History&DataCollectionsheetforEquipment(Heatexchangers)

KemiraPlantHistory(Inspection,Maintenance,Replacements,Failures,Modifications,ResultantOperationalupset,Efficiencyloss)
P&IDNo EquipmentTag EquipmentDescription VendorName 1990 1991 1992 1993 1994 1995 1996 TA'96 E093wasnewlyintoducedasaresultof ENCON5studyandnewexchangerwas NoConcern installedwithSS321tubes,SS304Lshelland Duplextubesheetmaterials. Slightcorrosionwasobservedontubes, tubesheetandchannelcover.Packingfaceof NoConcern partitionribalsoshowcorrsionbutwas acceptable NoConcern NoConcern 1997 1998 1999 2000

Mothballing& Relocation(Condition, refurbishmentetc.)

ConstructionphaseInspection Findings
2009

FFLHistory(RefertoKemiradetails)

2010

2011

2012

E093

CATACARBReboiler

BRONSWERK

NotInstalled

NotInstalled

NotInstalled

NotInstalled

NotInstalled

NotInstalled

NoConcern

NoConcern

NoConcern

E102

C101Surface Condenser

NEM

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

Exchangerwashealthyand Exchangercleaningwasplanned haveslightcorrosion NoConcern Exchangerwashealthy.

E103

C101VacuumJetCooler KORTING

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E104

C101TurbineGland Condenser

RHEINKALTE

Noconcern

Noconcern

Noconcern

NoConcern

NoConcern

NoConcern

Pittingobservedontubesandtubesheet howeveritwasinacceptablerange(approx. 0.05mm). NoConcern Corrosionwasalsoobservedoncover howeveritisalsoacceptable

NoConcern

NoConcern

NoConcern

E105A1

C102FirstStageAfter Cooler

BundlewasorderedwithCSmaterial

BundleA1(Upper)with CSmaterialwasputin serviceinTA1991

NoConcern

NoConcern

NoConcern

SSduplexbundlewasordered

Feb'97:After03monthsof operation,E105A1bundle(duplex tubes)startedleaking(top04rows CSbundlewasreplacedwithDuplexbundle. oftubeswasfounddamageddueto Thedecisionwasmadekeepinginviewthe bafflecutting)anddeclarednotfit replacementfrequencyofCSbundles(07 foruse.SinceBundleE105A1 bundlesreplacedsince1968).Dia.offloating (duplex)wasrejected,oldCSbundle NoConcern headofDUPLEXbundleissmalleras ofE105A2wasplacedinE105A1 comparedtoCSBundle. shellafterinspectingthecondition CSBundleinspectedduringTA96andtubes ofbothbundles.Andtheotherwas sentforretubing. werefounddamaged. CSbundlealsostartedleakingafter fewmonthsofoperationandlater wasreplacedbyretubedCSbundle. Feb'97:Bundlepulledoutand inspected.02tubeswerefound brokenduetobafflecutting, damagedtubepulledoutandbaffle holeswereplugged.Bundletubes, tubesheetandbaffleplatewere NoConcern foundlittlecorroded.UToftubes wascarriedoutandfoundOK. Pulledbundlewasagaininserted backintoshell. Coatingofshellwascompletely damaged.

NoConcern

OldCSbindlewasreplacedby newDuplexSSbundle

Nospareavailable.New spare(commonforbothA1 &A2)bundleneedstobe procuredwithimproved baffledesigntoavoidbaffle cutting

E105A2

C102FirstStageAfter Cooler

BundleA2(B)withCSmaterialwasordered

BundleA2(B)withCS materialwasputin serviceinTA1991

NoConcern

NoConcern

NoConcern

SSduplexbundlewasordered

Duplexbundlewasbuiltandputinservice. OldCSbundlewasreservedasemergency spare.

NoConcern

NoConcern

E106A/B(02 C102SecondStage Nos, AfterCooler upper/lower)

BRONSWERK FEYENOORD

NoConcern

NoConcern

NoConcern

NoConcern

BundleB(Lower)hydro testedin02/94. 02tubesplugged

NoConcern

ModifiedbundleA(upper)wasinstalled. 1.Designchangedbyinstalling12lesstubes. 2.Reconstructionoffloatinghead(BCsmaller diameter,suitableforcamprofilegasket). 3.TubesinternallycoatedwithZacosin2000 Q. NoConcern Meanservicelifeis8years. OldBundlepulledfromtheuppershell clearedhydrotestinTA96at8.5bar. ThesamebundlewasplacedinE106B. BundleB(A2)removedfromE106(lower) wasscrapped

NoConcern

Itwasrecommendedto replacebundleB (Lower)withnewone.

Replaceoldofthetwo availablebundlewithnew one. Repair/refurbisholdbundle.

E107A2

C102ThirdStageAfter BRONSWERK Cooler FEYENOORD

Oct.1969,Nov.1971,May1973 UltraSonicwallthicknessmeasurementofshellwas carriedout.Itwasok. Feb1975 DuringT.A,bundlebuilt1967waspulledandwas replacedwithanewreservebundlewithcoatedtubes (Zacosin2000Q)built1974wasinstalled. Sept.1975 NoConcern Orderwasplacedforthenewbundle. March1983 Totaltwotubeswereplugged.Bundlewascleanedby meansofhighpressurewaterjetting.Itwastestedat 5barsandwasok.Someblisterswereobservedon thecoating. April1986 DuringT.A,bundlewaspulled.Newbundlebuilt1981 wasinstalled.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 Bundlebuilt1981wasremovedandnew bundlebuilt1996wasinstalledinE107A1 shell.UltraSonicwallthicknessmeasurement NoConcern ofshellwascarriedout.Theresultwas acceptable.

NoConcern

NoConcern

2000 E107A1shellhadthebundle built1996.

E107A1

C102ThirdStageAfter BRONSWERK Cooler FEYENOORD

Oct.1969,Nov.1971,May1973 UltraSonicwallthicknessmeasurementofshellwas carriedout.Itwasok. Feb1975 DuringT.A,bundlebuilt1967waspulled.Anew reservebundlewithcoatedtubes(Zacosin2000Q) built1974wasinstalled. Sept.1975 NoConcern Orderwasplacedforthenewbundle. March1983 Totaltwotubeswereplugged.Bundlewascleanedby meansofhighpressurewaterjetting.Itwastestedat 5barsandwasok.Someblisterswereobservedon thecoating. April1986 DuringT.A,bundlewaspulled.Newbundle(built 1981)wasinstalled.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 Bundlebuilt1981wasremovedandnew bundlebuilt1996wasinstalledinE107A1 shell.UltraSonicwallthicknessmeasurement NoConcern ofshellwascarriedout.Theresultwas acceptable.

