BAHXIOM.pdf - Chart Industries

The following checklists are for reference only, and are not intended to be comprehensive for all situations.

Serial Number:Plant Item Number:

BAHX Arrival Relevant IOM Section Checked By / Date1. Verify nameplate and record serial number II. A.2. Check for external damage II. A.3. Verify shipping stream pressure II. A. (typically 15 psig, if applicable) 4. Store per IOM instructions II. B.

BAHX Installation 1. Verify nameplate serial number2. Lift into position following general lifting II. C. instructions in IOM and specific instructions supplied with unit (if applicable)3. Verify correct BAHX orientation and nozzle locations II. D. 1.4. Install Micarta® or equivalent insulation II. D. 1. c. between support angle mounts and mating support surfaces (if applicable)5. Tighten bolted support connections to finger tight only II. D. 1. e. (does not apply to bolted flange pipe connections)6. Verify no water or debris trapped in field piping III. B. 1. to be attached to BAHX.7. Connect all nozzles to pipes II. E.8. Connect Smart Layer® (if applicable) II.1.4.9. Remove all temporary shipping supports II. D. 1. a.10. Remove all vent plugs (if applicable) II. F.11. Perform piping system leak / proof test III. A., IV. A.12. Install insulation II. G.

BAHX Initial Startup 1. Verify overpressure protection for all streams III. C. 2.2. Verify filters installed for all applicable streams III. B. 1.3. Verify no water trapped in or upstream of BAHX III. C. 1.4. Bring to operation conditions following IOM instructions, III. C. 3. with special attention to temperature rate of change guidelines

Arrival, Installation, and Startup Checklists Inside

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

for Chart Brazed Aluminum Heat Exchangers (BAHX) and Core-in-Kettle® Assemblies.

Chart Energy & Chemicals, Inc. is an ISO:9001,

ISO:14001, and OHSAS:18001 registered company

Chart Energy & Chemicals, Inc.

Brazed Aluminum Heat Exchangers

2191 Ward Avenue

La Crosse, WI 54601

Tel: 608-787-3333

E-mail: [email protected]

www.ChartIndustries.com

Chart Lifecycle, Inc.

8665 New Trails Drive, Suite 100

The Woodlands, TX 77381

Tel: 1-844-GTLS-911 (1-844-485-7911)


www.ChartLifecycle.com

JANUARY 2021



JANUARY 2021

ARRIVAL, INSTALLATION, AND STARTUP CHECKLISTS













2191 Ward Avenue

La Crosse, WI 54601

Tel: 608-787-3333






Tel: 1-844-GTLS-911 (1-844-485-7911)



JANUARY 2021



JANUARY 2021


FIGURE I FIGURE IIBasic Components of a Chart

Brazed Aluminum Heat Exchanger (BAHX)

How a Chart Core-in-Kettle® Works

The Chart Energy & Chemicals, Inc. (“Chart”) brazed aluminum heat exchanger (BAHX) business began in 1985 with the acquisition of The Trane Company’s BAHX operation in La Crosse, Wisconsin. Chart is a recognized global leader in the design and manufacture of large BAHX, battery assemblies, and cold boxes for cryogenic applications.

Chart incorporates the former Altec and Marston BAHX brands and consequently all rights to engineering and equipment produced by these companies.

“Core-in-Kettle” is a registered trademark of Chart Energy & Chemicals, Inc.

Brazed aluminum heat exchangers are also referred to as plate fin heat exchangers and abbreviated to PFHE within the industry.

© 2021 Chart Energy & Chemicals, Inc. All rights reserved.

Nozzle

Header

Distributor fin

Parting sheet

Side barWear plate

Heat transfer fin

Support angle

Cap sheet

2JANUARY 2021

Chart Lifecycle has qualified Field Service Engineering teams to provide full installation, commissioning and startup related

services. Chart highly recommends these OEM trained services to ensure a successful equipment startup. Chart also

provides best practices 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 commissioning and startup services, spares,

repairs, warranties, technical expertise, project development, field services, and training. Other services include:

• Annual service agreements

• Extended warranties

• Enhanced operator training and best practices

Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline



Installation, Commissioning & Startup ServicesCHART LIFECYCLE IS HERE TO HELP!

1. The warm process stream fluid enters the Brazed Aluminum Heat Exchanger (BAHX) through steel inlet nozzle(s) on the vessel shell. The inlet nozzles are connected to the aluminum inlet pipes of the exchanger by an aluminum to stainless steel transition coupling.

2. Inside the BAHX the warm stream cools as it flows against a cold stream.

3. The cold stream enters the vessel either as a liquid or 2-phase fluid directly from a distillation column (or expansion valve in the case of a refrigerant).

4. A liquid level is formed outside the BAHX core to create a liquid head that drives the cold stream liquid through the core

5. A disengagement space above the core causes the liquid and vapour to separate.

6. The cooled warm stream leaves the BAHX and vessel.7. The cold stream vapour exits the vessel through the outlet

nozzles whilst the liquid falls back to be recirculated.8. A manway is provided in the vessel shell.





Chart incorporates the former Altec and Marston BAHX brands and consequently all rights to engineering and equipment produced by these companies.“Core-in-Kettle” is a registered trademark of Chart Energy & Chemicals, Inc.


“Chart”, the Chart logo, and the Cooler By Design® tagline are registered trademarks of Chart Inc.


Nozzle

Header

Distributor fin

Parting sheet

Side barWear plate

Heat transfer fin

Support angle

Cap sheet

2JANUARY 2021









Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline











JANUARY 2021

FOREWORDI. INTRODUCTION A.Configuration ....................................................6 B.CodesandMaterialsofConstruction .............. 8II. INSTALLATION A.ArrivalInspection ............................................ 10 B.Storage .......................................................... 11 C.LiftingandHandling ...................................... 13 1.SingleBAHX ............................................ 14 2.MultipleBAHXAssemblies ...................... 17 3.Core-in-Kettle®Assemblies ..................... 17 D.Mounting,Bracing,andShippingSupport..... 19 1.SupportAngleMountingSystem ............. 19 2.PedestalBaseMountingSystem ............. 21 3.Core-in-Kettle®Assemblies ..................... 21 E.PipeConnections ...........................................22 1.PipeLoads ...............................................22 2.ConnectionConfigurations ......................23 3.TransitionJoints .......................................25 F.Venting ............................................................26 G.Insulation ........................................................27 H.Instrumentation ..............................................28 I.SmartLayers® ..................................................29III. TESTING AND OPERATION A.FieldProofTesting..........................................33 B.FoulingandCorrosionProtection ...................34 1.Filtering.....................................................34 2.HydrateSuppression(MethanolInjection) .....34 3.CorrosionProtection ................................35 C.Startup,Operation,andShutDown ...............36 D.OperatingRecords .........................................40IV.MAINTENANCE A.WarningSigns ................................................ 42 B.FieldLeakTesting ..........................................43 1.PressureDecayTest ................................44 2.Air-SoapTest ...........................................44 3.InternalLeakTesting ................................45 C.Cleaning .........................................................46 1.Deriming,BackFlushing,andDrying .......46 2.BackPuffing ............................................. 47 D.Mothballing .....................................................49 E.RepairandService .........................................50 F.Disposal ..........................................................50

TABLE OF FIGURESFIGURE I BasiccomponentsofaBAHX ...............................2FIGURE II BasiccomponentsofCoreinKettle® ....................2FIGURE III TypicalChartBAHXnameplate ............................8FIGURE IV RemovingBAHXfrommetalshipping

containers ........................................................... 13FIGURE V Horizontalliftingandmovinginstructions

(SteelchannelskiddedBAHX) ........................... 14FIGURE VI Horizontalliftingandmovinginstructions

(UnpackagedBAHX) .......................................... 15FIGURE VII TypicalmethodforrollingBAHXfromshipping

attitudetoalternatesides. (UnpackagedBAHX) .......................................... 16

FIGURE VIII TypicalmethodliftingBAHXtoverticalposition usingprovidedliftinglugs. .................................. 16FIGUREIX TypicalmethodliftingBAHXtoverticalposition

usingnozzlesontheBAHX. ............................... 17FIGUREX Typicalsupportanglemountingsystem(Singleor

multipleBAHXassemblies) ................................. 18FIGUREXI Typicalpedestalbasemountingsystem(Singleor

multipleBAHXassemblies) .................................20FIGUREXII TypicalconnectionsforBAHXandassemblies

shippedwithpressure .........................................22FIGUREXIII Typicaltransitionjointsforpipingconnections ... 25FIGUREXIV Ventplugtag .......................................................26FIGUREXV SmartLayer® Connections .................................. 31FIGUREXVI Typicalmethanolspargesystemtopview ..........34FIGUREXVII Temperaturedifferencerecommendations ......... 37

TABLE OF CONTENTS

3

JANUARY 2021 4

ThismanualincludesChart’sinstructions,practices,

andproceduresregardinginstallation,operation,and

maintenanceofChartBAHX,assemblies,andCore-

in-Kettle®assemblies.PleasecontactChartLifecycle

forassistanceintheinstallation,commissioning,and

startupservicesrelatedtothisequipment.Charthighly

recommendstheseOEMtrainedservicestoassurea

successfulequipmentstartup.

Thismanualisbasedonextensiveexperience,including

morethan60yearsinthedesignandmanufactureof

BAHXforlowtemperatureapplications,includingair

separationandliquefaction,naturalgasprocessingand

liquefaction,heliumliquefaction,andhydrogen,ethylene,

andotherlighthydrocarbonproductrecoveries.

THROUGHOUTTHISMANUAL,SAFETYITEMSARE

HIGHLIGHTEDINCAPITALLETTERSANDLABELED

WITHTHECAUTIONMARKSHOWNHERE.

Thismanualisupdatedperiodically.Beforeattempting

anyprocedureyoushouldverifywithChartthatyouare

usingthecurrentversion.

Thismanualcannotcoverallpossiblevariationsin

equipmentdesignorprovideanswerstoallspecific

installation,operation,andmaintenancequestionsthat

mayarise.Ifforanyreason,anyvariationsorquestions

arisethatarenotaddressedinthismanual,oranyofthese

instructions,practices,andprocedurescannotbefollowed,

thecontractororownermustcontactChartforfurther

information,interpretation,andguidance.Failuretofollow

theinstructions,practices,andproceduresmayresultin

seriousbodilyinjuryordeath,propertydamage,irreparable

damagetotheChartequipment,andthevoidingofany

warrantiesapplicabletotheequipment.

Whentheseinstructions,practices,andproceduresare

followed,extendedandreliableservicefromBAHXand

Core-in-Kettle®assembliescanbeexpected.

FOREWORD

THESEITEMSSHOULDBEREADWITHEXTREMECAREANDTHOROUGHLY

UNDERSTOODBEFORECOMMENCINGANYINSTALLATION,OPERATION,OR

MAINTENANCEOFCHARTEQUIPMENT.FAILURETOPROPERLYFOLLOWINSTRUCTIONSSODESIGNATED

COULDRESULTINRUPTURESOREXPLOSIONSOROTHERDANGEROUSSITUATIONSWHICHMAYRESULT

INSERIOUSBODILYINJURYORDEATHANDPROPERTYDAMAGEASWELLASIRREPARABLEDAMAGETO

THECHARTEQUIPMENTANDTHEVOIDINGOFANYWARRANTIESAPPLICABLETOTHEEQUIPMENT.

DONOTMODIFYTHEEQUIPMENTORDEVIATEFROMTHEINSTRUCTIONS,PRACTICES,ANDPROCEDURES

INTHISMANUAL.

THECONTRACTOROROWNERINSTALLINGCHARTEQUIPMENTMUSTCOMPLYWITHTHESE

INSTRUCTIONS,PRACTICES,ANDPROCEDURESALONGWITHANYLIFTINGANDHANDLINGANDOTHER

INSTRUCTIONS,PRACTICES,ANDPROCEDURESPROVIDEDWITHINDIVIDUALUNITS.

