“AIR COOLER” Heat Exchanger

Inlet General Assembly view

Floating Header
Tubes
Stationary Header
Plug

Outlet Fan
Conveyor

Scaffold Electric motor

Structure

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 “AIR COOLER” Heat Exchanger
Vapor Inlet
Tube Bundle Details

Stationary Header Floating Header

Fin Tubes

Plug

Condensate Outlet
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 “AIR COOLER” Heat Exchanger
Tube Assembly and Plug Detail
Inlet
Stationary Header

Fin Tubes
Gasket

Grooves for expansion

Plug

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 “AIR COOLER” Heat Exchanger
Maintenance Activity Cases Summary

1. Leakage from Header Plugs

1.1. On Line leak elimination [Temporary solution]

2. Leakage from Tubes

2.1. Leak elimination from expanded area
2.2. Leak elimination from broken tube
2.3. On line Leak elimination from broken tube
[Temporary solution, Bottom & Top row only]

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Do Not Start The Job Without a Safety Plan

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 “AIR COOLER” Heat Exchanger
1. Leakage from Header Plugs Drill blind hole and thread
the leaking Plug on situ
1.1. On Line leak elimination [Temporary solution]
Screw in the threaded stud
This is a Maintenance Assembly the special cap
Innovation made by IZ device with gasket and
Inlet Header
screw it in until the leak
stops
Special device
Replace gasket & Plug
Leak later in Shutdown
Fin Tubes

Leaking Plug

Additional Gasket

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 “AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
Shutdown, isolate & drain the equipment
PG Blind Stationary Header Inlet & Outlet
Stationary Header
Install Pressure Gauge
Connect water pump

Fill system by water

Leak
Raise the pressure
Locate leaks from outside
Discharge water

Open Plugs at leak position

Remove gasket

See continuation

Fin Tube
Plug

Water Pump
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 “AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
Insert Expander tool, expand the tube up
to the established torque
PG
Stationary Header Remove expander tool
Reinstall new gasket and plug

Fill the system by water

Raise the pressure
Re-check leaks from outside
Leak [No more leak]
Discharge water
Remove PG & water pump
Remove In-Out Blinds and
tight flange bolts

Fin Tube
Plug

Water Pump
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 “AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 2.2. Leak elimination from broken Tube
Shutdown, isolate & drain the equipment

PG Blind Stationary Header Inlet & Outlet

Stationary Header
Install Pressure Gauge

Connect water pump

Fill system by water

Raise the pressure

Leak Locate leaks from outside

Drain water

Open Plugs at leak position both

sides And remove gasket

Plug the leaking tube [both sides]

Reinstall gasket & plugs [Both sides]

Fill in water again

Raise pressure & check sealing

Fin Tube
Plug Drain water, remove PG & pump

Remove in-out blinds, tight bolts

Water Pump Remove field blinds 10

 “AIR COOLER” Heat Exchanger
2.3. On line Leak elimination from broken tube : [Temporary solution]
[Bottom & Top row only]

B
C

B
Leak See continuation

Special Device

Section “B-B” Section “C-C”

Drain Valve

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 “AIR COOLER” Heat Exchanger
2.3. On line Leak elimination: from broken tube : [Temporary solution]
[Bottom & Top row only]
Stop the fan set only

Erect scaffold below fan

Remove fins at leaking

area
Install the upper half
Steam
body with gasket
Install the lower half body
with the drain open

Tight the body bolts

Install packing and gland

at left side and tight bolts
Condensate Leak
Install packing and gland
at right side and tight
bolts
Close the drain

DEVICE INSTALLATION METHOD

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 “AIR COOLER” Heat Exchanger
Handover & Final House Keeping By Maintenance

 Remove tools and equipment  Remove scaffold before El. Fan start-up
 Clean and wash the area  Close Work permit

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