Challenge
Glacier Energy were approached on an urgent basis as our client’s tube bundle had a significant condensate leak, meaning that they had to shut down a critical module of the plant.
The tube bundle was required to be removed from the shell as soon as possible so that the flange sealing faces could be inspected, a pressure test could be carried out and the tube bundle could be reinserted. Contingency machining was also required for the flange faces in case of any damage or corrosion.
The Glacier Energy team were under significant time constraints due to the client’s urgency to get their module back up and running.
Solutions
Glacier Energy reviewed the scope then mobilised our toolkit and materials to the client’s site within a few days. Glacier Energy efficiently located some stock materials which were suitable for the scope, preventing the usual 2–3 week lead time.
To remove the tube bundle, Glacier Energy utilised WSG and their semi-automated 45T bundle extractor. They were on site within 24 hours. This was a challenging extraction due to the tube bundle with the floating head weighing 16 tonnes and it hadn’t been extracted from the shell in 33 years.
To assist in pulling the bundle from the shell onto the bundle puller, Glacier Energy and the client fabricated steel cradle. Regardless of the challenges, the extraction was completed successfully and safely.
Once the tube bundle was removed from the shell, Glacier Energy’s technicians carried out external inspection and a pressure test to locate any leaking tubes.
Glacier Energy was asked to supply machining contingency for the shell flange and tube sheet in case of any defect/corrosion. A specific machining tool would be required which wasn’t available in the UK at the time. However, using our expertise, our machining division came up with a solution to machine the flanges through modification to an existing machine, therefore saving the client time waiting on the specific tool. Our machinists were mobilsed to site on standby but no machining was required as after inspection no defect or corrosion was found.
The bundle was then reinserted into the shell and flanges torqued as required.
Benefits
- Glacier Energy successfully pulled, tested and refit the tube bundle within the required timescales, allowing the client to restart their critical module which would have been costing them a lot of money and resources per day.
- Glacier Energy saved the client time and money through efficient mobilisation of the toolkit and materials.
- The client benefitted from Glacier Energy’s multi skilled team of both heat transfer technicians and machinists.