NoConcern

NoConcern

2000 E107A1shellhadthebundle Bundleshealthy.Spareavailable built1996.

E107A2

C102ThirdStageAfter BRONSWERK Cooler FEYENOORD

May1968,Oct.1969,Nov.1971: UltraSonicwallthicknessmeasurementofshellwas carriedout.Itwasok. Feb1975 DuringT.A,Tubeswereinternallycleanedbymeansof highpressurewaterspray.Tubestothechannelside wereslightlycorroded.Floatingheadandcovers showedsomepitcorrosion.Noleakedtubeswere April1991 observed. DuringT.A,bundlebuilt Oct.1976 1976waspulled.Bundle Bundlewaspulled.Newbundlebuilt1976withcoated NoConcern built1990wasinstalledin tubes(Zacosin2000Q)wasplacedinitsplace.Ultra E107A2shell. Sonicwallthicknessmeasurementofshellwascarried out.Itwasok. June1981 Channelcoversandfloatingheadweredismantled. Inspectionwascarriedout.Someblisteringwas observedonbothsides(eastandwest)ofthecoating. April1986 Onetubewasremovedforthepredictionofthe remaininglifeofthebundle. Mar.1983 Thetubesandtubesheetswerefounddirty.Itwas cleanedbymeansofhighpressurewaterjetting.After cleaningthebundle,itwasagaininspected.Corrosion ofabout0.1mmintubesand0.5mmintubesheet NoConcern wasobserved. June1988 Bundlewascleanedbywaterjetting.Pittingcorrosion ofabout0.5mmwasobserved. May1973 Condenserwasopenedforinspection.Headswereok. Tubesendconnectionswerelightlycorroded.. Mar.1983 DuringT.A,Shellwiththebundlewasinspectedandit wasdirty.BundlewasgivenforRetubing.After NoConcern retubing,bundlewastestedatapressureof6bars andaccepted. June1988 Outsidetubesconditionwasgood.Pitcorrosionof0.2 mminsidethetubeswasfound.Pittingcorrosionof 0.5mmwasalsofoundontubesheet. 3leakedtubesofE110Ebundlewereobservedand plugged.E110Dbundlewasinstalled. E110Dbundlewas removedandE110C bundleinstalled.

NoConcern

NoConcern

NoConcern

April1996 Bundlebuilt1990wasremovedandbundle built1981installed(removedfromE107A1 shell)inE107A2shell.Bundlewastested NoConcern andok.UltraSonicwallthickness measurementofshellwascarriedout.The resultwasacceptable.

NoConcern

July1999 Itwassuggestedtobuy thenewbundle. 2000 1999 E107A2shellhadthebundle Newsparebundlewas built1981. available

E108

C102Surface Condensor

NEM

NoConcern

NoConcern

NoConcern

NoConcern

April1996 Pittingcorrosionwasobservedonthetubes NoConcern andtubesheet.Corrosionwasalsoobserved onthesealingsurface.Butitwasacceptable.

NoConcern

NoConcern

NoConcern

E109

C102VacuumJetInter KORTING Condensor

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E110

SecondaryReformer SteamGenerator

KOERVERUND LERSCH

E110Cbundle wasleakedand replacedwithE 110Dbundle.

Nodataavaialble Tubes/tubesheet/channelwereinspected andfoundgrooveonchannelgasketsurface (acceptable).Blackdustwasfoundatthe outletandwascleaned.MPIwascarriedout Clampwasinstalledon fornozzlesandfoundok.Wallthickness NoConcern NoConcern NoConcern thermocoupleT130torectify measurementwasalsoconductedandfound leakage. ok. Coldendwasopenedbuttubeendspastthe tubesheetwerenotinspectedforcorrosion damage. BundleCrepairedbecauseof Retubingandmodification leakingtubes,certaintubeswere ofthereservebundleB plugged.Duringhydrostatictesting, wasdone. waterfromdiaphragmalsoshowed MajorModificationswere: leakages.oneweeklaterrepair 1.Changeintubepattern procedurewasmadeanditwas oftubesheetaccordingto Modificationandretubing repairedaccordingly. E112bundledrawingEC completed.01leakingtubewas Shellwasvisuallyinspected,surfaceofgasket Recommendationwasfloatedthat 0103E112011. ofshellflangewasslightlydamaged,was olddiaphragmmustbereplaced foundduringpressuretest, 2.Atotalof22tubescould withanewone.Atthisstageslightly therewaspressureoftotal10 repairedanddeclaredok. notbeinstalleddueto Scratcheswerefoundincladdingagain. damaged9tubeswerepluggedin barinBundleB. changeintubepattern. thetubesheet. Newdiaphragmwasinstalled Insulationfromshellwasremovedfor NoConcern 3.Removetheinstalled butDPTshowedthatwelding inspectionandnozzlesN1andN2werealso Total26tubeswerepluggedi.e. "HollowPlugs"and"Bar wasnoteffiecient.Newgasket inspected.Wallthicknesswasalsoacceptable about5.5percentoftotal464. Plugs"whichareintotalof wasalsoinstalledatoutlet . approx.16pieces. flange BundleB(builtin76)afterretubingin95was DuringpressurizingwithN2another 4.Install"HollowPlugs"in installedagainandwasnamedbundleC. tubewasfoundleaked.Sometubes remainingtubesheet werepreventivelypluggedalso. holes. Total55(12%)werepluggeduptill 5.Modificationand 97. improvementoftubeto Hydrotestunder170bargpressure tubesheetconnectionbya wascarriedoutandwasokayed. revisedweldingandrolling procedure. IntheTAof1996theE113resistakenout andoriginalbuddleE113Awhichwas repairedin1995isinstalledithasbeen hydrotestedandisclear.FurtherDPTwas conductedontheshellofE113Aandthe liftinglugsarefounddamagedsotheyare repaired.Thisisthebuddlethatwasshifted toPakistan

BundleE110G(new)was installedandbundleE110D removed.

E111

HTSEffluentHPBFW Heater

LUIGIRESTA

NoConcern

Newbundleinstalledwith tubematerial1.25Cr NoConcern 0.5Mo.

NoConcern

NoConcern

NoConcern

Recommendedtoopenthe coldendofE111for inspectionoftubeendspast thetubesheetforinternal corrosion.Anddecidere orderingofnewbundle basedoninspectionfindings

100 KE-6

E112

LTSfeedwater Exchanger

KOERVER UNDLERSCH

BundleB(reservebundlebuiltin76)wasinthe service.

DuringTA'91oldbundleB (reservedbundlebuiltin 76)wasgivento Stoomwezenforperiodic Itwassuggested inspection.Bundlewas toremove22 pulledoutduetoleaking tubesfromBundle NoConcern B.Itwouldbe tubes.Claddingwas damagedduringbundle retubedand modified. pullingactivity.OldA bundle(BuiltYear75)was installed.Everythingelse wasfoundok.

Anewbundle'sbundle BundleDisnowinstalledin "D"PRwasinitiatedin FFCL.theretubedbundle"B" 99. wasinthescrapyard.

StartupdonewitholdHeatexchanger.

3Tubesleaked.PlantS/D.Pluuged

100 KE-7

E113A

SemiLeanSolution RegeneratorReboiler

D.BONALDI

E113Abundleispulledoutandinspectedfoundok andinsertedbackin

ThereservebundleofE 113whichwastakenout ofE113Bshellisin1989 NoConcern isrepairedin1990and has46pluggedtubesthis bundleisinstalledinE 113Ashell.

