Sample Inspection Report of Exchanger

CHEVRON ORONITE PTE LTD

INSPECTION TEST REPORT

Rev.5 / Sept 2011 of 22


ITEM TESTED E-2570

INSPECTION DATE 30th January 2013

INSPECT BY Khalid

___________________ __________________________ Signatory of Inspector Signatory of R&I Supt/ Engineer

DESIGN DATA

YEAR MANUFACTURED 2002 DESIGN PRESSURE 15 (S) / 2,5 (T) kg/cm2

CONSTRUCTION MATERIAL CS / SS 304L TEST PRESSURE 22 (S) / 4.8 (T) kg/cm2

CORROSION ALLOWANCE 1.0 (S) / 0 (T) mm PRESSURE TEST DATE 2002

FREQUENCY/ INTERVAL OF INSPECTION

INSPECTION INTERVAL (API)

MAX PERMITTED

120 Month(s)

LAST INSPECTION DATE 30th September 2009

NEXT INSPECTION DATE 30th January 2023

REMAINING LIFE <10 years

REASON FOR INSPECTION

Planned Un-plan Other (Process upset)

TYPE OF EXAMINATION/ TEST PERFORMED

TYPE IF INSPECTION Internal External

INSPECTION METHODS / TESTS USED Visual UTG

HYDROSTATIC TEST Entire Coil

OTHERS (PLEASE SPECIFY)



Rev.5 / Sept 2011 of 22

RECOMMENDATION/ ACTION ACTION PARTY DATE

CLOSED

To perform hydrotest for the exchanger as per test pressure. Results passed

Mechanical

3rd Feb 2013

INSPECTION SUMMARY

E-2570 was shutdown for maintenance due to process upset. The exchanger was remove and inspected at Ad-meth workshop before cleaning condition. Inspection findings are as follows: Shell side appeared in good condition No plugging of tubes was observed except for fouling built up on tubesheets Expanded bellow also appeared in good condition Baffle tie rod noted slight bend. No issue Eddy current testing could not be performed due to heavy deposits on the internal side of tubes



Rev.5 / Sept 2011 of 22

THICKNESS DATA

Location Current (t) mm Previous (t) mm Design (t) mm Corrosion

Allowance (mm) Condition

Channel plate 11.86 - 12.00 1.00 Thickness within tolerance Shell plate 12.57 - 12.70 1.00 Thickness within tolerance

Shell cone 12.72 - 12.70 1.00 Thickness within tolerance

4” Glycol inlet nozzle(N5) 6.15 - 6.02 1.00 Thickness within tolerance

8” Glycol outlet nozzle(N6) 15.9 - 11.18 1.00 Thickness within tolerance

4” Hot oil inlet nozzle(HOS) 8.12 - 8.56 1.00 Thickness within tolerance 4” Hot oil outlet nozzle(HOR) 8.44 - 8.56 1.00 Thickness within tolerance 1” Drain nozzle(D) 6.20 - 6.35 1.00 Thickness within tolerance 1” Vent nozzle(V1) 3.77 - 3.38 1.00 Thickness within tolerance

1” Vent nozzle(V2) 6.02 - 6.35 1.00 Thickness within tolerance



Rev.5 / Sept 2011 of 22

EQUIPMENT GA / LAYOUT



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INSPECTION PHOTOGRAPHIC RECORD Photo Findings

Overview of E-2570

Exchanger shell overview



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Internal shell appeared in good condition

Channel head overview



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Internal channel head condition

Shell cover(cone) overview



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Internal view condition

Internal view condition



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Floating tube sheet and tube bundle condition.

