Santos

Facility Engineering Technical Bulletin

Air Cooler Plug Guidelines
Air coolers in gas and oil service require regular inspections to check for fouling and pressure integrity they are subject to fouling, CO2 and H2S corrosion and erosion mechanisms. Inspection work can involve removal, inspection and replacement of header plugs. These plugs are often sites for damage. Strict attention to detail is required for a successful return to service. Some general guidelines follow:
1) Visually inspect all plugs on cooler header boxes with particular attention to those in the final pass. Record any stampings on the header end face and plugs. Mark and record any evidence of leaks or welding on plugs. Where required, carry out sufficient ultrasonic thickness (UT) checks on plugs to establish integrity. Check all plugs in the final pass of each header box. Report any exceptions for Engineering assessment. Where required, carry out UT checks on header box plates, particularly in areas where previous losses have been recorded. Record results, report exceptions for Engineering assessment. Confirm that all stores stock for any replacement plugs and gaskets complies with the material specification and dimensions called up on OEM drawings and data sheets. Check that plug engagement matches Original Equipment Manufacturer (OEM) requirements particularly if engagement is less than 1.00 to 1.25 diameters. If in doubt, seek technical or Engineering advice e.g. Jord International. Note: Cooler plugs use UNF parallel threads, not NPT. Incorrect threads or material can gall or seize in the plug sheet. (Continued)

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Facility Engineering Technical Bulletin

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Ensure cooler is correctly isolated. Remove plugs on an as-required basis only. Do not use impact guns. Assessment of corroded or leaking plugs may require the removal of additional plugs, and retapping of threads or installation of OEM recommended oversize plugs. Seek Engineering advice for assessment and repair of galled or seized plugs. ALWAYS remove and replace the gasket where a plug has been backed-off for whatever reason. Hardness of new gaskets should be no greater than BHN 107 / HRB 68 for carbon steel and BHN 133 / HRB 82 for stainless steel material. Review and apply OEM instructions for cleaning threads, plug sheet repair, application of lubricant and gasket material. Verify plug torque or gasket crush or other assembly requirements. Torque or tighten to Manufacturers Instruction e.g. use a torque wrench, or nip-up, mark and apply turn for carbon steel and turn for stainless steel. Record using MAC tag or other QA system. Review plug sealing performance during hydrostatic test, at leak test and for gas service, by a soap-bubble check at commissioning and after one month and thereafter periodically in operation. Note: AS 1210 site retest is 1.25 x design pressure, see AS 4037 for other pressure test requirements. ALWAYS replace corroded or leaking plugs and gaskets, and report galled or seized plugs for Engineering assessment.

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DO NOT WELD without Engineering approval. Welding can weaken the joint, reduce corrosion resistance and decrease pressure integrity, and it may also invoke pressure vessel registration and code requirements. ALWAYS leak check on pressuring. NEVER retorque plugs in service as the plug may dislodge and injure. If in doubt, always seek written technical or Engineering advice.
Originator: Russell Schulz, Principal Mechanical Engineer (08) 8116 7768 Reissued By: Project Development Engineering Department, December 2007