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BAHX PRODUCT BULLETIN
Issue 1 - April 2016
BAHX PRODUCT BULLETIN
TABLE OF CONTENTS INTRODUCTION........................................................ 3
CO2 ICE FORMATION.............................................. 12
Who should read this
What it is and why it’s bad
What this bulletin covers
What can cause it
OPERATION............................................................... 5
How to detect it
Lifespan
How to prevent it
End of life
How to fix it
Principles of operation
EXCESSIVE THERMAL GRADIENTS................... 13
PLUGGING................................................................. 7
What they are and why they’re bad
What it is and why it’s bad
What can cause them
What can cause it
How to detect them
How to detect it
How to prevent them
How to prevent it
How to fix them
How to fix it
OTHER HAZARDS TO BAHX................................. 15
FOULING..................................................................... 8
INSPECTING OPERATING DATA.......................... 15
What it is and why it’s bad
BAHX ASSESSMENT.............................................. 16
What can cause it
How to detect it
Visual inspection
How to prevent it
How to fix it
Internal
While out of service
External
CHEMICAL ATTACK.................................................. 9
Pressure test
What it is and why it’s bad
Leak test
What can cause it
How to detect it
Visual inspection
How to prevent it
Fluid composition testing
How to fix it
Monitor operating data
During operation
ICE FORMATION..................................................... 10
IN CONCLUSION..................................................... 18
What it is and why it’s bad
What can cause it
CONTACT US........................................................... 19
How to detect it
How to prevent it
How to fix it
Other BAHX Resources
HYDRATE ACCUMULATION.................................. 11
What it is and why it’s bad
What can cause it
How to detect it
How to prevent it
How to fix it
Issue 1 - April 2016
© 2016 Chart Energy & Chemicals, Inc. All rights reserved.
BAHX PRODUCT BULLETIN
INTRODUCTION Chart Energy & Chemicals, Inc. (Chart) is committed to assisting our customers in getting the most out of their Chart Brazed Aluminum Heat Exchangers (BAHX). To that end, Chart has developed this bulletin to help educate users by outlining what they should and should not do with respect to operating, inspecting, and maintaining their BAHX. Chart’s BAHX heritage dates back to the 1950’s when, under the Trane name, the company was the first to adapt plate fin heat exchanger technology from aerospace to industrial applications, beginning with the separation of air. Trane eventually became ALTEC and Chart’s ‘Heat Exchanger Group’ was born in 1998 with the acquisition of Marston in the UK. It’s important to mention these historic brands as the longevity of Chart equipment is such that there are still plenty of BAHXs in the field bearing those nameplates.
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BAHX PRODUCT BULLETIN
Who Should Read This Anyone who owns, operates, maintains, or is responsible for overseeing the operation and/or
Nozzle
maintenance of a Chart BAHX.
Header Distributor Fin
Parting Sheet
Side Bar
Wear Plate Heat Transfer Fin Support Angle
Cap Sheet
What This Bulletin Covers This bulletin addresses recommended operation,
If, for any reason, questions arise that are not
inspection, maintenance, and assessment
addressed in this bulletin, or the IOM, you must
philosophies that will promote optimal and extended
contact Chart for further information, interpretation,
operation of Chart BAHXs. These recommendations
and guidance. Failure to follow correct instructions,
are based on Chart’s 60+ years of experience in
practices, and procedures may result in serious bodily
designing, manufacturing, troubleshooting, and
injury or death, property damage, and irreparable
repairing our heat exchangers.
damage to the Chart equipment.
This bulletin is intended to supplement the Chart Installation, Operation, And Maintenance (IOM) Manual and ALPEMA Standards, which contain further detail and additional topics to those covered here. Other valuable resources on brazed aluminum heat exchangers can be found at the end of this bulletin.