NoConcern

NoConcern

Jobpackagewasissuedforthe sealweldingoftubetotube sheetconnectionofE113A Bundle

NoConcern

NoConcern

NoConcern

NoConcern

100 KE-7

E113B

SemiLeanSolution RegeneratorReboiler

D.BONALDI

In1989thereservebundleispulledoutofE113B shellandoriginalE113Bbundleisplacedinshell.

Bundleispulledout inspectedandplaced backinside

NoConcern

NoConcern

NoConcern

ThebundleofE113Bispulledout, hydrotestedandvariousinspectionswere Leakagewasdetectedfromshell performed.Bundlewasfoundokandinserted NoConcern inletflangeandflangewas backin.Thisisthebundlewhichwasshifted renewed backtoPakistan.FurtherDPTofshellis conductedandlugsarerepaired.

NoConcern

NoConcern

NoConcern

Recommendationistobuy onesparebundleforE113 asreservebundleofKemira wasscrapped

100 KE-7

E114

REGENERATORSTEAM REBOILER

D.BONALDI/ CERMAITALIA

In1991thebundlewas pulledoutandinspected. Duringthisinspection eleven(11)tubeswere foundleakingandwere plugged,makingatotalof fifteen(15)plugged Inaninspectionin1986,four(4)tubesweredamaged tubes.Outoftheeleven duringbundlepulling.Thesetubeswereplugged. tubeswhichwerefound NoConcern In1990inspectionswerecarriedoutandnoissuewas leakingonetubehad found.Bundleinsertedbackinside. completelytornoffinto twohalves.Alsothere wasleakageinchannel headcovergasketthe coverandshellflange surfaceswererepaired throughmachiningand gasketreplaced.

NoConcern

NoConcern

ALLPSvalveatinlettoE114 getsstuckandismade operational.Nothingofconcern takesplacetotheexchanger itself

Thebundlewasinspectedandoneofthe pluggedtubesshowssomeporositywhich wasrepairedandbundlewasplacedback inside.

NoConcern

NoConcern

NoConcern

NoConcern

Basedoncondition& inspection,mayneedto orderanewbundle

E115

LeanSolutionL.P.BFeed BONALDI Water

Aug.1981 1981TA,bundlewaspulled.Slightpittingcorrosion wasfoundontheinsidesurface.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

April1996 Afterpullingthebundle,visualinspectionof theshellwasdone.N4nozzleandchannel NoConcern coverwerealsoinspected.Somepitcorrosion wasfound.Overallresultswereacceptable.

NoConcern

NoConcern

NoConcern

none

E117

1500#SUPERHEATER

KOERVER UNDLERSCH

Itisproposedtocarryoutreinforcementofshell aroundN3. Newdiaphramplatewasinstalled

Bundlepulledoutfor inspection.Bundleand shellfoundsatisfactory. NoConcern MPIofreinforcmentpad andnozzlewascarried outandfoundok. OldE118wasremoved. AspartoftheEncon3 projectacompletelynew unitE118Cisinstalledin itsplace.Thisexchangeris NoConcern biggerandbetterthanits predecessor.Thenew exchangerE118Cwas builtin1988to1989by LugiResta. April1991 Channelsdismantled. Exchangerforan alternativeperiodic inspectionwasofferedto NoConcern Stoomwezen.No abnormalitieswere found.UltraSonicwall thicknesswasmeasured.

NoConcern

NoConcern

NoConcern

Exchagershellwasvisuallyinspected;MPIof nozzlesN1,N2&30"diaweredoneandno NoConcern crackwasobserved

NoConcern

NoConcern

NoConcern

None

100 KE-5

E118

HIGHTEMSHIFTEFF. REFORMERFEED EXCHANGER

D.BONALDI/ CERMAITALIA

NoConcern

NoConcern

NoConcern

Lowerflangeleakageofthe exhaustHTSoccurredandis repairedasgoodaspossible.

Theleakingflangeof1995wasrenewedand leakagecompletelyremoved.Complete exchangerincludingbundle,shellandnozzles NoConcern wereinspectedrigorouslyandnothingof concernwasfound.

NoConcern

NoConcern

NoConcern

E119

ProcessCondensate Cooler

WERKSPOOR

NoConcern

NoConcern

NoConcern

NoConcern

Thetubebundleandtubesheetwerevisually inspectedinternally,andinthisrespectno abnormalitieswereobserved.Channelhead NoConcern andcoverwasalsoinspected.Also,the exchangerofferedtoStoomwezenfor periodicinspectionandwasfoundinorder.

NoConcern

NoConcern

NoConcern

E120A/B

METHANATORFEED EFFLUENTEXCHANGER

BRONSWERK FEYENOORD

NoConcern

E120A:Channel dismentledforinspection. Lowest05rowswere NoConcern founddirtyand tubesheetwasheavily scaled.

NoConcern

NoConcern

NoConcern

Apr'96:Bundle/shellwasinspectedandfound OK.Excessivesoilisfoundonlowersideand wascleanedthroughwaterjetting. Eastsidetubesheetflangeleaked.Clamp installedontubesheetflangewasremoved andcut(15mmwide,6mmdeep)was observedonthesurfaceoftubesheetflange. NoConcern Itwasrepaired. Jun'96:Leakagefromsameflangestarted againanditwasdecidedtousegasketwith greaterthicknesshoweverthiswasnot worked.Clampwasinstalledforrectification howeveritalsowasnotworked.Thenitwas decidedtoweldtheclamponbothsides circunferentiallyalongtheflange. In1996aleakagewasdetectedfromthe channelheadcover.Thediaphragmsurface wasweldedandmachinedforproperseating NoConcern andsealing.Theleakagewasrectified. Furtherinspectionsweredoneonthebundle andnoconcernwasfound.

NoConcern

E120A:Fireoccurred onflangeagaindueto flangeleakage.

Constructionofeastside flangewasmodifiedafter consultationwithSTWand Weld/lipsealweldwas introducedtocaterleakage problem. Shellandbundlewas inspectedandfoundOK

100 KE-9

E121

In1991,anewbundle whichwaspurchased In1990thematerialofthediaphragmofthe fromOlmiandwas OLMIITALY/D. METHANATORSTARTUP exchangerwaschangedfromInconel600toCSasper installedinplaceof BONALDI&CO. EXCHANGER areportonserviceswithlessamountofhydrogendid existingone.Theold CREMA notrequireInconelmaterial. bundlewassenttothe yard.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

100 KE-9

E122

METHANATOR EFFLUENTCOOLER

BRONZWERK FIJNOORDN.V

In1991waterboxesand channelheadcoversofE In1983existingE122isremovedandanewE122B 122Bweredismantled, NoConcern isinstalledatthislocation. rustanddirtwasfound thusexchangerwas cleanedandboxedup.

NoConcern

ChannelheadcoversofE122B In1994duetoan wereremovedandheavypitting emergencyshutdown andcorrosionwasobservedon resultingfromCGT102trip gasketsurfacesofchannelhead E122Bwasopenedand coverandshell.Theshellside In1996thecorrodedsurfaceswerecleaned thepartitionplatewas surfacewasveryseriously andthegasketsurfaceswererepaired.The foundinbulgedform(the corroded.Furtherthe exchangerwascompletelycleanedbyjetting. reasonwasunknown),the protrudingareasofthetubes Duringthisyearitwasplannedtobuyanew tubeswerecleanedvia fromthetubesheetwere exchangerwithimproveddesigntosolvethe hydrojetting.During corrodedandwerecarryingdirt. problemofcorrosionanddirtaccumulation. variousinspectionsone Itwasdecidedthatthe baffleplatewasalsofound exchangerwouldbecleaned andrepairingwillbedonein inbulgedform. TA96.

