TES E-102M engineering tie in

MUMBAI

INDIA

TOYO ENGINEERING INDIA LTD.

ENGINEERING SPECIFICATION

HEAT EXCHANGERS

TES

E-102M

ISSUED 16th Aug 06 PAGE 1 OF 36

3.1.3 Engg Spec for Heat exchanger.doc

C O N T E N T S PAGE

1. GENERAL 1.1 Scope 2 1.2 Codes, Standards and Regulations 2 1.3 Units 3 1.4 CONTRACTORs Drawings and Documents 3 1.5 VENDORs Drawings and Documents 4

2. DESIGN 2.1 Design Pressure 5 2.2 Design Temperature 5 2.3 Corrosion Allowances 5 2.4 Materials 6 2.5 Loading Conditions and Strength Calculation 6 2.6 Tolerances 7

3. DETAILED DESIGN 3.1 Shells and Channels 8 3.2 Tubes and Tube Bundles 8 3.3 Nozzles 9 3.4 Opening 10 3.5 Alloy Lining 11 3.6 Bolts, Nuts and Gaskets 11 3.7 Supports 12 3.8 Miscellaneous 12

4. FABRICATION 4.1 Plate Layout 13 4.2 Forming 13 4.3 Welding 13 4.4 Heat Treatment 14 4.5 Hardness 15 4.6 Miscellaneous 15

5. INSPECTION AND TESTS 15

6. NAMEPLATE, PAINTING AND MARKING 6.1 Nameplate 16 6.2 Painting 16 6.3 Marking 16

7. PACKING AND SHIPPING 7.1 General 16 7.2 Packing and Preparation for Shipping 16 7.3 Shipping 17

Appendix A Basic Design Requirements 18 Appendix B Inspection Requirements 22 Appendix C Special Design Code Reqirements 28 Appendix D Wind Load Calculation 29 Appendix E Requirements for Earthquake Design 30 Appendix F Requirements for Cathodic Protection 31 Appendix G Requirements for Hydrogen Service 36

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1. GENERAL

1.1 Scope

1.1.1 This specification together with the drawings or data sheets covers the requirements for the materials, design, fabrication, inspection, testing and supply of shell and tube heat exchangers including compressor intercoolers. This specification shall be read in conjunction with D-102M and requirements indicated in D-102M shall be applicable to relevant components of heat exchangers.

1.1.2 This specification does not apply, in general, to steam turbine condensers, double pipe heat exchangers, suction tank heaters or auxiliary heat exchangers for turbines, engines, pumps, compressors and other mechanical equipment which are normally designed under the manufacturers standard. However, compressor intercoolers and after coolers shall be covered by this specification.

When the application of this specification is required for such auxiliary heat exchangers, the heat exchangers shall be designed in accordance with the basic design requirements in Appendix A.

1.2 Codes, Standards and Regulations

1.2.1 Heat exchangers shall be designed, fabricated, inspected and tested in accordance with the requirements of the following codes, standards and regulations of latest edition.

(1) Applicable local regulations (2) ASME Boiler and Pressure Vessel Code Sec. VIII Div. 1 or Div.2, 2004 Edition with

2005 Addenda (Code stamping is not required unless otherwise specified.) (3) TEMA Standard, 1999 Edition.

1.2.2 Unless otherwise specified, TEMA Standard Class R shall generally be applied. TEMA Standard Class C may be applicable for exchangers in utility services with PMCs prior approval.

1.2.3 VENDOR shall be responsible for making all aspects of materials, design, fabrication, inspection and testing conform to the requirements of the specified codes, standards and local regulations.

1.2.4 Where there are conflicts between the requirements in the CONTRACTORs drawings / specifications and the specified codes/standards or local regulations, the order of precedence shall be as follows:

(1) Local regulations (2) LICENSERs data sheets (3) LICENSERs specifications (4) LICENSERs specific job requirements (5) PMCs specific job requirements (6) PMCs engineering specification (7) Codes and standards

In such a case, the CONTRACTOR/VENDOR shall promptly refer the conflicts to PMC in writing to obtaining PMCs instruction.

