TUV INDIA – EXPERTISE FOR YOUR SUCCESS

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 Crude distillation process

Video

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 HEAT EXCHANGER INSPECTION

To ensure safe and reliable operation

Used in refinery :

 Shell and tube type exchanger

 Reboiler

 Breech lock exchanger

Heat exchanger working video

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 No. of gaskets in Floating head heat exchanger

Most asked question by client:

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 External inspection :

 CUI inspection at locations of damaged insulation, nozzle

connections, bottom of shell to be checked.

 Support intactness to be checked, studs/bolts condition checked.

 Earthing strip connection to be checked.

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 Internal inspection :

Pre cleaning inspection:

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

 Note down the location of heavy deposits, their color and appearance

on all components. If required collect sample.

 Initial observation to be recorded for each component.

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 Post cleaning inspection:
Tube Bundle inspection:

 Check tube bundle cleaning for surface check & choking of tubes.

 Check tube sheet condition. Corrosion, erosion, pitting shall be identified. Tube end thinning must be

checked.

 Check entire tubes for corrosion, erosion, thinning bending.

 Check baffle condition for corrosion and erosion.

 Check any mechanical damage to baffles.

 Check gap between baffle hole and tube OD.

 Check impingement plate condition for thickness loss, corrosion, erosion.

 Check tie rod intactness.

 Check tube sheet gasket area for corrosion erosion.

 Check partition plate gasket seating groove condition.

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 Baffle mechanical damage Tube end thinning

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 Channel head inspection:

 Check entire channel head for corrosion erosion.

 Check partition plate corrosion, pitting.

 Check gasket seating area condition.

 Check I/L- O/L nozzle for any abnormalities.

 Check anode condition if any.

Gasket
Channel head cover inspection : seating area

 Check gasket seating area for any abnormalities like pits, serration

damage etc.

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 Sacrificial anode
on partition plate
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Floating head inspection :

 Check dish end inside and outer side surface for any corrosion erosion pitting.

 Check condition of partition plate.

 Check gasket seating area condition.

 Check anode condition if any.

Floating head cover inspection :

 Check for dish end inside outside for any corrosion erosion.

 Check choking of drain and vents.

 Check gasket seating area condition.

Shell inspection of heat exchanger:

 Check I/L – O/L nozzle from inside for any sign of corrosion erosion.

 Check entire shell from inside for any abnormalities.

 Check gasket seating area condition.

 Thickness survey shall be done at minimum nos. as shown below:

 Shell : 4 direction readings at every 2 M (min. 3 seats)

 Nozzles : All min.4 readings (Nozzles of 1 ½” and smaller to be hammer tested)

 Channel box : Min.4 readings, channel cover, F/H cover, Shell – 4 directions and 1 in

center

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TUBE INSPECTION METHODS :

 IRIS : Internal rotary inspection system

The IRIS probe is inserted into a tube that is flooded with water, and the

probe is pulled out slowly as the data is displayed and recorded.

 RFET : Remote Field Eddy Current Technique

Transmission of an electromagnetic field through the tube material

The RFET is generally used for detection of wall loss in Carbon Steel Tubes.
IRIS

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RFET
 Hydro testing of heat exchanger :

Heat exchanger with floating head

Ring Test : Shell shall be pressurized at test pressure to check and identify leaky tubes and gaskets of

channel box.

F/H Test : Tubes shall be pressurized up to test pressure to check the floating head gasket leak and also to

test the tensile strength of tubes.

Final Test : Shell shall be pressurized to check the final shell cover gasket tightness and soundness.

After completion of every testing slow release of pressure shall be followed.

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 Hydro testing of heat exchanger :

Heat exchanger with fixed tube sheet :

Shell test : shall be conducted at test pressure to detect tube leak / soundness of shell.

Tube test : shall be conducted at test pressure to see all gasket tightness and soundness.

‘U’ tube heat exchanger :

Shell test : shall be conducted at test pressure to detect tube leak / soundness of shell.

Tube test : shall be conducted at test pressure to see all gasket tightness and soundness.

 If a tube leak occur during testing, the tube will be plugged at both ends by identifying the leaky tube,

which may require individual testing of ‘U’ tubes.

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 Leak from TTS joint during hydro test
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 Leaky tube plugging :

 Tube bundles shall be inspected for tube end thinning and thickness loss due to pitting etc.

 Leaky tubes shall be plugged.

 Measure tube IDs, particularly in water service and where tube end erosion is expected.

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 BREECH LOCK EXCHANGERS

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 After disassembly, inspect following parts carefully after thorough cleaning

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 Threaded lock ring Internal threads of channel

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 Diaphragm

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 Hydro testing of breech lock heat exchanger:

 Shell side differential pressure test shall be done after partial re-assembly and fixing of the tube

bundle inside the shell at a test pressure equal to differential pressure as per the design data of the

exchangers.

 Simultaneous shell and tube side shall be pressurized slowly to the test pressures while maintaining

the differential pressure limited to the designed differential pressure.

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 REPAIR INSPECTION:

The exchanger may require following repairs.

 Tube plugging

 Shell / Channel weld repair/replacement /patching

 Epoxy Painting

 External painting

 Insulation

 Sacrificial Anode Replacement

 Tube – Tube sheet joint repair welding

 Impingement plate / Tie rod Replacement

 Retubing – Partial / Full

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 NOTE :

 Stage inspection shall be carried out to ensure that proper materials are used, the welding job is

done by qualified welders using qualified procedure and all final tests including hydro test are carried

out.

 For repair, the requirement of API STD 510 or ASME-PCC-2 needs to be met.

 The In-Service Inspection code for shell and tube heat exchangers is API STD 510.

 Recommended Practices API RP 572, API RP 577 & API RP 571 and also construction code sections

might be used, such as ASME Code Section VIII and ASME Code Section IX.

 For DPT follow ASME SECVIII DIV-1, APP-8 & ASME SEC V.

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 Epoxy painting Retubing of tube bundle Sacrificial anode

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Retubing of heat exchanger

Retubing when rejection is more than 10% of tubes due to thinning.

Steps :-

Tube removal: Cut the Tube to Tube Sheet Joint (TTSJ) and pull the tubes
Tube cutting video
Tube installation: after cleaning at tube sheet and baffle holes.
Tube pulling and installation video
Tube sheet repair: expansion/seal weld/strength weld

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Retubing of heat exchanger

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 Pressure testing after Repair/Alteration:

 Approved hydro test procedure to be followed.

 All heat exchangers shall be tested at 1.5 times the design pressure when shell or tube bundle is new or

any major repairs or replacement has been carried out.

 The duration of hydraulic test shall not be less than 30 minutes.

 During hydraulic testing the pressure gauge shall be installed at the highest point and lowest point.

 Pressure gauge range shall be 1.5 to 4 times of test pressure.

 Only calibrated Pressure gauge shall be used.

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 INSPECTION REPORT :

 Based on inspection findings, inspection report is be issued.

 The report includes observations in brief.

 Repair / replacement required with material specification,

 Welding procedure and electrode,

 Filler wire specification and testing.

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 DOCUMENTATION :

 Data sheet

 History sheet

 Development sketch of shell

 Inspection Check-list

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