JANUARY 2021

I. INTRODUCTION A.Configuration

B. CodesandMaterialsof Construction

5

JANUARY 2021

I. A. Configuration(seeFigureI,insidecover)

ChartBAHXareconstructedofaluminum.Thebasic

constructionconsistsoflayersofcorrugatedfins

whicharefurnacebrazedbetweenpartingsheets.

TheBAHXdimensioncreatedbythisstackoflayersis

referredtoasthestackheightdimensionoftheBAHX.

Therectangularplate-fin“block”createdbythis

stackoflayersisalsoreferredtoasa“core”andis

normallyspecifiedbyitsoutsideblockdimensions

of“W”(width)times“H”(stackheight)times“L”

(length).ABAHX’ssize,numberoflayers,typeoffins,

stackingarrangement,andstreamcircuitingwillvary

dependingontheapplicationrequirements.

Thebasiccomponentsofabrazedaluminumheat

exchangeraredescribedbelowinsectionsI.A.1

through1.A.10.SectionsI.A.11throughI.A.15

definetheterminologyusedtodescribetheChartheat

exchangerassembliesandassociatedpiping.

I. A. 1. Nozzles

Nozzlesarethepipesectionsusedtoconnectthe

BAHXheaderstothecustomerpiping.

I. A. 2. Headers

Headersarethehalfcylindersthatprovideforthe

distributionoffluidbetweenthenozzlesandtheports

ofeachappropriatelayerwithintheBAHX.

I. A. 3. Ports

Portsaretheopeningsineitherthesidebarorthe

endbar,locatedundertheheaders,throughwhichthe

fluidsenterorleaveindividuallayers.

I. A. 4. Distributor Fins

Distributorfinsdistributethefluidbetweentheport

andtheheattransferfins.Thedistributorfinused

adjacenttoaportiscalledaportfin.Thedistributor

finusedbetweenaportfinandaheattransferfinis

calledaturningfin.

I. A. 5. Heat Transfer Fins

Heattransferfinsprovideanextendedheattransfer

surface.Allfins,bothheattransferanddistributor,

provideaconnectingstructurebetweentheparting

sheets,therebycreatingtheessentialstructuraland

pressureholdingintegrityoftheBAHX.

I. A. 6. Parting Sheets

Partingsheets(sometimesreferredtoasseparator

sheets)containthefluidswithinindividuallayersin

theBAHXandalsoserveastheprimaryheattransfer

surface.

I. A. 7. Outside Sheets

Outsidesheets(sometimesreferredtoascapsheets)

aretheoutermostpartingsheets.Theyserveasthe

outerprotectivesurfaceoftheBAHXaswellasaland

forweldattachmentoftheheaders.

I. A. 8. Side and End Bars

Sideandendbarsencloseindividuallayersandform

theprotectiveperimeteroftheBAHX.

I. INTRODUCTION

I. A. CONFIGURATION

6

JANUARY 2021

I. A. 9. Support Angles

Supportanglesaretypically90°extruded aluminum

anglesweldedtotheBAHXbarfaceforthepurposeof

supportingorsecuringaBAHXinitsinstalledposition.

Othersupportconfigurations,suchaspedestalbases,

arealsoavailable(seeFigureXI).

I. A. 10. Lifting Lugs

Liftinglugsareliftattachmentpointsstrategically

locatedandweldedtotheBAHXbarfaceoraheader/

nozzleassemblyforthespecificpurposeofliftingthe

BAHXintoitsinstalledposition.

I. A. 11. Modular BAHX Assembly

AmodularBAHXassemblyconsistsoftwoormore

individuallybrazedBAHXblocksthatarewelded

togetherpriortoattachingtheheaderstoformasingle

pieceBAHX.Thisformofconstructionisusedwhen

thecustomer’sheatexchangerequirementsexceed

themaximumblocksizethatcanbefurnacebrazed.

Modularconstructioneliminatestheneedforcostly

pipingtointerconnectseparate,individualBAHX.

I. A. 12. Multiple BAHX Assembly

AmultipleBAHXassembly,oftenreferredtoasa

“battery,”consistsoftwoormoreBAHXpipedor

manifoldedtogetherintoasingleassemblywiththe

individualBAHXarrangedeitherinaparallel,series,

orcombinationparallelseriesarrangement.Multiple

BAHXassembliesareusedwhenthecustomer’sheat

transferrequirementsaretoolargeforeithersingle

pieceormodularBAHXconstruction.

I. A. 13. Cold Box

Acoldboxconsistsofaweldedairtightcarbonsteel

casing,usuallyrectangularinshape,whichsupports

andhousesBAHX,piping,otherrelated

cryogenicequipment,andinsulationmaterial.

MoreinformationcanbefoundintheColdBox

Installation,Operation,andMaintenanceManual.

I. A. 14. Transition Joint

Atransitionjointisabimetalliccouplingusedtomake

thetransitionfromaluminumtostainlesssteelpiping.

Transitionjointsareavailableinvariousconfigurations.

I. A. 15. Core-in-Kettle® Assembly

ACore-in-Kettle®assemblyconsistsofacylindrical

pressurevessel,usuallycarbonorstainlesssteel,

whichcontainsandsupportsoneormoreBAHX

andassociatedpipingincludingtransitionjoints.In

operation,onefluidispipedthroughtheheadered

streamoftheBAHXandtheotherpartiallyfillsthe

vesselandcommunicateswiththeopen(unheadered)

streamoftheBAHX.

I. INTRODUCTION

I. A. CONFIGURATION

7

JANUARY 2021

I. B. Codes and Materials of Construction

ChartBAHXarenormallydesignedandmanufactured

inaccordancewithSectionVIII,DivisionIofthe

ASMEPressureVesselCode,carrythe“U”stamp,

andareregisteredwiththeNationalBoardofBoiler

andPressureVesselInspectors.Associatedpipingis

normallydesignedandmanufacturedinaccordance

withtheASMEB31.3PipingCode.TheASME

pressurevesselandpipingcodeboundariesare

indicatedontheChartdrawing.

ChartBAHXandpipingaresometimesdesigned

andmanufacturedtoother(international)codes.The

governinginternationalcodeisspecifiedontheChart

drawingandBAHXnameplate.

Thefollowingtableindicatesthetypicalmaterialsof

constructionfortheBAHXcomponents.

I. INTRODUCTION

I. B.CODESANDMATERIALSOFCONSTRUCTION

8

COMPONENT TYPICAL MATERIALS (Aluminum Alloy)

OutsideSheets 3003

PartingSheets 3003

SideandEndBars 3003

HeatTransferFins 3003

DistributorFins 3003

Headers&Nozzles 5083*

Flanges 6061-T6*

SupportAngles 6061-T6*

LiftingLugs 5083*

*ActualmaterialsmaydifferandarespecifiedontheChartassemblydrawing.

FIGURE IIITypicalBAHXNameplate

JANUARY 2021

II. INSTALLATION A.ArrivalInspection

B.Storage

C.LiftingandHandling D.Mounting,Bracing,andShipping Support

E.PipeConnections

F.Venting

G.Insulation

H.Instrumentation

I.SmartLayers®

BRANDARCHITECTURE

9

JANUARY 2021

II. A. Arrival Inspection

Uponarrival,verifythenameplatematchesthepurchase

order.TheBAHXshouldbeinspectedforshipping

damageandcontamination.Closelyexamineallunits

forexternaldamage.Forunitsshippedunpressurized,

checkundertheshippingcoversforcontaminationofthe

portopenings.Forunitsshippedpressurized(normallyto

15psig[1barg])withdryairornitrogen,eachheadered

ormanifoldedstreamisprovidedwithavalveand

couplingtowhichapressuregaugecanbemounted

(seeFigureXII).Apositivepressureshouldbeindicated

onthegaugewhenthevalvesareopened.Ifastream

doesnotindicateapositivepressureandthevalveand

couplingconnectionshavebeencheckedforleakage,

itshouldberepressurizedwithdryairornitrogento15

psig(1barg).IfaleakintheBAHX,shippingdamage,

orinternalshippingcontaminationisconfirmed,contact

Chartforfurtherdirection.

II. INSTALLATION

II. A. ARRIVAL INSPECTION

10

JANUARY 2021

II. B. Storage

Anindoorstorageareaawayfromanymainworkarea

isrecommended.IndoorstorageisrequiredforBAHX

havingopenlayersornozzlesnotcoveredwithwelded

orboltedcovers.Anyingressofmoistureintothese

openlayersshouldbeavoided.Inallstorageareas,the

followingadditionalrecommendationsshouldbefollowed.

II. B. 1.

BAHXaretypicallyshippedonwoodorsteelchannel

skids.SkiddedBAHXmayalsobepackagedina

woodencrateormetalshippingcontainer.Donot

stackskiddedorcratedBAHX.

BAHXshouldbestoredintheoriginalpackaging,

whichisgenerallysuitableforthreeyears.Forlonger

termstorage,considerationshouldbegiventospecial

packaging.ConsultChartforpackagingoptions.

II. B. 2.

Thestorageareashouldprovidelevel,uniform

supportwithgooddrainage.

IftheBAHXhasbeenremovedfromitspackaging,

itshouldbelaidonwoodensleepersinahorizontal

positionontheoutsidesheetfaceoftheBAHX.The

woodensleepersshouldbeatleast6inches(152mm)

wideandextendbeyondtheedgesoftheBAHX.Failure

toextendsleepersbeyondtheedgesoftheBAHXcan

resultininternaldamagetotheoutsidelayers.Useonly

twosleepers–oneneareachendoftheBAHX–ata

distancefromeachendthatisapproximatelyonefourth

theBAHX’slength.Avoidpositioningthesleepersunder

anyheaders.Useasoft,resilientmaterialsuchasfiber

boardasabufferbetweenthesleeperandtheBAHX.

II. B. 3.

ThestorageareashouldbelocatedwheretheBAHX

isnotsubjectedtofluidsoratmospheresthatare

corrosivetoaluminum.

II. B. 4.

ThestorageareashouldbelocatedwheretheBAHX

isnotsubjectedtovibration.

II. B. 5.

Avoidalocationwhereotherworkactivityorfalling

objectswillbeinthevicinityofthestoredBAHX.

ExternaldentingoftheBAHXcandamagetheinternal

matrixoftheBAHXandcauseleakage.

II. B. 6.

Avoidalocationthatissubjecttolargefluctuationsin

temperature(especiallybelow32°F[0°C]),orhigh

humiditywhentheBAHXisnotsealedandweather-

proofed,asthiscancausecondensedwaterto

accumulateintheBAHXandfreezewhentheBAHX

isplacedinstorageoroperation.Waterfreezinginside

theBAHXcandamageitsinternalmatrix.

II. B. STORAGE

II. INSTALLATION

11

NEVERSTACKBAHX.STACKINGOFBAHX

COULDRESULTINABAHXFALLINGFROM

ITSSTACKEDPOSITIONWHICHMAYRESULT

INSERIOUSBODILYINJURYORDEATH

ANDPROPERTYDAMAGEASWELLAS

IRREPARABLEDAMAGETOTHECHART

EQUIPMENTANDTHEVOIDINGOFANY

WARRANTIESAPPLICABLETOTHEEQUIPMENT.

JANUARY 2021

II. B. STORAGE

II. INSTALLATION

12

II. B. 7.

BAHXmustbeproperlycoveredandsealedinsuch

amannerthatdirt,sand,water,orforeignmaterials

cannotenteropennozzles,ports,orthroughanyother

accessintotheBAHX.ForBAHXthatareshipped

pressurized,dryairornitrogenwithadewpointof

32°F(0°C)orlessshouldbesealedineachstream

duringstorage.Thedryairornitrogenpressureshould

be15psig(1barg),oronethirdthestreamdesign

pressure,whicheverisless.TheBAHXshouldbe

checkedperiodicallytoensurethatthepressureis

maintained.

