PROCEDURE TO REPAIR E-1423 HEAT

EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 1 of 13

1. PURPOSE
Establish the guidelines to service the heat exchanger, setting the environmental, safety,
and occupational health management as a priority.

2. SCOPE
This document is applicable to any inspection activities on heat exchangers as performed
by Confipetrol personnel.

3. PERSONS IN CHARGE
Service Leader.
Head of QSE.
Mechanical Maintenance Supervisor.
Instrument Maintenance Supervisor.
General Services Supervisor.
QA/QC Supervisor.
Planning and Programming Supervisor.

4. PERSONNEL
Specialists in mounting/demounting scaffolds.
Level I, II, and III Mechanical, Electrical, and Instrument Specialists.
Crane Operators.
Level I and II Piping Specialists.

5. PERSONAL PROTECTION ITEMS

5.1 Jockey-type or broad-brimmed 5.8 Leather gloves.
hats with beard protector 5.9 Safety harness.
5.2 Overall. 5.10 Rain suit.
5.3 Safety eyewear. 5.11 Full-leg boots.
5.4 Steel-tip footwear. 5.12 Neoprene gloves.
5.5 Half-face mask respirator. 5.13 Welder's mask.
5.6 Cartridges for gases and dust. 5.14 Welder's leather apron.
5.7 Ear plugs. 5.15 Welder's leather boots.

6. EQUIPMENT / TOOLS / MATERIALS

6.1 200-ton crane. 6.7 Hydraulic gun.
6.2 20-ton hoists. 6.8 Spark-proof impact wrench.
6.3 100-ton hydraulic jacks. 6.9 Spark-proof mixed wrench.
6.4 Hydraulic wedges. 6.10 Brass hammer.
6.5 60-ton roller. 6.11 Safety cones.
6.6 Pipe scaffolding.

PE102226Z.OM-MMP.01-Rev.2
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 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 2 of 13

7. PROCEDURE

7.1. Previous work

Check the work sequence to repair the heat exchanger in the field together with the
Maintenance and Operations personnel.

Note: According to the information received, Confipetrol proposes the following

sequence:

Dismount the E-1422 and E-1424 heat exchanger heads

Disconnect the E-1422 exchanger from E-1423 exchanger.
Disconnect the E-1424 exchanger from and E-1423 exchanger.
Disconnect the E-1423 exchanger loading and unloading pipes.
Remove the E-1423 exchanger from its base
Repair the E-1423 exchanger
Replace the thermal insulation covers.
Replace the E-1423 exchanger onto its base.
Connect the E-1422 exchanger to the E-1423 exchanger.
Connect the E-1424 exchanger to the E-1423 exchanger.
Connect E-1423 exchanger loading and unloading pipes.
Mount the E-1422 and E-1424 exchanger heads (loading and unloading
heads respectively)

Check the dimensions of the work area:

Check plant drawings and check the area free for maneuvering in the field.
Place crane in the exchanger area to simulate maneuvers (FIG 01).
Check location of scaffolds in the field.

FIGURE No. 01

PE102226Z.OM-MMP.01-Rev.2
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 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 3 of 13

Facilities.
Mount scaffolds to disconnect E-1423 exchanger loading and unloading
pipes.

At the head loading flange of E-1423 exchanger (E).

At the head unloading flage of E-1423 exchanger .
At the shell loading flange (B).
At the shell unloading flange (A1).

Mount scaffolds to disconnect loading and unloading pipes of E-1422 and E-

1424 exchangers.
Assemble on the floor supports (2) with wood blocks to place E-1423
exchanger.

7.2. Blocking and insulation of exchanger train.

Identification of blocking points at the exchanger train

Identify supply sources of the Exchanger Train.

PE102226Z.OM-MMP.01-Rev.2
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 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 4 of 13

Prior to service the exchanger, the equipment that supply gas to the Train shall be
blocked.

Tube Bunble Supply: K-1430 Compressor.

Heat Exchanger Shell: Not indicated in drawings.

Apply the company's blocking and tagging procedure.

Identify equipment insulating mechanical valves.

Place blocking items on valve flywheels as well as on loading and unloading pipes
of exchanger.