Exchangerwasexaminedthrough UTandboroscopy.Itwasfound filthyfromtheshellsidesoitwas NoConcern jettedwithwaterthroughtheoutlet nozzle.

AnewbundleE122C wasmade.This exchangerhadan improveddesign.This hasfourpassesinstead ofsixasperoriginal design.Thiswasdoneto NewE122Cisinstalledinthe reducetheflow year2000itwasonly requirementsofcooling operationalfortwomonths waterandalsoto andnoissuecameuoduring increaseflowvelocity, thosemonthsthisisthe sothatlessdeposits exchangerthatcameto weremadebytheCW Pakistan andcorrosioncanbe reduced.Further changesindesignwere incorporatedbearingin mindtheabove mentionedproblem rectifications. NoConcern NoConcern

E123
100 KE-10

MethanatorEffluent Chiller

KORPERSHOEK

June1988 Couplingthermowellwasmagneticexaminedincase NoConcern ofleakage.Nocrackobserved.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E124

SYNGASDRYER

D.BONALDI&C. NoConcern

Bundledrawnand cleanedbymeansof waterjetting.Inspection/ repairprocedure prepared.Bundle transportedtocompany forHeymanssealwelding oftube/tubesheetjoints NoConcern accordingtoapproved procedurewasdone.Leak testedbyairandDPT performedandapproved ok.Gasketsurfaceswere machinedandthickness monitoredofshelland tubes,foundok.

NoConcern

NoConcern

NoConcern

Exchangerwasopenedandthoroughly inspected,twobaffleplateswerefound damaged.Theyhaveacrosstearof5cm.It wasdecidedaftercalculatinganddiscussions withStoomwezenthatthishadnomajor influenceinoperationofexchangerso nothingwasdoneaboutit.Furthertheshell wasinspectedandacrackwasobservednear theshellsupport.Itwasgrindedandwelded againDPTperformedandfoundok.

Exchangerwasinspectedandtested in1997andwasfoundok.Steam valveatoutletlinewasleakingand NoConcern wasrepaired.Everythingelsewas ok.

NoConcern

NoConcern

E131

CT104VacuumJetInter KORTING Condensor

Feb.1987 Bundlewastestedat8bars.Tubesheetjointfaces wereheavilycorroded.Sometubeendconnections werealsocorroded. NoConcern June1988 Thebundlewasretubed.Gasketsurfacewasrepaired. Everythingwasok. May1973 Exchangerwasopenedforinspections.Corrosionwas foundonthetubesheets. April1979 DuringT.A,bundlewascompletelyretubed. May1981 Coverswereremoved.Bundlewaspulledandshell visuallyinspected.Slightcontaminationobserved.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 T.A1996,visualinspectionwasdoneafter waterjetting.Nospecialabnormalitywas observed.Coatingwasingoodcondition.

NoConcern

NoConcern

NoConcern

NoConcern

E132

CT104GlandCondensor

FUNKE DUITSLAND

May1991 Entireexchangerwas replacedbynewE132 builtin1990.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 T.A1996,Visualinspectionwasdone.Itwas ok.

NoConcern

NoConcern

NoConcern

NoConcern

100 KE-12

E133

CONVERTORFEED/ EFFLUENTEXCHANGER

HOCHDRUK WARME AUSTAUSCHER

In1990diaphragmwasreweldedtoremoveleakage. NoConcern

NoConcern

NoConcern

NoConcern

InJune1995,thedrainpointon shellofE133startedleaking NoConcern andsoaclampwasinstalled andfurmaniteinjected.

Inaninspection carriedoutduringthe year1998itwas suspectedthattheE 133anditsnozzle gasketswereloose Duetoanemergencyshutdown andsoconcentration resultingfromaleakagefromE112, ofammoniacouldbe asampleconnectionwasaddedin detected.ThusinTA theE133&E134exchangers. of1998boltswere properlytightened andspringtype washerswere introducedtoensure bettertightening.

Intheyear1999,Kemira wasabouttoordera newe133butthe orderwasneverplaced. NoConcern Correspondenceand jobscopeisavailablein files.

100 KE-12

E134

CONVERTORFEED/ EFFLUENTEXCHANGER

RHEINSTAHLAG MACHINEBAU/ RUHRSTAHL In1990diaphragmplatewaschanged. APPARATEBAU G.M.B.H

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

100 KE-12

E135A

SYNTHESISCONVERTOR OFFICINELUGI STEAMGENERATOR RESTA

In1983E135Dfromtopposition(whichisthe positionofE135A),wasremovedandE135Fwas installedinitsposition. In1990nothingofconcerntookplace.

In1991,thebundleE135 FwasremovedandE135 Dwasreinstalledandthis exchangerremained NoConcern installedtill2000.Before itsinstallationitwas thoroughlyinspectedand wasapproved.

NoConcern

NoConcern

NoConcern

In1996E135Dwasopenedforinspection andboltheads&metalpieceswerefoundon thepartitionplate.Aftertestingleakagewas detectedand01tubewaspluggedand welded.Thentheexchangerwasagaintested at50barthistime09tubeswerefound leaked.Thesetubeswerepluggedand welded,afterweldingexchangerwastested againat110barthistimeagain04tubes werefoundleaked.Theywerepluggedand weldedafterthisagaintestwasconducted andleakagewasfoundinsealweldsfortube NoConcern totubesheetjoint,thesewereweldedand testedagainthistimesealweldsofmore tubeswerefoundleakingsowithagreement ofbothprocessandoperationtheexchanger wasboxedup.Whenexchangerwasboxed upandtakenintoserviceexplosivitywas measured,theresultsshowedthattherewas leakagefromthediaphragmfromtwo locations.WhencoverwasremovedandDPT wasconductednoporesorcrackswere found,henceboxedup.

In1998E135Dwas nitrogentestedand lowersideplugs showedsome leakages.Thesewere weldedandtested again,itwasfound ok.Thediaphragm wasweldedandDPT conductedand exchangerwasboxed up.

In1999operationand processdepartment suspectedaleakageinE Intheyear2000,afterseveral TheexchangerE135Dwas 135Dlowersidetubes andthoroughinspectionsa plannedtobescrappedsoin thustheexchangerwas crackwasfoundatthebottom Pakistan,abrandnew openedbutaftertesting oftheheadofE135D.This exchangerE135Iwhichwas crackwasweldedandNDT nothingwasfound, builtin1999wasinstalledin wasperformedandapproved. Pakistan. henceboxedup.A brandnewexchangerE 135Iwasbuiltin1999.

