Gujarat Refinery

DHDT
Breech Lock Exchangers
Maintenance Report
24th Feb, 2011 to 30th March, 2011

Contents
• Background

• 2091-E-01B
(TLR got Stuck)

• 2091-E-01C
(Originally Planned)

• 2091-E-01D
(Gasket Face Machining)

• 2091-E-01E

• 2091-E-01F
(Tube Plugging) Prepared by: Vivek Gupta (SMLE
(SMLE-RUP)
RUP) Reviewed by: Sunil Kanti (SMNM-
(SMNM
RUP)
• Resource/ Spares Gujarat Refinery
Utilization 4/1/2011
 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

Background
DHDT unit of Gujarat Refinery was commissioned in June’10 and was running smoothly till 23 Nov’10.
During last week of Nov’10, Sulfur Level in Diesel Rundown was observed to be 90 ppm. In order to
establish any possible leak in the reactor effluent train, samples were taken from the outlet of each
exchanger and tested.

It was established that in the case of 2091-E01C & E01D, Sulfur at the outlet was greater than the inlet
Sulfur. The manufacturer L&T were approached for troubleshooting and a possible solution. L&T
indicated that there is scope of further tightening of pusher bolts. On 13th Dec’10, tightening of 2091-
E01C & E01D were carried out under the supervision of L&T expert, with required torque value, and the
problem was resolved.

On 26th Jan’11, after an interruption caused due to tripping of Hydrogen Unit 3 on 22nd Jan’11, it was
again observed that Sulfur level at the outlet of 2091-E01C was found higher than inlet sulfur, indicating
a possible leak. Again the matter was referred to L&T and further tightening up to the permissible
torque value was done. However, there was no improvement in the situation. Hence, after detailed
discussion with L&T, it was decided to open the exchanger 2091-E01C for further assessment.

DHDT Unit was taken under shutdown on 24th Feb, 2011, in order to rectify suspected tube-sheet gasket
leak in exchanger Reactor Feed/ Effluent Exchanger 2091-E-01C. In order to ensure that the tube-sheet
gasket integrity of other 5 exchangers, it was decided to carry out shell side of these exchangers.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

2091-E-01B
Reason for Maintenance
As the shell side of exchangers 2091-E-01A/B (combined) was pressurized, leakage was observed from
the tube-side drain of 2091-E-01B. Exchanger 01B was isolated from 01A, barrel cover push bolts were
tightened to design torque value and shell side was repressurized. Still leakage was observed, hence it
was decided to replace the tubesheet gasket of the exchanger 2091-E-01B.

Equipment Details
Description Shell Side Tube Side
Tag No. 2091-E-01B
Construction Type H-H Type Breech Lock Exchanger
Design Pressure (kg/cm2) 159 136
Differential Design Pressure (kg/cm2) 40
Design Temperature (oC) 350 390
Hydrotest Pressure (kg/ cm2 g) 216 170
Differential Hydrotest Pressure (kg/cm2 g) 54.4
Number of Passes One two
Operating Fluid Reactor Feed Reactor Effluent
No. of Tubes 1132

Exchanger Dismantling
Following dismantling procedure was followed,

1. Passivation of tubeside as well as shell side of the exchanger was carried out.
2. Measurements of TLR to guide ring face, TLR to barrel cover face and push bolts standout length
was done. TLR/ Barrel/ Shell relative angular position marking was done.
3. Threads of the TLR were lubricated through the three tapped greasing points located inside the
ring.
4. TLR & Barrel Cover Push bolts were removed.
5. Guide ring & holding studs (with square nut) were removed.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP
6. TLR/ Barrel Cover removal fixture was installed and TLR rotation was attempted. The TLR was
observed stuck-up and hence the crane load was increased, however at approx. 35T load the
fixture arm broke down.

Fig01: Broken Arm Fig02: Welding of Broken Arm

7. The fixture was removed from the position and the broken arm was welded.
8. Extra torque was provided for TLR rotation by fabricating special arrangement as shown in
Fig03. Rotation of approx. 4 threads (out of total 12) was achieved by using chain-pulley
arrangement as well as crane, after which the TLR got stuck again.

