Competency 4 Section A 1. 2. 3. 4. 5. 6. 7.

C A C B C B B

Section B 1. List the process parameters that may indicate that the heat exchanger is plugged. High pressure drop & low temperature difference between the inlets and outlets. 2. What are the factors that will affect the performance of heat exchangers? Temperature difference, surface area, material density, flow rates and contaminants. 3. Write down the function(s) to the different components of a heat exchanger as listed in the table below. Component Tubes Function Provide heat transfer surface between the fluid flowing inside the tube and the other fluid flowing across the outside of the tube Hold the tubes in place forming the tube bundle Container for the shell fluid Control tube side flow into and out of the tube Act as the support for the tube bundle Needed in two or more tube pass exchanger to create the channels for the different passes. 1. Support tubes during assembly and operation and reduce tube vibration. 2. Guide shell side fluid flow for better heat transfer efficiency

Tube Sheet Shell Tube Side Channel Head Tie Rod Pass Divider Baffles

4. Explain why tightness test has to be carried out before commissioning the heat exchanger after maintenance? What are the fluids which can be used to perform the tightness test?

To make sure that all the flanges are not leaking at operating pressure and the bleeders are closed. N2, air or water(depending on the process) can be used to perform tightness test. Section C 1. The figure below shows a cooling water heat exchanger in the KDU, cooling water in the tube side and kerosene in the shell side. A technician is instructed to prepare the exchanger for internal inspection.

a. Write down the type of work permit required before the technician can begin with the decommissioning of the heat exchanger? Cold Work Permit b. Which parties are involved in the permit to work system? Permit Applicant, working part and approving party. c. What is the full form of the abbreviation LOTO? Explain why LOTO is necessary. LOTO: Lock Out Tag Out; Prevent Injury to personnel or damage to equipment or the environment from unexpected energizing or releasing of stored energy during repair/maintenance of equipment or systems. d. Indicate the sequence of valve isolations (using the letters A, B, C, D as shown in the figure above) for taking the exchanger out of service D-B-A-C / D-B-C-A

e. The technicians are done with the maintenance. They are preparing to remove the blinds that were previously inserted. If the flange of the exchanger contains 12 bolts, calculate the number of bolts needed to be removed in order to remove a blind. Show your working clearly. Number of bolts to remove = f. In what order should the bolts and nuts of the flange be tightened? Give a reason to support your answer. They should be tightened in a diagonal manner to ensure even tightening throughout. g. After de-blinding, how should the technicians proceed next before the technicians could commission the heat exchanger back in service? Explain the reason for doing so. The next step would be to introduce nitrogen gas so as to conduct tightness test as well as create oxygen-free atmosphere within the system before commissioning it back in service.