100 KE-12

E135B

SYNTHESISCONVERTOR OFFICINELUGI STEAMGENERATOR RESTA

In1991E135H,which wasacombinationofE 135Eshelland completelynewbundle, In1975E135Bistakenoutfrombottomlocation wasinstalledinlocation andtakentoyard.InitsplaceE135Eisinstalled.In ofE135B(bottom 1983E135EistakenoutfrombottomlocationandE location).ThebundleE 135Gisinstalledinitsplace.In1984itisdecidedthat NoConcern 135Gwhichwas thebundleofE135Ewillbetakenoutanditsshell removedfromthe willberetained.BundleE135Hwillbemadeand bottomlocationistested, placedinshellofE135E. repairedandplacedin yardundernitrogen pressure;thisexchanger isingoodcondition

NoConcern

NoConcern

NoConcern

In1996theexchangerE135Hwasnot opened.Itwasonlyinspectedthroughnozzle NoConcern (N1);thetubesheetwasvisuallyinspected andwasfoundingoodcondition.

NoConcern

In2000thelowerbundleE 135Hisopenedandalmost In1999operationand 20kgofforeignmatteris foundonthepartitionplate. processdepartment suspectedaleakageinE Ananalysisofthematteris 135,thiswasonthe madeandfoundthatitis TheexchangerE135Hwas basisofhighammonia catalystdustfromconvertor. replacedbythesparebundle percentageinBFWtoD Theexchangeristhoroughly E135GinPakistanandnow 105,theleakagewas tested.02leakedtubeswere E135Gisinservicefurther soughtforintopbundle pluggedandaccordingtoa thatE135Hisgoingfor E135Dwhichwasok plan03tubeswereplugged refurbishment. butactuallyprocess aroundeveryleakingtube. foundthatleakagewas Henceatotalof08tubeswere inlowerbundleE135H pluggedandwelded.Afterthe abovementionedjobsthe exchangerwasboxedup.

100 KE-12

E136A1

Feb1971 19tubesweredamaged.Thesetubeswereplugged andsealweldedwithSL12(lowhydrogen)electrode. DPtestofsealweldwasperformed. August1972 13leakedtubeswereobserved.Thesewereplugged. April1991 SCHELDE Totalnumberofpluggedtubeswas32.DPtestofseal SYNTHESISCONVERTOR E136B1built1967was weldwasperformedandapproved. EXOTECH pulledoutandE136B2 EFFLUENTEXCHANGER (BUNDLE)/KLK Jan.1973 built1974wasinstalled. Tenmoreleakedtubeswereobserved.Thesewere pluggedwithSL12electrode.Totalnumberofplugged tubeswas42. Mar.1983 E136resbundlewaspulledandE136B1built1967 installed.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 DuringT.A,visualinspectionwasdone. Bundlewascleanedbywaterjetting.Coating NoConcern wasnotinagoodcondition.Itwassuggested tobuythenewbundle.

NoConcern

2000 E136B2bundlebuilt1974 waspulledandnewE136A1 built2000wasinstalled.

E136A2

May1973 BundleE136A2built1967waspulledandcleanedby highpressurewater.Slightcorrosionwasobserved. Bafflesalsoshowedsomepitcorrosion.Sealingstrips weredamaged.Thesewererepaired. December1974 Coversanddiaphragmwereremoved.4Leakedtubes NoConcern wereobservedandplugged.35tubeswerealso pluggedduetopreventivemaintenance.Total39 tubeswereplugged. Feb.1975 Bundlewaspulled.NewE136A2built1974was installedintheshellE136A2shell.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 Bundlewasinspected.Coatingwasnotina goodcondition.Itwassuggestedtobuythe newbundle.Thetypeofdiaphragmplateis changedfromaflatplatetoaplatewitha raisedfacedring,whichmustsealthemain featuresincombinationwithasealweld.

NoConcern

NoConcern

NoConcern

2000 E136A2bundlebuiltin1974 waspulledandnewE136A2 built2000wasinstalled.

E136B1

March1973 Thewallthicknessofthebundlewasreducedto30to 40%ofthenominalwallthickness.Bundleputinshell andpressuretestedatabout8kg/cm2.Total233 tubeswereplugged. August1973 44moretubeswerefoundleakedandplugged.Total numberoftubespluggedwere277. Sept.1973 Atthistime19othertubeswereplugged. NoConcern March1974 Duringthisbriefshutdown,theremaining352tubes werealsopluggedsonowall648tubeswereplugged. Oct.1976 E136B1built1967waspulledoutandE136A1built 1967installed. Mar.1983 E136A1bundlewaspulledandE136resbundle installed.

NoConcern

NoConcern

NoConcern

NoConcern

June1996 E136resbundlewaspulledoutandE136B1 NoConcern built1967(retubed)installed.

NoConcern

NoConcern

2000 E136B1shellhasE136B1 retubedbundlebuiltin1967 whichwasinstalledinJune 1996.

E136B2

Feb.1975 E136B2bundlebuilt1967waspulledoutandE136 B2built1974installed. June1981 Thebundlecoatingwasinspectedandtheoverall NoConcern conditionofthecoatingwassatisfactory. June1988 E136B2bundlebuilt1974waspulledoutandE136 A1built1975installed.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

2000 E136B2shellhasE136A1 bundlebuilt1975whichwas installedinJune1988.

100 KE-13

E137

KOERVER& SYNTHESISHIGHLEVEL LERSCHKREFELD NoConcern CHILLER KESSELFABRIK

Modificationin diaphragmplate.New typediaphragmplate installed.

NoConcern

NoConcern

Shellwasvisuallyinspected andfound 1.Corrodednozzles NoConcern 2.Covercoatingwasloose 3.Thecoatingonheadwas alsoreduced Shellwasvisuallyinspected andfound 1.Corrodednozzles NoConcern 2.Covercoatingwasloose 3.Thecoatingonheadwas alsoreduced

ObservationsfromTA'94wererepaired

NoConcern

NoConcern

NoConcern

NoConcern

100 KE-13

E138

KOERVER& SYNTHESISLOWLEVEL LERSCHKREFELD NoConcern CHILLER KESSELFABRIK

Modificationin diaphragmplate.New typediaphragmplate

NoConcern

NoConcern

ObservationsfromTA'94wererepaired

NoConcern

NoConcern

NoConcern

NoConcern

100 KE-13

E139

AMMONIABOOSTER COMPRESSORCOOLER

N.VDE PLAATWELLERIJ

TherewasahistoryofE139beingfilthywhenever openedforinspection,butnotubeleakageshave beenmentionedfrom1983to1990.

Duringinspectionin1991 therewereelementsof pitcorrosionontheshell NoConcern andthetubesheet.The bundlewasnotpulled out.

NoConcern

NoConcern

NoConcern

Duringinspectionin1996,heavypitting corrosionontheshellandthetubesheetwas found.Whentestedthebundleshowed NoConcern severeleakageshencethebundlewaspulled outandretubed,theninsertedbackinafter testing.

NoConcern

Thereweresuggestions tobuyanewheat NoConcern exchangerbutitnever wasdone.

100 KE-16

E145A1

AMMONIAABSORBER EXCHANGER

BRONSWERK FIJNOORDN.V

During1987TA,bundlewastakenoutafterheavy leakagesfromofE145A1andtheshellofE145A1 wasblinded.TheA1bundleafterremovalwasre tubedandhydrostaticallytested,theninDecember 1987itwasinstalledinE145A2

NoConcern

NoConcern

NoConcern

In1994E145A1bundle wascleanedthroughwater jetting,aftercleaningof NoConcern tubesalotofpitting corrosionwasobserved.