Fig03: Special arrangement for TLR opening Fig04: Shell Heating Arrangement

9. Heating of shell was carried out to approx 300 oC, with air cooling at barrel cover. Centering of
barrel w.r.t. TLR was also ensured. Still no rotation of TLR could be achieved.
10. Reverse rotation of TLR was tried, and after a rigorous attempt approx. ½ rotation in reverse
(TLR closing) direction was achieved. However as the TLR opening was tried again, it got stuck up
after ½ rotation in forward (TLR Opening) direction.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP
11. As no rotation was getting achieved, another TLR opening arrangement was fabricated (fig05).
This arrangement was prepared using 35mm CS plate, and provision was provided that
simultaneous torque could be applied in 3-4 locations.
12. Before installation of the special
fixture it was tried to push back the
barrel cover to its original position,
where it could be locked with the
help of locking bolt arrangement,
however it could not be achieved as
the barrel cover & outer compression
ring had lost its original position.
13. Rotation of TLR was tried using 2Nos.
of 10T chain pulley blocks and one
50T crane however, no movement
was achieved.
14. In order to get extra torque through Fig05: Special fixture for TLR opening
jacking a square plate arrangement
(fig06, 08) was then fabricated.
Exchanger guide ring was welded at
inner part of the square plate and
support plates were welded at 4
diagonal locations for providing
reaction and holding location for
hydraulic jacs. Strengthening of the
square plate was carried out by
welding structural members at the
rear side.
15. Special arrangement was installed on Guide
the exchanger (fig07), heating was Ring
continued, barrel cooling was carried
out by making a water sprinkler Fig06: Square plate for Jacking arrangement
arrangement.

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Gujarat Refinery
Mechanical Maintenance- RUP

Hydraulic
Jacks

Chain
Pulley

Fig07: Special fixture & Square plate installed

Hydraulic Structural members

Jack Support for strengthening

Guide
Ring

Hydraulic
Jack

Support
Packing
Fig08: Square Plate Assembly

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Gujarat Refinery
Mechanical Maintenance- RUP

16. Rotation of TLR was then tried using 2 Nos. of 50T hydraulic jacks, and chain pulley arrangement
at 2 locations and 50T crane. With this arrangement balance 7-8 thread were opened in 5 days
of continuous effort. About ½ to 3/4th rotation was being achieved in a shift of 12hrs.
17. Barrel Cover was then removed using the same special fixture (fig 05).
18. Thereafter inner & outer compression rings, diaphragm and channel gasket were removed.
Diaphragm removal was done using a pipe with a bolt welded at one end.
19. Square plate arrangement was then removed.
20. Guide block was installed inside the channel and internal sleeve was removed.
21. Internal flange push bolts were then removed, internal flange was slightly pushed with the help
of hydraulic jacks and split ring was removed.
22. Internal flange, Partition cover plate & cover gasket was removed in sequence.
23. Gland flange & Gland sleeve were dismantled and removed.
24. Channel box assembly was taken out.
25. Eye bolts were then installed on the tube sheet, and the bundle was pulled out with the help of
bundle puller.

Fig09: Utilization of Bundle Puller for Bundle removal

Repair Activities
1. Heavy damage was observed in approx. 3threads of TLR as well as corresponding shell (fig 10,
11). Same was repaired by grinding and polishing.
2. 2 Nos. of TLR push rods got stuck in the TLR and were not coming out by hammering. TLR was
sent to MR Shop, where drilling of the push rods was done. One of the push rod was successfully
removed by drilling. The other one was drilled from both ends, upto the drill bid length,

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Gujarat Refinery
Mechanical Maintenance- RUP
however it still remained stuck. TLR was brought back to site where push rod removal was tried
by heating-hammering and then by using hydraulic jack. However it still remained stuck and it
was decided to keep it as it was.

Fig10: Damaged TLR threads Fig11: Damage in Shell side Threads

3. Polishing of TLR & Shell Threads, Gasket seating areas, push rod faces etc. was done by using
portable buffing machine.
4. DP Testing of push rods, gasket seating areas, complete diaphragm etc. was carried out.
5. Hydrojetting cleaning of tube bundle (internal as well as external) & shell was done.
6. Cleaning of the channel was done using rustolene.