ForBAHXthatarenotshippedwithpressureanddo

nothaveweldedshippingcoversonthenozzles,all

nozzleopeningsontheBAHXshouldbecoveredand

sealedwhiletheunitisinadrycondition.

FAMILIARIZATIONWITHALLAPPLICABLE

CHARTDRAWINGSISREQUIREDBEFORE

ANYINSTALLATIONWORKPROCEEDS.

PARTICULARCARESHOULDBETAKEN

WHENEVEROFF-LOADING,MOVING,OR

LIFTINGTHEBAHX.

FAILURETOHANDLEEQUIPMENT

PROPERLYCOULDRESULTINTHEBAHX

BEINGDROPPEDORSOMEOTHER

EQUIPMENTACCIDENTWHICHMAYRESULT



IRREPARABLEDAMAGETOTHE

CHARTEQUIPMENTANDTHEVOIDINGOF

ANYWARRANTIESAPPLICABLETOTHE

EQUIPMENT.

JANUARY 2021

II. C. Lifting and Handling

Reviewliftingdrawingsthatshipwitheachunit.

Confirmtheweight,dimensions,andliftconnection

locationsoftheBAHX.Selecttheappropriatehoisting

machines,spreaderbeams,slings,shackles,and

othermaterialhandlingtoolsinconsiderationofthe

height,theBAHXweight,andtheangleanddirection

ofthehoisting.Careshouldbetakentoavoidimpacts

totheBAHX.Roughorimproperhandlingcancause

damagetotheinternalmatrixoftheBAHX.

BAHXmayberemovedfrommetalshipping

containersbytowingwithachain,cable,orforklift

(seeFigureIV).Onlytowfromtheindicatedendofthe

skid,donottowfromanypartoftheBAHX.

II.C.LIFTINGANDHANDLING

II. INSTALLATION

13

FIGURE IVRemoving BAHX from metal shipping containers

Chainorcablemethod Forkliftmethod

JANUARY 2021

II. C. 1. Single BAHX

II. C. 1. a. Crated or Skidded (Lifting and Moving in

a Horizontal Position)

Itispreferredtolifttheexchangerwithacrane.Crated

orskiddedBAHXshouldbeliftedwithacraneorhoist

byusingslingsandaspreaderbeam(seeFigureV).

Usenylonslingsorpolyesterropewithscuffanglesto

protecttheexterioroftheBAHX(seeFigureVI).Wood

skiddedorcratedBAHXcanbetowedwithafork

truck,butdonottowsteelchannelskiddedBAHX.Ifa

forkliftisusedensureadequateprotectionagainstthe

aluminumandtheforksextendfullwidthoftheBAHX.


II. INSTALLATION

14

FIGURE V Horizontal lifting and moving instructions

(Steel channel skidded BAHX)

Slingmethod

Spreaderbeam

JANUARY 2021

II. INSTALLATION

FIGURE VIHorizontal lifting and moving instructions

(Unpackaged BAHX)


LIFTDIRECTLYFROMTHEBAHXBLOCK

ITSELF.DONOTLIFTFROMANYHEADER,

NOZZLE,ORPIPINGUNLESSSPECIFICALLY

INDICATEDONTHECHARTDRAWING.




EQUIPMENTACCIDENTWHICHMAY

RESULTINSERIOUSBODILYINJURYOR

DEATHANDPROPERTYDAMAGEAS

WELLASIRREPARABLEDAMAGETOTHE



EQUIPMENT.

II. C. 1. c. Rolling to Alternate Side

RollingoftheBAHXfromtheshippingattitudeis

permittedwhenspecifiedontheChartassembly

drawing.Whenpermitted,arollinginstructionis

shippedwiththeBAHX.

II. C. 1. d. Rotating and Lifting to a Vertical

Position

ThemethodforliftingaBAHXfromitshorizontal

shippingpositiontotheverticalinstallationposition

willdependuponBAHXconfigurationandweight.

LiftinginstructionsareprovidedontheChartdrawings

shippedwiththeunit.

II. C. 1. b. Unpackaged (Lifting and Moving in a

Horizontal Position)

DonotusecablesdirectlyontheexterioroftheBAHX

astheycandentorcutintotheexterioroftheBAHX

andcausedamagetoitsinternalmatrix.Scuffangles

are90°anglesplacedonthecornersoftheBAHX

undertheslingorbelt.

15

Supportangle(BoltholesbycustomerunlessspecifiedonChart

drawing)

Crane

Spreaderbeam

Polyesterropeornylonsling

ScuffangleBAHXprotectors

Outsidesheetface

Sidebarface

Halfcorelength

90°bentangle

JANUARY 2021

II. INSTALLATION

FIGURE VII

FIGURE VIII

Typical method for rolling BAHX from shipping

attitude to alternate sides (Unpackaged BAHX)

Use only when authorized on Chart assembly drawing.

Typical method lifting BAHX to vertical position using

provided lifting lugs.


IFLIFTINGLUGSAREPROVIDED,THEY

SHOULDBEUSEDASTHEATTACHMENT

LIFTING POINT. IF LIFTING LUGS ARE

NOTPROVIDED,ANDSPECIFICLIFTING

INSTRUCTIONSFORTHEUNITARENOT

AVAILABLE,CONTACTCHART.DONOT

LIFTUSINGTHENOZZLESORANYOTHER

PIPINGUNLESSSPECIFICALLYSHOWNIN

THECHARTDRAWINGFORTHEUNIT.

Therearetwobasicmethodsforliftingtothevertical

position.Othermethodsareapprovedonlyifspecified

ontheChartdrawingfortheunit.Bothmethodsare

similarexceptforthepointofliftingattachment.

Onemethodinvolvestheuseofliftinglugsprovided

withtheChartunit(seeFigureVIII).

16

Polyesterropeornylonsling Donotusesteelcables

Note:ForBAHXexceeding 12ft(3.7m)inlength,aspreaderbeamandtwobeltsshouldbeusedfortheroll

Useslingprotectionatcorners

Padding

Liftinglug

JANUARY 2021

TheothermethodinvolvesliftingusingtheBAHX

nozzles(seeFigureIX).Theseliftingmethodsare

usedforbothsupportanglemountingandpedestal

basemountingofBAHX.

II. C. 2. Multiple BAHX AssembliesConsideringthenumerouspossiblevariationsinBAHX

andpipingassemblyconfigurations,size,andweight,

asinglelifting,handling,anderectionprocedurefor

multipleBAHXassembliesisnotpossible.

Fortheseassemblies,liftinginstructionsareincluded

ontheChartassemblydrawingoronaseparate

erectiondrawing.MultipleBAHXassembliesshouldbe

handledwiththesamecareaffordedindividualBAHX.

II. C. 3. Core-in-Kettle® Assemblies

Core-in-Kettle®assembliesareeitherprovidedwith

appropriateliftinglugsonthekettleorinstructionsas

towheretoslingaroundtheassembly.

II. INSTALLATION


WHENLIFTINGLUGSAREPROVIDEDON

CHARTCORE-IN-KETTLE® ASSEMBLIESFOR

LIFTINGANDHANDLINGTHEYSHOULDBE

USEDWHENEVERMOVINGTHECORE-IN-

KETTLE®ASSEMBLY.




EQUIPMENTACCIDENTWHICHMAY






EQUIPMENT.

17

FIGUREIXTypical method lifting BAHX to vertical position

using nozzles on the BAHX

Liftingwithnozzle

JANUARY 2021

II. INSTALLATION

FIGUREXTypical support angle mounting system

(Single or multiple BAHX assemblies)

Warm end up (typical)


18

Stainlesssteelbolts,nuts,andwashers(bycustomer)Boltsmustbefingertightandsmallerthanboltholestoprovideclearanceforthermalexpansionand/orcontraction

Aluminumsupportangle(holesbycustomerunlessspecifiedonChartdrawing)

0.5inches(13mm)minimumthicknessMicarta®(bycustomer)

0.5inches(13mm)recommended-1inch(25.4mm)maximumfromsidebarfaceoftheBAHX

Continuousstainlesssteelsupportbeam(bycustomer)

JANUARY 2021

II. INSTALLATION

II.D.MOUNTING,BRACING,ANDSHIPPINGSUPPORT

II. D. Mounting, Bracing, and Shipping Support

II. D. 1. Support Angle Mounting System (Single or

Multiple BAHX Assemblies)

ChartBAHXarenormallyinstalledverticallywiththe

warmendup(seeFigureX).Otherorientationsare

permissibleonlyifspecifiedontheChartassembly

drawing.ChartBAHXarenormallyprovidedwith

aluminumsupportanglesweldeddirectlytotheside

barfaceoftheBAHXformountingpurposes.

Thefollowingaregeneralmountingrecommendations

forbothsingleBAHXandformultipleBAHX

assembliesutilizingsupportanglemountingsystems

(seeFigureX).

II. D. 1. a.

Allshippingsupportsshouldberemovedasshownon

theChartdrawings.Extremecareshouldbetakento

keepallsteelworkingtorchesandflame-cuttingtools

ataproperdistancefromthealuminumBAHXinorder

topreventseveredamagetobrazedjointsandtothe

internalmatrix.

II. D. 1. b.

ThesupportanglesurfacesontheBAHXareinplane

within0.06inches/foot(0.5%).Thematingsupport

surface(bycustomer)shouldbeacontinuousmember

andbeinplanetothissamestandard.Shimmingis

acceptablebutisnotpreferred.

II. D. 1. c.

SincetheseBAHXarenormallyinstalledincryogenic

services,somemethodofinsulatingbetweenthe

Chartaluminumsupportanglesandthecustomer

matingsupportsurfaceisrecommended.

Aminimumof0.5inch(13mm)thickpieceof

Micarta®(phenoliccanvasbaselaminate)blockis

recommendedforthispurpose.Theinsulationmaterial

thicknessshouldbesufficienttominimizeheat

leakandpreventfrostspotsfromdevelopingonthe

supportsorcoldboxwallsduringoperatingconditions.

II. D. 1. d.

Provisionsforthermalexpansionandcontraction

oftheBAHXinthehorizontalplaneatthesupport

locationmustbeprovided.

Theexpectedthermalmovementshouldbecalculated

inbothhorizontaldirectionsbythefollowingequation:

D=12.6 x 10-6 x L x ∆T

whereListhedistanceininchesbetweenextreme

boltsinthedirectionunderconsideration,∆Tisthe

changeintemperaturein°Fatthesupportlocation

fromtheinstalled(ambient)temperaturetothecoldest

possibleoperatingtemperature,andDistheexpected

thermalmovementinincheswhichwillresultfromthis

calculation.

19

JANUARY 2021

II. INSTALLATION

FIGUREXITypical pedestal base mounting system

(Single or multiple BAHX assemblies)

Warm end up (typical)


20

Iftheexpectedthermalmovementinbothdirectionsis

0.5inches(13mm)orless,theboltholediametersin

thealuminumsupportanglesshouldbeoversizedby

addingthemaximumexpectedthermalmovementto

theboltdiameter.

Iftheexpectedthermalmovementexceeds0.5inches

(13mm)inoneofthehorizontaldirections,aslotted

holeshouldbeusedwithaslotlengthequaltothe

boltdiameterplusthemaximumexpectedthermal

movement,andaslotwidthequaltotheboltdiameter

plustheexpectedthermalmovementintheother

direction.

Iftheexpectedmovementexceeds0.5inches(13mm)

inbothdirections,theholesinthealuminumsupport

anglesshouldbeslottedasperaboveinonedirection

andtheholesinthestainlesssteelsupportbeam

shouldbeslottedasperaboveintheotherdirection

withslotwidthsequaltotheboltdiameterplus0.12

inches(3mm).