No information on valves.

Identification of valves to depressurize pipes.

Once the equipment blocking valves are closed, check that pipes do not have
residual pressure. As mentioned, the pressure relieving points shall be identified.

Note: Check that the loading and unloading line gauges are in good condition to
ensure that the system pressure readings are correct.

Identification of plate and blind flange installation points.

Check drawings (piping) to identify the points where plates and blind flanges must
be installed. Furthermore, check location of said points in the field to arrange
necessary facilities for their installation, such as scaffolding, hoisting devices, etc.

Note: No information is available.

7.3. Disconnection of E-1422 and E-1424 exchanger heads

Dismount E-1424 exchanger head

unloading pipe

Remove thermal insulation from the

unloading pipe flange.
Tie the unloading pipe to the crane.
Remove stud bolts and nuts that attach
the E-1424 exchanger head to the
unloading pipe.
Hoist unloading pipe.
Place a blind flange.

PE102226Z.OM-MMP.01-Rev.2
The printed version of this document is considered an uncontrolled copy, unless it bears the stamp "controlled copy"
 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 5 of 13

Dismount E-1424 exchanger head

Remove thermal insulation from the E-

1424 exchanger head.
Tie the head to a crane.
Remove bolts from the head.
Hoist the head.

Dismount E-1422 exchanger head loading

pipe

Remove thermal insulation from the

loading pipe flange.
Tie the loading pipe to a crane.
Remove stud bolts and nuts that attach
the exchanger head to the loading pipe.
Hoist the loading pipe.
Place blind flanges.

Dismount E-1422 exchanger head

Remove thermal insulation from the E-

1422 exchanger head.
Tie the exchanger head to a crane.
Remove bolts from the head.
Hoist the head.

PE102226Z.OM-MMP.01-Rev.2
The printed version of this document is considered an uncontrolled copy, unless it bears the stamp "controlled copy"
 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 6 of 13

7.4. Disconnection of E-1422 exchanger.

Remove the insulation from flanges attaching E-1422 and E-1423 exchanger
heads.
Remove stud bolts and nuts from E-1422 flange (D).
Loosen nuts of stud bolts from the loading pipe flange (B).
Loosen nuts of stud bolts from the unloading pipe flanges (A1, C).
Place 04 100-ton hydraulic jacks at the E-1422 exchanger supports.
Remove 04 anchoring bolts from E-1422 exchanger.
Jack the exchanger and place a 60-ton roller under each supporting point.
Move the E-1422 exchanger using the roller (0.05 meters) to the loading side.

7.5. Disconnection of E-1424 exchanger.

Remove the insulation from flanges attaching E-1424 and E-1423 exchanger
heads.
Remove stud bolts and nuts from E-1422 flange (E).
Loosen nuts of stud bolts from the loading pipe flange (B).
Loosen nuts of stud bolts from the unloading pipe flanges (A1, C).
Place 04 100-ton hydraulic jacks at the E-1424 exchanger supports.
Remove 04 anchoring bolts from E-1424 exchanger.
Jack the exchanger and place a 60-ton roller under each supporting point.
Move the E-1424 exchanger using the roller (0.05 meters) to the unloading side.

PE102226Z.OM-MMP.01-Rev.2
The printed version of this document is considered an uncontrolled copy, unless it bears the stamp "controlled copy"
 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 7 of 13

7.6. Disconnection of E-1423 loading and unloading pipes

Dismount the exchanger instruments.

Dismount the A1 flange unloading pipe

Remove the thermal insulation from A1 flange.

Tie the unloadind pipe to a crane.
Remove stud bolts and nuts from A1 flange and
elbow flange at the lower part of the vessel.
Remove the spiral wound gasket.
Hoist the unloading pipe.
Fasten the free end of the unloading pipe
entering to the plant.
Place a blind flange on unloading pipe using a
corresponding gasket.

Disconnect loading pipe (B).

Remove the thermal insulation from flange (B).

Tie the loading pipe to a crane.
Remove the stud bolts and nuts from the flange.
Install a blind flange and corresponding gasket.

Disconnect C unloading pipe

Remove the thermal insulation from flange (C).