Assembly
1. New tubesheet gasket (spiral wound) was wrapped with sticker type grafoil tape and was fixed
on channel step using adhesive (fevi-quick).
2. Guide blocks (Type-I & Type-II) were inserted to facilitate insertion of tube bundle and to avoid
trapping of baffles / tube sheet in the channel. Nylon rope was fixed on guide block type 1 for
pulling the same later.
3. Tube bundle was inserted using bundle puller.
4. Channel assembly was also inserted using the bundle puller.
5. Gland flange & Gland sleeve were installed in the channel-box groove. Internal flange was
installed using connecting device and equalizing bar.
6. Split ring was installed.
7. Internal flange push bolts were tightened using torque tool.

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Gujarat Refinery
Mechanical Maintenance- RUP
8. Shell side hydraulic test was successfully carried out at 54.4 kg/cm2.
9. Partition plate was installed and bolts were tightened.
10. Internal sleeve was installed.
11. New channel gasket (spiral wound) was wrapped with sticker type grafoil tape and was fixed on
the step using adhesive (fevi-quick).
12. Diaphragm plate was installed using the same arrangement as while disassembly.
13. Outer compression ring was brought to position and was locked in centre with the help of
slotted set screws
14. Inner compression ring and barrel cover was preassembled and installed using the L&T supplied
TLR/barrel removal fixture. Counter weights were adjusted to maintain the assembly horizontal
(using spirit level). Position of barrel cover was locked with the help of slotted set screws.
15. TLR/ Barrel removal fixture was taken out from barrel and TLR was bolted to the fixture.
Maintaining the assembly horizontal (check by plum as well as spirit level), the assembly was
brought near channel. Hand rotation of the entire assembly was done for approx. 2-3 threads.
Thereafter the rotation was done using crane till the original position of the TLR.
16. Push bolts were inserted and tightened using torque tool. Barrel cover push bolts were
tightened using hydraulic torque tool and TLR push bolts were tightened using manual torque
tool
17. Simultaneous hydrotest was carried out; however leakage was observed from the drain hole at
about 100 kg/ cm2 pressure. Push bolt tightening was done again upto the design torque value,
however continuous water leakage was observed from the drain hole.
18. It was decided to replace the diaphragm gasket, for which push bolts were removed, TLR was
removed using original fixture (with barrel cover locked at position), Barrel cover was removed,
Outer compression ring & diaphragm were removed.
19. Gasket was replaced with new gasket and box-up was done again using same procedure as
above.
20. Differential hydrotest was started again, and as the tubeside pressure was taken to 15kg/cm2
and shell side to 170 kg/cm2 leakage was observed in the tubeside main RTJ blind. The leakage
was arrested by torque tightening in pressurized condition itself and pressure was taken to 190
kg/cm2, at which leakage was observed from shell side main RTJ flange (although this flange was
not opened in the shutdown). As the flange leakage was being arrested water started coming
out from drain hole as well as slotted set screw holes.
21. Pressure was taken down however leakage continued, hence it was decided to replace the
diaphragm gasket again.
22. As the disassembly of TLR, barrel cover, compression rings and diaphragm was done crack was
observed on the diaphragm (fig12).

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Mechanical Maintenance- RUP

Fig12: Crack in Diaphragm Fig13: Weld-build-up of Diaphragm crack

(one of the locations)

23. Grinding of the crack locations was done in order to expose the cracks completely, DP test was
carried out and then welding was done using GTAW (argon) welding with filler ER347.
Continuous cooling from the opposite side of diaphragm was ensured immediately after weld
runs. After weld build up (fig 12), grinding was done and DP testing was done again.
24. Diaphragm, compression rings, barrel cover, TLR, push bolts/ rods were reassembled.
25. New gasket was arranged locally from M/s Industrial Gaskets and the dimension was modified
from 1685X1725X6.35 to 1687X1725X6.35 considering the difficulty faced with during
installation of original OEM supplied gaskets. In order to have a sturdy gasket the spot welding
pitch was improved from regular 2” to 1”.
26. TLR was given an extra rotation of approx. 30o in order to bring the face to face distance
between TLR & guide ring in line with other exchangers.
27. Considering repeated pressurization of tubesheet gasket, it was decided to carry out hydrotest
at 130 kg/cm2 (equalized).
28. At pressure of 100 kg/cm2, minor leakage was observed again. Pressure was brought down to 20
kg/cm2, and push-bolt tightening was carried out.
29. Pressure was taken again upto 130 kg/cm2 (equalized) and was held for 30minutes. No leakage
was observed. Pressure was brought down, and tubeside hydrotest was carried out successfully
at 40 kg/cm2
30. De-blinding of the exchanger was done.