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1.3 Units

Unless otherwise specified, Metric units shall be applied as the measurement system for the drawings and documents to be submitted. However, nominal sizes of piping components shall be in accordance with inch system.

1.4 CONTRACTORs Drawings and Documents

1.4.1 The CONTRACTOR shall provide Engineering Drawing for each heat exchanger which contains such information as the shape, basic dimensions, estimated thickness and weight, design conditions, materials for primary parts, nozzle specifications, tube arrangement as required by VENDOR to accomplish his mechanical design of the heat exchanger. The stages of engineering drawings are as described in scope of work and are to be followed by the CONTRACTOR.

When sketches or data sheets are provided, VENDOR shall prepare Engineering Drawings covering the same contents as specified above. Such drawing may be used as VENDORs assembly drawings with necessary information that may be added.

1.4.2 Engineering Drawings will be issued in the following steps, and at each step additional information and/or revisions will be incorporated. VENDOR shall proceed with his work in accordance with the purpose of each issue. This is elaborated in detail in scope of work in specific job requirements.

(1) Preliminary or For Approval : Preliminary information on design conditions, basic dimensions, thickness for major parts and weight estimation are indicated.

(2) Approved for Design (AFD) : Almost all design information are settled and confirmed except nozzle locations. No further major revisions are expected.

(3) Approved for Construction (AFC) : Nozzle location is fixed and VENDOR can start the fabrication based on this issue.

The CONTRACTOR shall send these engineering drawings to PMC at every stage for approval/review as described in specific job requirements.

1.4.3 The CONTRACTOR/VENDOR shall use D-123M Vessel Standard which supplements the above drawing and determines the detail construction of heat exchangers. Applicable drawing numbers of Vessel Standard will be shown in each Engineering Drawing. The CONTRACTOR may add some additional drawings, if required. When LICENSERs drawings are provided for particular part, it shall supercede D-123M drawing. The CONTRACTOR shall list such drawing reference in engineering drawing.

When data sheets are provided, VENDOR shall confirm the CONTRACTOR the application of each drawing in Vessel Standard.

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1.5 VENDORs Drawings and Documents

1.5.1 VENDOR shall submit to the CONTRACTOR drawings and documents as called for in the CONTRACTORs requisition sheets. The CONTRACTOR in turn after their review shall send these drawings & documents to PMC for approval/review/information as the case may be. The details are given in the List of drawings/documents required from the CONTRACTOR after award of contract.

1.5.2 All drawings and documents shall give the name of OWNER (end user), PMCs work no., PMC Name and logo, the CONTRACTORs Work No., Item No. and service of the commodity.

1.5.3 Drawings shall be prepared to scale and in third angle projection.

1.5.4 Drawings shall contain:

(1) Title block (PMCs work no., PMC Name and logo, the CONTRACTORs Work No., Requisition No., Item No. and service of the commodity)

(2) Design Data (conforming to the CONTRACTORs drawings or data sheets) (3) Material list (material specifications and quantities for all parts including spare parts) (4) Nozzle list (conforming to the CONTRACTORs drawings or data sheets) (5) All weld seams, and weld and surface finish symbols (6) Detailed dimensions and thickness

1.5.5 Strength calculations shall cover:

(1) Code calculations for all pressure retaining parts including reinforcements for nozzle openings

(2) Structural calculations for internals, lifting lugs and transportation fittings (3) Stability check of heat exchanger and support for wind/seismic load (4) Stability check of heat exchanger and support at transportation, loading & unloading

and erection (5) Flow induced vibration of bundle when specified (6) Local stress analysis against external loading on nozzles

1.5.6 For heat exchangers fabricated and/or assembled at job site, VENDOR shall submit the instruction for the work.

1.5.7 The CONTRACTORs/PMCs Approved on VENDORs document means that VENDOR may proceed his work without re-submitting the documents unless further revisions are made. Approved as noted on VENDORs document means that VENDOR may proceed his work provided the notes are concurred by VENDOR. Re-submission of the revised documents are required for confirmation. Not approved on the document means that VENDOR may not proceed the work without re-submission of the corrected document for approval. The CONTRACTORs/PMCs approval for VENDORs drawings and documents shall not relieve VENDOR of his responsibility to meet all requirements of the purchase order.