Remove the stud bolts and nuts from the flange.
Fasten the free end of the unloading pipe to a temporary support.
Install a blind flange and the corresponding gasket.

7.7. Removal of E-1423 exchanger from its base

Remove the insulation from the exchanger hoisting points.

Install shackles and chains at the exchanger hoisting points.
Remove the exchanger service platform.
Remove the anchoring bolts from the exchanger.
Hoist the exchanger (move it toward the area between the two cranes).
Place the exchanger onto the supports set with wood blocks.

PE102226Z.OM-MMP.01-Rev.2
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 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 8 of 13

7.8. Repair of E-1423 exchanger

Perform leakproof test on equipment shell (casing).

Seal exchanger shell.

Place blind flange with nipple to install a regulating valve, "T" joint, and gauge
for nitrogen supply.
Connect shell to a pressure relief valve (set to 3 bar).
Connect the nipple to a high-pressure hose supplying nitrogen from the plant.
Open the N2 gas intake at 2.9-bar pressure (1.3 x working pressure).
Apply a soapy substance over the tubesplates to identify leaks by detection of
bubbles. Damaged tubes will show bubbles.
Identify the tubes from which N2 gas is leaking.
Mark damaged pipes.

Repair of tube bundle

Prepare the inner surface of damaged tubes to place plugs inside.

Place plugs made of the same material as tubes.
Weld plugs placed in damaged tubes to the tubes plate.

Leakproof test for tube bundle Leak Test.

Place the dismounted E-1424 head at the E-1423 unloading side by using a
crane.
Place head gasket and bolts.
PE102226Z.OM-MMP.01-Rev.2
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 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 9 of 13

Place the dismounted E-1422 head at the E-1423 loading side by using a crane.
Place head gasket and bolts.
Install a blind flange at the head unloading flange of E-1423 (head that came
from E-1424).
Place a blind flange with nipple to install a regulating valve, "T" joint, and gauge
at the E-1422 head loading flange of E-1423 (head that came from E-1422) .
Connect a high-pressure hose supplying nitrogen from the plant to the nipple
mentioned above.
Open the N2 gas intake at 73.97-bar pressure (1.3 x working pressure). Once
the tube bunble is full, close the N2 intake.
Check that no pressure is lost because of nitrogen leak from the shell pipes.

Note:
If there is evidence of pressure loss, remove one of the two heads of E-1423 and
perform the leakproof test again on the shell. Certainly, more tubes requiring repair
will be detected. Proceed to repair the tubesshowing leaks and replace the head
that was removed before. Perform the leakproof test on the tube bundle again. If
there is no more pressure loss, the tube bundle is completely repaired. Repeat this
procedure as many times as necessary until pressure is equalized by the tube
bundle.

Confipetrol assumes that the plant will provide nitrogen gas at the volume and
pressure required to perform leakproof test on the casing and tube bundle.

Dismount heads

Hook the E-1424 head to a crane.

Remove E-1424 head bolts and gasket.
Dismount the head.
PE102226Z.OM-MMP.01-Rev.2
The printed version of this document is considered an uncontrolled copy, unless it bears the stamp "controlled copy"
 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 10 of 13

Hook the E-1422 head to a crane.

Remove E-1422 head bolts and gasket.
Dismount the head.

7.9. Repair of thermal insulation covers previously removed.

Inspect thermal insulation covers previously removed.

Remove the thermal insulation covers from the work area.

Check the cover condition.
Set aside covers in good condition.

Take measurements for cover manufacturing.

Take measurements in the field for cover manufacturing.

Assemble or repair insulation covers.

Manufacture the insulation covers that need replacement (evaluate the

possibility of manufacturing removable covers at points where now there are
fixed covers).

7.10. Replace E-1423 exchanger onto its base.

Hoist the exchanger (raise it high enough to skip any obstacle on its way to the
base)
Sit the E-1423 exchanger on its base.
Level and align the exchanger.
Install the anchoring bolts to the exchanger.
Remove shackles and hoisting mechanism.
Reinstall the exchanger service platform.
Replace the thermal insulation covers to the exchanger hoisting points.

