API Inspection / Repair Recommendation
| Site | Calder Bay · Weller Parish | RR # | OLE-RR 001 |
|---|---|---|---|
| Equipment ID | E-301 | RR # | OLE-RR 001 |
| Process Description | Charge Gas Aftercooler | RR # | OLE-RR 001 |
| Inspector | Ray Thibodeaux | RR # | OLE-RR 001 |
| Date of Finding | 8/8/26 | RR # | OLE-RR 001 |
FINDINGS:
During the 2026 Olefins Unit Turnaround, visual inspection of E-301 (Charge Gas Aftercooler) — Tubesheet revealed mechanical damage that exceeded the acceptance criteria per ASME PCC-1 Table D-3 / TEMA RCB-6. Refer to the information below for specific dimensions of the aforementioned defects.
Radial scoring up to 0.045 in deep across the pass-partition lands, consistent with the previous bundle pull. Serration profile is gone over roughly 40 percent of the seating width. Remaining ligament thickness measured at four positions is above the minimum required.
Land 1, 0 deg:
- Depth: 0.045 in
- Flange thickness: 3.62 in
Land 2, 120 deg:
- Depth: 0.031 in
- Flange thickness: 3.64 in
Land 3, 240 deg:
- Depth: 0.028 in
- Flange thickness: 3.63 in
RECOMMENDATIONS:
- Option 1: Option 1 (recommended): machine the full face to a flat finish of 125 to 250 Ra, then re-serrate. Restores the design seating surface within the existing corrosion allowance.
- Option 2: Option 2: weld overlay the damaged lands and re-machine. Longer outage impact and adds a PWHT question the schedule cannot absorb.
JUSTIFICATION(S):
The scoring exceeds the surface finish the gasket manufacturer requires for a seated joint, and the joint has leaked on two prior runs. Machining is inside the remaining corrosion allowance and returns the joint to its design condition without introducing weld metal.
PHOTO REFERENCE:
