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Using chemical tracers to detect leaks in heat exchangers

Tracerco has been at the forefront of the development of online leak detection for the last 65 years. The method allows the detection of leaks as small as 0.5%. However, the demand to measure smaller leaks that affect product quality, has led to extensive research into alternative online methods. Through the development of Tracerco’s specialist chemical tracers, they are detectable in samples at concentrations as low as 1 ppb, meaning that extremely small leaks can be detected.

The Field Test
Exchangers A and B were condensing naphtha from a crude distillation column on the shell side, using raw crude as the cooling media on the tube side. Customer laboratory results showed that the naptha was out of colour specification, indicating that there may have been damage to the internals of the crude column, or a leak in

an exchanger. A Tru-Scan™ was performed on the crude column, and the results indicated there was no damage to the column internals, or operational issues such as flooding or severe entrainment. A review of the process showed there was no sample point between exchangers on the naphtha side, so a common sample point downstream of the bank of exchangers was used. However, there was an injection point before each of the two exchangers on the crude side (Figure 1). The first chemical tracer (T105) was injected into the high-pressure crude inlet to the bottom exchanger (A) of the bank of exchangers. This tracer passed through the crude side of the bottom exchanger, and then to the top exchanger (B). As the tracer was injected into the feed, the first sample cylinder was opened, allowed to fill, and then closed. Additional sample cylinders were opened, filled, and closed at intervals appropriate to the system. After the last sample was collected from the first test, a different chemical tracer (T205) was injected into the crude inlet line between the exchangers. The second chemical tracer passed through the crude side of the top exchanger (B) only. The sample point was the same as for the first test. Sample cylinders were then analysed for tracer presence.

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