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Mechanical Maintenance- RUP

Key Learnings
1. Hot greasing of the TLR threads through the greasing holes (on TLR face) should be carried out
before commencement of shutdown, i.e. in hot condition itself.
2. Lubrication of push bolts should be carried out approx. one day before starting of removal of
push bolts.
3. Whenever the TLR and barrel cover assembly are simultaneously being removed using the
removal fixture, and if the fixture arm breaks, it is advisable that in-situ repair/ strengthening of
the fixture should be carried out. Unless absolutely required, the fixture should not be removed,
as the barrel cover will tend to lose it’s centering and the assembly removal will become more
difficult.
4. Bundle removal by use of Bundle puller saves lot of time and effort. Hence it is advisable to use
bundle puller for bundle removal/ insertion instead of the OEM supplied fixtures.
5. In-order to achieve distributed torque and higher strength of the TLR/barrel cover removal
fixture, modification of the fixture as shown in fig 14 can be done before taking shutdown.

Fixture as supplied by M/s L&T Modified/ Strengthened fixture

Fig 14

6. In case the TLR gets stuck up during opening, low voltage heating through pad type heating
arrangement should be carried out as first resort.
7. Reverse rotation is also an effective method to free the TLR in case it is stuck up. Reverse
rotation of 1-1½ threads can be tried.

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Gujarat Refinery
Mechanical Maintenance
Maintenance- RUP
8. Holding down studs should be loosened only to free the barrel cover, and outer compression
ring should be held in position. This can be of great help wh
whenen TLR gets stuck up. If the Outer
compression ring is kept in position, and TLR gets stuck up, the barrel cover can be moved inside
and locked to its original position. With barrel cover locked in its original position, independent
rotation of TLR can be tried.
9. Apart from the maintenance spares and regular consumable following consumable/ items must
be kept ready before taking shutdown of any breech
breech-lock exchanger,
i) About 30-40 40 sleepers for keeping the components taken out during dis
dis-assembly.
assembly.
ii) 10-12 kg of Molykote--1000
1000 (or equivalent antiseize compound) per exchanger.
iii) 25-30
30 ltrs of cleaning solution (eg rustolene) per exchanger.
iv) 5-66 kg of Binding compound (eg. StagB) per exchanger.
v) Adequate amount of sticker type grafoil tape.
vi) Differential hydrotest arrangem
arrangement (fig 15).

Vent Vent
Pressure
Gauge

Valve
1-2” pipe

To Hydrotest Pump

Fig15: Differential Hydrotest Arrangement

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

2091-E-01C
Equipment Details
Description Shell Side Tube Side
Tag No. 2091-E-01C
Construction Type H-H Type Breech Lock Exchanger
Design Pressure (kg/cm2) 159 136
Differential Design Pressure (kg/cm2) 40
Design Temperature (oC) 350 390
Hydrotest Pressure (kg/ cm2 g) 216.2 170
Differential Hydrotest Pressure (kg/cm2 g) 54.4
Number of Passes One two
Operating Fluid Reactor Feed Reactor Effluent
No. of Tubes 1132

Exchanger Dismantling
Following dismantling procedure was followed,

1. Passivation of tubeside as well as shell side of the exchanger was carried out.
2. Measurements of TLR to guide ring face, TLR to barrel cover face and push bolts standout length
was done. TLR/ Barrel/ Shell relative angular position marking was done.
3. Threads of the TLR were lubricated through the three tapped greasing points located inside the
ring.
4. TLR & Barrel Cover Push bolts were removed.
5. Guide ring & holding studs (with square nut) were removed.
6. TLR/ Barrel Cover removal fixture was installed and TLR/ Barrel Cover were removed.
7. Thereafter inner & outer compression rings, diaphragm and channel gasket were removed.
Diaphragm removal was done using a pipe with a bolt welded at one end.
8. Guide block was installed inside the channel and internal sleeve was removed.
9. Internal flange push bolts were then removed, internal flange was slightly pushed with the help
of hydraulic jacks and split ring was removed.
10. Internal flange, Partition cover plate & cover gasket was removed in sequence.
11. Gland flange & Gland sleeve were dismantled and removed.

