NGHI SON REFINERY AND PETROCHEMICAL LLC

Amendment Table

Rev. Prepared Reviewed Approved

Date Description
No. by by by
NS.Binh/
00 24.06.2016 Initial release NQ.Tung T.Sugimura
T.Kimura

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 2 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

AMENDMENT REPORT FORM

No. Item Original Revised Reason

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 3 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

Contents

1. PURPOSE ..................................................................................................................... 5
2. SCOPE .......................................................................................................................... 5
3. RESPONSIBILITY ......................................................................................................... 5
4. DEFINITION & ABBREVIATION .................................................................................... 5
5. REFERENCE ............................................................................................................... 6
6. PROCEDURE ................................................................................................................ 6
6.1 Overview of Heat Exchangers: ................................................................................. 6
6.2 Preparation the work ................................................................................................ 8
6.3 Execute the work.................................................................................................... 10
6.4 Work Order closure ................................................................................................ 15
7. APPENDIX ................................................................................................................... 15

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 4 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

1. PURPOSE
This procedure is to provide the maintenance instruction for preventive maintenance
of two most common kinds of Heat Exchangers in Nghi Son Refinery &
Petrochemical LLC. (NSRP), hereafter called “Refinery” or “NSRP”.

2. SCOPE
This procedure is applied for preventive maintenance of two most common kinds of
Heat Exchangers in Refinery. This document includes maintenance instruction and
also provides the safety requirements for NSRP/DMC personnel.

This procedure extracts important prescriptions from Vendor or Manufacturer’s

maintenance manual. Refer to Vendor’s maintenance manual for further information.

3. RESPONSIBILITY
This procedure is approved by Division Manager (DM) of Maintenance division.
Section Manager (SM) of Reliability Engineering section is responsible for issuing
and distributing the procedure. The procedure will be reviewed periodically, revised
and updated as needed. SM of Reliability Engineering section reserves the right to
make any amendment and modification to this procedure subject to requirements of
proper management.

4. DEFINITION & ABBREVIATION

CMMS Computerized Maintenance Management System
DMC Daily Maintenance Contractor
HSE Health, Safety and Environment
PPE Personal Protective Equipment
LOTO Lock-Out Tag-Out
MRO Maintain, Repair and Operate material
MSDS Material Safety Data Sheets
NSRP Nghi Son Refinery & Petrochemical LLC.
PM Preventive Maintenance.
PTW Permit To Work.
WO Work Order.
DCS Distributed Control System
IAT Inspection Advice Ticket
NDT Non - Destructive Testing

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 5 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

5. REFERENCE
Document Number Title
- ISRS V8.1 Book of Knowledge
- ISRS V8 Workbook
Preventive Maintenance Workflow for Production
MD-03-MT-WF-001
Facilities
Breakdown Maintenance Workflow for Production
MD-03-MT-WF-005
Facilities
Predictive Maintenance Workflow for Production
MD-03-MT-WF-006
Facilities
MD-03-MT-WF-012 Workshop Management Workflow
MD-04-MT-MS-PD-006 Maintenance Closure Procedure
MD-04-HSE-HS-PD-003 PTW Procedure
6. PROCEDURE

6.1 Overview of Heat Exchangers:

Figure 1. Flow Scheme of Heat Exchangers.

Heat Exchanger is the device that allows heat from a fluid (a liquid or a gas) to pass
to a second fluid (another liquid or gas) without the two fluids having to mix together
or come into direct contact. The essential principle of a heat exchanger is that it
transfers the heat without transferring the fluid that carries the heat.
The two most common kinds of heat exchanger are the shell and tube heat
exchanger and plate heat exchanger.
 Shell and tube heat exchangers: one fluid flows through a set of metal tubes
while the second fluid passes through a sealed shell that surrounds them. The

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 6 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

two fluids can flow in the same direction (known as parallel flow), in opposite
directions (counter-flow or counter-current), or at right angles (cross flow).

Figure 2. Shell and Tube Heat Exchanger.

 Plate heat exchanger: have lots of thin metal plates with a large surface area
that exchanges the heat more quickly.

Figure 3. Plate Heat Exchangers

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 7 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

6.2 Preparation the work

6.2.1 Confirmation of Work Order and Safety requirements

Any preventive maintenance activity shall be performed in accordance with approved
preventive maintenance schedule. Through CMMS, WO will be generated and
approved before execution. Maintenance team leader and his team members who
are assigned the work shall carefully check the requirements on WO and carry-out
following activities:

- Check the Equipment ID/Tag name as per Work Order.

- Check the location, elevation, and access way possibility to the Heat Exchangers.