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2. DESIGN

2.1 Design Pressure

2.1.1 Design pressure shall be as specified on the CONTRACTORs/PMCs drawing or data sheet.

2.1.2 When design pressure of F.V. (Full Vacuum) is specified, exchangers shall be designed to withstand for external pressure of 1.033 kg/cm2 (101.3 kPa).

2.1.3 Unless otherwise specified, exchangers normally subject to internal pressure shall be designed to withstand for external pressure of 0.175 kg/cm2 (17.2 kPa) at the ambient temperature (20 C).

2.1.4 Unless otherwise specified, parts in contact with both shell and tube side fluids such as tubes, tubesheets and floating heads shall be designed for the pressure on one side only or the combination of the pressure, whichever that requires the maximum material thickness for the part.

2.1.5 Maximum Allowable Working Pressure (MAWP) is the maximum gauge pressure at each side of a completed exchanger, which is obtained from the calculation for every element of the exchanger based on the used thickness under corroded condition. VENDOR shall calculate the MAWP of each exchanger.

2.2 Design Temperature

2.2.1 Design temperature shall be as specified on the CONTRACTORs/PMCs drawing or data sheet. Two kinds of design temperature, one for maximum design temperature (called as Design Temperature) and the other for minimum design temperature (called as Minimum Design Metal temperature = MDMT) are specified.

2.2.2 When operating temperature is 15 C and below, the design temperature shall be the minimum anticipated operating temperature.

2.2.3 When design temperature or MDMT cannot coincide with the maximum pressure, the corresponding design pressure shall be designated together with the temperature.

2.2.4 Exchanger parts in contact with two fluids having different temperatures shall be designed for both higher and lower design temperatures.

2.2.5 When the exchanger inside is insulated from high temperature fluid, the design temperature may be determined by heat transfer calculation.

2.3 Corrosion Allowances

2.3.1 The corrosion allowance for the shell and channel sides shall be as specified on the CONTRACTORs/PMCs drawing or data sheet.

2.3.2 The necessity of corrosion allowances for various heat exchanger parts shall be in accordance with applicable codes and standards.

2.3.3 No corrosion allowance is required for such parts not in contact with the inside fluid as outside surface of exchanger, support, anchor bolt and so on.

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2.3.4 Unless otherwise required by the governmental regulations, no corrosion allowance is added to tubes.

2.3.5 Corrosion allowance is not usually required for non-pressure parts such as tie-rods, spacers, baffles, support plates and pass partition plates.

2.3.6 When it is not practicable to provide corrosion allowance by increasing the thickness of base metal, a corrosion resistant material shall be used in solid, lining, cladding or weld overlay construction. Any change of these construction materials shall be referred to PMC for approval.

2.4 Materials

2.4.1 The materials for primary parts shall be as specified on the CONTRACTORs/PMCs drawing or data sheet.

2.4.2 Materials of the parts not specified on the CONTRACTORs/PMCs drawings, data sheet or Vessel Standard shall be decided by VENDOR and shall be submitted by showing them on the VENDORs drawings for the CONTRACTORs/PMCs approval.

2.4.3 VENDOR may propose the use of alternative materials. Such alternatives shall be clearly indicated on his proposal giving official material designation or the chemical composition and physical properties for such materials having only a trade or supplier designation, and shall be submitted for the CONTRACTORs/PMCs approval.

2.4.4 Gaskets, bolts and nuts for blind nozzles and manholes shall be as specified in the CONTRACTORs/PMCs drawing or data sheet.

2.5 Loading Conditions and Strength Calculation

2.5.1 The thickness indicated on the CONTRACTORs/PMCs drawings/data sheets are those proposed only and to be considered as minimum.

2.5.2 Lining, cladding and weld overlay thickness shall not be considered to contribute to the strength of pressure parts.