DuringanemergencyshutdownE 145A1,whichwasinstalledinplace In1996thebundleE145A1waswaterjetted ofE145A2,wasinspected.Ithad aftercleaningagainpittingcorrosionwas NoConcern heavycorrosionontheportionof observedbutthiswasinacceptablerange. thetubesprotrudingoutofthe tubesheet. May1997 LeakagewasobservedinA1bundle April1996 andwastakenoutandretubed Visualinspectionofshell,cover,andchannel bundleA3wasinstalled.After andgasketsurfacewasdone.Gasketsurface NoConcern pulling,theshellwasvisually wascorrodedandrepaired. inspectedandfoundthatpartition platedeformedtowardstopside.

NoConcern

NoConcern

E145A2

AMMONIAABSORBER EXCHANGER

BRONSWERK FIJNOORDN.V

LeakedA2bundlewaspulledoutandretubedA1 bundlewasplacedinA2shell.Aug.1988 Fiveleakingtubeswereplugged.A3bundlewas replacedbyA2bundleinA3shellduetotheleakage NoConcern problem. Jan.1989 DuringshortshutdownofammoniaplantA2bundle waspulledoutfromA3shell.A3retubedbundlewas placedinshellA3.A2wasthenplaceintheyard. Aug.1988LeakedA3bundlewaspulledand replacedbyA2bundle.A3bundleretubedandtested on30bars.A3bundlewasonstandby. Jan.1989 NoConcern DuringammoniaplantshutdownA2bundlewas removedandA3retubedbundlewasinstalled.Gasket surfacewasseriouslycorrodedandrepaired.

NoConcern

NoConcern

Sept.1994 Afterremovingcover, tubesandtubesheetwere visualinspected,dirtwas NoConcern foundandcleanedby waterjetting.

NoConcern

NoConcern

E145A3

AMMONIAABSORBER EXCHANGER

BRONSWERK FIJNOORDN.V

NoConcern

NoConcern

Sept.1994 Afterremovingcover, tubesandtubesheets visualinspected,dirtwas foundandcleanedby waterjetting. Sept.1994 BundlesofE146A/B/C wereretubed.

NoConcern

Feb.1997 April1996 RetubedA2bundlewasplacedin Visualinspectionofshell,cover,andchannel theshellA3andA3bundlewas andgasketsurfacewasdone.Gasketsurface removed. wasfoundcorrodedandrepaired.

NoConcern

NoConcern

NoConcern

E146

T106AquaAmmonia StripperBottom

UHDE

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E147

T106TopCondensor

March1977 Thebundleofyear1967waspulledandthebundle builtin1977wasinstalled.Atthelevelofthelocations April1991 KOERVER& ofthebaffles,theshellwascorrodedtoabout0.5 Bundlewaspulledand NoConcern LERSCHKREFELD mm.June1988 cleanedbywaterjetting. KESSELFABRIK NewbundleofDuplexmaterialwasinstalled.

NoConcern

NoConcern

NoConcern

April1996 Shellandbundlewerevisuallyinspected. NoConcern Everythingwasfine.UltraSonicwallthickness measurementwasdoneanditwasok.

NoConcern

NoConcern

NoConcern

E148

T106Reboiler

KORPERSHOEK

Feb.1987 Onetubewasplugged.

April1991 Bundlewaspulledand cleanedbywaterjetting. Shellwasquiterusty. Recommendationwas givenforbrushcleaning NoConcern andcoatingrepair.Flange renewedduetothe damageonthegasket surface.

NoConcern

NoConcern

NoConcern

Thebundlewasvisuallyinspectedand blackishdirtwasdetected.Thesamewas foundonthecovers.Itwascleanedandok.

NoConcern

NoConcern

NoConcern

NoConcern

E150

ColdExchanger

RUHRSTAAL

Itwassuggestedtoinstalldiaphragmwithdifferent material

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern April1996 Afterwaterjetting,thebundleandchannel werevisuallyinspectedandtherebyno detailsfound,exceptthatthecentral partitionplategasketsurfacewasseverely corroded.Thiswasrecognizedandrepaired.

Springwasherswereusedforhead NoConcern coverbolts.

NoConcern

NoConcern

E151

CT105GlandCondensor RHEINKALTE

Dec.1984 Bundlewaspulledandinspected.Theconditionofthe bundlewasnotgood.Itwasdecidedtobuyanew bundle. NoConcern April1986 Newbundlewasinstalledintheshell.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E153

C102TurbineGland Condensor

April1976 Completebundlewasretubed. June1981 Tubeswerestronglycorrodedandgasketsurfacealso corroded. RHEINKALTE/RVH NoConcern June1988 Bundlebuilt1967waspulledandreplacedbynew bundlebuilt1988.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E154A

C101Lube&SealOil Cooler

BRONSWERK NIJKERK

Mar.1983 Thecompleteequipmentwithcoatedbundlewas installed.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

Visualinspectionofshell,bundleandchannel coverwasdone.Ontheeastsideandwest NoConcern side,coatingatonelocationoftheplate disappearedandrepairedandok. April1996 Visualinspectionofshell,bundleandchannel coverwasdone.Ontheeastsideandwest NoConcern side,coatingatthreelocationsandone locationrespectivelyoftheplatedisappeared andrepairedandok.

NoConcern

NoConcern

NoConcern

E154B

C101Lube&SealOil Cooler

BRONSWERK NIJKERK

Mar.1983 Thecompleteequipmentwithcoatedbundlewas installed.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E157A

C104Lube&SealOil Cooler

LAUFER

June1981 Channelcoverandfloatingheadwereremoved.Visual inspectionwasdoneandtubeswerefoundverydirty. NoConcern Bundlewascleanedbywaterjetting.Afterinspection itwasfoundthattubeshadsomepitcorrosion.

NoConcern

NoConcern

Mar.1994 Visualinspectionwasdone NoConcern andfoundthat70%ofthe tubeswereclosedbydirt.

May1996 Bundlewasinbadcondition.Remarks: InstallationofnewbundleinnextT.A.

Thefloatingheadwasleakingalittle bit.Leakagewasstoppedby NoConcern mechanicaltighteningofthebolts.

NoConcern

NoConcern

E157B

C104Lube&SealOil Cooler

LAUFER

NoConcern

NoConcern

NoConcern

NoConcern

June1995 Mar.1994 Byvisualinspectionofthe Visualinspectionwas exchanger,itwasfoundthatthe NoConcern done.Slightcorrosionwas gasketsurfacewasdamaged.It foundinsidethetube. wasrepairedandok.

Nov.1997 Emergencyshutdownofammonia plant,bundlewaswaterjettedand declaredok.Hydrostatictestwas performed.Thefloatingheadwas NoConcern leakingalittlebit.Leakagewas stoppedbymechanicaltighteningof thebolts.

NoConcern

NoConcern

E158A

C105Lube&SealOil Cooler

BRONSWERK NIJKERK

Dec.1984 Bundlewaspulledandcleanedbywaterjetting. Bundlewasingoodcondition.Partitionplateslightly damaged. NoConcern June1988 Coatingwasdamagedontheeastsideduetothe mechanicalwork. June1988 Coatingwasdamagedontheeastsideduetothe mechanicalwork.