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BAHX PRODUCT BULLETIN
OPERATION Lifespan
In situations where gradual accumulation of fatigue
The lifespan of a BAHX depends entirely on the care
damage controls the operational life of a BAHX,
with which it is operated and maintained, especially
predicting remaining service life is still difficult. API
with respect to thermal gradients. Heat exchangers
572 (8.2.5) states that:
that have been operated diligently with respect to the operating and maintenance guidelines can
“It is important for the owner-user and the inspector
have service lives of 40 years or more, while poorly
to understand that fatigue cracking is likely to cause
controlled processes can cause a heat exchanger to
vessel failure before detection with any NDE methods.
fail even during initial startup. Chart has found that
Of the fatigue cycles required to produce failure, the
typical industry expectation is an approximate 20 year
vast majority are required to initiate cracking and
service life.
relatively few cycles are required to propagate the crack to failure.”
End of Life BAHXs don’t ‘wear’ like brake pads or tires do during
Advanced simulations can be used to predict fatigue
normal operation, where there is a predictable change
failure if the historical operating conditions are well-
in a measurable value and a minimum safe value
known. Fortunately, the vast majority of BAHXs that
for operation (e.g. brake pad thickness or tire tread
experience thermal stress cracking, either from high-
depth). Chart’s experience has shown that the majority
cycle fatigue or from low-cycle thermal shock events,
of BAHXs are retired from service due to leaks, and
will exhibit small leaks that can be detected and
the majority of leaks are caused by some form of
repaired in the field.
thermal stress damage. In situations where a large percentage of the operational life of a BAHX is consumed by relatively few high stress events, the critical events usually occur when operating conditions are changing rapidly and the operations’ group has not established procedures to control them. This makes it extremely difficult to predict end of life when the lifespan is largely determined by events that are unexpected, or for which control procedures are not in place to address.
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BAHX PRODUCT BULLETIN
Principles of Operation In a few words, “Keep it clean, keep it dry, and
D
manage thermal gradients.”
C
E
Following this advice will protect against the majority
B
of issues that a BAHX faces during operation. “Keep it clean” and “keep it dry” refer mostly to preventing harmful compounds and contaminants from entering the exchanger, while “manage thermal gradients”
A
refers to proper control of the stream temperatures and flow rates to minimize temperature differences and thermal stress within the heat exchanger. In Chart’s experience, improper management of thermal gradients is responsible for the majority of leaks and damage suffered by BAHXs in the field. Simply
A
put, excessive thermal gradients decrease the life expectancy of a heat exchanger. This can occur, either by slow accumulation of damage due to thermal cycling, or sometimes, even just one thermal shock event. Virtually all hazards to brazed aluminum heat exchangers can be prevented by keeping them clean, keeping them dry, and managing thermal gradients.
D
B C
E
Keep It Clean A BAHX operates most efficiently when the stream passages are free from obstructions and fouling, and will have the longest life expectancy when corrosive or chemically reactive compounds are prevented from entering the heat exchanger. The best way to keep a BAHX clean is to ensure the incoming streams are appropriately conditioned before they enter the heat exchanger.
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BAHX PRODUCT BULLETIN
PLUGGING What it is and why it’s bad
Another plugging avoidance measure is to establish
The passages inside a BAHX can become obstructed
a program or procedure to clean upstream piping and
when particulate matter entrained in the streams
vessels prior to commissioning and after construction,
becomes deposited inside the BAHX, when larger
repair, turn arounds, and any other time the system is
debris blocks the inlet port opening inside the headers,
opened.
or if significant fouling or hydrate accumulation occurs. These conditions can restrict flow and completely
If the potential plugging medium is mole sieve dust,
plug some passages, which can increase pressure
prevention is best achieved by proper maintenance of
drop, deteriorate thermal performance, and cause
the mole sieve filter system.
flow maldistribution leading to higher thermal stresses. Theoretically, local fin and parting sheet erosion may
How to fix it
occur at high velocity areas due to maldistribution, but
If a BAHX has become plugged with particulate
no confirmed instances of this occurring in the field
matter, the particulate can often be removed by
have come to Chart’s attention.
backpuffing. Contact Chart for further guidance.
What can cause it
Larger debris must be identified and located by
Pipe scale and mole sieve dust can each plug
examining the inside of the inlet headers with
an exchanger, and construction debris such as
a borescope.
cardboard, hand tools, and welding dams left in pipes can become lodged inside the inlet headers. These issues can arise during initial commissioning or after maintenance has been performed. How to detect it Plugging and obstruction can be detected by measuring abnormally high pressure drop across the heat exchanger while it is in operation. How to prevent it Plugging can be prevented by installing permanent 80 Mesh Tyler Standard filters in all streams. Dual filters are recommended to allow replacement of filters while maintaining operation.
