SHS 01009-92(英文版) 管壳式换热器维护检修规程.doc
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The Chinese version of standards has precedence to their English translations which are only for internal reference. 本英文版为内部资料,仅供参考,以中 文版为准。 Maintenance and Service Procedure for Petrochemical Equipment- General Equipment Maintenance and Service Procedure for Shell and Tube Heat Exchanger ( 管 壳 式 换 热 器 维 护 检 修 规 程 ) SHS 01009-92 (For Trial Implementation) Promulgated by SINOPEC SINOPEC Publishing House 1 Contents 1 GENERAL.2 2. PERIOD AND CONTENT OF MAINTENANCE .2 3. MAINTENANCE AND QUALITY STANDARD.2 4. TESTING AND ACCEPTANCE 6 5. SERVICE AND TROUBLESHOOTING .9 2 1 General 1.1 Subject and scope 1.1.1 This procedure specifies the period and content of maintenance, maintenance and quality standard, testing and acceptance, and service and troubleshooting of heat exchanging equipment. 1.1.2 This procedure is applicable to the petrochemical steel shell-and-tube heat exchangers like fixed tubesheet exchanger, floating-head exchanger, U-tube exchanger etc., and kettle-type reboilers, with operating pressure below 35Mpa. 1.1.3 The service of pressure elements shall comply with SHS01004-92 “Maintenance and Service Procedure for Pressure Vessels” 1.1.4 References SY21003-73 Maintenance and Service Procedure for Heat Exchanger in Oil Refinery GB151-89 Steel Tubular Exchanger 2. Period and Content of Maintenance 2.1 Maintenance period The maintenance interval can be determined by individual enterprise according to the features of its production equipment. 2.2 Maintenance content 2.2.1 Cleaning tube bundle and shell. 2.2.2 Welding joint and expanded joint treatment of tube bundle and the replacement individual tube. 2.2.3 Check and repair the tube box, front and back cover, small and big floating heads, and fittings etc., as well as their seal faces, replace gaskets and test with pressure. 2.2.4 Replace some of the bolts and nuts. 2.2.5 Repair the thermal insulation of the shell and make anticorrosion treatment 2.2.6 Replace the tube bundle or the shell. 2.2.7 Replace the shell. 3. Maintenance and Quality Standard 3.1 Preparations prior to Service 3.1.1 Have full knowledge of the operation conditions, and make all the necessary 3 drawings and documents at hand. 3.1.2 Prepare all the necessary service tools, test stand, clamping apparatus etc. 3.1.3 Displace and clean out the internal fluid, to meet the requirements of safety service. 3.2 Content of the inspection 3.2.1 Clean the tube bundle and shell. 3.2.2 Inspect visually the shell, tube bundle, and components for any corrosion, crack, deformation, etc. Have a spot check with surface flaw detection, if necessary. 3.2.3 Inspect the anticorrosive coating for any sign of aging and peeling off. 3.2.4 Inspect the lining for any corrosion, swell, fold, and crack. 3.2.5 Check the seal faces and the gaskets. 3.2.6 Check the wear condition of the fasteners. Clean and examine the high-pressure bolts and nuts one by one, and carry out surface nondestructive inspection if necessary. 3.2.7 Inspect the foundation for any settlement, inclining, damage and crack. Check its anchor bolts and pats to see if they are loosened and damaged. 3.3 Maintenance quality standard 3.3.1 The scaling on the inner and outer surface of the tube bundle shall be cleaned out. 3.3.2 In case there is a partition plate in the tube box, its gaskets shall be machined monolithically, and shall be free of any defects that may affect the sealing. 3.3.3 When blocking leaking tubes of tube bundles, on the same tube side, the number of tubes being blocked to stop leaking shall not exceed 10% of the total number of the tubes. Within the allowed range of process index, the number of blocked tubes may be increase by an appropriate amount. 3.3.4 All the parts and components used shall conform to the relevant technical specifications, and shall be provided with certificate of compliance for materials. 3.3.5 Replacing tube bundles 3.3.5.1 The tube surface shall be free of such defections as cracks, folds, double-skin, etc. 3.3.5.2 When it is necessary to splice the tubes, only one welding joint as maximum is allowed on the same heat exchanging tube (U-tube may have two welding joints). The minimum tube length shall be no less than 300mm and no welding joints for splicing shall not be allowed within the elbow section of U-tube, while the length of straight tube section shall be no less than 50mm, and the unfitness of butt joint shall not exceed 15% of the tube wall thickness and not be greater than 0.5mm. 3.3.5.3 Test the hardness of the tubes. Normally it is required that the hardness of the tube shall be 30HB lower than that of the tube sheet. In case the tube hardness is higher than or closer to the tubesheet hardness, the annealing treatment shall be made to the two ends of the tubes. The tube length subjected to the annealing treatment shall be 80mm100mm 4 longer than the thickness of the tube sheet. 