Transcript Air cooler maintenance.

Inlet
“AIR COOLER” Heat Exchanger
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
Plug
Grooves for expansion
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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
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
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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
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
Water Pump
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“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
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
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
Water Pump
Remove field blinds
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“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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“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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“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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