Challenge
During a scheduled total shutdown, a comprehensive inspection of an air-cooled condenser (ACC) is planned. Part of this inspection is carried out during commissioning to monitor performance under operational conditions. During this phase, we detect a leak. However, due to limited accessibility, it is not possible to determine the exact location and cause. This poses a potential risk to the progress of the scheduled shutdown.
Approach
We carry out a comprehensive inspection—both during operation and during shutdown—and systematically assess all critical components of the air-cooled condenser (ACC). This includes, among others: the finned tubes, headers, tube/tube sheet connections, pumps, vacuum unit, and other appendages. Based on the initial findings, we develop several technical repair options, with the aim of effectively resolving the leakage within the available downtime. The approach we choose consists of carefully re-welding the tube/tube sheet transitions, with specific attention to stress distribution and material integrity. Thanks to thorough preparation and close coordination with the client, we execute the repair process efficiently and in a controlled manner.
Result
We successfully eliminate the leakage well within the planned shutdown period. The installation restarts after completion of the work without complications.
Technical solution with a proactive approach: the reliability of the ACC has been restored and valuable input has been gathered for future maintenance planning.
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