BP was dreading pulling their FCC heat exchangers.
Every floating head, shell and tube heat exchanger generally gets pulled from its shell In order to clean and inspect
This is primarily done for insurance purposes and of course to improve production throughput and reduce energy consumption. The benefits of cleaning and inspection are high but the associated costs to extract bundles is also extremely high.
For example to extract one heat exchanger bundle and take it to the cleaning bay incurs the following costs and risks.
A) Risk of de- bottlenecking issues
B) Critical path over run
C) Bundle damage
D) New gaskets
E) New bolts
H) Bundle puller
J) 3rd party costs etc.
H) Extended downtime.
With over 200 global shutdowns worth of experience, Tube Tech suggested performing all cleaning and inspection in-situ “without” pulling the heat exchangers which would reduce downtime and associated costs by ca. 50%.