RELIABILITY DEPARTMENT

EXCHANGER INSPECTION REPORT TA Feb 2015

AREA/UNIT: MTBE I / 200

EQPT.TAG #: 200-E-09A

EQPT
DATA

Service

Material

SHELL

H2, C1-C4
Effluent

TUBES

Cooling Water

DESCRIPTION:

Reactor Effluent Cooler.

Size &
Thickness.

Design Pr.
Kg/Cm2

Test Pr.
Kg/Cm2

A516 Gr. 60

ID# 1930 mm and

13 mm THK

2.9 Kg/Cm2

2.9
Kg/Cm2

A210 Gr.A-1

OD#19.05 mm and
2.11mm THK

7.0 Kg/Cm2

7.0
Kg/Cm2

QTY: 1478

PAST HISTORY: 1992-2000: Shell side deposit and fouling. 2002: Extensive fouling. 2004:

Thick carbonaceous deposit 1.2mm on the shell inner and tube outer surface. Pass partition
plate edge 250mm long X and 20mm depth was corroded and repaired by weld build up.
2006: Heavy deposit. Bottom rows were not clean due to time constraint. 2007: Thick hard
sludge deposit found on shell interiors and on tubes. 2009: Thick black sludge deposit found
on tube external. 10 nos Baffle plates found bent. Spare tube bundle was installed. 2011:
2 nos of tube was found in bent conditions on top side between baffle plate due to poor
handling. Top of the tie rod was found in bent condition.2013: No major concern.

Tube
Bundle

EXPANDED

Tube to tube sheet joint.

Electrode : ER 70 S2 / E7018

Observations:

1. Thick and blackish oily sludge noticed at the bottom, inside the shell.
2. Nozzle observed with thick and blackish deposits.
3. Tube bundle external observed with thick blackish deposits.
4. Slight bends were noted in the bottom tubes during inspection.
5.

The Spare bundle inserted was noted with 7 tubes in plugged condition (counting from left).
Row 1- column 1 & 7
Row 44- column 1
Row 62- column 4,5,6,7

Actions Taken:

1. Tube bundle, shell and channel end covers cleaned (Removed bundle).
2. The spare tube bundle was cleaned, Eddy Current tested (15%) and was inserted.
3. Shell side and tube side hydrotest carried out.
Recommendations:

1. To be inspected as per RBI recommendation.

2. Document controller shall update the MIP to reflect the internal inspection carried out.

RELIABILITY DEPARTMENT
Pic#01

Tube bundle inside the dummy shell