3.3.5.4 The ends of the tube shall be clean and free of grease and dirt, and shall not have any defects that may affect the tightness of the expanded joints, such as penetrated, longitudinal or spiral scores. 3.3.5.5 The both ends of tubes shall project beyond the tube sheets, and the length of the tube ends projected from the tube sheets shall be 4 1mm. 3.3.5.6 The degree of expanded tube joint shall be within the range of 0.71.6%. (dID dID) (d0 d) Degree of expanded tube joint = 100% d0 where: dID the inside diameter of the tube after expanded for joint; dID the inside diameter of the tube before expanded for joint ; d the outside diameter of the tube before expanded for joint ; d0 the aperture of the tubesheet before expanded for joint. 3.3.5.7 The expanding operation should not be carried out at a temperature below 0oC. After expansion, the expanded section and the transition section of the tube shall be smooth, without any crack and groove. The re-expansion of each expand shall not exceed twice. 3.3.5.8 When welding the tube and tubesheet together, the surface of the cut on the tube shall be smooth, and free of burrs, convex and concave, crack and lamination, and the position for welding shall be free of such foreign matters as slag, iron oxide and greasy dirt, which may affect the welding quality. 3.3.6 The integral replacement of the tube bundle shall be carried out according to GB151-89 “Steel Tubular Exchanger” or the requirements of design drawing. 3.3.7 The repair of the shell shall be made according to SHS01004-92 “Maintenance and Service Procedure for Pressure Vessels” 3.3.7.1 After repair welding, the steel plate, which has been heat-treated before, shall be retreated. 3.3.7.2 Pass the pressure-tight test or air-tightness test. 3.3.7.3 Data and records are complete. 3.3.8 The replacement of gaskets shall comply with the design requirements, or refer to Table 1. 5 Table 1 Medium Flange Nominal Pressure Mpa Medium Temperature oC Type of Flange Seal Facing Description of Gasket Material or Brand of Gasket 200 Oil-resistant rubber asbestos plate gasket Oil-resistant rubber asbestos plate 1.6 201300 Wound type gasket Metal strip, asbestos 2.5 200 Oil-resistant rubber asbestos plate gasket Oil-resistant rubber asbestos plate 4.0, 6.4 200 Wound type gasket Metal strip, asbestos 2.5 4.0 6.4 201450 Clad rubber asbestos plate gasket Tin or zinc plated iron sheet, rubber asbestos plate, 0Cr18Ni9 2.5, 4.0 6.4 451600 Flat face, Male-female face, Tongue P the maximum operating pressure of the tube side or shell side, MPa; the allowable stress of the material under test temperature, MPa; t the allowable stress of the material under the operating temperature, Mpa; t 4.1.3.2 When making the pressure test, the pressure shall be increased gradually to the specified value. Holding time of constant pressure for low-pressure heat exchanger shall not be less than 5min, for medium and high pressure heat exchanger shall not be less than 20min. Then, reduce to the operating pressure and make careful inspection. Exchangers without fracture, leakage and residual deformation will be taken as qualified. If there are problems as leakage etc., the exchanger shall be re-tested after the remedy is made. 4.1.3.3 Sequence and requirements of pressure test 4.1.3.3.1 Fixed tubesheet exchanger a. Pressure test of shell side: check the shell body, the joints to connect heat exchanging tubes with the tube sheet, and other related positions. b. Pressure test of tube side: check the tube box and other related positions. 1.8, the value 1.8 will be taken for the calculation. When 8 4.1.3.3.2 U-tube exchanger, kettle-type reboiler (with U-type tube bundle) and stuffing box exchanger a. Pressure test of shell side (use the proving ring): check the shell body, tube sheet, the connections between heat exchanging tubes and tube plate, and other related positions. b. Pressure test of tube side: check the related positions of the tube box. 4.1.3.3.3. Floating heat exchanger, kettle-type reboiler (with floating-head tube bundle) a. Make pressure test to the connections between the tubes and tubesheet with proving ring and special pressure test tools for floating head. For kettle-type reboiler, a special shell for pressure test on the connections between the tubes and tubesheet shall also be used, in order to check the connections between heat exchanging tubes and the tube sheet, and the related position. b. Pressure test of tube side: check tube box, floating head and the related positions. c. Pressure test of shell side: check the shell body, connections between heat exchanging tubes and tube plate, and the related positions. 