II. D. 1. e.

Bolts,nuts,andwashersemployedtosecuretheBAHX

tothesupportingsurfacemustbestainlesssteel,and

tightenedtofingertightonly(thisrequirementapplies

tobothangletypeandpedestalbasetypemounting

systems).Donotuselockwashers.Useadoublenut

orinterrupttheboltthreadstopreventthenutfrom

workingloose.Wrenchtighteningtheboltscouldallow

relativelysmallhorizontalpipeloadsappliedtoeither

endoftheBAHXtodevelopbendingmomentson

theBAHXwhichmayproduceunacceptablestress

concentrationsatthesupportangles.

Boltlocations(BoltholesbyChart,bolts,nuts,andwashersbycustomer)

0.5inches(13mm)MinimumthicknessMicarta® (bycustomer)

JANUARY 2021

II. INSTALLATION


II. D. 1. f.

Toavoidexcessivebendingmomentsonthesupport

angleitself,theedgeofthesupportsurfacemustbe

nomorethan1.0inches(25.4mm)fromtheBAHX

sidebarface.Adistanceof0.5inches(13mm)is

recommended(seeFigureX).

II. D. 1. g.

Thesupportsystemshouldbesafeguardedbythe

provisionofaswaybrace,locatedattheoppositeend

oftheBAHXawayfromthemainsupportanglesor

pedestalbase,wheneverthetotalexternalloads

(pipe,wind,andearthquake)aresufficienttocause

lateralmovementoftheBAHX.

AclosefitbetweentheBAHXwearplateandthe

swaybraceisrequiredsincechangingfromambient

tooperatingatcryogenictemperaturesatthisposition

canproduce0.12inches(3mm)ofmovementfrom

thermalcontraction.Ifrequested,wearplatescanbe

furnishedontheBAHXbyChart.

DonotfastenanyswaybracedirectlytotheBAHX.The

BAHXmustbefreetomoveintheverticaldirection.

II. D. 1. h.

Forreversing(airseparationservice)BAHX,supporting

directlyfromthebottom(warmend)manifoldsis

acceptableifprovidedforontheChartassembly

drawing.WarmendmanifoldsforreversingBAHX

shouldalwaysbeprovidedwithsumpsanddrainsof

adequatesizetoreturnanycondensedwaterfromthe

manifoldpipingsothatwaterwillnotbeentrainedinthe

fluidstreamorsluggedintotheBAHXduringpressure

reversals.

II. D. 2. Pedestal Base Mounting System (Single

or Multiple BAHX Assemblies)

Analternativemethodtothesupportanglemounting

systemisanaluminumpedestalbasemounting

systemprovidedwiththeBAHX(seeFigureXI).The

pedestalbasemountingsystemisgenerallyemployed

whencoldboxinstallationisnotrequiredandthe

BAHXcanbemountedatgroundlevelasthisis

usuallyalesscostlymethodformounting.

Thesamerecommendationsregardingshimming,

insulation,boltholesize,bolttightness,andbracing

forsupportanglemountingsystemsinSectionII.D.1.

shouldbefollowedforpedestalbasemountsystems.

II. D. 3. Core-in-Kettle® Assemblies

Theholesfortheanchorboltsareslottedinthesliding

saddletoallowforthermalcontractionandexpansion.

WheninstallingaCore-in-Kettle®assemblyitiscritical

toaligntheanchorboltsinthecenteroftheslots.

Inrarecasesthesaddlegeometrymayrequirethe

anchorboltsbeinstalledoffsetintheslots.Inthese

casestherequiredpositioningisspecifiedonthe

Core-in-Kettle®assemblydrawing.

21

JANUARY 2021

II. INSTALLATION

FIGUREXIITypical connections for BAHX and assemblies

shipped with pressure

II. E. PIPE CONNECTIONS

22

II. E. Pipe Connections

II. E. 1. Pipe Loads

Atableindicatingmaximumallowablepipeloadsfor

theBAHXorassemblyisprovidedwiththeChart

drawing.Thistableindicatesthemaximumallowable

bendingmomentandtheaxialloadthatcanbe

appliedateachheaderlocationontheBAHX.These

maximumloadsarenottobeappliedsimultaneously.

Instructionsforsummingappliedmomentsandforces

aresuppliedwiththistable.

Itisthecustomer’sresponsibilitytoprovidesufficient

pipingflexibilityoranchorpointsinthecustomer

pipingtoensurethatthecombinedloadsoneach

nozzleandontheBAHXarewithintheallowablelimits

specifiedbyChart.

FAILURE TO PROVIDE SUFFICIENT PIPE

FLEXIBILITYORANCHORPOINTSCOULD

RESULTINCOMBINEDPRESSUREAND

EXTERNALPIPELOADSBEINGAPPLIED

WHICHEXCEEDTHEALLOWABLELOADS

OFTHEBAHXANDMAYRESULTIN

SERIOUSBODILYINJURYORDEATH




WARRANTIESAPPLICABLETOTHE

EQUIPMENT.

Valve and coupling

Blind flange

Raised face weld neck aluminum flange

Instructional tag showing 15 PSIG dry air or N2 charge

Slugged end

Location for field cut off

Typical slugged connection

Typical flanged connection

JANUARY 2021

II. INSTALLATION


Priortoremovingtheplugorpressuregaugefrom

theshippingvalve,besurethevalveisintheclosed

position.Exercisecautionandacceptedsafety

proceduresforremovalofaplugfromapressure

vessel.

II. E. 2. Connection Configurations

II. E. 2. a. Slugged Connections

Thepropercutofflocationofthenozzleorpipe

canbefoundontheChartassemblydrawing(see

FigureXII).Bevelingandweldingproceduresmustbe

followedpertheapplicablecoderequirements.Before

makingfinalconnectionstotheBAHX,careshould

beexercisedtoremoveanysawchips,torchslag,

orotherforeignmaterialfromthepipe,nozzle,and

headerarea.TheseitemscanplugtheBAHX.

II. E. 2. b. Flanged Connections

Aluminumorsteel(stainlessforcryogenicservice)

matingflangesaretypicallyusedwiththeChart

flangedconnection.

Careshouldbeexercisedtoprotectthemachined

faceoftheflangeagainstscratches,dents,andother

damagethatwillreducetheeffectivenessofthe

gasketinmakingaproperseal.

Thetwomatingsurfacesoftheflangesshouldbe

parallelwitheachotherpriortoconnecting.Flange

facesmustbealignedtothedesignplanetowithin

0.06inches/foot(0.5%)maximum,measuredacross

thediameteroftheflangematingface,andflangebolt

holesmustbealignedtowithin0.12inches(3mm)

maximumoffset.

Connectionsshouldbemadebygraduallytightening

diametricallyoppositeboltpairsandtighteningthe

pairsinasequencethatuniformlyloadsthegasket.

Installedboltsandgasketsshippedwiththeblind

flangemustnotbeusedformakingfinalconnections

astheyarenotdesignedforcryogenicservice.

Stainlesssteelboltsandnutsmustbeusedforthe

finalfieldconnectionforcryogenicservice.Stainless

steelwashersmustbeusedundertheboltheadsor

nutsonthealuminumflange,andthreadsshouldbe

lubricatedforpropertorquewrenchapplications.

23

FAILURETOCONFIRMTHESHIPPING

VALVEISINTHECLOSEDPOSITION

PRIORTOREMOVALOFTHEPLUGOR

PRESSUREGAUGECANRESULTINTHE

PLUGORGAUGEBECOMINGA

PROJECTILEWHICHMAYRESULTIN






EQUIPMENT.

JANUARY 2021

II. INSTALLATION


Gasket Recommendations For Use With Aluminum

Flanges:

ChartrecommendsFlexitallicFlexprogaskets

orequivalent(m=2.0,y=2500psi[17.2MPa]).If

stainlesssteelspiralwoundgasketsareused,Chart

recommendstheybelowseatingstresssuchas

FlexitallicLS(m=3.0,y=5000psi[34.5MPa]).Ifhigher

seatingstressgasketsareselectedconsultChart

todetermineifChart’sstandardrecommendedbolt

torquesareadequate.

Bolting recommendations:

Recommended Bolt Torques:

Allboltingmustbegivenafinaltighteningbytorque

wrench.Boltsaretobetorquedtothefullvalue

showninthetablebelowandthenre-torquedafter15

minutes.Torquevaluesarebasedonaresultantbolt

stressof30,000psiassumingwelllubricatedstuds,

nuts,andwashers.

Bolt torques for use with flanges:

II. E. 2. c. Weld Prepared Connections

Weldpreparedconnectionsareproperlytrimmedto

lengthandbeveledforwelding.Thetrimlengthand

bevelingdetailisprovidedontheChartdrawing.

Connectionspreparedforweldingarecoveredduring

shipments.TheBAHXorassemblydoesnotshipwith

pressure.

Bevelingofthematingpipeandweldingprocedures

mustbepertheapplicablecoderequirements.Before

makingfinalconnectionstotheBAHX,removeany

sawchips,torchslag,orotherforeignmaterialfrom

thepipe,nozzle,andheaderarea.Theseitemscan

plugtheBAHX.

24

Downto-50°F(-45°C)

Below-50°F (-45°C)

StudDiametersthru1.5inches

(38mm)

Below-50°F (-45°C)

StudDiametersabove1.5inches

(38mm)

BoltSize TPI Torque Torque(in) (ft-lbs) Increments

Studs SA193B7 SA320B8CL2 SA193B8M2

Nuts A194GR2H SA194GR8 SA194GR8

1/2 13 30 Snug,thenfulltorque

5/8 11 60

3/4 10 100

7/8 9 160 Snug,1/2torque,

1 8 245 thenfulltorque

1-1/8 8 355

1-1/4 8 500

1-3/8 8 680

1-1/2 8 800 Snug,1/3torque,2/3

1-5/8 8 1100 torque,thenfulltorque

1-3/4 8 1500

1-7/8 8 2000

2 8 2200 Snug,1/4torque,

2-1/4 8 3180 1/2torque,3/4torque,

2-1/2 8 4400 thenfulltorque

2-3/4 8 5920

3 8 7720

JANUARY 2021

II. INSTALLATION


25

II. E. 3 Transition Joints (seeFigureXIII)

Unlessauthorizedbythejointmanufacturer,transition

jointsaretobeattachedonlytopipingcomponents.

Topreventfailureofthebondduringwelding,

precautionsmustbetakentoavoidoverstressing

thebondduetodifferentialexpansionbetweenthe

aluminumandstainlesssteeljointcomponents.These

stressescanbemaintainedwithinallowablelimitsby

takingthefollowingprecautions:

•Placeachillblockordampragsonthealuminum/

steeloverlappingbondarea.Ifdampragsareused,

careshouldbetakentokeeptheragsorcloths

damp.Adryclothwillallowthejointtobecome

excessivelyhot.Temperatureinthealuminum/

steeloverlappingareamustbeheldtoamaximum

of300°F(149°C),unlesshighertemperaturesare

permittedbythejointmanufacturer.

•Wheninstallingaloosetransitionjoint,weldthe

stainlesssteelendfirstwheneverpossible.Thiswill

providealargersinkfortheheatgeneratedbythe

aluminumwelding.

•Useweldtechniquesandsequencestominimizethe

heatinput.

•Careshouldbetakentoavoidnon-uniformheating,

weldsequences,orweldtechniquesthatwouldcause

isolatedhighstressareas,i.e.“BlockWelding,”local

repairwelds,orothersimilartypesoflocalizedwelding.