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12. Channel box assembly was taken out.
13. Eye bolts were then installed on the tube sheet, and the bundle was pulled out with the help of
bundle puller.

Repair Activities
1. Polishing of TLR & Shell Threads, Gasket seating areas, push rod faces etc. was done by using
portable buffing machine.
2. DP Testing of push rods, gasket seating areas, complete diaphragm etc. was carried out.
3. Hydrojetting cleaning of tube bundle (internal as well as external) & shell was done.
4. Cleaning of the channel was done using rustolene.

Assembly
1. New tubesheet gasket (spiral wound) was wrapped with sticker type grafoil tape and was fixed
on channel step using adhesive (fevi-quick).
2. Guide blocks (Type-I & Type-II) were inserted to facilitate insertion of tube bundle and to avoid
trapping of baffles / tube sheet in the channel. Nylon rope was fixed on guide block type 1 for
pulling the same later.
3. Tube bundle was inserted using bundle puller.
4. Channel assembly was also inserted using the bundle puller.
5. Gland flange & Gland sleeve were installed in the channel-box groove. Internal flange was
installed using connecting device and equalizing bar.
6. Split ring was installed.
7. Internal flange push bolts were tightened using torque tool.
8. Shell side hydraulic test was successfully carried out at 54.4 kg/cm2.
9. Partition plate was installed and bolts were tightened.
10. Internal sleeve was installed.
11. New channel gasket (spiral wound) was wrapped with sticker type grafoil tape and was fixed on
the step using adhesive (fevi-quick).
12. Diaphragm plate was installed using the same arrangement as while disassembly.
13. Outer compression ring was brought to position and was locked in centre with the help of
slotted set screws

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Mechanical Maintenance
Maintenance- RUP
14. Inner compression ring, barrel cover & TLR wer weree preassembled and installed using the L&T
supplied TLR/barrel removal fixture. Counter weights were adjusted to maintain the assembly
horizontal (using spirit level). Position of barrel cover was locked with the help of slotted set
screws.
15. Maintaining the assembly horizontal (check by plum as well as spirit level), the assembly was
brought near channel. Hand rotation of the entire assembly was done for approx. 5-6 5 threads.
Thereafter the rotation was done using crane till the original position of the TLR.
16. Push bolts were inserted and tightened using torque tool. Barrel cover push bolts were
tightened using hydraulic torque tool and TLR push bolts were tightened using manual torque
tool
17. Simultaneous hydrotest was carried out with Tubeside @ 170 kg/cm2 & Shell
Shel side @ 216.2
2
kg/cm . Pressure was kept on hold for 1hr and no leakage was observed
18. Shell side pressure was brought down to 170 kg/cm2 and then shell side as well as tube side
pressure was brought down simultaneously to
19. De-blinding
blinding of the exchanger was done.

Photographs

Fig16: Torquing of Push bolts Using Manual Fig17: TLR/ Barrel Cover Push Bolts/ Rods
Torque Tool

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Fig18: TLR/ Barrel Cover removal fixture

Fig19: TLR/ Barrel Cover removal fixture installed at location

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Maintenance- RUP

Fig20: Torque Direction for TLR opening

Fig21: TLR/ Barrel Cover being removed

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Maintenance- RUP

Fig22: TLR

Fig23: Diaphragm/ Outer Compression ring visible after TLR/Barrel cover

removal

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Fig24: Diaphragm

Guide Ring

Outer
Compression Ring

Inner Compression
Ring

Fig25: Guide Ring, Inner Compression Ring & Outer Compression Ring

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Split Ring Partition Cover

Channelside Tubesheet
Gasket Face on
Shell

Gland Flange
Internal Flange
Push Bolts

Diaphragm
Support Ring

Fig26: Channel Assembly balance components as visible after Diaphragm

Removal

Fig27: Diaphragm Support Ring a.k.a. Inner Sleeve

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Mechanical Maintenance
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Fig28: Split Ring