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BAHX PRODUCT BULLETIN
FOULING What it is and why it’s bad
How to prevent it
Fouling occurs when compounds in the streams solidify
Ensure proper stream compositions before they enter
inside the BAHX and coat the heat transfer surfaces.
the BAHX. Pretreatment systems must remove all
The primary detriment of fouling is reduced heat transfer,
contaminants from incoming streams before they enter
however severe fouling can lead to obstruction and
the BAHX.
plugging of the passages. Fouling can increase pressure drop, deteriorate thermal performance, and cause flow
How to fix it
maldistribution leading to higher thermal stresses.
If a BAHX has become fouled, chemical cleaning is often necessary. The cleaning agent should be selected based
What can cause it
on the specific fouling compound, and must be safe for
Sources of fouling include oils and heavy hydrocarbons,
use with the BAHX. Specialized cleaning companies
waxes such as paraffin, TEG, and other substances that
having experience cleaning BAHX are preferred. Contact
can coat the fins in a BAHX.
Chart for a list of recommended vendors.
How to detect it Fouling can be detected by measuring decreased heat transfer in the heat exchanger, or by measuring abnormally high pressure drop. Additionally, some types of fouling can be seen by visually inspecting the inlet or outlet headers and port fins.
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BAHX PRODUCT BULLETIN
CHEMICAL ATTACK What it is and why it’s bad
How to detect it
Keeping a BAHX clean also entails preventing
Monitor the streams to ensure the appropriate pH
corrosive or chemically reactive compounds from
level and monitor stream composition for harmful
entering the heat exchanger. Corrosion and chemical
compounds.
attack will thin pressure retaining parts, and can result in catastrophic failure. BAHX’s have no allowance
How to prevent it
for corrosion.
Control stream compositions to prevent harmful compounds from entering the exchanger. Maintain the
What can cause it
pH of streams between 5 and 7. Ensure the BAHX and
Chemical attack can come from many different
upstream piping and equipment are free of water prior
sources. Some of the more common sources are:
to operation.
• Chlorides
• Amines
How to fix it
• Acids / Bases
There is no remedy for accumulated corrosion
• Cleaning Agents
damage. The stream compositions must be corrected
• Mercury
and controlled to prevent further damage. Perform a pressure test to ensure design pressure retaining
Trace impurities of certain compounds can react with
capability is intact if corrosion is suspected to have
liquid water to form acids, which can attack aluminum.
occurred.
These compounds include:
• H2S, NH3, CO2, SO2, NO2, CO, Cl
Keep It Dry Most BAHXs are operated at cryogenic temperatures, which can cause certain compounds to freeze within the unit. Hydrates, water, benzene, and CO2 are notable examples of compounds that may freeze inside a heat exchanger. If there is liquid water anywhere in the exchanger, it can turn to ice, which will expand as it freezes and cause layers to rupture. Streams with hydrates or high water content can cause hydrates to accumulate in a core and cause plugging, and streams with high CO2 concentrations can cause CO2 ice to form and cause plugging. Mole sieve beds or glycol dehydration units are commonly used to remove water from incoming streams, and amine units are commonly used to remove excess CO2.
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BAHX PRODUCT BULLETIN
ICE FORMATION What it is and why it’s bad
How to prevent it
If water is present in incoming streams, it can create
Ice formation can be prevented by continuous dew
a thin layer of ice coating the fins. This can increase
point monitoring of stream inlets and a properly
pressure drop, deteriorate thermal performance, and
functioning dehydration system. Ensure dryness of
cause flow maldistribution leading to higher
BAHX and upstream piping and equipment before
thermal stresses.
startup by draining low points and purging with dry gas with a dew point below -40° C. During operation,
If pockets of liquid water are allowed to freeze inside
the dew point of a stream should be below the coldest
a BAHX, they will expand and rupture the fin layers.
temperature of that stream.
A single ice rupture will fail the fins in the originating layer, and damage the fins in multiple layers adjacent
How to fix it
to the originating layer.