2.5.3 The following loading conditions shall be considered in designing heat exchangers including its support and anchor/setting bolts. (1) Operating condition The loadings shall include those from:

(a) internal or external design pressure (b) weight of exchangers and contents at operating condition (including static head of

liquids) (c) weight of insulation and fire proofing (d) weight of combined equipment, as specified by the CONTRACTOR (e) reactions from piping systems, as specified by the CONTRACTOR (f) cyclic or dynamic reactions from combined equipment, as specified by the

CONTRACTOR (g) wind or seismic load whichever is greater

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(2) Erection condition The loading shall include those from:

(a) weight of exchangers and contents at erection (b) weight of other attachments, if any (c) weight of combined equipment, as specified by the CONTRACTOR (d) wind or seismic load whichever is greater

(3) Testing condition (in the installed position and corroded condition) The loadings shall include those from:

(a) test pressure (b) weight of exchangers and contents at testing condition (including static head of

liquids) (c) weight of piping and other attachments (d) weight of combined equipment, as specified by the CONTRACTOR

2.5.4 Wind load shall be determined in accordance with Appendix D Wind Load Calculation which is based on IS 875-1987 Part 3.

2.5.5 Seismic load shall be determined in accordance with Appendix E: Seismic Load Calculation which is based on IS 1893-2002.

2.5.6 Classification and evaluation of stresses at various loading conditions shall be done in accordance with the applicable codes and standards. Higher allowable stresses may be used according to the category of the stresses for short time and local loads.

2.5.7 Allowable tensile stress of foundation bolts of A307Gr.B shall be 10 kgf/mm2 (100 N/mm2) for long-term loading conditions as per CL. 2.5.3 (1) and 15 kgf/mm2 (150 N/mm2) for short-term loading conditions as per CL. 2.5.3 (2) & (3).

2.5.8 Local stresses at shell around attachments such as nozzle, vessel supports and lifting lug and so on shall be calculated and evaluated when requested by the CONTRACTOR. The CONTRACTOR shall inform local loads on nozzles.

The following generally accepted calculation procedure, or the equivalent, may be applied.

(a) Bulletin of Welding Research Council No. 107 or 297 (for nozzle to shell) (b) L.P. Zicks Method (for saddle to shell)

2.6 Tolerances

2.6.1 Tolerances shall be in accordance with Appendix B Inspection Requirement or LICENSERs specifications and data sheets, if specified, whichever are more stringent.

2.6.2 The thickness after forming of any pressure holding parts shall not be less than the calculated thickness. Plates with an under tolerance of not more than the smaller value of 0.25 mm or 6 % of the nominal thickness may be used, unless required otherwise by the applicable code.

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3. DETAILED DESIGN

3.1 Shells and Channels

3.1.1 When shell diameter is 600 mm and under, pipes may be used.

3.1.2 The minimum nominal shell thickness including corrosion allowance shall be in accordance with TEMA including RECOMMENDED GOOD PRACTICE.

3.1.3 The shape of the formed head shall be as specified on the CONTRACTORs/PMCs drawing or data sheet. 2:1 ellipsoidal or hemispherical head are used, in general.

3.1.4 The nominal thickness of 2:1 ellipsoidal or dished head shall be selected to assure that the minimum thickness after forming shall not be less than the minimum required thickness of head. Also, the nominal thickness shall not be less than the minimum required thickness of connecting cylindrical shell.

3.1.5 Except for kettle and U-tube types, exchangers with removable tube bundles shall be provided with bolted shell covers.

3.1.6 The angle of a conical section of kettle type exchangers shall generally be 30

3.1.7 For fixed tube sheet construction, VENDOR shall determine the necessity of expansion bellows according to the TEMA standard. The metal temperatures of shell and tubes will be specified on the CONTRACTORs/PMCs drawings or data sheets. Subtract 20 C from those temperatures in calculation in general. Unless otherwise specified, the necessity of expansion bellows shall be evaluated for the normal operating condition.

