Sample Inspection Report of Exchanger

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT
INSPECTION TEST REPORT ITEM TESTED INSPECTION DATE INSPECT BY DESIGN DATA YEAR MANUFACTURED CONSTRUCTION MATERIAL CORROSION ALLOWANCE 2002 CS / SS 304L 1.0 (S) / 0 (T) mm DESIGN PRESSURE TEST PRESSURE PRESSURE TEST DATE 15 (S) / 2,5 (T) kg/cm2 22 (S) / 4.8 (T) kg/cm2 2002 E-2570 30th January 2013 Khalid
FREQUENCY/ INTERVAL OF INSPECTION

MAX PERMITTED
INSPECTION INTERVAL (API) LAST INSPECTION DATE NEXT INSPECTION DATE REMAINING LIFE
120 Month(s) 30th September 2009 30th January 2023 <10 years
REASON FOR INSPECTION
Planned
Un-plan
Other (Process upset)
TYPE OF EXAMINATION/ TEST PERFORMED TYPE IF INSPECTION INSPECTION METHODS / TESTS USED HYDROSTATIC TEST OTHERS (PLEASE SPECIFY) Internal Visual Entire External UTG Coil
___________________ Signatory of Inspector Rev.5 / Sept 2011
__________________________ Signatory of R&I Supt/ Engineer Page 1 of 22
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
RECOMMENDATION/ ACTION To perform hydrotest for the exchanger as per test pressure. Results passed
ACTION PARTY Mechanical
DATE CLOSED 3rd Feb 2013
Rev.5 / Sept 2011
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THICKNESS DATA Location Channel plate Shell plate Shell cone 4 Glycol inlet nozzle(N5) 8 Glycol outlet nozzle(N6) 4 Hot oil inlet nozzle(HOS) 4 Hot oil outlet nozzle(HOR) 1 Drain nozzle(D) 1 Vent nozzle(V1) 1 Vent nozzle(V2) Current (t) mm 11.86 12.57 12.72 6.15 15.9 8.12 8.44 6.20 3.77 6.02 Previous (t) mm Design (t) mm 12.00 12.70 12.70 6.02 11.18 8.56 8.56 6.35 3.38 6.35 Corrosion Allowance (mm) 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 Condition Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance
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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
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Floating head plate condition
Expansion bellow condition
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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
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Tubesheet condition
Close view of tubes
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Close view of tubes
Tube bundle. One tie rod noted slight bend. No issue
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Close view.
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INSPECTION CHECKLISTS RECORD
Pressure Vessel Inspection Checklist

Tick relevant boxes
Item
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
Completed [ ] NA
Comments
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) 8) Inspect the impingement or wear plates for any sign of corrosion or erosion 9) Obtain thickness for shell/ nozzles and dead legs area 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 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 NA NA Thickness within tolerance
Furnace (Fire Heater) 1) Check before and after cleaning NA
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2) Check for porous refractory by hammer test and mark out for repair (if any) 3) Any damage of baffle brick 4) Check and damage or crack ferrules 5) Check any expose anchor 6) Replace feed tube (R1/R2) with correct material construction of Inconel with PMI (for F-8010 only) 7) Vacuum or remove dust on furnace bottom circumference of the refractory brick (for F-8010 only) 8) Fill up the bricks to bricks joints with Ceramic fibre if gap approximately >4mm (if any) 9) Check internal radiant coil thermo bond secured (for Hot Oil Heater only) 10) Check any sign of loose supports securing the radiant coils (for Hot Oil Heater only) 11) Check any ash formation built up / refractory drop out at the crossover fin coils from small doors area (for Hot Oil Heater only) 12) Obtain thickness for shell/ nozzles and dead legs area 13) Check any insulation damage / CUI/ external corrosion 14) Check foundations/ support condition 15) Check platform, ladders, handrails and davis condition 16) Check any painting damage 17) Check all internal apparatus like thermo well, etc condition Boiler 1) Check before and after cleaning 2) Check internal Steam drum and tubes condition 3) Check internal water drum condition 4) Check internal spacer tubes condition 5) Check for porous refractory by hammer test and mark out for repair (if any) 6) Perform require NDT 7) Obtain thickness for shell/ nozzles and dead legs area 8) Check any insulation damage / CUI/ external corrosion
NA NA NA NA NA NA
NA NA NA NA
NA NA NA NA NA NA
NA NA NA NA NA NA NA NA
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9) Check foundations/ support condition 10) Check platform, ladders, handrails and davis condition 11) Check any painting damage 12) Check all internal apparatus like thermo well, etc condition
NA NA NA
Pressure Vessel (Column/ Vessel/ Reactor) 1) Check before and after cleaning 2) Visual check internal wall condition 3) Check chimney tray condition 4) Check bottom vortex strainer condition 5) Check demister pads condition 6) Check internal packing for any fouling or plugging in bed 7) Inspect the impingement or wear plates for any sign of corrosion or erosion 8) Perform require NDT 9) Inspect any loose of U-bolts & sign of cut or erosion between pipe 10) Check spray nozzle condition 11) Check any damage or weld shear off support 12) Check any bolt/ nuts loose for impeller blade 13) Check any sign of lining/ cladding failure 14) Obtain thickness for shell/ nozzles and dead legs area 15) Check any insulation damage / CUI/ external corrosion 16) Check foundations/ support condition 17) Check platform, ladders, handrails and davis condition 18) Check any painting damage 19) Perform hydro test for external/ internal coil 20) Check all internal apparatus like thermo well, etc condition NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Others Comment.
Rev.5 / Sept 2011
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Sample Inspection Report of Exchanger

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

FREQUENCY/ INTERVAL OF INSPECTION

REASON FOR INSPECTION

Other (Process upset)

___________________ Signatory of Inspector Rev.5 / Sept 2011

__________________________ Signatory of R&I Supt/ Engineer Page 1 of 22

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

ACTION PARTY Mechanical

DATE CLOSED 3rd Feb 2013

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

INSPECTION PHOTOGRAPHIC RECORD Photo Findings Overview of E-2570

Exchanger shell overview

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal shell appeared in good condition

Channel head overview

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal channel head condition

Shell cover(cone) overview

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal view condition

Internal view condition

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Floating tube sheet and tube bundle condition.

Tubesheet observed no plugging however fouling built up was observed

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view of fouling built up

Generally tube bundle appeared in good condition

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Floating head plate condition

Expansion bellow condition

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

After cleaning condition Shell internal

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Expansion bellow condition

Channel head condition

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Channel head cover

Floating head plate condition

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view of tubes

Rev.5 / Sept 2011

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view of tubes

Tube bundle. One tie rod noted slight bend. No issue

Rev.5 / Sept 2011