEMA, or any similar code might be ‘accepted which meeting the requirements of UHX part. ‘The heat exchanger stil Is a pressure vessel and all requirements for [ASME pressure vessel does apply for heat exchanger as woll. We are Going to avold to repeat those requirements for the heat exchanger. You ‘may review peussure vessel inspaction ancl for those requirements. There are several inspection requirements that only apply to the heat ‘exchanger and not regular preseure ves: Tube Inspection The tube outside clameter,nsde diameter, thickness, and ovalty shal be checked before the bulding of the tube bundle. You need to reer to wet in Touch Search this Site! More than 600 Articles! Cy Saudi Aramco API 510, API 570, API 653, and API 571 Classroom LoginIndustrial Inspection ‘Aust contrl Plant inspection Coating Inspection Pre-Shipment Inspection Vendor List FIX EQUIPMENT Pressure Vessel Heat Exchanger Piping System Industrial Vave ‘Steam Boiler ‘Storage Tank Process Heater ROTARY EQUIPMENT Ccontritugal Pump Contritugal Compressor Reciprocating Compressor Gas Turbine Steam Turbine Fan & Blower E&I EQUIPMENT Electric Generator Electric Motor Power Transformer Control Pane! ‘Switchgear Power Cable GET IN TOUCH About Us Contact Us My ASME Section II to get the acceptance tolerances. For example, If your tube material Is SA.179, you have to refer tothe SA 4179 and that wil refer you to the SA 450 ( Specification for Genova Roquirements for Carbon, Fert Alo, and Austenite Aloy Steel Tubes) for acceptance tolerance. YoU have to use your caliper, machinist ruler, ‘tc, to make these measurements and make sure the vales fall within acceptance range. Tube Bundle Inspection ‘The bundle dimension shall be checked based on the approved drawing The batfle diameter and distance between them shall be contolled and ‘mae the accoplance tolerances in the drawing ‘The tightness of stay bolls and spacers must be controled. The shel cleanness 1d and make sure the inside welds are complete and are ground as per drawing requirements yeds to be ved Tubesheet Inspection ‘The Tubeshest shall be inspected before weling tothe shell. The hole iameter, grooves dimensions, dling pattem, the thickness ofthe tubesheet ane surface fnish shall be measured and checked agins ‘acceptance tolerances in the approved drawing ‘Tye tube colin shallbe checked based on customer spectfeation, The wall reduction (ater roling) and depth of rol shall be measured and shall ‘meet the customer specification, The wal reduction should not be less ‘han 5% and should not be more than 8% ofthe tube wal thickness, Leak Testing of Seal Weld (Tube to Tubesheet) Ir seal welding considered, then the leak tet willbe a mandatory requirement. The shell sie wil be subjected tothe air pressure, né ‘water and soap sluton wil be sprayed to the tubesheet to make sure all seal wolds are detec ree. The buble wil be developed if there was any welding detect such as crack, pinhole, te Shell le Hydrostatic Testing ‘Alter manufacturing completion, the heat exchange shell side willbe subjected tothe hydrostatic testing. The test pressure amount shal be consstent wih the vale indicated inthe approved drawing. The hokting time shall be based on the supplier approved test procedure, Tho pressure gages calloration and range shall be controlled. The pressure gage range shal be within 1.5 thr 4 times of test prssure. The shall body and welding seams shall be Inspected. The tubeshoet also shall be checked, No leakage i allowes The test pump hose shall be disconnected, and no pressure drop is alowed. The test result willbe salstactory if no leakage being observed and no pressure being dropped wile the shel side was under pressure, Tubeside Hydrostatic TestingPrivacy Policy ‘We wit be updating and growing hs se wth more and mere of indus inspecton 1 atc. Please subecnbe to my monthly rnowseter so you dont miss a thing Enter Your Fit Name(optional) (Ol understand tat you wi use ‘After successful completion of shell side hydrostatic testing, the bonnets are assombled, and tube sie i subjected to hydrostatetstng. Simla, the