3.1.8 Girth flanges shall have a confined gasket joint to hold the gasket in place during assembling.

3.1.9 Gasket contact surface of girth flange shall have a finish equivalent to the following in m:

(1) For asbestos sheet gasket : Ra 3.2 (2) For spiral wound gasket : from Ra 1.6 to Ra 3.2 (3) For metal jacket, solid metal gasket : Ra 1.6 and finer

3.1.10 All girth flanges shall be of welding neck construction.

3.1.11 Vent and drain holes of approx. 6 mm in diameter shall be provided at the highest and lowest points of each pass partition plate.

3.2 Tubes and Tube Bundles

3.2.1 Each U-tube shall be formed from a single length, and mean radius of U-tube bend shall not be less than 1.5 times the tube outside diameter.

3.2.2 All tube-to-tubesheet joints shall be strength welded followed by light expansion, except that heavy expanded tube-to-tubesheet joints are applied when all of the following conditions apply. Tube-to-tubesheet joint type is specified on the CONTRACTORs/PMCs drawings, generally.

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(1) Design pressure is 50 kg/cm2 (5,000 kPa) and smaller. (2) Design temperature, both Max. and Min., are from -10 to 350 C. (3) Hydrogen partial pressure is 7 kg/cm2 (700 kPa) and smaller. (4) Tubes are non-ferrous

3.2.3 VENDOR shall submit the welding procedure, welding methods and inspection methods of strength welded tube-to-tubesheet joints for the CONTRACTORs approval. WPS and PQR for tube to tubesheet welding shall be prepared separately from other fillet welding.

3.2.4 Tubesheets shall be designed in accordance with the TEMA Standard, provided that calculated thickness meet the code requirement. Extended Tubesheet shall be applied to removal type tube bundle.

3.2.5 Baffles and support plates shall be tied together with rods and spacers, and for horizontal exchangers they shall be provided with notches at the lowest point to permit full drainage of the shell.

3.2.6 When the specified shell-side corrosion allowance exceeds 3 mm, the minimum baffle and support plate thickness specified in the TEMA standard shall be increased by the shell-side corrosion allowance in excess of 3 mm.

3.2.7 For exchangers which do not require baffles, support plates of 45 % vertical cut shall generally be provided. Support plates need not be cut for kettle type exchangers. These support plates shall be so spaced that unsupported tube length does not exceed the value indicated in the TEMA Standard.

3.2.8 When longitudinal baffles are welded to the shell, the welding seams shall not be close to the longitudinal welded seams of the shell.

3.2.9 Clamp bands shall be installed for kettle type exchanger with the shell diameter of 400 mm and over, and the tube length 1 500 mm and over.

3.2.10 Tubes shall be extended by 3 mm beyond the channel side surface of each tubesheet. For vertical exchangers, minimum one tube per each tube block shall be flush with top tubesheet surface to facilitate drainage.

3.3 Nozzles

3.3.1 Nozzle and manhole size shall not be changed by VENDOR. However, if nozzles, reinforcement pads, and main seams should interfere with each other, these dimensions may be changed upon the CONTRACTORs approval.

3.3.2 The type, rating and facing of nozzle flanges shall conform to those specified in the CONTRACTORs drawing or data sheet. The CONTRACTOR shall ensure that those matches with Process & Instrument diagram and piping specification.

3.3.3 Each manhole cover with mass over 20 kg (200 N) shall be supported by a davit or hinge as specified on the CONTRACTORs drawing. The details of davit or hinge shall be in accordance with Vessel Standard. Davit details for manhole covers of 900# rating and above shall be decided by VENDOR and supported with strength calculations.

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3.3.4 Nozzle flanges 24 inch and smaller shall be as per ASME B16.5. Nozzle flanges larger than 24 inch nominal shall be as per ASME B16.47 Series B or designed per ASME Sec. VIII Div.1. In case a non standard flange is designed by VENDOR, the companion flange with bolt, nut and gasket shall be supplied with by VENDOR.

3.3.5 The nozzle neck thickness shall be selected in accordance with Vessel Standard as per materials, nominal size, flange rating and corrosion allowance. The pipe material for nozzle neck shall be seamless, unless otherwise approved by PMC.

3.3.6 Unless otherwise specified, the nozzle gasket surface finish shall be same as the matching flange of corresponding piping class.

