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DKL Engineering, Inc.
Handbook of Sulphuric Acid Manufacturing
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Preface
Contents
Maintenance and Inspection - Gas-to-Gas
Heat Exchangers
September 8, 2003
Introduction Maintenance and Inspection Schedule |
Associated Links |
All gas-to-gas heat exchangers in an acid plant should receive regular maintenance and inspection in order to minimize the amount of downtime experienced due to problems with the exchangers. The units that will require the most maintenance are the unit in 'cold' service such as the Cold, Cold Interpass/Reheat and SO3 Coolers.
Maintenance and Inspection Schedule
Daily |
At least once a day the shell and tube side
drains of the gas-to-gas heat exchangers should be checked by briefly
opening the isolation valve to see if any liquid has collected in the heat
exchanger. This requirement applies
mainly to the Cold and Cold Interpass Exchangers due to their operating
conditions. The Hot and Hot
Interpass Exchangers operate at a high enough temperature that condensation
of liquid will not occur. |
Monthly |
At least once a month a complete plant pressure
profile and temperature survey should be performed. This will include collecting the relevant operating data for the
heat exchangers as well. Analysis of
the data will indicate the degree of fouling and pressure drop increase.
This information can be used to plan any work required on the heat
exchangers during a plant shutdown. |
Shutdown | During the
annual plant shutdown all gas-to-gas heat exchangers should be inspected
internally. The tube side is
typically fully accessible for inspection while limited access is generally
available to the shell side. Items
to consider during the inspection are:
If a leak is suspected in the heat exchanger, test will need to be carried out to determine which tubes are leaking and repairs done. A tubesheet map should be maintained identifying which tubes have been plugged. All problems that have
been identified during the inspection should be rectified and the exchanger
completely cleaned out prior to placing it back in service. |