FIGUREXIIITypical transition joints for piping connections

Photo courtesy of Groupe RBDH

Photo courtesy of Asahi Kasei Corporation

JANUARY 2021

II. INSTALLATION

II. F. VENTING

26

II. F. Venting

Externalventingofinactiveornon-operationalinternal

zonesofsomeBAHXisrequiredwhenspecified

ontheChartdrawing.Examplesofinactivezonesthat

requireventingare:

•themodularspaceformedbyweldingtogethertwo

BAHXblocks.

•thedeadcornerofareversingstreamwarmend

distributoremployingtheslantbardrainability

feature.

•thespaceformedbetweentwotandemstreams

havingadjacentsideheadersatmidBAHX.

•otherspecialcases.

ChartBAHXthathaveaninactivezonearenormally

designedtobeselfventingandsimplyrequirethat

theplasticshippingplugsberemovedjustprior

toinsulatingandpressurizinganystream.This

requirementisstatedontheChartdrawingandona

tagattachedtoBAHX.

Ifyouwishtomonitoraninactivezonebyattachinga

ventline,besuretoextendtheventlineoutsidethe

coldboxorinsulationandprovideareliefvalveon

theventlinetoprotecttheinactivezoneoftheBAHX

againstpressurizationover15psig(1barg).Maintain

theventlineinaninternallyfrostfreecondition

toeliminatethepossibilityoflineblockagefrom

freezingliquids.A3/4”NPS(20DN)orlargerlineis

recommendedtoavoidpotentialflowrestriction.

FIGUREXIVVent plug tag

FAILURETOLIMITTHEPRESSURIZATION

OFINACTIVEZONESINTHEBAHXTOA

MAXIMUMOF15PSIGCOULDRESULTIN

ARUPTUREOFTHEBAHXWHICHMAY

RESULTINSERIOUSBODILYINJURY

ORDEATHANDPROPERTYDAMAGE

ASWELLASIRREPARABLEDAMAGE

TOTHECHARTEQUIPMENTAND

THEVOIDINGOFANYWARRANTIES

APPLICABLETOTHEEQUIPMENT.

JANUARY 2021

II. INSTALLATION

II. G. INSULATION

II. G. Insulation

SinceBAHXusuallyoperateatcryogenic

temperatures,highlyefficientinsulationshould

beappliedbythecustomertominimizeheatleak.

Insulationmaterialisnormallyappliedaftertheunitis

installedatthejobsite.Flammablematerialsshould

beavoidedforinsulation.Insulationmaterialsare

notnormallyappliedtotheBAHXpriortoinstallation

becauseinsulationmaterialsareeasilydamagedin

transit,theyrestricttheuseofshippingtiedowns

andsupports,andtheywouldimpairaccessibilityto

theunitforlifting,mounting,leaktesting,andother

installationpreparations.

WhentheBAHXisnotmountedinsideacoldbox,

theBAHX’sexteriorisnormallyinsulatedwithrigid

polyurethanefoam,orotheralternativessuchas

Foamglass®insulation,accordingtothethicknessand

requirementsspecifiedbytheengineeringcontractor.

Theseinsulationsarepositionedandfastenedaround

theBAHXandcoveredwithavaporbarrier.Protective

metalcoveringsorflashingcanbeusedforthis

purpose.

Inallinstallations,someformofinsulationsuchasa

Micarta®spacershouldbeusedbetweentheBAHX

supportmemberandthesupportingbeamorplatform

(seeSectionII.D.1.c.).

Cautionshouldalwaysbeexercisedwheneverwelding

orflamecuttingnearinsulationmaterials.

RefertotheColdBoxInstallation,Operation,and

MaintenanceManualforinstructionsoninsulating

BAHXinstalledincoldboxassemblies.

27

JANUARY 2021

II.H.INSTRUMENTATION

II. H. Instrumentation

Properinstrumentationmustbeinstalledtoproperly

operateBAHXwithintheguidelines(seeSectionIll.C.).

Fluidtemperaturesandpressuresshouldbemonitored

attheinletandoutletofeverystreamatintervalsof1

minute.Forboilingstreamsinreboilerservicesexternal

tothecolumn,adedicateddifferentialpressure

instrumentshouldbeusedtomonitorforpressure

oscillationsindicatingunstableflow.Fluidflowrates

shouldbemonitoredwithflowmeters,orapproximated

withvalvepositions,pressuredrop,orvesselliquid

levels,atintervalsof1minute.Fluidcompositionshould

bemeasuredandloggedatintervalsof1monthata

minimumorasfrequentlyasthecompositionchanges.

Ifdesired,coreblocktemperaturecanbedirectly

measuredusingtemperaturedevicesinstalledby

Chart.

Gasdetectorsshouldbeinstalledinthevicinitytoalert

ifanyexternalleaksexist.

28

II. INSTALLATION

JANUARY 2021

II. I. 1. Smart Layer®

SmartLayerisawarningsystemcomprisedofinactivelayers

locatedontheoutsideofthestackthathavebeendesigned

andprooftestedforthefulldesignpressureoftheadjacent

processstream(s).Theyareequippedwithconnectionsfor

apressuremonitor,pressurereliefvalve,andaNitrogen

chargingport.ThepurposeofSmartLayeristoalert

operatorswhenacriticalthresholdofthermalstressdamage

hasoccurred,priortoanyexternalleakoccurring.

SmartLayerisanoptionalfeaturenotincludedonall

designs.Thenameplatewillindicateifaunitisequipped

withSmartLayer.

II. I. 2. Function

SmartLayerfunctionsbyaccumulatingthermalstress

damagefasterthanotherpartsoftheBAHX.Whena

criticalthresholdofdamagehasaccumulated,itwillresult

inan“indicationleak”intheSmartLayer.Theindication

leakispartoftheintendedfunctionofSmartLayer,andwill

notcauseanyprocessfluidstoleaktoatmosphere.When

anindicationleakoccurs,theDCSwillsignaltheoperator

thataSmartLayeralarmhasbeenactivated.

II. I. 3. Smart Layer Hardware

Typicalhardwareincludesapressuretransmittertomonitorthe

SmartLayerpressure,apressurereliefdevicethatventseither

toatmosphereortoflare,andaconnectionforchargingand

drainingtheSmartLayers

II. I. 4. Smart Layer Field Installation

SmartLayerisshippedwithtemporaryshippingblinds.The

balanceoftheSmartLayercomponentssuppliedbyChart

(ifany)areshippedloosetoreducetheriskofdamage

duringtransport.AftertheBAHXhasbeeninstalled,remove

thetemporaryshippingblindsandinstalltheSmartLayer

components.FilltheSmartLayerwithnitrogentoacharge

pressureasdescribedbelow.SmartLayerisnotintendedto

beconnectedtoacontinuouslyregulatingnitrogensystem.

SoapbubbletestallSmartLayerconnectionstoensureleak

tightness.

II. I. 5. Smart Layer® Charge Pressure Setpoint

ChargeSmartLayer’snitrogenblankettoalevel

sufficienttoallowforproperoperationofthePSV.The

Chargepressuremustalsobesetbetweenthehighand

lowlevelalarmsdescribedbelow.

II. I. 6. Smart Layer® High-Level Alarm Setpoint

Setthehighlevelalarmbelowoperatingpressureofthe

stream(s)designatedintheSmartLayernotesontheGeneral

AssemblyDrawing.Ensurethereisameasurablepressure

differencebetweenthechargepressureandthehighlevelalarm.

II. I. 7. Smart Layer® Low-Level Alarm Setpoint

Thelow-levelalarmsetpointisslightlyaboveatmospheric

pressure.Thechargepressurewilldecreaseduringcooldown.

Ensurethispressuredecreasewillnottripthelowlevelalarm.

II.I.SMARTLAYER®

FAILURETOINSTALLTHESMARTLAYER

PRESSURERELIEFVALVEMAYRESULTIN

OVERPRESSURIZATIONOFTHESMART

LAYERWHICHMAYRESULTINSERIOUS

BODILYINJURYORDEATHANDPROPERTY

DAMAGEASWELLASIRREPARABLE

DAMAGETOTHECHARTEQUIPMENT

ANDTHEVOIDINGOFANYWARRANTIES


29

II. INSTALLATION

JANUARY 2021

II. I. 8. DCS Integration

Thepressuretransmittershouldbeconnectedtothe

plantDCStorecordandmonitortheSmartLayer

pressure.Pressureshouldberecorded(typicallyat1

minuteintervals)toaidinrootcauseanalysisinthe

eventofaSmartLayeralarm.

II. I. 9. Smart Layer® Alarm

TheDCSshouldbeconfiguredtoalarmtheoperatorif

theSmartLayerpressuredropsbeloworrisesabove

theAlarmsetpoints.ASmartLayeralarmistriggered

byanindicationleakinSmartLayerandsignifiesone

ormorestresscrackshaveoccurredintheBAHX.

Thisismostlikelythermalfatiguedamagecausedby

operationoutsideoftheIOMguidelines.ContactChart

forguidanceifaSmartLayeralarmisreceived.

II.I.SMARTLAYER®

30

II. INSTALLATION

JANUARY 2021

II.I.SMARTLAYER®

High Level AlarmAhighlevelalarmindicates

communicationbetweentheSmartLayer

andtheadjacentprocessstream(s).This

ismostlikelyduetoapartingsheetcrack.

Low Level Alarm

Alowlevelalarmindicates

communicationbetweenthe

SmartLayerandtheatmosphere.This

ismostlikelydueacapsheetcrack,

butmayalsobearesultofanon-stress

relatedleakthroughagasket,fitting,or

instrument.

Maintenance

TheSmartLayerpressurereliefdevice

andpressuretransmittershouldbe

includedintheplantmaintenance

program.

Priortoshippingfromthefactory,the

SmartLayerisleaktestedtoensurea

leaktightnesssufficienttocontainthe

SmartLayerchargepressure.After

installationinthefield,gasketdegradation

ordifferentialthermalexpansionmay

resultinapersistentleakfromSmart

Layertoatmospherethatisnotindicative

ofthermalstressdamage.Ifthisisthe

case,theSmartLayermayberecharged

periodicallytomaintainfunction.Monitor

theleakrateforchangesthatmay

indicatethermalstresscracking.

OPERATIONALTOP END

®

®

31

II. INSTALLATION

FIGUREXVSmart Layer® Examples

JANUARY 2021 32

III. TESTING AND OPERATION

A.FieldProofTesting

B.FoulingandCorrosionProtection

C.Startup,Operation,andShutDown

D.OperatingRecords

BRANDARCHITECTURE

JANUARY 2021


III. A. FIELD PROOF TESTING

III. A. Field Proof Testing

Mostcodesrequireapressuretestofthepiping

systemaftertheBAHXorassemblyisinstalled.

Apneumatictestismostoftenperformed.

Onlyclean,drygasesshouldbeusedforpneumatic

proofandsubsequentleaktesting.Water,oranyfluid

thatmayfreezeunderoperatingconditions,shouldnot

beusedinanytestingorcleaningoftheChartBAHX

asitisextremelydifficulttodrytheBAHXinthefield.

TrappedwatercanfreezeintheBAHXmatrixand

develophydraulicpressuressufficienttorupturethe

internalsoftheBAHXwithoutanyexternalevidence.

IfwaterisaccidentallyintroducedintotheBAHX,see

SectionIV.C.1.fordryingprocedures.InSectionIV.

B.,severalpracticalfieldtestsarerecommendedfor

determiningleaks.

Thepneumaticprooftestpressuremustcomply

withNationalBoardInspectionCoderequirements

or,ifapplicable,internationalpressurevesselcode

inspectionrequirementsandmustnotexceed1.1

timesthemaximumworkingpressurespecifiedonthe

Chartnameplate.

33

OVERPRESSURIZATIONOFTHEBAHX

COULD RESULT IN A RUPTURE OF

THEBAHXWHICHMAYRESULTIN






EQUIPMENT.