amount of test pressure shal be as te one indicated Inthe approves drawing. Other requirement is smlr tothe shol est. No leakage and pressure drop shal be observed whe the tue sid is under pressure. ‘ed Party nso for Shall and Tube aa! Exchangar atte proves Yo a procedural content for heat exchanger inspection. Review folowing Standard nsaacon and Test Pin fr Shella Tuba Heat Exchanoar ‘You might be inerested in reviewing folowing read aris Ha Exchanger Thasey in Tube Haat Exchanoa asaction ‘Tied Party Inspection for Fin Tbe Heat Exchanger Inspection and Tes ian or Fin Tube Heat Exchanger Shell and Tube Heat Exchanger Application pa i ‘Shell and Tube heat exchangers are the most popular ype in the industry, ‘This type is made from 3 components as listed below: + Two heads (one rear head, and the other one stationary head) + Shall + Tube (One fui isin the ube side and the other one in the shel side, The heat transfers done through the tube wall ‘So your heat exchanger with more tubes will have mere heat transfer surfaces, and at the same time will have a higher heat exchanger diameter, ‘There are diferent kinds of shell and tube heat exchangers with diferent ‘applictions.The reason for the high amount of applications is that they are easy to maintain. Besides, the shell and tubs heat exchanger isthe only type that can be signed and operated ai a temperature greater than 360 degrees. centigrade, a8 wel asin pressure higher than 30 bar. In-Service Inspection of Shell and Tube Heat ExchangerThe In-Service Inspecton code for shell ang tube heat exchangers is APL ‘STO 510, The other API recommended practices and codes also have to be used in with this Code, ‘Some of these Recommended Practices are API RP 572, API RP 577, ‘and API RP 571, and also construction code sections might be used, such ‘a8 ASME Cade Section Vil and ASME Code Section IX For repair, tho roquiroment of API STD 510 or ASME-PCC-2 needs to be The tile of ASME-PCC-2, which was fst published in 2006, is pair of Pressure Equipment and Piping.” Please note: f your shell and tube heat exchanger is “U" stamped ang YoU need to do the ropa, you have to use a Repair Organization holding {anR" Stamp from the Natonal Board Inspection Code ‘The API 510 Prossure Vossel Inspectors are qualified persons to perform shell and tube heal Exchanger inspection. You may also review the Industial Plan Inspection article What are the Important Items in the Shell and Tube Heat Exchanger Inspection in Overhaul? ‘Shell and Tube Heat ExchangorInspectons are categorizes inthe following way Shell and Structure in Heat Exchanger Inspection + Neutralization of Austentie Stainless Steel shell clads, line or weld ‘overlay, which contains H2S service. The process needs to be donebased on approved procedures by a corrosion engineer. + Noutalizaton is also required fr shell material with admiralty brass to reduce the risk of SCC, + Newtalizaton of thermocouples, i necessary, and doing dye penetration test + Sampling trom shell fouling and coresion products and making fab analysis and making Interpretation by corrosion engineer i nevescary) + Cutting small area of isulation sheet and removing the insulation and doing visual inspection for any sign of corrosion under insulation + Thickness measurement of aifrent parts of shell and shell nozzles and making cortosion rate and remaining + Inspection of shell cleaning ane approval. water jtting et. cking inside surface for any cladding, tn failure or separation + Inspection of Shel lange gasket seating area for any erosion, ddamage and cracking + Inspection of longitudinal and cicumferental weld joins, inlet and outlet nozzles, reinforcement pads and small bore connections for ‘any crack, corrosion and mechanical damage and deformation + Dye ponetration test on wed joints that are susceptible o cracking, austenitic Mange face, weld overlay and cladding surface and ‘exchangers exposed to amine and caustic + Hydragan blistering inspection in hydrogen services (hand lamp procedure) + Hoat exchanger suppor, steel structure, foundation, bol and nut