"AIR COOLER" Heat Exchanger MAINTENANCE "AIR COOLER" Heat Exchanger

“AIR COOLER” Heat Exchanger General Assembly view Inlet Floating Header Tubes Stationary Header Plug Scaffold Outlet Fan Conveyor Electric motor Structure

“AIR COOLER” Heat Exchanger Vapor Inlet Tube Bundle Details Stationary Header Floating Header Fin Tubes Plug Condensate Outlet

“AIR COOLER” Heat Exchanger Tube Assembly and Plug Detail Inlet Stationary Header Fin Tubes Gasket Grooves for expansion Plug

“AIR COOLER” Heat Exchanger Maintenance Activity Cases Summary 1. Leakage from Header Plugs 1.1. On Line leak elimination [Temporary solution] 2. Leakage from Tubes 2.1. Leak elimination from expanded area 2.2. Leak elimination from broken tube 2.3. On line Leak elimination from broken tube [Temporary solution, Bottom & Top row only]

Do Not Start The Job Without a Safety Plan MAINTENANCE "AIR COOLER" Heat Exchanger Safety First Plan Do Not Start The Job Without a Safety Plan

“AIR COOLER” Heat Exchanger 1. Leakage from Header Plugs Drill blind hole and thread the leaking Plug on situ 1.1. On Line leak elimination [Temporary solution] Screw in the threaded stud This is a Maintenance Innovation made by IZ Assembly the special cap device with gasket and screw it in until the leak stops Inlet Header Special device Replace gasket & Plug later in Shutdown Leak Fin Tubes Leaking Plug Additional Gasket

“AIR COOLER” Heat Exchanger 2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area Shutdown, isolate & drain the equipment Blind Stationary Header Inlet & Outlet PG Stationary Header Install Pressure Gauge Connect water pump Fill system by water Raise the pressure Leak Locate leaks from outside Discharge water Open Plugs at leak position Remove gasket See continuation Fin Tube Plug Water Pump

“AIR COOLER” Heat Exchanger 2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area Insert Expander tool, expand the tube up to the established torque PG Remove expander tool Stationary Header Reinstall new gasket and plug Fill the system by water Raise the pressure Re-check leaks from outside [No more leak] Leak Discharge water Remove PG & water pump Remove In-Out Blinds and tight flange bolts Fin Tube Plug Water Pump

“AIR COOLER” Heat Exchanger 2. Leakage from Tubes: 2.2. Leak elimination from broken Tube Shutdown, isolate & drain the equipment PG Blind Stationary Header Inlet & Outlet Stationary Header Install Pressure Gauge Connect water pump Fill system by water Raise the pressure Leak Locate leaks from outside Drain water Open Plugs at leak position both sides And remove gasket Plug the leaking tube [both sides] Reinstall gasket & plugs [Both sides] Fill in water again Raise pressure & check sealing Fin Tube Plug Drain water, remove PG & pump Water Pump Remove in-out blinds, tight bolts Remove field blinds

“AIR COOLER” Heat Exchanger 2.3. On line Leak elimination from broken tube : [Temporary solution] [Bottom & Top row only] Drain Valve Section “B-B” Section “C-C” Leak B C See continuation Special Device

“AIR COOLER” Heat Exchanger DEVICE INSTALLATION METHOD 2.3. On line Leak elimination: from broken tube : [Temporary solution] [Bottom & Top row only] Stop the fan set only Erect scaffold below fan Remove fins at leaking area Install the upper half body with gasket Steam Install the lower half body with the drain open Tight the body bolts Install packing and gland at left side and tight bolts Condensate Leak Install packing and gland at right side and tight bolts Close the drain DEVICE INSTALLATION METHOD

“AIR COOLER” Heat Exchanger Handover & Final House Keeping By Maintenance Remove tools and equipment Remove scaffold before El. Fan start-up Clean and wash the area Close Work permit