INTRODUCTIONOFWATERTOANY

BAHXEXPOSEDTOMERCURY

CONTAMINATIONCANRESULTIN

ACCELERATED CORROSION AND CAN

CAUSEIRREPARABLEDAMAGEAND

POTENTIAL CATASTROPIC FAILURE AND

EXPOSEPERSONNELTOHAZARDOUS

ANDUNSAFEWORKINGCONDITIONS.

JANUARY 2021


III. B. FOULING AND CORROSION PROTECTION

34

III. B. Fouling and Corrosion Protection

BAHXarecapableofhandlingawidevarietyoffluids.

Fluidsshouldbeclean,dry,andnon-corrosiveto

aluminum.Fluidscontainingparticulatematter,waxy

components,orcorrosiveelementsshouldnotbe

usedintheBAHX.

III. B. 1. Filtering

Thepresenceofparticulatesintheprocessstreams

maynotonlyleadtoBAHXpluggingandfouling,but

mayalsocauseerosioninthehighvelocityareasof

theBAHX.FoulingoftheBAHXcanbedetectedby

agradualorsuddenincreaseinpressuredropanda

lossofheattransferperformance.

AllconnectingpipelinescarryingBAHXfluidsshould

bethoroughlycleanedofallpipescale,dirt,sand,and

otherdebrisbeforeplacingtheBAHXinservice.

Allstreamsshouldbefilteredwitha177micron

(80MeshTylerStandard)screenorfiner,directly

upstreamoftheBAHX,BAHXassemblyorcoldbox.

Thefiltersshouldremaininplaceatalltimeswhilethe

BAHXisoperating.Theusershouldconsideradual

filtersystemwithsufficientvalvingtoallowafiltertobe

changedwithoutshuttingdown.Heavyduty,cleanable

filtersorstrainersarerecommended.

III. B. 2. Hydrate Suppression (Methanol Injection)

Duringstartup,upset,orevennormaloperating

conditions,thepresenceofhydratesorheavy

hydrocarbonsinthefeedorotherstreamsmay

freezeintheBAHXatoperatingtemperatures.These

hydratesorheavyhydrocarbonsmayeventuallyblock

someorallofthelayersintheBAHX.

FIGUREXVITypical methanol sparge system top view

(warm end)

Methanol

Sparge pipe

Feed gas

0.125 inches (3 mm) diameter methanol injection holes spaced 0.5 inches (13 mm) apart (extra drain holes provided on opposite side of sparge pipe)

JANUARY 2021


III. B. FOULING AND CORROSION PROTECTION

Whencompleteshutdownforderimingisundesirable

(seeSectionIV.C.1.)methanolinjectioncanbeused

toremovehydratesduringoperationiftheoperating

temperatureiswarmerthan-170°F(-112.2°C)(methanol

freezesatapproximately-170°F).Thismethodofhydrate

suppressioninvolvesinjectingmethanolintotheprocess

fluidupstreamoftheChartBAHX.Analuminumsparge

pipeinjectorcanbeprovidedforthispurposeinsidethe

headeroftheChartBAHX(seeFigureXVI).Methanolis

injectedintotheincomingfeedgasviathisspargepipe.

ThefeedgasthencarriesthemethanolintotheBAHX.

Ifamethanolinjectionspargesystemisnotusedforan

extendedperiodoftime,themethanolshouldbepurged

fromthepipingtoeliminatethepotentialformethanol

corrosion.Thiscanbeaccomplishedbyblowingdryair

ornitrogenthroughthemethanolpiping.Drainholes

ontheundersideofthespargepipeareprovidedfor

drainingpurposes.

Ifhydratecontaminationisanongoingproblem,any

upstreamequipmentwherewatercouldentertheBAHX

streamshouldbeinspectedforleaks.

III. B. 3. Corrosion Protection

TraceimpuritiesofH2S,NH2,CO2,SO2,NO2,CO,CIand

otheracid-forminggasesmaycausecorrosionwhen

liquidwaterispresentinthestream.Additionally,certain

wateraciditylevelscancausecorrosionofaluminum.

Toavoidcorrosion,thepHlevelofthewatercondensate

shouldbebetween5and7.

Carefullyguardagainsttheingressofwatervaporor

liquid,eitherduringcommissioningorsimilarplantevents

wheretheBAHXisvulnerabletowateringress(for

example,duringcorerepairinvolvingremovalofpiping

totheBAHX),orbyprocessfluidscontainingwater.If

allowedtofreeze,accumulatedwaterintrappedareasof

theBAHXcanstructurallydamagetheinternalsof

theBAHX.

Externalsurfacecorrosioncanbeavoidedbykeeping

theexternalsoftheBAHXunderadryenvironment

duringinstallationandoperation.Suchprecautionswill

eliminatethepotentialforintergranularcorrosionattack

orstresscorrosioncrackingoftheBAHXcomponents.

Undercertainconditions,mercurycancorrode

aluminumandthereforecautionmustbeusedwhen

handlingprocessfluidscontainingmercury.However,

ChartBAHXhavebeensuccessfullyusedwithfluids

containingmercuryprovidedtheproperequipment

designandoperatingproceduresareimplemented.

Ifmercuryissuspectedoranticipated:

•BAHXshouldnotbeexposedtoprocessfluids

containingmercuryconcentrationsgreaterthan0.1

μg/Nm3.Abovethislimit,mercuryguardbedsshould

beinstalledandmercurytolerantfeaturesshouldbe

consideredinthedesignoftheexchanger.

•Below0.1μg/Nm3,purchasersshouldconsiderusing

exchangerswithmercurytolerantfeaturesandmercury

guardbedsbecausethesamegasfieldcansometimes

containlargevariationsinmercurylevelsovertime.

35

JANUARY 2021


III.C.STARTUP,OPERATION,ANDSHUTDOWN

36

III. C. Startup, Operation, and Shut Down

ChartBAHXcanbeexpectedtoprovidemanyyears

ofusefullifewhenoperatedinstrictaccordancewith

theinstructions,practices,andproceduresoutlined

inthismanual.Therangeoflifecanvarydepending

ontheprocessdesign,howdemandingtheoperating

conditionsare,andotherfactors.Atypicalusefullifeis

20yearsormore.

III. C. 1.

Priortostartup,purgeanddryoutprocedures

mustbecompletedtoremovemoistureandheavy

hydrocarbonswhichmayfreezeatcryogenic

operatingtemperatures.Athoroughdryoutmustbe

carriedoutatthecommissioningandafterevery

subsequentshutdownwheremoisturemayreach

thecryogenicequipment.Awarm(70to100°F)(21

to38°C)drygasmustbeusedtoachieveadequate

dryness.Alldeadlegsinthepipingmustbedrained

andpurged.

FAILURETOOPERATEWITHINTHE

GUIDELINESMAYRESULTINSERIOUS

BODILYINJURYORDEATHAND

PROPERTYDAMAGEASWELLAS




EQUIPMENT.

ALLOPERATINGCONDITIONSMUST

BEWITHINTHESPECIFIEDCHART

NAMEPLATELIMITSANDTHECHART

SPECIFICATIONSFORTHEBAHXBEING

OPERATED.THEMAXIMUMWORKING

PRESSUREANDTEMPERATURESARE

SHOWNONTHECHARTNAMEPLATEAND

THECHARTDRAWING(SEEFIGUREIII).

THEBAHXMUSTBEOPERATEDAT

PRESSURESTHATDONOTEXCEED

THEMAXIMUMWORKINGPRESSURE

FOREACHSTREAMONTHECHART

NAMEPLATE.THEBAHXMUSTBE

OPERATEDATTEMPERATURESWITHIN

THELIMITSOFTHECHARTNAMEPLATE

WORKINGTEMPERATURES.

JANUARY 2021



III. C. 2.

Appropriatepressurereliefvalveswithsettingsbelow

theChartnameplatemaximumworkingpressures

mustbeprovidedbytheuser.

III. C. 3.

Aswithanypressurecontainingequipment,stresses

ineachcomponentofaBAHXmustbemaintained

withinallowablelimitsduringoperation.Pressure

loads,externallyappliedloads(e.g.pipingforcesand

moments),andthermallyinducedloadseachproduce

stressinthecomponents.Theresultantstressfrom

theseloadingsmustbecontrolledwithinallowable

limitstopreventcomponentdamageorfailure.

LimitpressureandexternalloadsintheBAHXto

thosespecifiedbyChart.

Chartoffersthefollowingguidelinestominimize

thermalfatigue.

1.Limitthetemperaturedifferencebetweenthe

streamsatanypointalongtheexchangerlengthto

50°F(28°C)(SeeFigureXVII).

2.Ifastreamtemperaturedifferenceatintroduction

exceeds50°F(28°C),introducetheflowslowly

(crackthevalve)untilthestreamtemperature

differenceiswithin50°F(28°C)andthenslowly

ramptheflowratetofullflow.

3.Forfrequentevents(whatcouldbelabeledsteady

stateflow)limitthecyclicstreamtemperature

fluctuationsto1.8°F(1°C).

4.Forinfrequenteventslikestartupandshutdown,

limitthestreaminletandoutlettemperaturerates

ofchangetolessthan108°F/hr(60°C/hr)with

allowanceupto3.8°F/min(2°C/min).

37

EXCEEDINGANYOFTHEMAXIMUM

WORKINGPRESSURESOR

TEMPERATURESSPECIFIEDONTHE

CHARTNAMEPLATECOULDRESULTIN

ARUPTUREOFTHEBAHXWHICHMAY






EQUIPMENT.

FIGUREXVIITemperature Difference Recommendations

Warmendmax

stream-to-stream

andstream-to-metal

temperaturedifference

<50°F(28°C)

Maxtemperature

difference<50°F

(28°C)

Coldendmax

temperaturedifference

<50°F(28°C)

JANUARY 2021



38

Notethatalltemperatureratesofchangeshouldbe

calculatedusingthetimeintervalspecifiedintherate

ofchangetimeunit,i.e.useoneminuteintervalswhen

calculatingtemperatureratesofchangeagainstrates

ofchangeperminuteanduseonehourintervalswhen

comparingagainstratesofchangeperhour.Donotuse

instantaneousratesofchangecalculations.Forexample

ifastreamtemperaturechangedby0.5°Cin3seconds

(aninstantaneousrateofchangeof10°C/min)butthen

onlychangedbyatotalof1°Coveraone-minuteinterval,

thetemperaturerateofchangeis1°C/min.

Iftheflowinonestreamstopssuddenly,oftenthe

recommendedcourseofactionistoimmediatelystopthe

flowofallotherstreamstoavoidarapidwarm-uporcool-

down.Thisshouldbeevaluatedbythesystemdesigner

/operatoronacase-by-casebasisforimportance(e.g.,

stoppingastreamwithinsignificantcontributiontothe

overallheatexchangemightnotbecauseforstopping

flowofallotherstreams).

III. C. 4.

Theguidelinesabovereferencestreamtemperatures

sincestreamtemperaturesarereadilyavailabletoplant

operations.However,theseguidelinesweredeveloped

forlocalmetaltemperaturedifferencesandlocalmetal

temperatureratesofchange.Thermalstressarisesfrom

localmetaltemperaturedifferencesinBAHXcomponents

thatarecloseandrigidlyattachedinalldirections.

However,localmetaltemperaturedifferencesarenot

readilyavailablenoreasilymeasured.Commercially

availablesoftwaretoolscalculateadjacentparting

sheetwalltemperatures;onecansubstituteadjacent

partingsheettemperaturesforstreamtemperaturesin

theguideline.Inmostcases,aproperlydesignedheat

exchangerwillhavemuchloweradjacentpartingsheet

walltemperaturedifferencesthanstreamtemperature

differences.