Fig29: Internal Flange being pushed out using Hydraulic Jack

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Maintenance- RUP

Fig30: Removal of Internal Flange

Fig31: Partition Cover being removed

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Fig32: Partition Cover being removed

Fig33: Channel Box Being removed

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Maintenance- RUP

Fig34: Gland Sleeve being removed

Fig35: Gland Packing

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Maintenance- RUP

Fig36: Jack bolts installed for bundle removal

Fig37: Bundle Removal Using Bundle Puller

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Fig38: Tube Bundle

Guide Block:
Type--I

Guide Block:
Type-II

Fig39: Type-I and Type-II Guide Blocks

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2091-E-01D
Reason for Maintenance
As the shell side of exchangers 2091-E-01D/E/F (combined) was pressurized, leakage was observed from
the tube-side drain of 2091-E-01D. Exchanger 01D was isolated from 01E/F, barrel cover push bolts were
tightened to design torque value and shell side was repressurized. Still leakage was observed, hence it
was decided to open the TLR/ Barrel Cover and tighten the internal flange push bolts as an attempt to
arrest the tubesheet gasket leak.

Equipment Details
Description Shell Side Tube Side
Tag No. 2091-E-01D
Construction Type H-H Type Breech Lock Exchanger
Design Pressure (kg/cm2) 159 136
Differential Design Pressure (kg/cm2) 40
Design Temperature (oC) 320 370
Hydrotest Pressure (kg/ cm2 g) 209.1 170
Differential Hydrotest Pressure (kg/cm2 g) 52.6
Number of Passes One two
Operating Fluid Reactor Feed Reactor Effluent
No. of Tubes 1132

Exchanger Dismantling
Following dismantling procedure was followed,

1. Passivation of tubeside as well as shell side of the exchanger was carried out.
2. Measurements of TLR to guide ring face, TLR to barrel cover face and push bolts standout length
was done. TLR/ Barrel/ Shell relative angular position marking was done.
3. Threads of the TLR were lubricated through the three tapped greasing points located inside the
ring.
4. TLR & Barrel Cover Push bolts were removed.
5. Guide ring & holding studs (with square nut) were removed.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance
Maintenance- RUP
6. TLR/ Barrel Cover removal fixture was installed and TLR/ Barrel Cover were removed.
7. Thereafter inner & outer compression rings, diaphragm and channel gasket were removed.
Diaphragm removal was done using a pipe with a bolt welded at one end.
8. Tightening of innerflange push bolts was carried out.
9. Water taken on shell side for hydrotest; however leakage observed from gasket and it was
decided to
o replace the tubesheet gasket.
10. Guide block was installed inside the channel and internal sleeve was removed.
11. Internal flange push bolts were then removed, internal flange was slightly pushed with the help
of hydraulic jacks and split ring was removed.
12. Internal
ernal flange, Partition cover plate & cover gasket was removed in sequence.
13. Gland flange & Gland sleeve were dismantled and removed.
14. Channel box assembly was taken out.
15. Eye bolts were then installed on the tube sheet, and the bundle was pulled out with the help of
bundle puller.

Gasket Face Machining

1. Damages were observed in tubesheet as well as corresponding shell side gasket faces. Hence it
was decided to carry out in
in-situ machining of the gasket faces (Fig 40 & 41).
2. M/s Moon Engineering was lined up on emergency basis as per OEM recommendation to carry
out gasket face machining.