Tubesheet observed no plugging however fouling built up was observed



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Close view of fouling built up

Generally tube bundle appeared in good condition



Rev.5 / Sept 2011 of 22

Floating head plate condition

Expansion bellow condition



Rev.5 / Sept 2011 of 22

After cleaning condition

Shell internal Close view



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Close view Shell cover(cone)



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Internal view Close view



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Expansion bellow condition Channel head condition



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Channel head cover Floating head plate condition



Rev.5 / Sept 2011 of 22

Tubesheet condition Close view of tubes



Rev.5 / Sept 2011 of 22

Close view of tubes Tube bundle. One tie rod noted slight bend. No issue



Rev.5 / Sept 2011 of 22

Close view.



Rev.5 / Sept 2011 of 22

INSPECTION CHECKLISTS RECORD

Pressure Vessel Inspection Checklist

Item Tick relevant boxes

Completed[ ]

Comments

Heat Exchanger (Shell & Tube)

1) Check before and after cleaning

2) Visual check shell, cover, channel cover, floating head cover and nozzles condition

3) Visual check any erosion-corrosion attack on the tube ends

4) Visual check external tube any corrosion or damage condition

5) Perform NDT for tube NA Could not be carried out due to heavy deposits on internal tubes

6) Visual check any disclose grooving of tubes and enlargement of baffle holes.

7) Check anodes condition (if any) NA

8) Inspect the impingement or wear plates for any sign of corrosion or erosion

9) Obtain thickness for shell/ nozzles and dead legs area Thickness within tolerance

10) Check any insulation damage / CUI/ external corrosion

11) Check foundations bolting is double-nutted/ support condition

12) Check platform, ladders, handrails and davis condition NA

13) Check any painting damage

14) Gasket seating surface any damage

15) Hammer test on Lifting lugs

16) Hammer test on Shell small piping connection

17) Kettle-type exchanger check weir condition NA

Furnace (Fire Heater)

1) Check before and after cleaning NA



Rev.5 / Sept 2011 of 22

2) Check for porous refractory by hammer test and mark out for repair (if any)

NA

3) Any damage of baffle brick NA

4) Check and damage or crack ferrules NA

5) Check any expose anchor NA

6) Replace feed tube (R1/R2) with correct material construction of Inconel with PMI (for F-8010 only)

NA

7) Vacuum or remove dust on furnace bottom circumference of the refractory brick (for F-8010 only)

NA

8) Fill up the bricks to bricks joints with Ceramic fibre if gap approximately >4mm (if any)

NA

9) Check internal radiant coil thermo bond secured (for Hot Oil Heater only)

NA

10) Check any sign of loose supports securing the radiant coils (for Hot Oil Heater only)

NA

11) Check any ash formation built up / refractory drop out at the crossover fin coils from small doors area (for Hot Oil Heater only)

NA

12) Obtain thickness for shell/ nozzles and dead legs area NA

13) Check any insulation damage / CUI/ external corrosion NA

14) Check foundations/ support condition NA


16) Check any painting damage NA

17) Check all internal apparatus like thermo well, etc condition NA

Boiler


2) Check internal Steam drum and tubes condition NA

3) Check internal water drum condition NA

4) Check internal spacer tubes condition NA

5) Check for porous refractory by hammer test and mark out for repair (if any)

NA

6) Perform require NDT NA





Rev.5 / Sept 2011 of 22




12) Check all internal apparatus like thermo well, etc condition

Pressure Vessel (Column/ Vessel/ Reactor)


2) Visual check internal wall condition NA

3) Check chimney tray condition NA

4) Check bottom vortex strainer condition NA

5) Check demister pads condition NA

6) Check internal packing for any fouling or plugging in bed NA

7) Inspect the impingement or wear plates for any sign of corrosion or erosion

NA

8) Perform require NDT NA

9) Inspect any loose of U-bolts & sign of cut or erosion between pipe

NA

10) Check spray nozzle condition NA

11) Check any damage or weld shear off support NA

12) Check any bolt/ nuts loose for impeller blade NA

13) Check any sign of lining/ cladding failure NA






19) Perform hydro test for external/ internal coil NA

20) Check all internal apparatus like thermo well, etc condition NA

Others Comment.

Sample Inspection Report of Exchanger

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