- Check the datasheet and make sure to understand the process condition and type
of Heat Exchangers.

- Identify any escape route in case of emergency.

- Confirm and obtain necessary advices from Operation.

- If the maintenance work is high risk, discuss the contingency and mitigation plans.
Also, request HSE to approve.

- Obtain approval of hot work permit where the work could create a sparking (fire)
hazard including use of electric testing equipment (with or without battery cells).

- Obtain all Permits to Work required within the scope of work as per PTW
Procedure.

- Conduct a Safety Toolbox Meeting with dedicated craftsmen and workers to discuss
the following:

 Work purpose, scope, expected duration, risk assessment, MSDS, Vendor

documents, drawings, etc.

 Do not operate or do any maintenance activity even opening equipment cover

of other equipment that are not in PTW’s scope.

 Un-controlled PTW’s scope or incorrect isolation will become hazardous e.g.:

equipment damage, human injury, explosion, or Refinery shutdown.

 Required isolation, LOTO certificates to be done shall be confirmed.

 Consider any possible interference in the work area, and any possible action
to be taken.

6.2.2 Special Personal Protective Equipment

The personnel who involves into the activity are required to wear the standard

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 8 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

personal protective equipment (PPE). Additional PPE must be worn for this procedure
due to the nature of the work or the location.

- Personal protective hydrogen sulfide (H2S) detector must be worn in designated

areas.

- Suitable gloves must be worn when handling hazardous materials or contacting a

cold or hot surface.

- Double ear protection (Ear plug & Ear muff) must be attached before entering the
area with noise level above 85 dB.

- Be aware of potential hazards when working around oil and gas lines.

6.2.3 Environmental Precautions

Maintenance is conducted in accordance with governmental requirements for
protection of the environment.

- Make sure good housekeeping is carried out during and after each work.

- Do not drain or vent any liquid or gas to an open space, on the ground, or into the
sea. Use only the approved method to drain or vent the systems.

- Gather all waste maintenance materials produced during work. After work, move
and store them at the reserved place.

6.2.4 Equipment and Tools

Except conventional equipment and tools, the following equipment and tools may be
necessary for maintenance work:

- Gas/oxygen detector.

- Ladders and scaffolding.

- Fans or Blowers for ventilation.

- Water jet machine for cleaning inside tubes or plate surface.

- Soft nylon brush for cleaning the plate surface.

- Hoists, Pulley Blocks, Cranes, Slings and Cables as required for lifting the covers,

- Pneumatic wrench for loosening and tightening nuts of cover studs.

6.2.5 MRO for maintenance

Depending on the requirements on WO, the following MRO may be required:

- Tube plugs.
- Plate gaskets.

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 9 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

- Channel head cover gasket.

- Spiral wound gaskets.

- Isolation blinds (base from blind list supplied from operator).

- Chemical agent for cleaning (need approval from Technical and HSE before using).

- RP7 or WD40 spray lubricant.

- Teflon or Loctite thread sealants.

In addition to the above, conventional or consumable material is required, such as

rag, brush, molykote.

6.3 Execute the work

6.3.1 Maintenance Procedure for Plate Heat Exchanger

Work
Description Remark
step
Inform the Control Room operator before commencing
the work. The radio shall be kept to make sure
1. communication with operator in the control room in case
the piece of equipment needs to be returned to service
for any reason.
2. Ensure isolation of fluid systems from exchanger.
Lock-out/tag-out action.
3. Perform required blinding according to blinding list.
4. Connect drain hose to the coolant side of exchanger.
5. Drain the coolant side of the exchanger.
6. Connect drain hose to the product side of the exchanger.
Drain the product side of the exchanger
7. The wearing of face shields and chemical resistant
gloves is mandatory for personal safety.
8. Flush the product side of the exchanger with clean water. In case using
Flush until clear water comes out of the exchanger. of fire water
needs permit
from Safety
department.
9. Disconnect the inlet and outlet piping for follower side of
the exchanger.
10. Make a scribed diagonal line on the outside edge of the
frame plates a reference for reassembly.
11. Measure and make note of the dimension between the
two outside frame pressure plates that hold the
exchanger plates together (Head and Follower).
12. Inspect the sliding surface of upper bar and clean (if
necessary)
Loosen the tie bolts that hold the plates together
13. Loosen each of all the tie nuts. Nuts are loosen
alternately and diagonally one side then the other. It

