3 replies to this topic

[EUH]

One of our forced draft air cooler developed leak from a tube and regeneration gas started to leak in the atmosphere. This exchanger has a cyclic exposure to high temperature of 300 degree C and it cools down to 50 degree C. There were 02 problems we faced.

Simple solution will be remove the tube and replace with a new one but the tube is in the middle rows and we may have to cut out many tubes to replace the leaking one.

 

1. Correctly identify the leaking tube as it is in the middle of the tube bundle

2. What method to be used to plug the tube as normal plug insertion has failed due to cyclic temperature exposure as mentioned earlier.

 

Please inform of techniques to identify finned tube bundle leaking tubes and then to plug or isolate the leaking tube from process side.

 

Best Regards

EUH

[srfish]

What type of plug did you use ?  There are types that provide a better seal than the normal single piece with a taper. There are two piece tapered plugs that have more contact between the plug and the tube wall. For really good contact there is the explosive plug.

[Padmakar Katre]

Hello,

Was there any root cause analysis for this incident? Is there only one tube which is failed? What is the header type if you can share?

[EUH]

We are planning to replace the leaking tubes in our upcoming ATA next week. We have also initiated for detialed investigation of our other finfan coolers as the gas quality from reservoir has been found as a major player.

Thanks to both srfish and Padmakar Katre for responding to my query. srfish suggestion of explosive plugs may well be a solution to used by our maintenance crew for any future tube leakages.

 

EUH