Leak in the fractional distillation air-cooling tube bundle – how to fix it?
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Our unit recently discovered oil leakage in the fractional air-cooling tube bundles. However, when checking under the air coolers, it was not possible to determine which specific tube bundle was leaking; as a result, we had to seal off all the tube bundles in the area where leakage was suspected. Is there anyone who can figure out exactly which tube bundle is leaking using some method? Thank you.
If the valve can be closed tightly, steam can be used for purging as a way to determine this (using a temporary rubber hose).
Yes, if it’s possible to remove that leaking heat exchanger, steam can be introduced for pressure testing, which will help determine which tube bundle is leaking. Fixing the leaking tube bundle is quite simple; all that’s needed is to inform the manufacturer, who has specialized tools and can handle it in no time!
Increase the pressure a bit, provided that it does not affect the quality, and see if anything can be observed
You can remove the air cooler for which space is available, and increase the capacity of other air coolers or those that are used as backups to ensure the desired cooling temperature. Then, the inlet and outlet valves are closed, and steam is introduced through the inlet for testing!
It is indeed difficult to make an accurate judgment in such situations; only through regular inspections can the location of leaks be identified. If the leakage occurs at the connection between the tube bundle and the tube sheet, especially when the leak site is in the middle layer of the tube bundle, it can be difficult to determine the issue using steam testing methods due to obstructions in the line of sight. As the original poster said, sometimes it’s really impossible to make a judgment, so one simply blocks off all nearby areas as well – it’s better to mistakenly kill a thousand people than to let even one escape, because heavy oil leaks are truly annoying!
It’s the same with our exhaust oil air cooling as well; we should cut it into sections one by one and use steam for purging and inspection
It’s hard to tell just by looking; perhaps a steam pressure test is needed to determine it
The method of pressure testing with a single heat exchange tube can be used; by identifying the approximate location and employing specialized tools for single-tube pressure testing, it is possible to locate the leak point quickly. In the event of a leak in the high-pressure air cooling system, it is recommended to block the surrounding heat exchange tubes as well to ensure safety.
1. The air-cooling tube bundles are generally integrated; if a few tubes are damaged and it’s possible to identify them, they can be simply sealed off, but in the case of extensive damage, the entire tube bundle must be replaced. . . 2. If there is a leak in the air-cooling tubes, the fan can be stopped for inspection; the location of the oil leak is easily identifiable. . . :lol
There’s no good solution for this; our catalytic unit has experienced multiple instances of air leakage. After such leaks, it’s very difficult to introduce steam. Each time a leak occurs, it’s first necessary to determine the approximate location of the leak, then remove the fins on the surface of the finned tube to identify the issue, and finally seal it up.
The air coolers of distillation towers are generally operated at low pressures; the presence of condensate water can easily lead to corrosion and thinning of the material. Using steam for pressure testing may result in leaks in other areas prone to corrosion, and steam purging can be employed during the processing stage. The method we used to handle this in the past was to add two kilograms of water, then stop the fan and go inside the air cooler to conduct an inspection. It can make accurate judgments.
During the shutdown of this installation, we also discovered leaks in the air-cooling tube bundles. We closed the inlet and outlet valves and then used demineralized water to test for leaks. But it’s only possible to estimate the approximate location; 1/3 of the area is blocked by the seal, so the effect isn’t very good~