RANTO MANULLANG

KDTP - 2008
 AGENDA
HEAT EXCHANGER
 Type & Parts of Heat Exchanger
 Inspection of Heat Exchanger
 Testing of Heat Exchanger

BOILER
 Boiler in general
 PT Badak’s Boiler
 Inspection Requirement

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Heat Exchanger

SHELL & TUBE

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 Heat Exchanger
AIR COOLER / FIN FAN

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Heat Exchanger
PLATE & FRAME

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 Heat Exchanger
Shell & Tube

TUBE BUNDLE
FLOATING HEAD
SHELL
CHANNEL BOX
END COVER
FRONT COVER

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BASIC COMPONENT

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 Heat Exchanger
 Types of Shell & Tubes
Heat Exchangers based
on TEMA

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 Inspection of Heat Exchangers
 During On line
 Wall thickness
 Visual Check for any leakage from nozzle
drain, vents and welds.
 Visual check insulation and CUI
 During Off Line
 Visual check on disassembled parts of
Heat Exchanger.
 Testing the Heat Exchangers

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 Shell & Tube Type
 Common Problems
 Tube leak  plug or re-tube
 Plugged/blocked tubes  clean
 Erosion on the tubesheet, divider plates,
floating head  repair by welding or by
epoxy
 Scale on internal shell and tube bundle 
clean.
 Vibration on high velocity stream 
redesign, plugged the future leak tubes.
 Inspection Program
 Regularly shutdown, disassembled,
internally inspected and tested.

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 Air Cooler
 Common Problems
 Scale on external tubes or fins 
regularly clean.
 Leak on roll joint of tube to tubesheet 
reroll or plug.
 Erosion on header box  replace plate or
reinforced externally.
 Inspection Program
 Visual inspection

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 Plate and Frame
 Common Problems
 Gasket defect between element 
retighten or replace
 Inspection Program
 Testing regularly.

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 HEAT EXCHANGER TESTING

 Water Pass Test

 Hydrostatic Leak Test
 Pneumatic Leak Test
 Operating Leak Test

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 Water Pass test
 Leak test on Divider Plate toTubesheet of Shell
and Tube Heat Exchanger
TUBE SHEET
 Performed:
TUBE
 After Opening Cover
TUBE
 Prior to closing Cover
DIVIDER PLATE

TUBE

TUBE

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Water Pass test

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 Hydrostatic & Pneumatic Leak Test

Hydrostatic Pneumatic
Media Utility Water Nitrogen
Temperature < 50 0C < 50 0C
Press.Test 1.5 x Opr Pres 1.1 x Opr Pres
Press Direct Step by Step
Increment

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 Hydrostatic & Pneumatic Leak Test
 General Requirement
 Inlet Supply
 Venting
 Drain
 PSV
 Pressure Indicator (PI)
 Temperature Indicator (If Required)
 PSV Requirement
 Setting PSV = 1.1 x Test Pressure
 Example :
 Pressure Test = 30 kg/cm2.
 Set of PSV = 33 kg/cm2.
 Pressure Indicator Requirement
 Calibration Date is still valid
 In good condition
 Max Scale of PI use is in range of 1.5 - 2 2 x Test pressure
 Example :
 Pressure Test = 20 kg/cm2.
 Max Scale of PI = 30 – 40 kg/cm2.

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 Hydrostatic & Pneumatic Leak Test
 Persyaratan pelaksanaan
 PI shall be clearly shown and monitored
 Leak at connecting pipes, nozzles & test
rings are not allowed
 For Pneumatic test, pressure shall be
increase and decrease gradually
 After test pressure is reached the inlet
supply shall be blocked
 Test duration = Extent of Inspection

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 Hydrostatic & Pneumatic Leak Test
 Shell Side Test
 Search any tube leak
 Check gasket tightness between bundle – shell
 Check any leak from weld and nozzle of shell
side
PI
PS
VENT V
Test
Ring
= close
= open