Fig41: Damages on Gasket Face-

Face Shell
Fig40: Damages on Gasket Face
Face- Tubesheet
Side
side

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(SMNM(I/C)
 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance
Maintenance- RUP

3. M/s Moon Engineering was lined up on emergency basis as per OEM recommendation to carry
out gasket face machining.

Fig42: Shell Side Gasket Face Machining Arrangement

Fig43: Shell Side Gasket Face Machining

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Vivek Gupta (SMLE-RUP) Sunil Kanti (SMNM(I/C)-RUP)
(SMNM(I/C)
 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance
Maintenance- RUP

Fig44: Tubesheet Side Gasket Face Machining

Fig45: Tubesheet Side Gasket Face Machining

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(SMNM(I/C)
 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

Other Repair Activities

1. Polishing of TLR & Shell Threads, Gasket seating areas, push rod faces etc. was done by using
portable buffing machine.
2. DP Testing of push rods, gasket seating areas, complete diaphragm etc. was carried out.
3. Hydrojetting cleaning of tube bundle (internal as well as external) & shell was done.
4. Cleaning of the channel was done using rustolene.

Assembly
20. New tubesheet gasket (spiral wound) was wrapped with sticker type grafoil tape and was fixed
on channel step using adhesive (fevi-quick).
21. Guide blocks (Type-I & Type-II) were inserted to facilitate insertion of tube bundle and to avoid
trapping of baffles / tube sheet in the channel. Nylon rope was fixed on guide block type 1 for
pulling the same later.
22. Tube bundle was inserted using bundle puller.
23. Channel assembly was also inserted using the bundle puller.
24. Gland flange & Gland sleeve were installed in the channel-box groove. Internal flange was
installed using connecting device and equalizing bar.
25. Split ring was installed.
26. Internal flange push bolts were tightened using torque tool.
27. Shell side hydraulic test was successfully carried out at 54.4 kg/cm2.
28. Partition plate was installed and bolts were tightened.
29. Internal sleeve was installed.
30. New channel gasket (spiral wound) was wrapped with sticker type grafoil tape and was fixed on
the step using adhesive (fevi-quick).
31. Diaphragm plate was installed using the same arrangement as while disassembly.
32. Outer compression ring was brought to position and was locked in centre with the help of
slotted set screws
33. Inner compression ring, barrel cover & TLR were preassembled and installed using the L&T
supplied TLR/barrel removal fixture. Counter weights were adjusted to maintain the assembly
horizontal (using spirit level). Position of barrel cover was locked with the help of slotted set
screws.

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Gujarat Refinery
Mechanical Maintenance- RUP
34. Maintaining the assembly horizontal (check by plum as well as spirit level), the assembly was
brought near channel. Hand rotation of the entire assembly was done for approx. 5-6 threads.
Thereafter the rotation was done using crane till the original position of the TLR.
35. Push bolts were inserted and tightened using torque tool. Barrel cover push bolts were
tightened using hydraulic torque tool and TLR push bolts were tightened using manual torque
tool
36. Simultaneous hydrotest was carried out with Tubeside @ 170 kg/cm2 & Shell side @ 216.2
kg/cm2. Pressure was kept on hold for 1hr and no leakage was observed
37. Shell side pressure was brought down to 170 kg/cm2 and then shell side as well as tube side
pressure was brought down simultaneously to
38. De-blinding of the exchanger was done.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

2091-E-01E
Reason for Maintenance
As the shell side of exchangers 2091-E-01E/F (combined) was pressurized, leakage was observed from
the tube-side drain of 2091-E-01E. It was hence decided to carry out gasket replacement of Exchanger
2091-E-01E also.

Equipment Details
Description Shell Side Tube Side
Tag No. 2091-E-01E
Construction Type H-H Type Breech Lock Exchanger
Design Pressure (kg/cm2) 159 136
Differential Design Pressure (kg/cm2) 40
Design Temperature (oC) 270 340
Hydrotest Pressure (kg/ cm2 g) 198.8 170
Differential Hydrotest Pressure (kg/cm2 g) 50
Number of Passes One two
Operating Fluid Reactor Feed Reactor Effluent
No. of Tubes 1132

Exchanger Maintenance
Maintenance procedure as mentioned for Exchanger 2091-E-01C, was adopted for this exchanger and
the hydrotests were carried out as per above mentioned values.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

2091-E-01F
Reason for Maintenance
As the shell side of exchanger 2091-E-01F was pressurized, leakage was observed from the tube-side
drain, hence it was decided to carry out gasket replacement of Exchanger 2091-E-01F also.