NoConcern

NoConcern

NoConcern

NoConcern

May1996 Visualinspectionofbundle,shellandchannel coverwasdone.Westsideofthetubesheet coatingwasdisappearedatthreelocations.It NoConcern wasrepairedandok.Shellandchannelcover wereinreasonablecondition.

NoConcern

NoConcern

NoConcern

E158B

C105Lube&SealOil Cooler

BRONSWERK NIJKERK

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

May1996 Visualinspectionofbundle,shellandchannel coverwasdone.Gasketsurfacewasseverly NoConcern corroded.Itwasrepairedanddeclaredok.

NoConcern

NoConcern

NoConcern

E159A

C103Lube&SealOil Cooler

June1985 Theoriginalbundlewasremoved.Newcoatedbundle whichwasmadein1984andinstalled.June1990 Bundlewaspulledincaseofleakage.Onetubewas NoConcern pluggedaswellaswelded.Twomoretubewere alreadypluggedandnowwelded.Pittingwasfound insidetheshell. June1985 Theoriginalbundlewasremoved.Newcoatedbundle whichwasmadein1984installed. Dec.1989 NoConcern Leakagewasfoundonthenozzle.Temporarily repaired.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E159B

C103Lube&SealOil Cooler

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E165

LTSCatalystReduction Cooler

KORPERSHOEK

Oct.1979 Innersideofthetubeswasheavilycorroded.Two leakedtubeswereobservedandplugged. Nov.1979 Bundlewascompletelyretubed. Dec.1979 NoConcern Bundlewasinstalled. Sept.1985 Aleakagewasfound.Bundlewaspulledandsentfor retubing. Oct.1985 Bundlewasplacedinshell.

July1992 Bundlewastested at6bars.21tubes wereclogged.It wascleanedby NoConcern highpressure waterjetting.No leakagewas found.

NoConcern

NoConcern

NoConcern

NoConcern

May1998 4leakedtubeswere observedand plugged. Nov.1998 Exchangerwastaken outofservicebecause NoConcern ofleakage.Itwas inspectedand7 leakedtubes observed.Thesewere plugged.Itwas recommendedtobuy thenewbundle.

Jan.2000 Bundlebuilt1999was installedintheshell.

E172

F101MAINSTEAM SUPERHEATER

Wallthicknessmeasurementswerecarriedoutand wasacceptable.

Wallthickness measurementsand magneticsurveywas conductedatthecoils, andnodiscrepancies werefound.Hydrotest wasperformedat175 bar.Itwasalsoofferedto NoConcern Stoomwezenfor inspectionandwasfound acceptable.Weldolets andcircumferentialwelds werealsomagnetically examined.

NoConcern

NoConcern

RepairwasperformedonSVE 172Pilotvalve(ventvalvewas overhauled).

E172superheater78V(25years): Itwasvisuallyinspectedandnoparticulars weredetected. research: TheweldsontheheadersofEI72,tothe extentpossibletoreachweremagnetically investigatedandwasfoundacceptable. Also,theweldingoftheinletandoutletof mainsteamsuperheaterwasmagnetically NoConcern investigatedandwasfoundacceptable. Moreover,theinletandoutletheaderofE 172wasultrasonicallyexaminedconcerning wallthicknessandwasfoundacceptable. Thesuperheaterwasperiodicallytestedon 141.2bargandforthestandingtimeof1 hourbyStoomwezenandwasfoundinorder. Alsoafter25years,inspectionwasdoneby Stoomwezen,andwasfoundokay.

NoConcern

NoConcern

NoConcern

E173

F101ISOLATEDSTEAM SUPERHEATER

NoConcern

Coilwasperiodically inspectedvisuallyandby magneticparticle inspectiontechniqueby Stoomwezenonheaders NoConcern includedconnecting connections.Everything wasentirelyinorder.

NoConcern

NoConcern

NoConcern

E173superheater(25yearsoflife)was visuallyinspectedanddidnotshowany abnormalities.. TheweldsontheheadersofE173,tothe extentpossibletheywerereachablewere magneticallyinvestigatedandfound acceptable. Also,theweldingattheinletandoutletof NoConcern separatesteamsuperheaterwasmagnetically investigatedandfoundacceptable. Moreover,theinletandoutletheaderE173 wereultrasonicallyexamined,concerning shellthicknessandfoundacceptable. Thesuperheaterwasuncoatedandwas offeredtoStoomwezenforperiodic inspectionanditwasalsofoundinorder.

NoConcern

NoConcern

NippleofASTMA105was usedbymistakeduring replacementoftwovent valves.P11materialwas specifiedinBraunspec. ItwasthendecidedthatASTM A105nipplewillbereplaced bynippleofmaterialGradeP 11. Theweldwas penetrant examinedandfoundinorder.

E174

F101PREHEATCOIL "B"FEEDGAS

NoConcern

InEncon4project,the pipebetweenE174andE 174Bwasremoved.Inlet headerofE174was connectedtoline10" NoConcern GF142.Systemwashydro testedat67bar.Itwas conductedby Stoomwezenandfound acceptable. DuringtheEncon4, headerswerechanged. Devicewashandedover toStoomwezen. NoConcern Connectingpipeswere changedduringTA'91. Weldoletweldingwas magneticallyexamined.

NoConcern

NoConcern

NoConcern

Periodicexternalinspectionwasdone. Magneticinspectionofweldingasfaras NoConcern possibletoreachwasdone.USwallthickness monitoringwascarriedout.

NoConcern

NoConcern

NoConcern

E174B

F101PREHEATCOIL "B"FEEDGAS1981

NoConcern

NoConcern

NoConcern

NoConcern

Weldingontheheaderattheeastsidewas magneticallyinspectedandfoundok.Periodic externalinspectionwasdone.USwall NoConcern thicknessmonitoringwascarriedout.Itwas alsomagneticallyinspectedatrandompoints.

NoConcern

NoConcern

NoConcern

E175

F101ECONOMIZER

USwallthicknessmonitoringwasdone,no particularitieswereobserved

Wallthickness measurementsand magneticsurveywas conductedatthecoils, nodiscrepancieswere observed.Hydrotest performedat175bar. OfferedtoStoomwezen andfoundacceptable.

NoConcern

Radiographic inspectionwascarried outatinlettubesweld NoConcern jointsandwasfound ok.

NoConcern

EconomizerE175wasvisuallyinspected.and noabnormalitiesweredetected. TheweldingtotheheadersoftheE175asfar aspossibletoreachwasmagnetically investigatedandwasfoundacceptable. Also,theweldingattheinletandoutletof economizerwascheckedandmagnetically NoConcern inspectedandwasaccepted. Moreover,theinletandoutletheaderE175 wereultrasonicallyexaminedconcerningshell thicknessandwasfoundacceptable. Theeconomiserwasperiodicallytestedon 170bargwithastandingtimeof1hourby Stoomwezenandwasfoundinorder.

NoConcern

NoConcern

Theupperventvalvewas replaced.Theweldingwas performedthereandwas visuallyexaminedand approved.

