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UNIT CDU/VDU PREPARED BY Mastram Hathesh

LOCATION TS-1 REVIEWED BY Mr. K.K. Shibukumar
DATE 21-05-2018 REPORT NO.

13-EE-AS-103A/B NSU Overhead Condenser

Location: 3rd Floor
Introduction:
The overhead product of Naphtha Stabilizer column is condensed through these exchangers
and outlet goes to NSU reflux drum.
Code & Standard: ASME Sec VIII Div. 1
Type of Exchanger: AES
Total Number of tubes : 514 in each
Shell Tube
Fluid circulated Stabilizer overhead Cooling water
2
Working pressure (Kg/cm ) 9.4 3.5
Working 69.9/40 33/40
Temperature(in/out) C 0

Design Pressure(Kg/cm2) 14.5 10.9

Design Temperature 0 C 85 65
MOC SA-516 Gr70 SA-179

Observation:
These exchangers are having a history of frequent leakages from August 2013 onwards and
inspection of these bundles has revealed scaling and thinning from outside and cooling water
deposits inside the tubes.
Tube failure details are as follow:
13-EE-AS-103A 13-EE-AS-103B
August 2013 Scaling & thinning from tube OD,
One tube found leaky
September 8 tubes found leaky other 10
2013 thinned tubes were also plugged
July 2014 Tube bundle replaced with new
spare bundle & painting of cooling
water side components done
TA 2015 No significant observation No significant observation
August 2017 After leakage bundle replaced with
repaired spare bundle with 8 tubes
plugged. Cooling water deposits
were observed inside the tubes
November External scaling on tubes, thinning
2017 and tubes found choked from inside

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March 2018 One tube found leaky, heavy MIC

deposition and cooling tower fills
observed inside the tubes during
boroscopy. Deposition also
observed on tube sheet.
May 2018 Scaling on tube OD observed and
tubes are thinned out. Heavy MIC
deposition observed on tube sheet and
inside the tubes. Cooling tower fills
also observed inside the tubes.
Repaired spare bundle taken in line
with 20 tubes plugged.

Photographs

Image showing external scaling of tubes

Image showing Cooling water deposits on tube sheet

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Image showing cooling water fills observed after opening of channel head

Conclusion:
 Shell side fluid is corrosive in nature because of presence of H2S, HCl and water
causing the scaling and under deposit corrosion of tubes from OD.
 There is less flow/stagnation of cooling water inside the tubes causing the MIC/under
deposit corrosion.
 Cooling Tower fills choked the tubes and caused the stagnation resulting in severe
deposition.

Recommendation:
 Close control and monitoring of shell side fluid pH to control the corrosion rate.
 Fills kind of things which can choke the tubes or reduce the flow of cooling water shall
not be allowed to reach to the exchanger tubes.
 Proper flow of cooling water shall be maintained in all the tubes.

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11-EE-00-122A/B LGO Product Trim Cooler

Location : Ground Floor
Introduction: These exchangers take outlet of LGO air fin coolers (11-EA-00-126) as input
and again cools it down by using cooling water and outlet goes to run down.
Code & Standard: ASME Sec VIII Div. 1
Type of Exchanger: AES
Total Number of tubes : 442 in each

Shell Tube
Fluid circulated LGO Product Cooling water
Working pressure (Kg/cm2) 11.4 4
Working 65/40 33/45
Temperature(in/out) 0C
Design Pressure(Kg/cm2) 23.7 18.2
Design Temperature 0C 80 85
MOC SA-516 Gr60 SA-179

Observation: During pre-cleaning inspection 5 tubes found plugged in exchanger A (bottom)

and severe deposition observed inside the tubes and on the tube sheet. After hydro blasting
boroscopy done and found that the MIC tubercles were still there inside the tubes. The
extent of tubercles in exchanger A (bottom) is far more than in top (B).

Image showing deposits on tube sheet and inside the tubes

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Boroscopic image showing tube internal deposit (tubercle)

Boroscopic image showing tube internal deposit (tubercle)

Conclusion: Since this exchanger is in the ground floor and hence there should not be any
stagnation/less flow issue still severe deposition (tubercles) has been observed inside the
tubes which indicates that tubes were not getting the enough flow. Also lab analysis of the
tube side deposit indicates high percentage of hydrocarbon in it.
Recommendation:

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 Proper flow of cooling water to be maintained inside the tubes to avoid stagnation.
 Effectiveness of cooling water treatment and dosing system to be checked properly.
 In TA’18 effective cleaning of tubes to be carried out to facilitate inspection and RFET
for assessing the health of tube bundles.