Inspection culation Bonnet in Heat Exchanger Inspection + Thickness measurement and making corrosion rale and remaining fe calculation + Girth lange inspection for comosion and erosion + Intomal surface inspection for corrosion and fouling + Painting inspection of external surace + Dye penetration or magnetic particle examination of weld jonts| Tube Bundle in Heat Exchanger Inspection + Taking care inthe pulling out of tube bundle to avid any mechanical damage + Sampling trom tube side fouling and corrosion products and making lab analysis and making itorpetaion by corrosion engineer (t necessary) + Contoing of water jetting or tancing cleaning process + Convoling wre brushing process of nner tube edge and roling area (preparation for ID measurement)‘+ Inside diameter measurement in tubes and tubes rolling areas: Rate off and accordingly phigging the tubes when thelr OD reaches to the ID plus one thickress + Retubing of tube bundle more tan 10% of tubes reach the above rejection limit + Inspection from tube bundle components such as tubesheet, tube, tie rods and spacers, traneter bates or support plate, Impingement af, floating head lange and loatng head backing device + Inspection from intemal sutace of tubes for corrosion and fouling + ling outa sample tube for sectioning and corrosion anlaysis if necessary + Retubing wnen sectioning result proves the thickness is hal ofthe ‘ominal value + Visual inspection and dye penetration test rom tube to tubes seal or strength weld + Eddy curont testing itis necessary Channel in Heat Exchanger Inspection + Thickness measurement and making corrosion rate and remaining fe calculation + Inspection of gaskel seating area, pass parton and nubbing for corrosion and deformation + Inspection of intemal surface for fouling, corrasion and soundness of Hinings (any) + Balance helo inspection fr corrosion an erosion + Welzing joints inspection for ary possible cracks + Reinforcement pad inspection and doing soap testi necessary + Cathoie protection anodes inspection and replacement ifnecessary + Diaphragm and division box visual inspection and dye penetration {est of ciaphragm for any possible cracks (for high press exchangers) Channel Cover in Heat Exchanger Inspection + Thickness measurement and making corrosion rate and remaining Ife calculation + Inspection oF gasket seating area for corrosion and deformation + Inspection fr internal surtace for fouling, ner, ladaing and coating soundness + Soap test in channel cover with ter + Liting lug wel joint inspection for any possible crack Floating Head Inspectior + Thickness measurement and making corrsion rate and remaining Me calculation + Inspection of gaskel seating area, pass parton and nubbing for any possible corrosion and deformation + Girth lange weld joint inspection for any possible crack and + Intomal surface inspection for corrosion and fouling ané soundness finer, coating and cladding (any)Expansion Joint Inspection + The heat exchangers with expansion jolnts neato be inspected for: + Flange inspections for cortosion and erosion + Inspection from intemal surface for corrosion and erosion + Alctost + The tube and shell hydrostatic test need to be done after the above sated inspection actives. Did you find this article useful? Click on below Like buttont New! Comments Have your say about what you just read! Leave me a comment inthe box below18 comments ‘Add a comment. on a sel. can know which standard has fallow for (fore aces ad nspecton eRe Spor sie can gv you mare examples and intormaton it requires Le Ret Bir Tucker Gta Neca a gaat ise of eoupment tol wit heat exchange ‘ube bur ing? Go to won caryl.com. Ce cei neon etn in Lo-Res 1-107 Syed Raza All Zale “Thank Yous vey Use Fal rele For Me Than again Le Rea 1-8 Gee Nice nermation, harks Le Rap 1-89 Pramone Trtohamjoyo Ine 9200 for eferncn. tis bonefiafor me, now ean get row standard API or shel apa ibe exchanger? “Ron 2 ty << ee ko Rany> 1-10) ao vor eset Leas 1-10) Masood Joiva Realy god tor new begine to eaming Le Res 18 Eesti: (eee epetartoiaaam connart 02012209 trapeceroinstycam