E179A

ExpanderDynanom.Oil Cooler

Sept.1971 3tubeswereplugged.Pitcorrosionwasalso observed. Oct.1971 TwosparebundleswereprocuredforE179AandB. Oct.1972 Thesparebundleswereinstalled.Oldbundleswere scrapped. June1981 Tubes,tubesheetandgasketsurfacewerehighly corroded.

NoConcern

NoConcern

NoConcern

NoConcern

Aug.1995 Coatingofthetubeswasdone.

NoConcern

NoConcern

NoConcern

NoConcern

E179B

ExpanderDynanom.Oil Cooler

Oct.1971 TwosparebundleswereprocurcedforE179AandB. Oct.1972 Thesparebundleswereinstalled.Oldbundleswere scrapped. May1973 Tubeswerecorrodedovertheentiresurfaceto0.3 NoConcern mmdeep. Feb1975 Newbundleofcoatedtubeswasinstalled. June1981 Tubes,tubesheetandgasketsurfacewerehighly corroded.Itwasobservedthatthetierodswere slightlybent. Feb1975 Tubeswereinternallyinspectedandthecoatingwas ingoodcondition. June1981 Tubes,tubesheetandgasketsurfacewerehighly corroded.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E179C

ExpanderDynanom.Oil KORPERSHOEK Cooler

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E182A/B

C106LubeOilCooler

Oct.1976 Tubesatfrontsideofthetubesheetwereaffected. Nov.1977 WARMETECHNIE Bundlewasheavilycorroded. June1981 KWALDMAHR Aftervisualinspection,itwasobservedthattubes werecorrodedupto2mmdeep.

NoConcern

NoConcern

Dec.1993 BundleAwasretubed. NoConcern

NoConcern

NoConcern

Bothbundles(A/B) weredismantled. Feb1997 Theywerecleaned.It BundleBwastestedwithair.Two wasfoundthatthe NoConcern leakedtubeswereobserved.These bundleswereseverely wereplugged. corroded.New bundleswere installed.

NoConcern

E183

CT106GlandCondensor RHEINKALTE

June1981 Bundlewasremoved.FlangedJointfacesandchannel NoConcern wereaffectedbycorrosion.

NoConcern

NoConcern

NoConcern

NoConcern

April1996 DuringT.A,inspectionofbundle,shelland coverwasdone.Nothingspecialwasfound.

NoConcern

NoConcern

NoConcern

NoConcern

E1851/2

CT107CondensorFeed KOOIMAN Exchangers PAPENDRECHT

NOCONCERN

April1991 DuringT.A,bundlewas hydrostaticallytestedata pressureof20bars. NoConcern Periodicinspectionfrom STWwasalsodone.Itwas foundsatisfactory.

NoConcern

NoConcern

NoConcern

April1996 Periodicinspectionwasdoneby Stoomwezen.UltraSonicwallthickness NoConcern measurementwasalsodone.Noabnormality wasfound.

NoConcern

NoConcern

NoConcern

E186A

T107Overhead Condensor

KOOIMAN PAPENDRECHT

E186B

T107Overhead Condensor

KOOIMAN PAPENDRECHT

Dec.1977 Decisionwasmadetobuythenewbundleassomany tubeswereleaked.Materialofthetubeswaschanged toSS316L.Orderwasplacedandequipmentwason thesiteinMay1978.Bothchannelheadswereused NoConcern forthenewbundle. June1978 Newexchangerwasinstalled. July1982 BundleAwasscrapped. Mar.1983 E186BwastakenoutofserviceandnewE186Cwas installed. June1986 Therewasasuggestionforretubingandrepairofthe bundleandshell.Atthesametimenewtubematerial wassuggested. NoConcern July1987 Therewascorrosionproblemonthestripperunit. Therewasarecommendationforcompletenew equipmentwithduplexsteelmaterial. Oct.1988 Itwasscrappedandbothchannelcoversareusedfor E186D. NoRecordFound May1988 Newequipmentwasbuiltanddelivered.Bothchannel coversofE186Bwereused. June1988 Completenewshellandbundlewasinstalled. April1979 DuringT.A,bundlewaspulled.Itwaspollutedbythe blacksubstance.Frompreventivepointofview,25 tubeswereplugged.Thebundlewasagainputback intotheoperation. Nov.1981 14leakedtubeswereobserved.Thesetubeswere plugged.Nowtotal39tubeswereplugged.Itwas furthernotedthatthegasketgroovewasdamaged becausethecoverhadbeenmountedcrooked. Mar.1983 Newbundlewasinstalled. NoConcern April1991 Coverswere disconnected.Shellwas hydrostaticallytestedat 7.8bars.Itwasok.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E186C

T107Overhead Condensor

MFBBREDA

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E186D

T107Overhead Condensor

RVHBORN

NoConcern

NoConcern

NoConcern

NoConcern

April1996 Visualinspectionofshell,channelcoversand bundlewasdone.Thesouthcoverandgasket NoConcern groovewererepaired.Wallthicknesswas acceptable.

NoConcern

NoConcern

NoConcern

E187

T107StripperBoiler

KOOIMAN PAPENDRECHT

April1991 Bundlewaspulled.Itwas cleanedbywaterjetting. NoConcern Itwasok.

NoConcern

NoConcern

NOCONCERN

May1996 DuringT.A,visualinspectionwasdone. Nothingspecialwasfound

NoConcern

NoConcern

NoConcern

NoConcern

E188

T107OverheadTrim Condensor

KOOIMAN PAPENDRECHT

Nov.1981 Bundlewastestedatapressureof8.5bars.Three leakedtubeswereobservedandplugged. Sept.1982 Duetoleakage,exhcangerwastakenoutofservice. Bundlewassentforretubing.Afterretubing,bundle wastakeninoperation. April1986 Exchangerwasdismantledforrepairwork.Corrosion wasfoundonthebacktubesheetofabout1mm. NoConcern Reartubesheetwasloose.Itwasweldedandrepaired. Oct.1986 Recommendationwasgivenforthenewmaterialof thebundle. July1987 Itwasrecommendedtobuyanewbundlewithduplex material. June1988 CompleteequipmentwasreplacedbyE188B(built 1988).

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

Sept.1998 Exchangerbuilt1974 hadbeenrepaired andwouldbeusedas NoConcern acondensatecoolerE 130.

NoConcern

E190A/B/C

RecycleCooler

GENIUS IJMUIDEN

E191A/B/C

AdditionalCooler

GENIUS IJMUIDEN

Jan.1982 Orderwasplacedforthemanufactureofthis Equipment. July1982 Equipmentwasinstalled. Jan.1982 Orderwasplacedforthemanufactureofthis Equipment. July1982 Equipmentwasinstalled. July1990 Orderwasplacedfortheequipment. Oct.1990 Equipmentwasinstalled.

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

E192

E174FeedGasHeater

HCG

NoConcern

NoConcern

NoConcern

NoConcern

NoConcern

April1996 DuringT.A,visualinspectionwasdone.Itwas NoConcern ok.Periodicinspectionwasalsodoneby Stoomwezen.

April1998 Thebundlewas testedat45bargand NoConcern noleakswere detected.

NoConcern