If ice formation is detected before it has ruptured fins, it can be dissolved by alcohol injection or removed
What can cause it
by deriming.
Ice formation is caused by streams with water content that is high enough to freeze inside the BAHX during
Ice formation that has caused fins to rupture typically
operation (streams with high dew point). It is also
affects many layers in a BAHX, and requires replacing
caused by residual liquid water in the BAHX or in
the unit. Fin failure is not repairable.
upstream piping and equipment that is fed into the unit and not purged prior to startup. How to detect it The first sign of ice formation is increased pressure drop. This can progress to fin rupture if it is not corrected. Fin rupture occurring in layers near the outside of the BAHX will create visible bulges in the cap sheets. If the fin rupture only occurs internal to the BAHX, then the bulges will be inside the BAHX and not visible from the outside.
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BAHX PRODUCT BULLETIN
HYDRATE ACCUMULATION What it is and why it’s bad
How to prevent it
Hydrates are substances containing water that form
Prevent hydrate accumulation by predicting the
snow or ice-like crystals at certain temperature and
hydrate formation pressure and temperature regimes
pressure regimes. Hydrate formation is distinctly
for the specific stream composition and ensuring they
different from ice formation, and it accumulates inside
don’t overlap with the operating conditions.
of BAHXs in a manner similar to particulate fouling. Accumulation can increase pressure drop, deteriorate
How to fix it
thermal performance, and cause flow maldistribution
If hydrate accumulation has occurred, methanol
leading to higher thermal stresses.
injection can be used to dissolve the hydrates. This can be done on an as-needed basis, or continuously.
What can cause it
If the hydrate accumulation is severe, then deriming
Hydrate accumulation is caused by hydrate formation
may be required.
upstream or inside of BAHXs, typically in natural gas feed streams. Hydrates can form at high pressure and warmer temperature regimes that vary with the stream composition. How to detect it Hydrate accumulation can be detected by increased pressure drop and decreased thermal performance.
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BAHX PRODUCT BULLETIN
CO2 ICE FORMATION What it is and why it’s bad
How to prevent it
CO2 can freeze inside a BAHX similar to water,
Ensure the concentration of CO2 is low enough to
except that it won’t expand and rupture fins. It
prevent ice formation. This is usually accomplished by
can increase pressure drop, deteriorate thermal
installing a CO2 removal system such as an amine unit
performance, and cause flow maldistribution leading
upstream.
to higher thermal stresses. How to fix it What can cause it
CO2 ice can be removed by deriming the BAHX.
CO2 ice formation is caused by streams with high CO2 concentrations. The critical concentration of CO2 depends on the stream composition and operating temperatures and pressures. How to detect it CO2 ice formation can be detected by high pressure drop.
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BAHX PRODUCT BULLETIN
EXCESSIVE THERMAL GRADIENTS What they are and why they’re bad
What can cause them
Thermal gradients are temperature differences within
Excessive thermal gradients are most often caused
the heat exchanger metal that cause thermal stress.
by transient events, where process conditions such
For many BAHX designs, the allowable thermal stress
as stream temperatures or flow rates are changing. A
at the steady state design conditions is twice as high
typical design will allow for a maximum temperature
as the allowable stress from the stream pressures.
difference of 28° C between adjacent parting sheets.
Excessive thermal stress is one of the most prevalent
Localized temperature differences within parting
causes of leaks in brazed aluminum heat exchangers,
sheets can also lead to high thermal stress.
and it is also one of the least understood by operators. How to detect them Thermal shock is the term for thermal gradients
Thermal shock in a heat exchanger will manifest
that are likely to cause heat exchanger failure after
as one or more leaks. These leaks can be between
relatively few occurences. Thermal fatigue is the slow
parting sheets and cause fluids from a high pressure
accumulation of damage due to repetitive temperature
stream to flow into adjacent low pressure streams,
cycling events. The stress level from each cycle might
or the leaks can allow a stream to leak to outside the
be very low, but the cumulative effect can eventually
heat exchanger.
lead to failure. Thermal fatigue will eventually result in leaks if it is allowed to continue to failure. There is no reliable way to directly measure fatigue damage before it results in a leak. Inspection of past operating data can identify events that are likely to have caused thermal shock or thermal fatigue. This can allow operations to be changed to avoid these potentially harmful events in the future.