7.11. Connection of E-1422 exchanger.

Install the hydraulic jacks, lift the exchanger and place 04 rollers under.
Move the E-1422 exchanger to its initial position.
Remove the rollers and get exchanger down.
Level and align the heat exchanger.
Replace the equipment anchor bolts.
Install the gasket, stud bolts and nuts onto the head flange that attaches to the
E-1423 heat exchanger.
Replace the thermal insulation covers.

PE102226Z.OM-MMP.01-Rev.2
The printed version of this document is considered an uncontrolled copy, unless it bears the stamp "controlled copy"
 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 11 of 13

7.12. Connection of E-1424 exchanger.

Install the hydraulic jacks, lift the exchanger and place 04 rollers under.
Move the E-1424 heat exchanger to its initial position.
Remove the rollers and get exchanger down.
Level and align the exchanger.
Replace the equipment anchor bolts.
Install the gasket, stud bolts and nuts onto the head flange that attaches to the
E-1423 heat exchanger.
Replace the thermal insulation covers.

7.13. Connection of E-1423 exchanger loading and unloading pipes

Connect loading pipe flange (B).

Remove blind plate from loading pipe flange (B).

Reinstall the gasket, stud bolts and nuts of the loading pipe flange.
Replace thermal insulation cover on flange (B).

Mount A1 flange unloading pipe

Remove blind flange from unloading pipe flange.

Hoist unloading pipe.
Reinstall the gasket, stud bolts and nuts of A1 flange and elbow flange at the
lower part of the vessel.
Replace thermal insulation cover on A1 flange.

Connect unloading pipe (C)

Align the unloading pipe.

Remove the blind flange.
Reinstall the gasket, stud bolts and nuts of the flange.
Replace thermal insulation cover on flange (C).

Mount instruments.

7.14. Mounting of E-1422 and E-1424 exchanger heads

Mount E-1424 exchanger unloading head

Hoist the unloading head with a crane.

PE102226Z.OM-MMP.01-Rev.2
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 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 12 of 13

Install the head gasket and bolts.

Replace the thermal insulator cover on the exchanger head.

Mount E-1424 exchanger head unloading pipe

Remove the blind flange.

Hoist the unloading pipe.
Install the gasket, stud bolts and nuts onto the exchanger head flange that
attaches to the unloading pipe.
Replace thermal insulation cover on the flange.

Mount E-1422 exchanger loading head

Hoist the loading head with a crane.

Install the head gasket and bolts.
Replace the thermal insulator cover on the exchanger head.

Mount E-1422 exchanger head loading pipe

Remove the blind flange.

Hoist the loading pipe.
Install the gasket, stud bolts and nuts onto the exchanger head flange that
attaches to the loading pipe.
Replace thermal insulation cover on the flange.

7.15. Work area cleanliness and neatness

7.16. Remove blocking and insulation of equipment

8. RESTRICTIONS
8.1. Do not perform the task if the High-Risk Work Procedure in Written (PETAR) is not
followed.
8.2. Do not perform the task if inspection of hoisting equipment (slings, strobes, chains,
etc.) is not performed.

9. REFERENCES
9.1 PE102226Z.CSMA-E.01.01 - PETAR.
9.2 Pl.PE102226Z-CSMA.15.01 - Daily Inspection of Working Conditions
MANTENAINCE.
9.3 Pl.PE102226Z.CSMA.12.16 - Inspection of hoisting equipment and accessories.
9.4 Pl.PE102226z.csma.15.02 - Daily Inspection of Working Conditions HOT WORK.

PE102226Z.OM-MMP.01-Rev.2
The printed version of this document is considered an uncontrolled copy, unless it bears the stamp "controlled copy"
 PROCEDURE TO REPAIR E-1423 HEAT
EXCHANGER
PLNG
Area: GENERAL SERVICE
Code:
MAINTENANCE
Revision Date: NOV/01/2014 Rev.: 2 Page: 13 of 13

PREPARED BY: REVIEWED BY: REVIEWED BY: APPROVED BY:

. .
. ..
Worker Area Supervisor Head of QSE Service Leader
Date: Date: Date: Date:

PE102226Z.OM-MMP.01-Rev.2
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