Fatigueisdefinedasrepeatedstressesresultingin

fracture.AstandardtoolinfatigueistheS-Ncurve,

stressversusthenumberofcycles.Fatigueisinfluenced

byboththemagnitudeofthestressandthenumberof

occurrencesofthestress.Anassumptionintheguideline

iswhentheguidelinesarefollowed,onewouldexpectto

achieveuninterruptedheatexchangeroperationwithouta

fracture(leak)fortheexpectedlifeoftheheatexchanger.

Itisalsowhythetemperaturerateofchangeof2°C/

minuteisallowedforinfrequenteventslikestartupand

shutdownsincetheassumptionisthenumberofevents

isnotfrequent.Butforsteadystateoperationwhere

thenumberofeventsisgreater,therateoftemperature

changeisreducedto1°C/minute.

Formanysituations,exceedingtheguidelineswill

notproducefractures.However,asthemagnitudeof

exceedingtheguidelinesincreasesandasthenumber

ofoccurrencesincrease,theprobabilitytoproduce

fracturesincrease.Highlyspecializedsoftwaretools

arerequiredtoassesstheimpactofthermaleventsand

thecalculatednumberofoccurrencesbeforefracture

occurs.Thecalculatednumberofoccurrenceshave

arangesincenotwoidenticallymanufacturedheat

exchangerswouldfractureattheexactsamemagnitude

ofloadsandoccurrences.Thecalculationsarelimited

toafewselectedexamplesofexcursions.Thismeans

thatpredictingexactlywhenaBAHXwillfailortheexact

lifetimeleftintheunitisnotpossible.Thecalculated

numberofcyclestofatigueshouldbeviewedasan

estimatewitharange.

JANUARY 2021



III. C. 5.

Thehighthermalconductivityofaluminumhelpsto

minimizetemperaturedifferencesinBAHX,butlarge

localmetaltemperaturedifferencescanarisefrom

operationalinstabilities,changesinoperatingconditions,

ortransienteventsassociatedwithstartup,shutdown,

orupsetconditions.Operationalinstabilitiescanresult

fromunstableboilingwithintheBAHXorfromexternally

producedhydraulicfluctuationscausedbyimproperly

designedpipingsystemsorinadequatecontrolsystems.

Detrimentaltransienteventsassociatedwithstartup,

shutdown,orupsetconditionscanresultfromimproper

proceduresorinadequatecontrolsystems.

Topreventdamagefromtheseconditionsthefollowing

isrecommended:

•Reviewplantoperationstoidentifyoperatingconditions

thathavethepotentialtocreatehighthermalstressand

developprocedurestominimizetheimpactofthese

events.Typicalconditionscausinghighthermalstress

includecoldandwarmrestarts.Acoldrestartisdefined

asrestartingflowwhiletheBAHXiscoldfromprior

operations.Awarmrestartisrestartingflowafterthe

BAHXhasbeenwarmedtonearambientconditions.

•Flowcontrolisparticularlycriticalwhenintroducing

liquidortwo-phasestreams.Liquidandtwo-phase

fluidshavealargecapacitytorapidlychangemetal

temperatureintheBAHX.Flowcontrolislesscritical

whenintroducingandsensiblyheatingorcooling

vaporsduetothelimitedcapacityofthevaporto

rapidlychangemetaltemperatureintheBAHX.

Forthisreason,coolingorwarmingoftheBAHXto

orfromoperatingconditionswithavaporpriorto

introducingaliquidortwo-phasestreamishighly

recommended.

•ContinuouslymonitortheBAHXinapplications

wherethefluidmustbetotallyvaporizedinthe

BAHXandthereispotentialforunstableboiling.

Adjusttheprocessconditions(flow,temperature,

pressure)whennecessarytoavoidthiscondition

(e.g.,increasingflowoftenhelpstostabilize

thiscondition).Therelativelylargetemperature

differencesassociatedwithunstableboilingalong

withsurgingofthevaporizingfluidwithintheBAHX

cancausethermallyinducedfatiguefailure.

•Designandoperatetheplantequipmentandpiping

connectedtotheBAHXtopreventflowinstabilities

(forexample,intermittentsluggingofliquidtothe

BAHX).Thisisextremelyimportantwithboiling

streams.

•Maintaincleanlinessofallstreamsfeedingthe

BAHXatalltimesduringoperation,andproperly

protecttheBAHXfromcontaminationwhennotin

use.Contaminationfromsoliddebris,foulants,and

materialfreezingoutofthestreamsinternaltothe

BAHXmayleadtostreammaldistributionwithinthe

BAHX.Internalmetaltemperaturedifferencescan

increasewithmaldistributionandmayhavethesame

detrimentaleffectasstreamtemperaturedifferences.

Theinternalmetaltemperaturedifferencesareoften

impossibletoobserve,sopreventingcontamination

andmaldistributionintheBAHXiscriticalto

eliminatethispossibility.

39

JANUARY 2021


III.C.STARTUP,OPERATION,ANDSHUTDOWN,III. D. OPERATING RECORDS•Whiletheguidelinescanbeusefultodetermine

plantcontrolalarmsettings,theguidelinesarenot

recommendedplantalarmsettings.Theprocess

licensorshouldbeconsultedonalarmsettings.

Whileexceedingtheguidelinesisnotrecommended

itisnotbeneficialtoinstallnuisancealarmsthat

maybeturnedoffbyoperations.Someoperations

benefitfromtemperaturerateofchangeindicators

ratherthanalarms.

Ininstanceswhereitisnotpossibletoadheretothese

guidelines,contactCharttodiscussyourspecific

application.

III. D. Operating Records

OperatingoutsidetheguidelinesstatedinSection

III.C.mayleadtoexcessivethermalstresswhich

couldresultinfailureofBAHXcomponentsorleadto

ruptureevenwhenoperatingwithinthedesignlimits

onthenameplate.Anoperatinglogshouldbekeptto

recordnormaloperationprocedures,anyplantupsets,

shutdowns,andanyotheroperatingconditions.It

iscriticaltheoperatingdatabemonitoredtoensure

operationiswithintheIOMstatedguidelines.

Giventheircriticalityindeterminingcause,resolution

andresponsibilityforanyissueswiththeBAHX,

theownershouldmaintainadequateinstallation,

operation,andmaintenancerecordstoensure

compliancewiththeguidelines(seeSectionII.H.and

III.C.).

40

JANUARY 2021

IV. MAINTENANCE

41

IV. MAINTENANCE A.WarningSigns

B.FieldLeakTesting

C.Cleaning

D.Mothballing

E.RepairandService

F.Disposal

BRANDARCHITECTURE

JANUARY 2021

IV. MAINTENANCE

IV. A. WARNING SIGNS

42

IV. A. Warning Signs

Potentialwarningsignswhereequipmentrequires

inspectionorrepairpriortocontinuedoperation:

•Operatingdataindicatesequipmentisbeing

subjectedtooperatingconditionsexceeding

guidelinesinSectionIII.C.

•Measurementofstreamcompositionsindicating

crosscontaminationhasdeveloped

•OtherBAHXatthefacilityhavedevelopedleaksor

failures

•Frostspotsoncoldboxwallorinsulationsheeting

•LiquiddrainagefromBAHXorfromunderinsulation

•Indicationsfromgasdetectionsensors

•VentingfromtheBAHX

•SmartLayer®Alarm

IfanyofthesewarningsignsarepresentcontactChart.

PRIORTOTHEINSPECTION,TESTING,

ORREPAIRINGOFANYUNIT,EITHERIN

SERVICEORRECENTLYREMOVEDFROM

OPERATION,THESYSTEMMUSTBE

SAFETYCHECKEDANDCLEAREDPRIOR

TOTHEADMITTANCEOFPERSONNEL

FORANYSERVICEFUNCTION.

JANUARY 2021

IV. MAINTENANCE

IV.B.FIELDLEAKTESTING

43

IV. B. Field Leak Testing

InternalleaksinaBAHXaregenerallyindicatedbya

changeofpurityinanyofthefluidstreams.External

leakscanbedeterminedbysight,smell,audible

soundsofleakingfluid,externalgasmonitoring

equipment,orlocalizedcoldspotsappearingonthe

externalinsulationorcoldboxcasing.Externalleaks

inBAHXmountedinacoldboxarealsogenerally

indicatedbyexcessiveventingthroughthebreather

valveorcoldspotsonthecoldboxcasing.Breather

valvegasdetectionmethodsarewithinthescopeof

operator.

CAUTIONMUSTBEEXERCISEDWITH

REGARDTOTHEFLAMMABILITY,

TOXICITY,EXPLOSIONPOTENTIAL,OR

PRESSUREPOTENTIALOFANYFLUIDOR

STREAMWITHINORINTHEPROXIMITY

OFTHEBAHX.ALLPERSONNELINVOLVED

WITHINSTALLATIONORMAINTENANCE

OFCOLDBOXASSEMBLIESMUSTBE

MADEAWAREOFTHEDANGERSOF

SUFFOCATION,ESPECIALLYINNITROGEN

FILLED CONTAINERS.

DONOTEXCEEDTHEMAXIMUM

WORKINGPRESSURESPECIFIED


NAMEPLATE.OVER–PRESSURIZATION








EQUIPMENT.

FAILURETOOBSERVEPROPERSAFETY

PRECAUTIONSINTHISREGARDCOULD

RESULTINEQUIPMENTRUPTURE,FIRES,

TOXICGASORFLUIDESCAPE,

SUFFOCATINGGASATMOSPHERESOR

OTHERACCIDENTSWHICHMAYRESULT






EQUIPMENT.

JANUARY 2021

IV. MAINTENANCE


44

ItiscriticalthatanyleakingBAHXberepaired

immediatelyandthatthecauseoftheleakbeidentified

andcorrected.Prolongedoperationmayleadtofurther

damageoftheunitwhenthecauseisduetocyclical

thermalormechanicalfatigue.Prolongedoperationof

anexternallyleakingBAHXinstalledinaperliteinsulated

coldboxmayleadtofurtherdamageandincreased

leakageduetoperliteerosionoftheBAHXmetal.

Commonfieldtestsusedfordeterminingleaksare

describedbelow.

IV. B. 1. Pressure Decay Test

Pressurizeastreamwithdryairornitrogen.

Astreamisconsideredleakfreeifitmaintainsthe

originalpressureforovereighthourswithcorrectionfor

temperaturechanges.Keepinmindthatthepressure

decaytimetestisafunctionnotonlyoftheleaksizebut

thetestpressure,temperature,andBAHXsize,

aswell.

ForlargeBAHXandassemblieswithlargeinternal

volumes,and/orforleaktestsatlowerpressures(less

than50psig[3.4barg]),leaksmaytakelongerthaneight

hourstodetect,dependinguponthesizeoftheleak.

TheBAHXtemperatureshouldbethesameatthetwo

pressurecheckssinceanychangeintemperaturewill

changetheairpressureintheBAHX.Ifitisimpractical

tomakethetwopressurecheckswhenthetemperatures

arethesame,thefollowingpressurecorrectioncanbe

used:

P1 T2

P2 = ---------

T1

Where

P =AbsolutePressure

T =AbsoluteTemperature(°RorK)

1 =InitialReading

2 =FinalReading

Forindividualrecommendations,contactChart.

IV. B. 2. Air-Soap Test (External Leaks)

Ifthestreamdoesnotmaintaintheoriginalpressure

duringthedecaytest,above,determinewhatkindof

leakexistsbyrepressurizingthestreamandchecking

theexterioroftheBAHXwithasoapbubbletest.Ifthe

BAHXpassesthistest,theleakisinternal.

DONOTEXCEEDTHEMAXIMUM

WORKINGPRESSURESPECIFIED


NAMEPLATE.OVER–PRESSURIZATION








EQUIPMENT.

JANUARY 2021

IV. MAINTENANCE


45

IV. B. 3. Internal Leak Testing

Themethodusedtolocatetheindividuallayerleak

involvesasoaptestovereachportofthestreamin

questionwhileairornitrogenpressureisappliedto

theotherstream.Thisoperationnormallyinvolves

removaloftheheaderandshouldonlybeperformed

byChartauthorizedservicepersonnel.

