1. "AIR COOLER" Heat Exchanger
MAINTENANCE
"AIR COOLER" Heat Exchanger

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

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

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

5. “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]

6. 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

7. “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

8. “AIR COOLER” Heat Exchanger
2. Leakage from Tubes: 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

9. “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

10. “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

11. “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

12. “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

13. “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