Water Bath Heater Internal Inspections

Presented by Marc Rullo Graduate Engineer

21/09/2011

Overview
What is a Water Bath Heater? My Project Heater H-03 Horsley Park Questions

Purpose of Water Bath Heaters In The Gas Industry

Widely used throughout the natural gas industry as an economical i l method th d f for h heating ti natural t l gas Important I to heat h natural l gas f for the h f following ll i reasons:
Avoids pipeline cracking after pressure regulation Avoids liquid formation Minimum Contractual temperature requirements Critical Equipment q p requirements q

Key y Components p of a Water Bath Heater

Insulated Shell

Process Coil P C il (Gas Flow)

Exhaust Stack

Fire Tube (Heat Source)

Control System
Source: Devco Process Heaters http://www.devcoheaters.com/indirect.htm
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Water Bath Heater Operating p g Principles p

Gas Out Gas In

Heated Water

Source: Devco Process Heaters http://www.devcoheaters.com/indirect.htm

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Water Bath Heater H-03

H Horsley l P Park kM Meter t St Station ti Eastern Gas Pipeline Dimensions
10 m long 2.7 m diameter

Heating capacity of 1,200 kW Maintains gas temperature at approx 30C 30 C

Water Bath Heater H-03

St ti has h three th it Station units
H-03 is the largest

pp y for Critical source of supply Sydney distribution network

Up to 1M Customers

Pressure regulation downstream of heaters H-03 needs to be offline during the inspection

Project j Constraints
Customer
Gas delivery temperature was not to be below minimum allowable Ensure no impact on the Sydney distribution network.

Potential damage to process coils

History of damage with other units

Timing
Needed to be completed by 2011 to be compliant with AS2885

Project j Preparation p
Capacity study
Conducted process modelling Actual testing (i.e. isolating the heater on-site) Confirmed heater could be taken offline

Determining the best period to conduct the inspection

March Low demand, warm ground temperature Schedule developed p for March p project j delivery y Planned over a weekend (reduced demand)

Project j Preparation p ( (Cont.) )

Development of Project Plan
Objectives, Obj ti scope, b budget, d t resources etc. t

Risk Assessment
Cranes on site Lifting above live pipe work Confined space entry P Possible ibl d damage t to process coil il

Development of Procedures
Job Hazard Assessments Safe Work Method Statements Development of a Contingency Plan
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Project j Preparation p ( (Cont.) )

Organising Contractors
Crane O C Operators t and dD Dogmen NDT personnel Water collection High Pressure cleaners Welders

All contractors were appropriately accredited

Rescue plans for confined space Welding certification NATA certified
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Project j Preparation p ( (Cont.) )

Review of mechanical design

22mm Clearance

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Developing p g the Contingency g y Plan

Additional spare process coil was procured in case of a replacement. l t Standby welding workshop organised Standby S db truck k to transport the h coil il b bundle dl f for repair i Appropriate waste management plans in place

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Developing p g the Contingency g y Plan ( (Cont.) )

P d i d and df bi t d Pre-designed fabricated Angled attached to baffle
p around the p Scalloped process coil 2 mm clearance around the process coil

Design reviewed by manufacturer

Si Similar il t to current t mechanism h i i in place

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Project j Timing g
Estimated completion time was 4 days
2 additional days contingency for repairs

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Pre-Work Planning g
Lifti Lifting plan l was agreed d to t with ith Crane operators. Heavy y duty y Scaffolding g set up p over live pipe work New bolts and gaskets procured New N end d plate l t gasket k t pre-drilled d ill d

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Performing g the Inspection p

Heater isolation Drainage of vessel

Liquids were collected in isolated tanks

Remo Removal al of ancillary ancillar piping Removal of spools

Day 1

Day 2

Day 3

Day 4
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Performing g the Inspection p ( (Cont.) )

Unbolting of vessel endplate Removal of process coil

110 T Crane 60 T Franner

Day 1

Day 2

Day 3

Day 4
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Performing g the Inspection p ( (Cont.) )

Lifting of bundle above pipe work Left to rest on stands away from hazardous area

Day 1

Day 2

Day 3

Day 4
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Performing g the Inspection p ( (Cont.) )

Hi High h pressure cleaning l i of f the th process coil bundle High g p pressure cleaning g of the inside of the vessel

Day 1

Day 2

Day 3

Day 4
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Performing g the Inspection p ( (Cont.) )

N Non Destructive D t ti T Testing ti of f the th process coils.
Ensure wall thickness was within the minimum allowable

General visual inspection of vessel.

Welds inspected, corrosion, etc Certified Vessel Inspector

Day 1

Day 2

Day 3

Day 4
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Key y Issue: Process Coil Contact

Rubbing across 150 mm of the process coil Deepest pit found to be 1.4 mm leaving 7.0 mm Minimum allowable wall thickness calculated as 5.0 mm
Calculation based on AS4041 2006: Pressure Piping
Deepest Pit 1.4 mm

Day 1

Day 2

Day 3

Day 4
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Key y Issue: Process Coil Contact (Cont.) ( )

Process Coil Bundle

Fire Tube Fire Tube

Day 1

Day 2

Day 3

Day 4
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Process Coil Protection

Angle piece scalloped around process coil

Day 1

Day 2

Day 3

Day 4
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Process Coil Protection (Cont.) ( )

Welded to other side of baffle

Day 1

Day 2

Day 3

Day 4
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Performing g the Inspection p ( (Cont.) )

Once modification was complete, inspector deemed compliant li t

Day 1

Day 2

Day 3

Day 4
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Reassembling g the Heater

Crane lifted coils back into vessel

Day 1

Day 2

Day 3

Day 4
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Reassembling g the Heater ( (Cont.) )

Replacement of endplate gasket Re Re-bolting bolting of endplate Reattachment of ancillaries and connecting pipe work Leak tested vessel and flanges Vessel was refilled

Day 1

Day 2

Day 3

Day 4
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Reinstatement of Heater

Heater left offline overnight Burners restarted Monitored Returned to service

Day 1

Day 2

Day 3

Day 4
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Project j Success
No lost time due to injuries No impact on customer deliveries or capacity Delivered within the 4 day timeframe Delivered within the allocated budget Heater remains compliant with Standards
AS 2885 AS 3788

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Key y Learnings g
Accurate project schedule Important! Crane lifting plan was critical Predrilled endplate gaskets Review drawings! Having a contingency plan in place Key!

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Thank You
Questions?
ASSETS 100% OWNED & MANAGED BY JEMENA (Customers) 1 2 3 4 5 6 Jemena Electrical Distribution Network (305,000) Jemena Gas Distribution Network (1,020,000) Queensland Gas Pipeline Eastern Gas Pipeline VicHub Colongra Gas Storage and Transportation Facility

ASSETS PARTIALLY OWNED & MANAGED BY JEMENA 7 8 9 ActewAGL Gas, Electricity Network (50%) (151,000) United Energy Distribution (34 (34.1%) 1%) (600 (600,000) 000) TransACT (6.8%)

ASSETS MANAGED BUT NOT OWNED BY JEMENA 10 11 Tasmanian Gas Pipeline p Multinet Gas Holdings

COMPANIES WHO ARE PART OF THE JEMENA GROUP 12 13 14 CLM Infrastructure Outback Power Cape Cable Layers

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