JANUARY 2021

IV. MAINTENANCE

IV. C. CLEANING

46

IV. C. Cleaning

IftheBAHXisfouledorplugged,severaloptionsare

availabletotheuserforcleaningtheBAHX.When

thefoulingissolidandcoatsthefinsintheBAHX,

theBAHXshouldbecleanedbychemicalremoval

throughaseriesofderiming,backflushing,anddrying

procedures(seeSectionIV.C.1.).

IftheBAHXisfouledorpluggedbyhydratesand/

orice,awarmderimeisrequiredandconsideration

giventoothermethodsforhydratesuppression(see

SectionIII.B.2.).

IftheBAHXisfouledorpluggedbyparticulatematter,

backpuffingproceduresareusuallysuccessfulin

cleaningtheBAHX(seeSectionIV.C.2.).

Thepipingandinstrumentationdiagramsshould

becarefullyreviewedattheplantdesignphaseto

ensureadequatenozzlesandvalvesonthepiping

areavailabletocarryoutanyoftheabovecleaning

proceduresthatareanticipated.

IV. C. 1. Deriming, Back Flushing, and Drying

Derimingandbackflushinginvolvestheuseof

heatand/orsolventstoremovehydrates,heavy

hydrocarbons,waxymaterials,compressoroils,or

othersolublematterwhichfreezeorcollectinthe

BAHX.Thepresenceofthesematerialsisdetectedby

anincreaseinthestreampressuredropand/orloss

ofheattransferperformance.Asageneralguideline,

ifthemeasuredpressuredropbeginstoexceed2

to3timesthedesignpressuredrop,Chartwould

recommendcleaningeffortsbeundertaken.

Whensystemsforinjectingmethanolduringoperation

havenotbeenprovided(seeSectionIII.B.2.),shut

downandpurgetheBAHXandallowittowarmand

defrostitselfbynaturalheatleakorbyanapproved

derimeprocedure.Normally,thecombinationof

warmingandbackflushingwithasolventrinsesuch

astrichloroethane,toluene,propanol,ormethanolis

successfulforthispurpose.

Priortostartup,purgeanddryouttheBAHXin

accordancewithIII.C.1.

Ifawaterbasedsolventisusedtoderimeorback

flush,orifwateraccidentallygetsintroducedintothe

BAHX,theBAHXmustbecompletelydriedbefore

returningtoserviceinordertopreventpluggingor

rupturecausedbyfreezing.Usedryairornitrogenor

otherdrygasasthedryingmedium.

IV. C. 1. a.

Thederime,backflushing,ordryingtemperature

shouldnotexceed150°F(65°C),unlessthe

maximumworkingtemperatureontheChart

nameplateishigher.Donotexceedthemaximum

workingtemperaturespecifiedontheChart

nameplate.

IV. C. 1. b.

Thederime,backflushingordryingmediamustbe

non-corrosivetoaluminum.Alwaysusecleanfluids.

Ifanyvessels,piping,ortemporarypipesections

areusedduringthecleaning,itisimportanttoclean

themofpipescale,dirt,weldslag,oranyotherforeign

materialwhichcouldenterandplugtheBAHX.

JANUARY 2021

IV. MAINTENANCE

IV. C. CLEANING

47

IV. C. 1. c.

Whenliquidsolventsareusedforpurposesof

derimingorbackflushingtheBAHX,thenozzlefluid

velocityshouldnotexceed10feet(3meters)per

secondtopreventerosioninsidetheBAHX.Liquid

solventsoranycleaningfluidsshouldalwaysbe

circulatedthroughtheBAHXinthereversedirectionof

normaloperatingflow.

IV. C. 1. d.

Cleaningsolventsshouldalwaysbechosenwith

regardtothesuspectedfoulingagent.Ifthefouling

agentisunknown,asampleofitshouldbechemically

analyzedtodetermineitscomposition.

Ifanyspecialproceduresarerequiredtomeet

uncommonderime,backflushing,ordryingconditions,

contactChartforfurtherevaluation.

IV. C. 2. Back Puffing

Whenproperprecautionsaretakenregardingfiltering,

manyyearsofcleanservicecanbeexpected.

However,whenforeignmaterial(pipescale,perlite,

desiccant,molesieve,etc.)isintroducedintothe

BAHXitself,byaccidentormisoperation,backpuffing

canbeaneffectivemethodforremovingentrained

particulates.

Sinceparticulatesnormallycauseblockagesinthe

BAHXattheinletportsanddistributors,puffinginthe

reversedirectionofnormaloperatingflowisrequired

topreventpushingtheparticulatesfartherintothe

BAHX.Thebackpuffingprocedureinvolvesattaching

arupturedisktotheinletnozzleorflangeoftheBAHX

streamtobebackpuffed.

ONLYCLEANINGSOLVENTSTHATARE

NON-CORROSIVETOALUMINUMMUSTBE

USED. CORROSIVE CLEANING SOLVENTS

CANWEAKENPRESSURERETAINING

STRUCTURESWHICHMAYRESULTIN






EQUIPMENT.

INTRODUCTIONOFWATER/AQUAEOUS

CLEANINGSOLUTIONSTOANYBAHX

EXPOSEDTOMERCURYCONTAMINATION

CAN RESULT IN ACCELERATED

CORROSION AND CAN CAUSE

IRREPARABLEDAMAGEANDPOTENTIAL

CATASTROPICFAILUREANDEXPOSE

PERSONNELTOHAZARDOUSAND

UNSAFEWORKINGCONDITIONS.

JANUARY 2021

IV. MAINTENANCE

IV. C. CLEANING

48

Thepluggedstreamisslowlyfilledwithdryairor

nitrogenuntiltherupturediskbursts.Thesudden

releaseofgasoutoftheBAHXwillhelpdislodge

particulatematter.Thisbackpuffingprocedureshould

berepeatedfivetotentimes,oruntiltheamount

ofparticulateremovedbecomesminimalandthe

dischargecloudisclear.

ContactChartforguidanceonthemaximumallowed

backpuffingpressure.Ifthemaximumallowable

pressureisreachedandtherupturediskhasnot

burst,thestreamshouldbedepressurizedandanew

rupturediskinstalled.

Abackpuffingeventdoesnotreducethelifeof

theequipment.However,remainingresidueinthe

equipmenthasthepotentialtodistortthethermal

profileandinducethermalstress,whichmayreduce

thelifeoftheequipment.

EXTREMECAUTIONMUSTBEEXERCISED

SOASNOTTOEXCEEDTHEMAXIMUM

WORKINGPRESSUREOFTHESTREAM

ONTHECHARTNAMEPLATE,OR100PSIG,

WHICHEVERISLESS.

FAILURETOLIMITPRESSURIZATION

TOTHESELIMITSCOULDRESULTINA

RUPTUREOFTHEBAHXWHICHMAY






EQUIPMENT.

ITISTHEUSER’SRESPONSIBILITYTO

TAKETHEAPPROPRIATESAFETY

PRECAUTIONSREGARDINGPERSONNEL,

CLEARINGTHETESTAREA,ANDTHE

SUITABILITYOFTHESUPPORTSAND

BRACINGTOWITHSTANDTHEREACTION

FORCESDEVELOPEDWHENTHE

RUPTUREDISKBURSTS.

EXTREMECAUTIONMUSTBEEXERCISED

ASTHERUPTUREOFTHEDISKAND

THERELEASEOFGASCANRESULTINA

RAPIDDISCHARGEOFGASANDFLYING

DEBRISWHICHMAYRESULTINSERIOUS

BODILYINJURYORDEATHANDPROPERTY

DAMAGEASWELLASIRREPARABLE

DAMAGETOTHECHARTEQUIPMENT

ANDTHEVOIDINGOFANYWARRANTIES


JANUARY 2021

IV. MAINTENANCE

IV.D.MOTHBALLING

49

IV. D. Mothballing

BAHXwhichhaveseenpriorserviceshouldbedried

andpressurizedpriortostorage.Aneighthouror

longerpurgewithdryairornitrogenhavingadew

pointlessthan32°F(0°C)isrecommendedtodry

theBAHX.

Followingthedryingoperation,eachstreamshouldbe

pressurizedwithdryairornitrogenwithadewpointof

lessthan-40°F(-40°C).Thislowdewpointis

recommendedtopreventgalvaniccorrosioninthe

BAHXwhichcouldresultiftracesofrustorother

foreignmaterialshavegainedaccesstotheBAHX

duringoperation.Thedryairornitrogenpressure

shouldbe15psig(1barg)oronethirdthestream

designpressure,whicheverisless.

The15psig(1barg)pressurelevelshouldbechecked

periodicallytoassurethattherearenoleaksinthe

BAHX.Inaddition,thestoragerecommendationsin

SectionII.B.shouldalsobefollowed.

JANUARY 2021

IV. MAINTENANCE

IV.E.REPAIRANDSERVICE,IV.F.DISPOSAL

50

IV. E. Repair and Service

Ifaleakisdetected,Chartshouldbenotifiedforrepair

recommendations.Chartiswellqualifiedandstaffed

toperformfieldorfactoryserviceandrepaironthis

typeofBAHXequipment.

RefertotheNationalBoardNumberandtheChart

serialnumbershownontheASMEU-1datareport

formorunitnameplatewhencontactingChart.

AllASMErepairsmustbecertifiedbyan“R”

stampandmustbeinaccordancewiththeChart

QualityAssurancePolicy,theNationalBoard

InspectionCode,andtheASMECode,andanylocal

jurisdictionalrequirements.

RepairtotheBAHXshouldbemadeonlybyChart

authorizedpersonnel.TheChartwarrantywillbe

voidedifrepairsmadetotheChartBAHXduringthe

warrantyperiodaremadebyunauthorizedservice

personnel.

ImproperweldingontheBAHXblockcandamage

thebrazejoints.Repairsnotmadeinaccordancewith

ASMEprocedure,andidentifiedbythe“R”stampon

theChartnameplate,willinvalidatetheNationalBoard

registrationoftheBAHX.

IV. F. Disposal

WhendisposingofaBAHX,Chartencourages

recyclingwheneverpossible.Adrainedheatexchanger

mayhaveresidualcompoundsinsidefromprioruse.

Duetoaccumulationovertime,theresidualcompounds

maybepresentinmoreconcentratedamountsthan

experiencedintheproductstream.Ownersshouldbe

awarethattheirBAHXmayhaveresidualcompounds

ofsufficientquantitytoposeasafetyorenvironmental

hazard.Ownersshouldknowthecompositionof

theresidualcompoundsandconsiderthesafetyand

environmentalimpactsofthosecompoundsbefore

sendingtheirBAHXtoametalrecycler.Disposal

mustbeinaccordancewithallapplicablelawsand

regulations.

IMPROPERLYREPAIREDBAHXMAY

NOTBESUITABLETOWITHSTANDTHE

NAMEPLATEMAXIMUMWORKING

PRESSURE RATINGS.

PRESSURIZATIONOFANIMPROPERLY

REPAIREDBAHXCOULDRESULT

INARUPTUREOFTHEBAHXWHICHMAY






EQUIPMENT.





Chart incorporates the former Altec and Marston BAHX brands and consequently all rights to engineering and equipment produced by these companies.

“Core-in-Kettle” is a registered trademark of Chart Energy & Chemicals, Inc.



Nozzle

Header

Distributor fin

Parting sheet

Side barWear plate

Heat transfer fin

Support angle

Cap sheet

2JANUARY 2021









Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline























2191 Ward Avenue

La Crosse, WI 54601

Tel: 608-787-3333






Tel: 1-844-GTLS-911 (1-844-485-7911)



JANUARY 2021



JANUARY 2021


Documents

BAHXIOM.pdf - Chart Industries