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CHEVRON Maintenance Heat Exchanger PDF
CHEVRON Maintenance Heat Exchanger PDF
Abstract
This section discusses the major maintenance requirements for heat exchangers.
This includes repairing and replacing body flanges, body flange gasketing and
torquing considerations, bundle replacement and repair, tube leak repairs, shell
repairs, and on-line leak repairs.
Contents Page
Weather
• Rain storms can deform uninsulated flanges and unseat the gasket.
Mechanical Damage
• Gasket was damaged during installation.
• Flange surface was scratched or gouged during maintenance.
• Poor torquing procedure caused uneven compression of the gasket around its
circumference.
Corrosion
• Flange is so extensively corroded there is not enough gasket seating surface
left.
Process Upsets
• Excessive temperatures or pressure surges can unseat the gasket and stretch the
bolts.
Inspection
The following inspection techniques can be used to analyze existing flanges:
• Check for flange rotation. Are the flanges “metal-to-metal” around any part of
the circumference?
• Inspect the gasket. See Figure 1000-2 for problems that examination of the
gasket can point out.
• Inspect the gasket seating surface for damage or corrosion.
• Measure the flange thickness to determine if it is at or below ASME tmin.
• Measure the critical dimensions and compare them with the original exchanger
and TEMA tolerances. Figure 1000-3 can be used for this purpose.
The following procedure can be used for analyzing existing flanges:
• Check the flange thickness versus ASME tmin and Chevron Method tmin using
the PCFLANGE program for the existing gasket design. If existing thickness is
less than ASME tmin then flange will need to be replaced.
• Determine if a different gasket will solve the problem. Use Figure 500-15, in
Section 540, to choose the optimum gasket. Determine the ASME tmin for the
new gasket. If the existing flange is not thick enough to properly compress the
gasket consider replacing the flange.
flanges. See Section 530 and Appendix G for more detailed discussions of the
design methods.
• Use integral body flanges if possible.
• Follow ASME Code procedures for replacing and inspecting the flanges.
• They prevent cocking the flange faces or pinching the gasket due to uneven
bolt loading.
Note These calculations can be performed using the PCFLANGE program. (See Appendix H)
• Change shell side pass configuration and baffling to improve heat transfer and
decrease fouling.
• Use different materials that will increase the bundle reliability and life. (As a
general rule, even in corrosive services such as sea water, a bundle should last
at least two operating runs. Contact the CRTC Materials and Equipment Engi-
neering Unit for help in this area.)
• Change from floating head to U-tube design. (See Sections 450 and 520.)
Safety Considerations
• The contractor must understand all local safety regulations applicable to the
work.
• The contractor must understand the nature of the leakage and why it is occur-
ring in order to use a safe procedure.
• All safety precautions and protective clothing required should be listed on the
Leak Sealing Checklist (Figure 1000-5) and reviewed with the contractor.
• A plant Safety Operator must be present during the execution of leak sealing
work on plant equipment.
• Sealant injections should not be made into any pressure relief valve or bursting
disc if the sealant could obstruct their free and full discharge requirements.
• If a clamp or enclosure was installed prior to 1984, the sealant compound may
contain asbestos. Normal asbestos procedures should be used when removing
these enclosures. Refer to Insulation and Refractory Manual, Section 500.
Repair Procedures
Figures 1000-6 through 1000-9 give the general work procedures to follow
depending on the specific situation. These procedures can be adapted to a specific
job and attached to the work order.
• Figure 1000-6 Procedure for Flange Joints with Less than 3/8" Gap Using Drill
and Tap Method
• Figure 1000-7 Procedures for Sealing Flange Leaks with Use of Injection Ring
Adaptor
• Figure 1000-8 Procedures for Sealing Flange Leaks on Pressures below 350 psi
with Lug Adaptors
• Figure 1000-9 Procedures for Sealing Flange Joints with Gap Width in Excess
of 3/8"
• Figure 1000-10 Methods for Sealing Flange Leaks
Fig. 1000-6 Procedure for Flange Joints with Less than 3/8" Gap Using Drill and Tap Method
1. When possible, change out studs one at a time with the use of boiler clamps.
2. Drill 3/16-inch diameter holes between studs approximately 4 inches apart from outer circumferential flange
surface at an angle to break through into gap area at bolt circle. (Outside stress area of flange.)