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 10 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

should take about 4-6 passes to relieve the pressure on

the gasket surfaces and for the plates to be free to move.
14. Remove the plates one at a time from the frame
assembly.
15. Lay the plates out on a horizontal surface for cleaning.
Clean the plates
16. Wash both sides of the individual plates using clean In case using
water at no more than 50 psig. chemical agent
needs approval
from Inspection
Engineer.
17. Use a soft nylon brush to remove deposits or film not
removed by the clean water.
18. Be very careful not to damage the rubber seal gaskets
that separate the plates.
19. Inspection Engineers inspect the cleaned plates. Replace the
defect plates
(pin hole,
deformation,
...)
20. All plate gaskets will be replaced with new ones.
21. Clean the bolts and nuts with a wire brush as required.
22. Apply grease on the threads to lessen friction when
tightening the assembly to close plates together.
Reassemble the Exchanger Body
23. The cleaned plates will be stacked one at a time into the
support frame.
24. Check to see that gaskets are properly seated between
the plates.
25. Ensure that the tie bolts are properly positioned for
tightening.
26. Tighten the tie bolts with a wrench.
27. Tighten the nuts evenly across all the tie bolts. An
alternating pattern of tightening should be used, one side
then the other.
28. The tightening of the nuts should continue until the Refer to
distance between the frame pressure plates is consistent previous value
with that given in the manufacturer’s specifications. The
measurement should be within allowable tolerances on
all sides.
29. Perform leak test as per manufacturer’s instructions.
Inspection Engineer to witness leak test.
If the leaks occur, check the following, making corrections as
necessary to stop leakage. Retest after correction.
30.  Unbalance tightening of the tie bolts.
 Tightening within allowable tolerance of two frame
plate.
31.  Gasket not positioned correctly.
 Reset the position

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 11 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

32.  Damaged gasket.

 Change gasket.
Closure
33. Remove blinds and any temporary hoses or piping used.
34. Remove lock-out/tag-out.
35. Clean area.
6.3.2 Maintenance Procedure for Shell and Tube Heat Exchanger
Work
Description Remark
step
Inform the Control Room operator before commencing
the work. The radio shall be kept to make sure
1. communication with operator in the control room in case
the piece of equipment needs to be returned to service
for any reason.
2. Erect scaffolding.
3. Remove insulation as required
4. Personnel to wear protective clothing as per HSE
Regulation and described on work permit.
5. Put damaged insulation in plastic bags for proper
disposal.
6. Ensure that heat exchanger has been isolated by the
closing of valves at all process and utility connection
points. Lock out/tag out procedure has been followed.
7. Isolate both sides of the exchanger from process and
utility streams by installing blinds as per blind list.
8. Connect drain for liquids draining.
9. Connect steam supply for steaming out shell or tube side
that was exposed to process materials.
10. Conducts steaming of exchanger and if possible followed
with flushing the tube side with cooling water, as per
manufacturer’s recommendation.
11. Disconnect piping after steaming is complete.
Remove channel head cover
12. Crane or other suitable lifting device to support and lift
covers.
13. Pneumatic wrenches used to remove nuts from studs.
14. Unbolt in the same sequence listed for bolting up. Refer to Bolting
up sequence
diagram.
15. Release bolt loads in several passes that unload the
bolts in approximately equal increments.
16. Remove channel head cover.
Hydrostatic shell-side test.
17. Fill exchanger shell with water.
18. Use hydraulic pump to bring pressure up to the
manufacturer’s specified test pressure.
19. Check exposed tube ends for leakage. Mark locations

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 12 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

of leaking tubes.
20. Shell side of exchanger to be cleaned by flushing or by
chemical cleaning as determined by Inspection
Engineers.
21. Tube side of exchanger will be cleaned by jet cleaning.
22. Heat exchanger auxiliary parts to be cleaned by jet
cleaning.
23. NDT of necessary tubes. Consider to
utilize Eddy
Current Testing
(ECT) method
if any
The inspection engineers will provide inspection to determine:
24. Necessary tubes need to inspect for the next inspection. Have been
corroded more
than normal.
25. Needed repair of damaged parts. IAT to describe repairs
and methods.
26. Leaking tubes to be plugged, Issue IAT for repairing
Leaking tubes will be plugged as following:
27. The tube end to be plugged shall be descaled.
28. Specify the standard tube plugs (material, dimension ...)
to be used.
29. Tube plugs will be “hammered in” until leaking is
stopped. Care should be taken to insert the plugs into
the tube end only as far as required to stop the leak.
Excess hammering may cause damage to ligaments
between tube sheet holes.
30. Plugging of leaking tubes which have been back welded
into the tube sheet will be accomplished by inserting the
plug and back welding it.
31. Repeat pressure testing to show a satisfactory repair.
32. When tube plugging is completed, the location, axial
position, date and expected cause of failure should be
recorded on a tube sheet layout sketch. This record of
tube repairs should be part of the Inspection record.
Inspection Engineer conducts the work as following:
33. Witness of pressure testing.
34. Approval to reassemble the heat exchanger.
Install Channel Head Cover
35. New gaskets should be used as per manufacturer’s
specifications.
36. Studs should be coated with an anti-seize compound.
37. Use the bolt up sequence. Torqueing should be done in 3
to 4 rounds in equal increments as per Bolting up
sequence.
Hydrostatic tube-side test for tube leaks
38. Fill tube side of exchanger with water.
39. Use hydraulic pump to bring pressure up to the

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 13 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

manufacturer’s specified test pressure.