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BAHX PRODUCT BULLETIN
EXCESSIVE THERMAL GRADIENTS How to prevent them
How to fix them
Prevention of harmful thermal gradients is primarily
Most leaks can be repaired in the field by qualified
achieved through control of stream inlet and outlet
personnel. However, there is no way to reverse
temperatures and flowrates.
damage accumulation due to thermal fatigue.
1. All adjacent stream temperature differences must be below 28° C at any given BAHX cross-section.
2. If a stream with no flow must be introduced into the exchanger, and the temperature difference between the stream and the exchanger is larger than 28° C, then introduce the stream at a very low flow rate. Maintain this low flow rate until the new temperature profile is established.
3. The rate of change of any stream inlet temperature must be less than 60° C/hr, with short periods of 2° C/min allowed. This will make sure localized temperature gradients in fins, parting sheets, and headers are allowed to equilibrate before they become large enough to cause damage. If any stream temperature changes are cyclic or recurring, keep the temperature rate of change to below 1° C/min to prevent thermal fatigue.
4. Change flowrates slowly enough such that stream outlet temps don’t change faster than 1° C/min. This applies even if all the stream inlet temperature changes are constant. If the flow in one stream stops suddenly, often the recommended course of action is to immediately stop the flow of all the other streams.
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BAHX PRODUCT BULLETIN
OTHER HAZARDS TO BAHX Brazed aluminum heat exchangers face hazards that aren’t covered by the topics discussed above, but they are much less prevalent and are typically specific to certain applications. These hazards include liquid mercury attack, acetylene generation / decomposition, and NOx gums / salts, among others. For these special hazards, refer to literature specific to the industries and applications that are affected. Refer to other resources listed at the end of this bulletin, or contact Chart for further information.
INSPECTING OPERATING DATA The most valuable thing an owner of a BAHX can do
to promote the longevity of their unit is to examine their
1. Pressures above nameplate max pressure specific for that stream.
operating data on a regular basis. Operating data includes
2. Temperatures above nameplate max temperature.
stream flow rates, inlet and outlet temperatures, and inlet
3. H igh rates of change of stream or metal
and outlet pressures for all streams in a BAHX, often
temperatures. This can indicate thermal shock
recorded at one minute intervals by a distributed control
in extreme cases, or thermal fatigue for regularly
system (DCS). This data contains information about how
occurring temperature cycles.
the unit has been controlled, events that may have caused
4. H igh local stream-to-stream temperature
high thermal gradients, and how well it is performing. If
differences. Indicates thermal shock, or higher
there are any issues or problems with a BAHX, including
susceptibility to thermal fatigue.
plugging, fouling, or high thermal stress, there will most
likely be indications of the issues in the operating data. Additionally, the operating data may indicate whether general operation or specific procedures can be improved
5. Rapidly or cyclically changing flow rates. This can cause thermal cycling, leading to thermal fatigue.
6. High pressure drop. This can indicate plugging, hydrate or ice formation, or fouling.
in order to minimize thermal stress and extend the service life of the BAHX.
For a well-controlled process, review the operating data at least on a monthly basis.
Periodic inspection of operating data is the easiest way to assess the history of a BAHX, and can be a valuable
For new operations, review the operating data
tool in improving current operations and procedures.
continuously until the operations are understood or until
In examining operating data, be on the lookout for the
known process control issues are under control.
following conditions:
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BAHX PRODUCT BULLETIN
BAHX ASSESSMENT The current status of a BAHX can be assessed in part by
WHILE OUT OF SERVICE
performing various inspections. Some inspections can
Visual Inspection
be performed while the unit is in operation, while others
External
require the unit to be out of service.
