A detailed analysis revealed the weaknesses of an existing gasket seating design and bolt tensioning effectiveness to be the root cause of a chronic leak issue.

Inadequate consideration of corrosion and material degradation of many older facilities has complicated the implementation of modern-day RBI programs. This article presents a case study of a heat exchanger with such a design.

The application of a detailed design-by-analysis method using ASME Sec-VIII Div-2 confirms field-observed ratcheting and fatigue type failures in the tubesheet due to the complex cyclical thermal-mechanical loading encountered during operation.

The purpose of baseline inspections is to provide cost savings upfront versus the cost incurred during operations. So, what are the possible heat exchange tubing defects or anomalies and how are they validated?

Decision trees can be used to help with decisions related to nearly any closed loop mechanical integrity or inspection workflow process. This article focuses on how decision trees can be applied to heat exchanger tubular inspection.

With class-leading thermal performance, superior CUI defense, and complimentary engineering support, our aerogel insulation solutions are a top choice in helping facilities drive energy efficiency, improve safety, increase yields, and reduce downtime

This article presents a case study from a Middle Eastern refinery that explores a heat exchanger that failed unexpectedly after five years in service. There are multiple initiators that can cause under deposit corrosion (UDC) in heat exchangers in...

HTHA of hydrogen-containing equipment can be prevented with appropriate material selection and fabrication, appropriate welding procedures, regular inspection of equipment using proven, effective technologies and equipment operated by qualified...

Cleaning of heat exchangers and other process equipment is typically done with the use of pressurized water (e.g., hydro-blasting). However, in some situations thermal decomposition, a technique that utilizes heat rather than water to break down...

Fired heaters are among the most critical equipment in refineries and chemical plants. This article provides an overview of what a fired heater tube mechanical integrity program should include.

Amine systems that scrub H2S from hydrogen-rich gas experience rapid fouling of the heat transfer equipment, especially in a hot summer. Learn how temporary cooling solutions can improve process conditions during critical periods of the year with no...

Lessen downtime by enhancing your plant infrastructure, ensuring mechanical integrity, and extending equipment lifespan. Contact us for on-demand engineering expertise in assessment, problem-solving, specialized testing, and preventative solutions.

Vacuum distillation plays a critical role in improving yields for petroleum refiners by producing high-value petroleum products out of the heavier oils left over from atmospheric distillation. When short-term disturbances cause temporary cooling...

Detecting, quantifying, and sizing indications characterized as a “crack" in critical equipment have long been the global benchmark of asset integrity programs. Therefore, the increased precision that inspection programs obtain using advanced...

Inspectioneering recently had the opportunity to chat with Barney Smith, Turnaround Manager at Aggreko, a global leader in power, heating, cooling, and oil-free compressor rental solutions. Our discussion focused on catalyst cooling during...

Heat exchangers operating in refineries or petrochemical plants must be thoroughly cleaned and inspected throughout their operational lifetime to ensure safe and efficient operations.

Inspectioneering recently had the opportunity to sit down and chat with Brian Fahnestock about heat exchanger issues in the refining and petrochemical sectors and how temporary solutions can help mitigate the damage should a problem arise.

Learn how you can safeguard integrity, reliability, instrumentation safety, and more.

This article is Part II of a three-part series that explores the various methods, benefits, challenges and solutions to efficiently and effectively clean heat exchangers, both onsite and offsite.

The tubes of heat exchangers (HX), whether for a shell and tube bundle or an airfin, are typically subject to some form of nondestructive examination (NDE) to try and quantify the remaining wall thicknesses and corrosion rates to help a plant to...

We talk about heat exchangers quite a bit here on Inspectioneering, most recently in the January/February issue of the Journal. This is because heat exchangers are vital pieces of equipment in nearly every type of plant or facility.

Whether onsite or offsite, the methods for cleaning shell and tube heat exchangers can vary. Refining and petrochemical operators will agree that high standards must be employed with each method. Choosing the right method can make the difference...

Dual mode pulse reflectometry shows promising results in detecting a wide range of defect types and sizes in heat exchanger mock-ups.

Say goodbye to juggling multiple tools! Our all-in-one solution automates NDT data acquisition and seamlessly transfers it to your inspection data management system. Simplify your workflow today - use DIMATE PACS!

A small leak from top tubesheet-to-tube welds prompted further inspection of the 1¼Cr- ½Mo Ammonia Converter Boiler Feed Water (BFW) Exchanger during a planned shutdown. Further cracks were identified in the top channel to tubesheet butt weld that...

At most operating facilities, a significant amount of time, effort, and money is expended on problem flanged joints that repeatedly leak. Joints that are repeatedly tightened online, that require installation of leak clamps, or that have resulted in...

Air-cooled heat exchangers (AC-HEs) are used extensively throughout the oil and gas industry, from upstream production to refineries and petrochemical plants, under high pressure and high temperature conditions, as well as corrosive fluids and...

Once again there is a crack found in the inlet tubesheet in your high-pressure high temperature heat exchanger. As head of the maintenance engineering effort, you know that plant management will ask you if it can run safely and reliability until...

Washington DC, January 27, 2011 - A U.S. Chemical Safety Board (CSB) case study released today on the 2008 heat exchanger rupture and ammonia release at the Goodyear Tire and Rubber Company in Houston, Texas, identifies gaps in facility emergency...

FER's extensive TA experience, combined with our custom software (RAMI Scope) that tracks all aspects of TA activities, we have the ability to keep your turnaround flowing flawlessly with the methodology to maximize your value of premium time.

In the first article in this series entitled How to Put It All Together - Guide to Organizing a Successful PEI Program, (1) I provided an overview of the necessary Management Systems (MS) for a successful program to achieve excellence in pressure...

This paper covers most of the common (and some not so common) types of NDE methods for heat exchanger (HX) tubular in-service inspections. In addition to noting some of the various advantages and limitations with these methods, the paper covers heat...

Tube Inspection is a vital tool for the refining and petrochemical industries. Heat exchangers and condensers are designed to sustain 100% separation between the products in the tube (tube side) and the products in the vessel (shell side). A...

Part 5 of this article continues to outline the 101 essential elements that need to be in place, and functioning well, to effectively and efficiently, preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers,...

This paper describes the use of a UT fixture for detection of stress corrosion cracking in ferrous heat exchanger tube-to-tubesheet welds and external tube corrosion or pitting near the tubesheets including crevice OD corrosion.

Southwest Research Institute (SwRI) has developed an innovative method for rapid screening of heat exchanger tubing using Guided Wave technology. This screening method can lead to an improvement in heat exchanger reliability and a reduction in the...