Process Heat Exchanger Replacement

Process Heat Exchanger Replacement

ICI was contracted to replace an aging synthesis converter steam generator to reduce process upsets and increase efficiency.  ICI’s scope of work included installing new foundations, demolition of the existing heat exchanger, setting the new heat exchanger, and all piping revisions, tie-points, coatings, and insulation and lagging.  This project occurred during a tight turnaround window with work occurring around the clock.  Piping system changes were significant considering efficiency improvements were accomplished by switching services from shell side to tube side.  Additionally, the piping metallurgy and wall thickness required tight quality control constraints to ensure integrity of the system.  The project details are as follows:

• Piping installation including:
• 18”, 2.5” Wall Thickness, 9 Chrome, SA 335-P9
• 18”, 1.5” Wall Thickness, 2.25 Chrome, SA 335-P22
• 10”, 1.75” Wall Thickness, 2.25 Chrome, SA 335-P22 and 9 Chrome, SA 335-P9
• Ancillary 2”-12” Carbon Steel Piping
• Weld Inlay and Machining/Counter Bore of Existing Piping Systems at Tie-Points
• Quality Control Constraints:
• Hydrogen Bake-Out of Existing Piping
• Fit-up Check
• Preheat and Inter-Pass Temperature Control
• MT Root Pass
• Phased Array at 1/3 Weld Fill and at Final Weld
• Post Weld Heat Treat
• Phased Array after PWHT
• Hardness Test
• Existing heat exchanger demo lift of 117,500 pounds
• New heat exchanger lift of 233,221 pounds