Visually examine the exterior of the exchanger for bulges in the cap sheets or other anomalies such as
The owners and operators should establish an
cracks. Bulges in the cap sheets indicate ice formation
inspection schedule based on service, operating
has occurred. Cracks likely indicate thermal fatigue or
conditions, code requirements, and manufacturers
thermal shock damage.
recommendations. Perform dye penetrant test on all external welds. The inspections should also be performed if damage is
Cracks most likely indicate thermal fatigue or thermal
suspected, or if there is concern about the current status
shock damage. Do not dye penetrant test the brazed
of the BAHX, or lack of knowledge of the operating history
surfaces, as the results will not be meaningful.
of the BAHX. Internal Insert a borescope into the header bodies and inspect the port fins. Debris or particulate indicates plugging, discoloration or residue may indicate corrosion or fouling, cracks may indicate thermal fatigue or thermal shock damage. Pressure Test A pressure test will confirm the pressure retaining capability of the BAHX. Pressure tests should be considered after any repairs have been made, or if chemical attack or corrosion is suspected, or if thermal shock or thermal fatigue is suspected. Leak Test A soap bubble leak test can detect external or internal cross pass leaks. Leak tests should be considered:
Issue 1 - April 2016
• After any repairs have been made
• If cross-pass or external leaks are suspected
• If chemical attack or corrosion is suspected
• If thermal shock or thermal fatigue is suspected
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BAHX PRODUCT BULLETIN
DURING OPERATION Visual Inspection While the unit is operating, inspect the exterior of the unit or insulation covering for anomalies such as frost spots, dripping fluids, and vapor clouds. These indicate external leaking is occurring. Perform this inspection every shift. Fluid Composition Testing Measure the fluid composition of the streams, both upstream and downstream of the unit. Changes in purity from upstream to downstream of the BAHX indicate internal cross pass leaking is occurring. In a closed-loop system, gradual changes in composition over time may also indicate cross pass leaking. The interval of this test depends on the variation patterns of the streams, and the industry norms for the specific application. Monitor Operating Data The operator of a BAHX should continuously monitor the real-time temperature, pressure, and flowrate operating data. Watch for indications of:
• High local stream temperature differences
• High rate of change of stream or metal temperature
• High pressure drop
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BAHX PRODUCT BULLETIN
IN CONCLUSION This document provides an outline of recommended best
ANSI NBIC Part 2: Inspection
practice for the optimum performance and maximum longevity of Chart BAHXs. Its contents are drawn from
API 510: Pressure Vessel Inspection Code: In-Service
our extensive experience and, together with the APEX
Inspection, Rating, Repair, and Alteration
series of informational webinars, provides unparalleled access to our technical experts. However, both are
API 572: Inspection of Pressure Vessels
intended as supplements to, rather than replacements for, the latest editions of Chart’s Installation, Operation, And
API 579: Fitness for Service
Maintenance manual and the ALPEMA standards; details for both, together with other useful references, can be
API 662: Plate Heat Exchangers for General Refinery
found below.
Services - Part 2
Other BAHX Resources
GPA technical bulletin GPA-TB-M-001 EIGA Doc 145: Safe Use of Brazed Aluminium Heat Exchangers for Producing Pressurized Oxygen UOP Technical Library – whitepapers on many topics
The APEX webinar series is the place to learn from
including mercury guard beds, LNG feed pretreatment,
Chart. Each topic is selected from customer feedback
molecular sieves, and more.
and delivered by a subject expert. The number of participants for each webinar is capped for maximum
www.petrowiki.org
effectiveness and interaction. Chart Energy & Chemicals Installation, Operation, and Maintenance Manual The Standards of the Brazed Aluminium Plate-Fin Heat Exchanger Manufacturers’ Association (“ALPEMA”)
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BAHX PRODUCT BULLETIN
CONTACT US Founded in 2016, Chart Lifecycle, Inc., was established to provide plant stakeholders, from process and mechanical engineers through to operation and maintenance personnel, with best practice for the maintenance and management of Chart proprietary equipment for optimized performance and lifespan. Chart Lifecycle, Inc., is also your 24/7 single point of contact for spares, repairs, warranties, technical expertise, project development, field services, and training. Other services include: •
Extended warranties
•
Predictive maintenance analysis
•
Customized operating solutions and best practices
•
Performance improvement consulting services
Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline E-mail: [email protected] www.ChartLifecycle.com
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BAHX PRODUCT BULLETIN Chart Energy & Chemicals, Inc. is an ISO:9001 Registered Company through TÜV CERT Certificate Registration No. 12 100 4343
Issue 1 - April 2016