RAW PYROLYSIS

GASOLINE
PRODUCT COOLER
Preventive Maintenance
Raw Pyrolysis Gas Cooler

Purpose: To cool the Raw pyrolysis gasoline temperature

to PGH reactor using the Cooling water.

Why should we clean?

Due to high differential pressure across the shell side and

increased temperature of the process feed to PGH reactor.
Shell and Tube Heat Exchanger. Generally built of a bundle of round
tubes mounted in a cylindrical shell with the tube axis parallel to that of
the shell.

Advantages:
• The configuration gives a large surface area in a small volume
• Good mechanical layout: a good shape for pressure operation
• Can be constructed from a wide range of materials
• Easily cleaned
Shell and Tube Heat Exchanger
The shell and tube exchanger parts:

• Front Header—this is where the fluid enters the tube side of the
exchanger. It is sometimes referred to as the Stationary Header.

• Rear Header—this is where the tube side fluid leaves the exchanger
or where it is returned to the front header in exchangers with multiple
tube side passes.

• Tube bundle—this comprises of the tubes, tube sheets, baffles and

tie rods to hold the bundle together.

• Shell—this contains the tube bundle.

Tube sheets—are used to hold tubes at the ends. Generally a round
metal plate with holes drilled through for the desired tube pattern, holes
for the tie rods (which are used to space and hold plate baffles), grooves
for the gaskets, and bolt holes for flanging to the shell and channel.
Baffles
Baffles are installed on the shell side to give a higher heat-transfer rate due
to increased turbulence and to support the tubes thus reducing the chance of
damage due to vibration. There are a number of different baffle types,
which support the tubes and promote flow across the tubes.
• Single Segmental can help maintain greater turbulence for the shell side
fluid, resulting in a higher rate of heat transfer. This is the most common.
• Double Segmental is used to obtain a lower shell side velocity and
pressure drop.
• Disc and Doughnut.
• Impingement Baffle are placed opposite the shell-side inlet nozzle. The
flow into the shell hits the impingement baffle and is dispersed around
the tubes, rather than impinging directly on the top tubes. This keeps the
full force of the momentum of the flow from impinging on and eroding
the top tubes.
Single segmental

Impingement Baffle

Double segmental

Disc or Doughnut
U-Tube
This is the cheapest of all removable bundle designs. It permits
unlimited thermal expansion, allows the bundle to be removed to
clean the outside of the tubes, has the tightest bundle to shell
clearances and is the simplest design. A disadvantage of the U-tube
design is that it cannot normally have pure counter flow unless an F-
Type Shell is used. Also, U-tube designs are limited to even numbers
of tube passes.
Heat Exchanger Nomenclature
DEFINITION OF TEMA CLASS "R" EXCHANGERS
The TEMA Mechanical Standards for Class “R” heat exchangers
specify design and fabrication of unfired shell and tube heat
exchangers for the generally severe requirements of petroleum
and related processing applications.
DEFINITION OF TEMA CLASS "C' EXCHANGERS
The TEMA Mechanical Standards for Class “C” heat exchangers
specify design and fabrication of unfired shell and tube heat
exchangers for the generally moderate requirements of
commercial and general process applications.
DEFINITION OF TEMA CLASS "B" EXCHANGERS
The TEMA Mechanical Standards for Class “B” heat exchangers
specify design and fabrication of unfired shell and tube heat
exchangers for chemical process service.
Raw Pyrolysis Gasoline Cooler

Design Data
Type: H-BEU TEMA: Class “R” 9th ED.
Weight: 3800 KG

Shell Side: Raw Pyrolysis Gasoline Tube Side: Cooling Water

Pressure Pressure
Design: 16.3 Barg Design: 10 Barg
Operating: 6.69 Barg Operating: 4.5 Barg
Temperature Temperature
Design: 130 °C Design: 65 °C
Operating: 106.8/40 °C (in/out) Operating: 34/40 °C (in/out)
Test Pressure Test Pressure
Hydro.: 21.19 Barg Hydro.: 13 Barg
Pass: 1 Pass: 2
SCOPE OF WORK

Date Activity

June 27, 2018

0900H-1200H Blinding of process fluid inlet and outlet;

Cooling water outlet spool removal; channel head removal
1200H-1500H Pull-out of tube bundle and cleaning by hydro jet washing;
Cleaning of shell side
1500H-1600H Inspection prior to box-up of tube bundle
1600H-1900H Box-up of tube bundle, channel head, and CW outlet spool;
Water filling and hydro testing of shell side for 21BarG;
Draining and turnover to operations
Housekeeping
Polymerized materials found on the
tubes.
As found condition of shell side.
• PROPOSED IMPROVEMENTS and CONCERNS
The job was carried out safely and efficiently however
improvements can be made so we can minimize the
downtime of the equipment. During the installation of
scaffolding, the workers and scaffolder should be present
when assembling the platform in order to save time and
attend any modification. Practice wearing of complete and
appropriate PPE when handling chemical like the pyrolysis
gasoline, preparation of tools and equipment, observe
proper work permit system, execute the job safely and
observe teamwork during shutdown maintenance.
• RECOMMENDATIONS
During pull-out of the tube bundle, a lot of Pyrolysis
Gasoline scattered on the ground. We recommend using a
larger catch basin instead of a single chemical drum. During
clean-up of tube bundle with Hydro Jet washer, we
recommend to provide barricade so that dirt from the tube
bundle will not be thrown further and the cleaning area
would be minimal. Housekeeping and proper disposal of
hazardous fluid must be observed during maintenance work.