Catalytic compressed rich gas cooler
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Dear experts, how should I deal with internal leakage in the rich gas cooler behind the compressor? When I tried to shut it down, I found that there was still internal leakage in the outlet valve, and the pressure couldn’t be fully relieved. What should I do?
Isn’t what you’re saying that it can’t be cut out? In such situations, the only solution is to prepare the necessary repair materials in advance (mainly for tube bundle replacement or pressure testing repairs), while also reducing the operation capacity of the relevant units and shutting down the turbine to divert steam to the flare; there is no other way. If neither of the upstream nor downstream valves can be sealed properly, the only option is to relieve the system pressure and then apply blind flanges before carrying out the repairs. This situation is common in that refining industry; after going through it a few times, there will be no problem.
Carry out emergency repairs on the bed; first replace the valves, and if there is a leak in the pipe bundle, identify which one it is and seal it with a plug
Carry out emergency repairs; either reduce the volume or cut off the material to prevent the bed from getting clogged. Stop the air compressor and rush to carry out repairs.
Without a backup machine, the only options are to reduce the volume or cut the material. .
Internal leaks cannot be removed. There is no good solution; if the leakage is low, vent the circulating water and prepare the materials for shutdown procedures. If the leakage is severe, operations must be stopped immediately.
How large is the internal leakage? If it is a heat exchanger with low pressure, considering installing a blind plate behind the valve, assembling a skilled team, using explosion-proof tools and protective gear against toxins, and minimizing pressure release; in the event of a leak, a blind plate should be installed behind the valve. We’ve done it; it’s not as difficult as imagined—just need to be well-prepared
First, it is unclear whether there is internal leakage in the rich gas side valve or the water side valve; the amount of leakage on either side is not significant. It is necessary to implement proper safety measures, and it is recommended to install blind flanges. The leakage of rich gas is significant; it is recommended to reduce the reaction volume. The outlet of the pressure gauge for the rich gas should be directed to a flare, and the valve connecting that outlet to the stabilizing valve should be closed. There is no need to shut down the pressure gauge itself and use the inlet instead to direct the gas to a flare, nor is it necessary to stop production for repairs. Of course, if environmental protection authorities don’t give permission, we can only work on it urgently despite the constraints.
Be careful when forcing blind plates in place, including the use of explosion-proof tools.
If there is internal leakage in the outlet valve and it’s not possible to reduce the pressure, sealing it while the system is still under pressure can be an option; although this involves higher costs, it’s still better than shutting down the system or reducing its operation capacity. After sealing, promptly send the valve for repair or replacement, and that’s it; the subsequent leak detection and maintenance tasks can then be carried out as usual