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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

Prepared by Carlo Leoni


[Stationary Section Adviser]-30August 2006

IBN-ZAHR
Inlet

MECHANICAL MAINTENANCE PROCEDURE


AIR COOLER Heat Exchanger
General Assembly view
Floating Header

Tubes
Stationary Header

Plug

Outlet

Fan

Conveyor

Scaffold

Electric motor

Structure

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

AIR COOLER Heat Exchanger


Vapor Inlet

Tube Bundle Details


Stationary Header

Floating Header

Fin Tubes

Plug

Condensate Outlet

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE


AIR COOLER Heat Exchanger
Tube Assembly and Plug Detail
Inlet
Stationary Header

Fin Tubes
Gasket

Plug

Grooves for expansion

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE


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]

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

Do Not Start The Job Without a Safety Plan


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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

AIR COOLER Heat Exchanger


1. Leakage from Header Plugs
1.1. On Line leak elimination [Temporary solution]

Drill blind hole and thread


the leaking Plug on situ
Screw in the threaded stud

This is a Maintenance
Innovation made by IZ
Special device
Leak

Inlet Header

Assembly the special cap


device with gasket and
screw it in until the leak
stops
Replace gasket & Plug
later in Shutdown
Fin Tubes

Leaking Plug
Additional Gasket

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

AIR COOLER Heat Exchanger


2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
Shutdown, isolate & drain the equipment
Blind Stationary Header Inlet & Outlet

PG

Stationary Header

Install Pressure Gauge


Connect water pump

Fill system by water


Raise the pressure

Leak

Locate leaks from outside


Discharge water
Open Plugs at leak position
Remove gasket

See continuation
Fin Tube
Plug

8
Water Pump

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

AIR COOLER Heat Exchanger


2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area
PG

Stationary Header

Insert Expander tool, expand the tube up


to the established torque
Remove expander tool

Reinstall new gasket and plug


Fill the system by water
Raise the pressure
Re-check leaks from outside
[No more leak]

Leak

Discharge water
Remove PG & water pump
Remove In-Out Blinds and
tight flange bolts

Fin Tube
Plug

9
Water Pump

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE

AIR COOLER Heat Exchanger


2. Leakage from Tubes: 2.2. Leak elimination from broken Tube
Shutdown, isolate & drain the equipment
Blind Stationary Header Inlet & Outlet

PG

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

Drain water, remove PG & pump

Plug

Remove in-out blinds, tight bolts

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Water Pump

Remove field blinds

IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE


AIR COOLER Heat Exchanger

2.3. On line Leak elimination from broken tube : [Temporary solution]


[Bottom & Top row only]
B
C

C
B
Leak

See continuation

Special Device

Section B-B

Section C-C

Drain Valve

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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE


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
body with gasket

Steam

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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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE


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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IBN-ZAHR

MECHANICAL MAINTENANCE PROCEDURE


List of Air Coolers
Installed in IBN-ZAHR
PP PLANT

MTBE PLANT

Non
1.

110-E09 A-B

2. 110-E15 A-B-C-D

13. 130-E15 I-L-M-N


14. 130-E15 O-P

3. 110-E15 E-F-G-H
4. 110-E15 I-J-K-L

15. 130-E19 A-B

5. 110-E15 M-N-O-P

16. 140-E03 A-B

6. 110-E19 A-B

17. 140-E06 A-B

7. 120-E03 A-B
8. 120-E06 A-B

18. 220-E29 A-B

9. 200-E29 A-B

19. 220-E30 A-B-C-D-E-F

10. 130-E09 A-B

20. 740-E01

11. 130E15 A-B-C-D


12. 130-E15 E-F-G-H

21. 740-E02

13. 130-E15 I-L-M-N

22. 770-E03 A-B-C-D

The End

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