– On full surface gaskets and metal to metal joints, drilling is done into stud clearance areas.
3. Drill out hole to 5/16-inch diameter by 1/2-inch deep.
4. Tap out holes to 3/8-inch NC thread.
5. Install shut-off adaptors in tapped holes.
6. Insert tight fitting wire into gap around flange.
7. Lightly peen lock edge of flanges over wire with a bull nose peening chisel approximately 1/8-inch over gap
size.
8. Starting 180 degrees from leak blow area, inject thermosetting compound around flange in both directions
until gap area and stud clearance areas are full with final injection on shut-off adaptor directly over leak area.
9. After appropriate cure time depending on the temperature for steam, water, and air services under 600 psi,
shut-off adaptors are removed and set screw plugs installed.
10. On pressures above 600 psi and on chemical services, shut-off adaptors are left in place.
Fig. 1000-7 Procedures for Sealing Flange Leaks with Use of Injection Ring Adaptor(1)
1. Change out studs one at a time along with installing ring adaptor under the nut of each stud.
– One ring adaptor on thin, narrow gap flanges
– Two ring adaptors (each end of stud) on thicker, wider gap flanges
2. Insert tight-fitting wire in gap and peen lock edge of flange over wire to retain it.
3. Install shutoff adaptors into injection ring adaptors.
4. Starting on adaptors farthest away from leak, inject all adaptors with thermosetting compound closing after
each injection, working around flange in both directions until flange is full and leak is stopped.
5. On steam, water, and air service with pressure below 600 psi:
– After proper curing time, shutoff adaptors are removed from ring adaptors and set screw plugs are
installed.
6. On pressures above 600 psi and chemical service, shutoff adaptors remain in place.
(1) Refer to Figure 1000-10, Type II
Fig. 1000-8 Procedure for Sealing Flange Leaks on Pressures Below 350 psi with Lug Adaptors
1. Change out studs one at a time with the use of boiler clamps.
2. Install injection adaptor on stud nearest leak area for exhaust port and one adaptor 180 degrees from leak
area.
3. Insert tight-fitting wire in gap and peen lock edges of flange over wire to retain it.
4. Start injection of thermosetting compound through adaptor furthest away from the leak.
5. After stud is full, remove adaptor and retighten stud and move to adjacent studs working around flange in
both directions until all studs are injected.
6. After injection of last stud, leave injection gun on adaptor until proper curing time allows the removal of the
last adaptor.
Fig. 1000-9 Procedures for Sealing Flange Joints with Gap Width in Excess of 3/8”(1)
1. Contractor will engineer and fabricate flange clamp.
2. When possible change out stud one at a time.
3. Install shutoff adaptors in flange clamp.
4. Install clamp in gap of flange.
5. Peen lock both flanges to clamp joints.
6. Inject thermosetting compound through shutoff adaptors starting at the point farthest away from leak working
around the flange in both directions until flange joint is completely full and leak is stopped.
7. On steam, water, and air services with pressures below 600 psi:
– After proper compound curing time shutoff adaptors are removed and set screw plugs installed.
8. On pressures over 600 psi and chemical service, shutoff adaptors are left in place.
9. Depending on flange dimensions, temperature, and special circumstances, ring adaptor or drill and tap tech-
niques may be used in conjunction with this procedure.
(1) Refer to Figure 1000-10, Type I
1070 References
1. Appendix G, “Heat Exchanger Body Flange Calculations.”
2. Appendix H, “PCFlange Program User’s Guide.”
3. ASME Code, Section VIII, Division 1. Latest ed.. Appendix S and 2.
4. ANSI B16.5, Latest ed. “Steel Pipe, Flanges and Flanged Fittings.”
5. TEMA (Tubular Exchanger Manufacturers Association), Latest ed.
6. Lamons Gasket Handbook, Latest ed.