TUV India FIN FAN Cooler Inspection

TUV INDIA – EXPERTISE FOR YOUR SUCCESS
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Why shutdown required ?
 To ensure safe and reliable operation

 Periodic maintenance
 Integrity check of equipment
Some refinery cases :
Explosion in FCCU Reactor video
Explosion due to ruptured elbow video
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Working of crude distillation unit
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FIN FAN COOLER INSPECTION

To ensure safe and reliable operation
1. EXTERNAL INSPECTION :
 Tube fins condition to be checked visually for any mechanical damage or deformation
 Check for surface corrosion on nozzles, header box, drain and vents.
 Check if paint is damaged.
 Identify any leaky point.
 Check for earthing strip connection, support and frame
 Check for PG /TG condition.
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2. INTERNAL INSPECTION
 In case of plug type header box, about 10% of plugs shall be opened in M&I shutdown. Plug marking to
be done.
 The tube bore shall be inspected by using fibro scope / narrow beam light source.
 If the tubes are found badly fouled, all the plugs shall be opened and thorough cleaning of the tubes shall
be done.
PRECLEANING INSPECTION :
 Take photos of all components in as it is condition.
 Note down the area of heavy deposition , their appearance, color and if required collect sample.
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Hydro jet cleaning of tubes
POST CLEANING INSPECTION:
 Tube plug thread to be checked for damage,
 Tube sheet internal thread for plug to be checked for any possible damage or erosion.
 Header box internal inspection to done through plug holes, any sign of corrosion erosion pitting shall be
checked.
 Tube choking to be checked,
 Tube end thinning shall be checked.
 Inlet outlet nozzles shall be check for any abnormality.
 All flanges gasket seating face and serration to be checked.
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Plug thread visual inspection Plug opening process
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Wall thickness measurement
 Header box (top, bottom and both side plate) thickness to be measured.
 Inlet/outlet nozzles thickness to be measured.
 Drain and vent thickness to be measured.
 Inlet /outlet piping bends thickness to be measured.
 If thickness loss observed is more than corrosion allowance, then remaining life
shall be calculated as per API 510.
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Tube inspection method and NDT
 Tube integrity to be ensured by RFET / IRIS.
 In case of repair/ alteration, approved procedure to be used and applicable codes and standard to be
followed (API 661, API 510, API RP 571, ASME SEC IX)
 DPT as per ASME SEC VIII DIV -1 APP-8
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Hydro test of fin fan cooler :
 All new gasket of plug should be used.
 Hydro test to be conducted as per approved procedure.
 Two PG required at top and bottom
 Calibration to be checked for both PG.
 PG range should be of 1.5 to 4 times of test pressure.
 Pressure holding time should be of 30 minutes.
 In case of pressure drop, leak location to be identified.
 Tube plugs at both end to be checked for any leak.
 If plug leak observed, then pressure to be reduced to 0, and tightness to be checked of plug.
 In case of internal thread of header box damaged then plug to be seal welded.
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Retubing of fin fan cooler video
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Inspection record :
 Observations in brief,
 Thickness and gauging record of all components including data readings prior to commissioning.
 In case of Repair / replacement jobs to be carried out :
 WPS/PQR/ITP
 Radiographic and other NDE results
 Procedure for stress relieving
 Electrode / filler wire specifications
 Material specification
 Stages of NDT required.
 Pressure test records.
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 Record of material replacement
Document record :
The data report should include the following information:
 Manufacturers Serial Number
 GA drawing
 Owner-Users Identification Number
 Pressure vessel dimensional data (width, height, diameter, etc.)
 Material of construction
 Original wall thickness data for pressure vessel and dished heads
 Original code of construction including NDE method
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TUV INDIA – EXPERTISE FOR YOUR SUCCESS

 To ensure safe and reliable operation

Some refinery cases :

Explosion in FCCU Reactor video

Explosion due to ruptured elbow video

FIN FAN COOLER INSPECTION

 Check if paint is damaged.

 Identify any leaky point.

 Check for earthing strip connection, support and frame

 Check for PG /TG condition.

 Take photos of all components in as it is condition.

 Tube plug thread to be checked for damage,

 Tube choking to be checked,

 Tube end thinning shall be checked.

 Inlet outlet nozzles shall be check for any abnormality.

 All flanges gasket seating face and serration to be checked.

 Inlet/outlet nozzles thickness to be measured.

 Drain and vent thickness to be measured.

 Inlet /outlet piping bends thickness to be measured.

shall be calculated as per API 510.

 DPT as per ASME SEC VIII DIV -1 APP-8

 Hydro test to be conducted as per approved procedure.

 Two PG required at top and bottom

 Calibration to be checked for both PG.

 PG range should be of 1.5 to 4 times of test pressure.

 Pressure holding time should be of 30 minutes.

 In case of pressure drop, leak location to be identified.

 Tube plugs at both end to be checked for any leak.

 In case of Repair / replacement jobs to be carried out :

 Radiographic and other NDE results

 Procedure for stress relieving

 Electrode / filler wire specifications

 Stages of NDT required.

 Pressure test records.

 Manufacturers Serial Number

 Owner-Users Identification Number

 Pressure vessel dimensional data (width, height, diameter, etc.)

 Original code of construction including NDE method

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