HEAT EXCHANGER/AFC Doc No: STS/QAC/SOP/02

Rev No: 00
RETUBING PROCEDURE Date Rev: 17 Dec 2008
Page No: 1 of 4

REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved
Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

1. SCOPE

This procedure comprise the aspect of basic specification for fabrication, installation, testing and
inspection of retubing work for AFC/Heat Exchanger

2. REFERENCE

2.1. ASME Section IX

2.2. ASME Section VIII DIV I 'R'
2.3. API 510 Pressure Vessel inspection Code Maintenance Inspection, repair and alteration
2.4. TEMA

3. DESCRIPTION

3.1. Equipment Tag No:

3.2. Equipment Name:
3.3. Tube Sheet Material
3.4. Tube Material:
3.5. No. Of Tubes:

4. PROCEDURES

4.1. Refer to inspection for defect location.

4.2. Conduct hydrotest (if required) to locate any other defect and leak location.
4.3. Marking the leak point (based on inspection report or result of hydrotest) and write down in
report (refer attachment).
4.4. Start tube pulling activity at marked tube position.
4.5. The affected location to be cleaned thoroughly using proper medium e.g air blow.
4.6. Then inspect the area visually to make sure the location is properly clean and free from any
detrimental medium.
4.7. Perform material inspection prior to start fabrication and retubing activity to comply with
specification.
4.8. Prior to start tube inserting activity; identify the mark location to ensure the exact location of
tubes to be replaced.
4.9. Surface preparation performed at tubesheet using power tool and then shall be visually
inspected by client representative.
4.10. Perform new tube inserting. Insert 1/3 of the tube, then visually inspect inside and outside
along the tube bundle to make sure the inserted tube free from any surface defect e.g ring
appearance or scratch or dented. Insert another 2/3 and repeat previous steps.
4.11. Upon completing the tube insertion, client representative shall perform visual inspection at
the tube location.
4.12. For connection of the tube to tubesheet, refer the detail drawing and follow the following
procedure;

4.12.1. By Seal Welding:

4.12.1.1. All the welding procedure strictly follows the WPS and WQT qualification that
approved by client and DOSH.
 4.12.1.2. Weld at the connection by using seal weld.
4.12.1.3. Perform DPT and visual inspection.
4.12.1.4. Final inspection by client representative.

4.12.2. By Expanding tube connection

4.12.2.1. The expand machine must follow the suitable material ( refer to drawing and
material specification)
4.12.2.2. Upon completion of expanding activity, perform visual inspection.
4.12.2.3. Final inspection shall be perform by client representative.

4.12.3. After completion of retubing activity and accepted by client representative, two stages of
hydrotest, tube and shell hydrotest shall be performed.

5. ACCEPTANCE CRITERIA

5.1. All repaired location shall be inspected and acceptance criteria shall be as follows;
5.1.1. Visual inspection shall be carried out after completion of seal welding.
5.1.2. DPT to be performed on weldment of the cover after grinding and any flows found shall
be removed by grinding and retest.

6. HYDROSTATIC TESTING

6.1. After the above repair work has been completed, hydrostatic test is to be carried out in the
presence of DOSH and Client representative.
6.2. Authorized safe working pressure shall be pre determined as per drawing. Minimum
holding time should be 30 minutes.

7. APPENDIX

7.1. Equipment Inspection Report

7.2. Drawing and SOE
7.3. WPS,WQT and PQR