Equipment Details
Description Shell Side Tube Side
Tag No. 2091-E-01F
Construction Type H-H Type Breech Lock Exchanger
Design Pressure (kg/cm2) 159 136
Differential Design Pressure (kg/cm2) 40
Design Temperature (oC) 200 290
Hydrotest Pressure (kg/ cm2 g) 198.8 170
Differential Hydrotest Pressure (kg/cm2 g) 50
Number of Passes One two
Operating Fluid Reactor Feed Reactor Effluent
No. of Tubes 1132

Exchanger Maintenance
Maintenance procedure as mentioned for Exchanger 2091-E-01C, was adopted for this exchanger and
the hydrotests were carried out as per above mentioned values.

During shell test at 50 kg/cm² pressure, water was coming from most of the tubes, and pressure drop
found to be 4 kg/cm2 in 1 hr. To confirm leakage, pressure was reduced to zero and all the tubes were
dried with plant air.

Again shell side was pressurized at 50 kg/cm². After 5 min of holding water was found coming from the
one tube (8th row from partition plate 12th column from east side of tube sheet). Two plugs were
made from B16 bolts and firmly fixed at the two ends of U-tube. Preheating up to 175°C was carried out
on the tube sheet around the plug. Considering the urgency of the job it was decided by maintenance
and Inspection to go for GTAW with filler Er NiCrFe-3. After welding, DPT of the weld joint was done, till
no defects observed.

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 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance
Maintenance- RUP

Taper: 1:20
MOC: B16

15.66
13.16

50

Fig 46: Tube Plug

Fig 47: Plugged Tubes (Minor weld defect observed in DP Test after welding which was corrected
afterwards.

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Vivek Gupta (SMLE-RUP) Sunil Kanti (SMNM(I/C)-RUP)
(SMNM(I/C)
 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

Rsource/ Spares Utilization

Tabulated below is a summary of resources and spares utilized for Breech Lock Exchangers Overhauling
Job.

Spares
SN Item Installed Qty Consumed for To be kept as
Qty 5 Exchangers stock

1 Tubesheet Gasket 6 7 12

2 Channel (Diaphragm) Gasket 6 5 12

3 Partition Cover Gasket 6 5 0

4 TLR Push Bolts 504 100 252

5 TLR Push Rods 504 100 252

6 Barrel Cover Push Bolts 360 50 180

7 Barrel Cover Push Rods 360 50 180

8 Internal Flange Push Bolts 360 30 180

9 Internal Flange Push Rods 360 30 180

10 Diaphragm 6 - 2

11 Holding Studs with SQ Nut 24 4 24

12 RTJ Gaskets: R24 (5Cr-1/2Mo) 20 8 10

13 RTJ Gaskets: R35 (SS321) 28 8 14

14 RTJ Gaskets: R71 (5Cr-1/2Mo) 12 6 6

15 RTJ Gaskets: R75 (SS321) 12 4 6

16 RTJ Gaskets: R79 (5Cr-1/2Mo) 16 10 8

17 RTJ Gaskets: R79 (SS321) 8 2 4

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Vivek Gupta (SMLE-RUP) Sunil Kanti (SMNM(I/C)-RUP)
 DHDT Breech Lock Exchanger Maintenance Report

Gujarat Refinery
Mechanical Maintenance- RUP

Agencies & Resources

Sr Work Description Agency
No.
1 Maintenance of Breech Lock Exchanger 2091-E-01C/D M/s Larsen & Tourbo

2 Maintenance of Breech Lock Exchanger 2091-E-01B/E/F M/s Domech Fabricators

3 Gasket Face Machining M/s Moon Engineering

4 Heating of Exchanger Shell M/s Heatreaters

5 Heating of Exchanger Shell M/s Gama

6 Bundle Puller M/s Dhaval Engg

7 Torque Tool, Blinding/Deblinding & Hydrotesting M/s Radiant Hitech

8 Hot Job (Welding, Grinding, Cutting etc.) M/s Kalpana Const. & M/s Shilpi

9 Hydrojetting of Tube Bundles M/s Arudra

10 130T Crane M/s Shilpi

11 100T & 50T Crane M/s Samarth

12 Hydra- 2Nos. M/s TMK & M/s Kalpana Const.

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Vivek Gupta (SMLE-RUP) Sunil Kanti (SMNM(I/C)-RUP)