DRAIN
SUPPLY

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 Hydrostatic & Pneumatic Leak Test
 Tube Side Test
 Check gasket tightness between Channel – Cover
 Check gasket tightness between Channel – Bundle
 Check gasket tightness between Bundle – Floating Head
 Recheck any tube leak suspicious
PI
VENT
PS
V

= close
= open

DRAIN
SUPPLY
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 BOILER
 Boiler is an equipment which produces
steam by heating water, and the steam
is utilized outside this equipment.
 Two types of Boilers
 Fire Tubes Boiler
 Water Tubes Boiler

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Fire Tube Boiler

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Water Tube Boiler

PT BADAK’S BOILER :
• WATER TUBE TYPE
• WITH ECONOMIZER
(PRELIMINARY HEAT)
• WITH SUPERHEATER

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PT BADAK NGL’S BOILERS

Manufacturer : Mitsubishi Heavy Industry (MHI)

Tipe : VU-60
Capacity : 294.8 Ton/hr
MAWP : 72 kg/cm2
Quantity : 11 ea  31-F-01 ~ 31-F-11
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PT BADAK NGL’S BOILERS

Manufacturer : Babcock & Wilcox (BW)

Tipe : SB-22
Capacity : 379 Ton/hr
MAWP : 1050 psi
Quantity : 10 ea  31-F-21 ~ 31-F-30
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 Module I Boilers
HEADE
R S/H
S/H TOP
RISER TUBES TIMUR & BARAT BENDING
SEBELAH ATAS & BARAT
HEADER TIMUR
SEBELAH ATAS

STEA
M
BANK TUBES BAGIAN BARAT
WALL TUBES & TIMUR
DRUM
ATAS
AATASATAS B
A
G
B
.
A
A
G
. S/H
B S/H
FRON REA
T R BANK/GENERATOR
TUBES

S/H 300 mm DARI BENDING BAWAH

INLET&OUTLET ECONOMIZER
BAG. ATAS
S/H BOTTOM
BENDING D
B C
A
BENDING
BELAKANG

FURNACE UPPER WALL

TUBES

WALL TUBES WALL TUBES

FRONT REAR ECONOMIZER BAG.
BAWAH
FURNACE LOWER WALL
TUBES BANK TUBES
BELAKANG
WALL TUBE
BAWAH

B
A
MUD
BOTTOM FEEDER G
DRU
o TUBES .
B M
BANK TUBES OD 2.5" 200 mm DARIMUD
DRUM & SWAGE

HEADER TIMUR & BARAT SEBELAH

BAWAH

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Module I Boilers

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 Module II Boilers
SUPERHEATER OUTLET
SATURATED
HEADER
STEAM
SUPERHEATER INLET
WALL TUBES TOP
HEADER
HEADER
RISER
TUBES STEA
M
o o o o o o
TOP WALL TUBES DRU
TOP WALL TUBES SECTION B M
SECTION A

BANK/GENERATOR
TUBES
S/H S/H
FRON REA
T R

SUPERHEATER
TUBES
MUD
BANK / GENERATOR
DRU TUBES TUBES
M END

INLET
ECONO H.
MIZER ECO.
OUTLET
H. ECO.
WALL TUBES WALL TUBES
FRONT REAR

BOTTOM WALL
BOTTOM WALL
TUBES
TUBES
SECTION A
o o o o SECTION
o B o
WALL TUBES REAR HEADER
WALL TUBES HEADER BOTTOM FEEDER BOTTOM
WALL TUBES FRONT HEADER
BOTTOM TUBES BOTTOM

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 PTB Boiler Inspection
 Extend of Inspection
 Refer the Regulation, Code and Standard
such as NBIC and API RP 573.
 Inspection Frequency
 Refer to Government Regulation.
 Indonesian Government requires 2 years
of Inspection Interval (UU UAP 1930)

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 Extend of Inspection
 Visual Inspection
 Flaw check using MT & UT on weld joints of
 Steam Drum & Mud Drum
 Superheater Headers
 Thickness check of critical parts
 Steam Drum and Mud Drum
 Superheater tubes system
 Wall tubes
 External Piping
 Hydrostatic Test
 Leak test
 Steam Test

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