4.1.3.3.4 When test pressure of the tube side is higher than that of the shell side, the pressure test of connections shall follow the specification on the drawing, or the method agreed by both the production unit and the construction unit. 4.1.3.3.5 Overlapping heat exchanger The pressure test for joints shall be carried out on the unit-by-unit basis. When the ranges of sides for each heat exchanger are jointed together, the pressure test of tube side and shell side shall be carried out after the overlapping assembling. Check the seal on the connecting flange. 4.1.3.3.6 After pressure test, the water inside shall be completely drained, and purged dry if necessary. 4.2 Acceptance 4.2.1 After the equipment has been put into operation for one week, all the indexes shall reach the technical requirements or meet the production needs, 4.2.2 The anticorrosion of the equipment is well preserved without any damage, and meets the standard of intact. 4.2.3 Submit the following technical documents 4.2.3.1 Notices for design change and material substitution, and the certificates of compliance for materials and parts. 4.2.3.2 Service records. 4.2.3.3 Inspection report on the quality of welding joints (including visual inspection and nondestructive test). 4.2.3.4 Test records. 9 5. Service and Troubleshooting 5.1 Routine maintenance 5.1.1 Carefully check the operation parameters of the equipment. Over-temperature and over-pressure are strictly prohibited. 5.1.2 The operator shall strictly observe the safety operation proceudres, conduct regular tour inspection to the heat exchanging equipment, to check for the stability of its foundation and supports, and the leaking of the equipment. 5.1.3 When the cold exchanging equipment with anticorrosive coating is under operation, the temperature shall be strictly controlled in order to avoid the damage to the coating. 5.1.4 Maintain the completeness of the insulation. 5.1.5 Painting the equipment periodically to prevent corrosion. 5.2 Common troubles and troubleshooting (see Table 3) Table 3 No. Trouble Condition Cause Troubleshooting 1 Two types of media mixed together (internal leakage) 1.Heat exchanging tube leakage caused by corrosion 2.The expand (welding seam) between the heat exchanging tube and tubesheet burst open. 3.Leakage of float flange on the floating exchanger. Replace or block the leaking tube Re-expand (repair welding) or block the leaking tube Tighten the bolts or replace the gasket. 2 Leaking of the seal on the flange 1.Insufficient pressure-bearing, corrosion, or deterioration of seal ring 2.Insufficient strength, loosing or corrosion of the bolt 3.Insufficient rigidity of the flange, which caused the defect on the matching surface to the gasket (curl). 4. Bad parallel of the flange, deviation of the center. 5. Improper structural selection for high pressure and high temperature conditions. Tighten the bolts, replace the seal ring Re-consider the bolt material, tighten the bolt or replace it. Replace the flange or fix the defect. Cut the flange open and re- center it, or replace the flange Reconsider the structure and materials of the flange, gasket, bolt etc. 3 Poor effect of heat transfer 1. Scaling on the heat exchanging tube. 2. Bad water quality, with lots of grease dirt and microbe. Clean and remove the Scales Increase the filtration, purify the medium. 10 No. Trouble Condition Cause Troubleshooting 3. Exceed the cleaning interval. 4. Short circuit of the division plate. Clean and wash the heat exchanging equipment and the filter periodically. Replace the gaskets of the tube box. 4 Resistance drop exceeded the allowable value 1. Ineffective filter 2. Pressure gauge does not work 3. Scaling on the shell and inside and outside of the tube. Clean or replace the filter Fix, calibrate or replace the pressure gauge. Clean the shell and tube manually or through chemical method. Additional Note: Jinxi Refinery and Petrochemical Plant is responsible for the draft of this procedure. The draftsman of this procedure is Mr. Xu Zhongliang.- 配套讲稿:
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