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CAT CRACKER – Regen Cat Coolers (North and South)
SPECS – 918 Tubes Schedule 160 X 1.38” X 15.2’
HISTORICAL DATA
Discussions have revealed that cleaning these tubes per IRIS inspection is a very difficult task. Historically it has taken 6 days working around the clock to clean the Cat Coolers. Only twice out of the last 10 to 15 years have the previous methods produced results that would pass IRIS inspection.
Kmac designed two systems specific for this task utilizing high volume 20K and 40K system with custom design nozzles. The 40K nozzle was built by the manufacturer per Kmac specs and is the first in existence. Both 20K and 40K systems are specially designed high volume systems.
JOB SCOPE
Removed the catalyst scale in the North and South Cat Cooler with 100% IRIS inspection compliance, required vessel entry by Kmac personnel into the channel head to operate our system. Waste generated during this process was allowed to drain to process drains.
SYSTEM DESIGN
Kmac Specialty Services, Inc. utilized a hi-volume 405 HP 20,000 PSI system and a hi-volume 500 HP 40,000 system that drove a specialized tube cleaning tool. The tooling used in this procedure is custom designed for these hi-volume 20,000 PSI and hi-volume 40,000 PSI systems.
PROJECT PERFORMANCE - SUMMARY
South cooler was completed in the first 12 hour shift after job set-up. The North cooler was approximately 50% plugged and took three shifts. There were 1800 tubes cleaned for IRIS inspection. Not one tube failed IRIS inspection on the first attempt. The IRIS inspector stated that these were the cleanest tubes he had ever worked with.
The cleaning of the Cat Cooler tubes was done safely, under the estimated time frame, and under the cost estimate for actual cleaning times. Total cost was within 10% of the original proposal even after 3 days of standby.
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