40. If the system maintains this level of pressure without
reduce, the exchanger tube leak repair is successful.
41. If the system pressure reduce and all external possible
sources of leakage, including the channel head cover
gasket, are confirmed as good, then the exchanger will
need to be retested with shell side pressure as identified
above. Additional repairs may be necessary.
42. Obtain clearance from Inspection Engineer that tube
repair is satisfactory and can be ready for service.
Leaking channel head cover gasket will be checked
as following:
43. Torque values on studs and nuts as per specification.
44. If necessary, drain water from exchanger, remove the
channel head and examine the channel head gasket for
proper seating, etc.
45. After reassembly, re-pressure the tube side to assure
channel head gasket leak is repaired.
46. Obtain Inspection Engineer agreement that hydro test
and repair is satisfactory and the unit can be readied for
service.
Remove blinds and reconnect piping
47. Obtain operation’s clearance to remove blinds.
48. New gaskets should be used.
49. Establish connection for purging or steaming as
determined by process conditions.
50. After steam out/purging is complete, remove the piping
connection.
51. Notify operations that lock-out/tag-out can be closed.
52. Repair and refit insulation as per the original condition
Closure
53. Insulation debris should be put in plastic bag and sealed
for disposal.
54. Take down scaffolding and remove from area.
6.4 Return equipment to service
Work
Description Remarks
step
Remove all temporary equipment and maintenance
equipment
1 NOTE:
 Make sure the equipment is ready to be returned
to service.
Keep the maintenance area tidy. Arrange for proper
2
disposal as directed by operations.
Close all PTW and confirm with Operation the work is
3
completed.

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 14 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

NOTE:
 Make sure all isolation, LOTO (if any) are released
and confirmed.
After Step 3, Operation will be responsible to carry-out
commissioning.
NOTE: (for special case)
4  If required, parameter or status of equipment shall
be recorded in check sheet during commissioning.
 The WO can be completed only after
commissioning is passed
6.5 Work Order closure
Refer document MD-04-MT-MS-PD-006_Maintenance Closure Procedure for further
requirements.
Work
Description Remarks
step
1 Sign-off all check sheets or record sheets

Return unused spare parts and reusable parts:

2  Gather unused parts and return them to

Warehouse after approval.
 Gather all reusable parts that can be refurbished
Record and summary of the maintenance work:
 Actual used MRO,
3  Actual used Equipment/Tool
 Actual man hour
Send the endorsed WO for CMMS recording
Record in CMMS.
To be done by
4 Complete WO on CMMS (Refer the note in Step 4 in NSRP (HOLD)
paragraph 6.4.3)
To be done by
5 Close WO on CMMS
NSRP (HOLD)
7. APPENDIX
1. Bolting up sequence for Shell and Tube Heat Exchanger (channel head cover).

2. Maintenance check sheet for Heat Exchangers (later).

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 15 of 16

 NGHI SON REFINERY AND PETROCHEMICAL LLC

1. APPENDIX 1: BOLTING UP SEQUENCE FOR SHELL AND TUBE HEAT

EXCHANGER (CHANNEL HEAD COVER).

Determining: Divide the flange into 4 quadrants: A, B, C, & D. Number the bolts
sequentially, beginning with the first bolt in quadrant A. Under each column heading,
list the bolt numbers in that quadrant. The bolting sequence then goes left to right
across the columns. Below are sequences for two popular channel head cover
flanges:

The sequence for the 24 bolt flange The sequence for the 20 bolt flange
is: is:

 1, 13, 19, 7  1, 11, 16, 6

 2, 14, 20, 8  2, 12, 17, 7

 3, 15, 21, 9  3, 13, 18, 8

 4, 16, 22, 10  5, 15, 20 and 10

 5,17, 23, 11

 6, 18, 24 and 12.

Document No.: MD-04-MT-RSSTA-PD-004 Title: Maintenance Procedure for Heat Exchangers

Date: 24 June 2016 Rev. No.: 00 Page 16 of 16