The Heat Exchanger Inspection article provides you with information about the inspection of heat exchanger and heat exchanger testing during the construction phase, as well as in the operational phase.
This article provides you lots of invaluable information about the following items:
This article, alongside other linked articles are useful for Manufacturer's Quality Control Personnel, Second and Third Party Inspectors, Purchasers, Sellers, Plant Inspectors, HSE Engineers, Integrity Engineers, Operation and Maintenance Engineers and any Other Interested Individuals.
We need to heat or to cool process fluids in industrial plants to facilitate process reactions.
So we need to use heat exchangers either to reduce the temperature or increase the temperature.
For more details, review the Heat Exchanger Theory article.
This article provides information only about the shell and tube heat exchanger inspection. For fin tube heat exchanger inspection, review following articles:
The content covers the shop inspection requirements during the manufacturing process and the In-service Inspection requirements in the operational plants.
What are the Shell and Tube Heat Exchangers?
Shell and Tube heat exchangers are the most popular type in the industry. This type is made from 3 components as listed below:
One fluid is in the tube side and the other one in the shell side. The heat transfer is done through tube wall.
So your heat exchanger with more tubes will have more heat transfer surfaces, and at the same time will have a higher heat exchanger diameter.
There are different kinds of shell and tube heat exchangers with different applications.
The reason for the high amount of applications is that they are easy to maintain.
In addition, the shell and tube heat exchanger is the only type that can be designed and operated at a temperature greater than 360 degrees centigrade, as well as in pressure higher than 30 bar.
What are the Shell and Tube Heat Exchanger Inspection Requirements in a Construction Shop?
The construction code for shell and tube heat exchangers is ASME Code Section VIII, and it covers the minimum requirements for design, materials, fabrication, inspection, testing, and preparation for initial delivery.
You may know after the 2003 addenda of ASME Code Section VIII Div. 1, the design of the shell and tube needs to be done based on Subsection C, in UHX part. And design base TEMA, or any similar code and standards is not allowed.
So this is when you require that your shell and tube heat exchanger meets the ASME Code requirement or when you need your heat exchanger to be “U” stamped.
As you may know, heat exchangers are also pressure vessels based on ASME Code requirements, and all requirements for other types of pressure vessels also apply for heat exchangers.
For more detail about Stamped pressure vessels and requirements, review the Pressure Vessel Certification article.
With the above explanation, your inspection and test plan (ITP) for the shell and tube heat exchanger need to meet the requirements of ASME Code Section VIII.
For more detail about heat exchanger inspection in the construction process, review the following articles:
What are In-Service Inspection Requirements for the Shell and Tube Heat Exchanger Inspection?
The In-Service Inspection code for your shell and tube heat exchangers is similar to other pressure vessel in API STD 510.
The other API recommendation practices and codes also have to be used in with this Code.
Some of these Recommend Practices are API RP 572, API RP 577, and API RP 571, and also construction code sections might be used, such as ASME Code Section VIII and ASME Code Section IX.
For repair the requirement of API STD 510 or ASME-PCC-2 needs to be met.
The title of ASME-PCC-2, which was first published in 2006, is: “Repair of Pressure Equipment and Piping.”
Please note: if your shell and tube heat exchanger is “U” stamped and you need to do repair, you have to use a Repair Organization holding an “R” Stamp from the National Board Inspection Code.
The API 510 Pressure Vessel Inspectors are qualified persons to do shell and tube heat Exchanger inspection.
You may also review the Industrial Plant Inspection article.
What are the Important Items in the Shell and Tube Heat Exchanger Inspection in Overhaul?
Shell and Tube Heat Exchanger Inspections are categorized in the following way:
Shell and Structure in Heat Exchanger Inspection:
Bonnet in Heat Exchanger Inspection:
Channel in Heat Exchanger Inspection:
Channel Cover in Heat Exchanger Inspection:
Floating Head Inspection:
Expansion Joint Inspection:
The heat exchangers with expansion joints need to be inspected for:
The tube and shell hydrostatic test need to be done after the above stated inspection activities.
Boiler Inspection, Above Ground Storage Tank Inspection, Piping Inspection, Valve Inspection, Heater Inspections, Pressure Vessel Certification, Pressure Vessel RT Test, Pressure Vessel Dimension Inspection, ASME Impact Test Requirement, ASME Pressure Vessel Joint Efficiencies, Pressure Vessel Plate Material