MAINTENANCE MAINTENANCE Of Heat Transfer Of Heat Transfer Equipment In The Equipment In The

Petroleum IndustryPetroleum Industry

More than More than 40,000 (forty 40,000 (forty thousands) thousands) tons of heat tons of heat transfer equipment is transfer equipment is manufactured annually for manufactured annually for the petroleum and gas the petroleum and gas industries.industries.

Objective of equipment maintenanceObjective of equipment maintenance Maintenance frequencyMaintenance frequency Inspection and TestingInspection and Testing Process types and operational Process types and operational

practicespractices Maintenance contractor qualificationMaintenance contractor qualification Case studiesCase studies ConclusionConclusion

Heat transfer equipment have different Heat transfer equipment have different maximum maintenance frequencies.maximum maintenance frequencies.

Frequencies are based on heat intensity, Frequencies are based on heat intensity, process type, and equipment reliabilityprocess type, and equipment reliability. .

EquipmentEquipment Max. Interval (Mo.)Max. Interval (Mo.)

Fired BoilerFired Boiler 2424

Unfired BoilerUnfired Boiler 3636

Process Fired Process Fired HeaterHeater

6060

Hydrogen ReformerHydrogen Reformer 4848

Heat ExchangerHeat Exchanger 6060

Inspection prior to maintenance.Inspection prior to maintenance. Inspection records.Inspection records. Inspection log.Inspection log. External Inspection.External Inspection. Internal Inspection.Internal Inspection. Pressure testing.Pressure testing.

Equipment Equipment handles different handles different types of types of processes.processes.

Erosion, Erosion, Corrosion, and Corrosion, and fouling.fouling.

Normal Operation Normal Operation and and abnormalities.abnormalities.

Equipment design Equipment design limits.limits.

Recommend Recommend maintenance maintenance friendly design.friendly design.

Repair Certification Repair Certification “R” Stamp per NIBC“R” Stamp per NIBC

Experience.Experience. Good reference list.Good reference list. Reliability.Reliability. Warranty.Warranty.

Water tube boiler.Water tube boiler. Short term Short term

overheating.overheating. Insufficient Insufficient

circulation design.circulation design. Design Modification Design Modification

of steam drum of steam drum internals.internals.

Repeat same Repeat same modification to modification to similar boilers.similar boilers.

Wrong Refractory Wrong Refractory Design.Design.

Sulfur Dew Sulfur Dew Condensation Condensation behind Refractory.behind Refractory.

Complete repair of Complete repair of the Furnace Shell the Furnace Shell Bottom.Bottom.

Qualified Qualified Contractor for the Contractor for the job.job.

Reaction Furnace Shell Reaction Furnace Shell Failure.Failure.

Sulfur Condenser.Sulfur Condenser. Wrong Shutdown Lay Wrong Shutdown Lay

up Procedure.up Procedure. Sulfuric Acid Sulfuric Acid

Formation.Formation. Tube Corrosion.Tube Corrosion. Complete Retubing of Complete Retubing of

1654 tubes.1654 tubes. Qualified Contractor Qualified Contractor

for the job.for the job.

Burn Pit.Burn Pit. Inadequate Refractory Inadequate Refractory

Structure.Structure. Premature Failure.Premature Failure. Structure Redesign.Structure Redesign.

Maintenance of heat Maintenance of heat transfertransfer equipment equipment requires:requires:

Adequate knowledge of the equipment.Adequate knowledge of the equipment. Maximum set forth frequencyMaximum set forth frequency Proper Inspection and TestingProper Inspection and Testing Handling by qualified personnel.Handling by qualified personnel.