3.3.7 When male and female (M&F) or tongue and groove (T&G) type flanges are specified, the nozzle flange facing of the exchanger shall be of female or groove type except for downward facing flanges for which reverse shall be applied.

3.3.8 Drain, vent and draw off nozzles shall be trimmed flush with the inside surface of the exchanger. Other nozzles may extend inward within the limits necessary for welding.

3.3.9 Nozzles to be welded directly to the connecting piping will be indicated on the CONTRACTORs drawings. Caps for pressure testing shall be attached to the nozzles by welding. After the pressure testing the caps shall be cut off, and the nozzles shall be machined to form the specified welding bevel.

3.3.10 The highest and lowest points on shell and tube sides, not otherwise vented or drained, shall be provided with 3/4 inch nominal size drain and vent.

3.3.11 The nozzle facing of the intermediate nozzles between the units which are to be stacked shall be flat face (FF) or raised face (RF) type.

3.3.12 Level gauge nozzles of kettle type exchangers shall be supported from the shell.

3.3.13 Each inlet & outlet nozzles on shell side and tube side shall be provided with one no. connection for pressure gauge/thermometers.

3.4 Opening

3.4.1 The opening reinforcement shall be so designed as not to limit the maximum allowable working pressure of the heat exchanger.

3.4.2 Nozzles made of pipe or plate and sized 2 inch nominal and larger shall generally be provided with reinforcement plates. Each reinforcement plate shall be provided with at least one tell-tale hole of NPT 1/8 inch. Irrespective of design calculations, reinforcement shall be minimum as per vessel standard VS-7.

Long weld neck (LWN) type nozzle may be used without reinforcement pad up to 3 inch nominal.

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3.4.3 The reinforcement for the nozzle opening shall be of integral type, when required by the applicable codes/standards or where any of the following conditions are met:

(1) Design temperature exceeds 450 C (2) Design pressure exceeds 100 kg/cm2 (10,000 kPa) (3) Design temperature exceeds 350 C and design pressure exceeds 30 kg/cm2 (3,000

kPa) (4) Plate thickness exceeds 50 mm (5) Size 1-1/2 inch and below (6) Material is NACE/HIC

3.4.4 In general, nozzles are subject to external loads. VENDOR shall check the strength of the nozzles and shells against external loads based on the CONTRACTORs information and shall provide additional reinforcements if required. See Par. 2.5.8 for calculation procedures.

3.5 Alloy Lining

3.5.1 Alloy lining shall be either integrally clad plate or overlay weld metal. The minimum thickness shall be 3 mm for cladding and 3.2 mm for weld deposit after machining. The minimum clad thickness for tubesheet shall be 8 mm.

3.5.2 Nozzles attached to alloy-lined shell shall be alloy-lined by integrally cladding or overlay welding with exception in Par. 3.5.3 and Par. 3.5.4.

3.5.3 Solid austenitic stainless steel nozzles, if not specifically prevented in LICENSERs specification/data sheets, may be welded to ferritic shells in case of the following. When post weld heat treatment is required, such nozzles shall be made of stabilized stainless steel or low carbon grade and welded by Inconel filler metal.

(1) Nozzle size is 2 inch and smaller with design temperature 400 C and lower (2) Nozzle size is 4 inch and smaller with design temperature 250 C and lower

3.5.4 Loose metal lining may be used for the nozzles of the following.

(1) Nozzle size is 4 inch and smaller with design temperature 400 C and lower (2) Nozzle size is 6 inch and larger with design temperature range of -10 C to 250 C

Expansion ring shall be provided when the design temperature exceeds 250 C. Each segment of liner welds shall be provided with tell-tale holes with threaded end for plugging.

When post weld heat treatment is required, such sleeve liner shall be made of stabilized or low carbon stainless steel. One end of loose sleeve liner shall be welded after post weld heat treatment.

3.6 Bolts, Nuts and Gaskets

3.6.1 Unless otherwise specified, all bolting threads to be used for heat exchangers shall be ISO Metric System. When bolt sizes are M30 and over, metric fine screw threads of 3 mm pitch series shall be used. When bolt size are M27 and less, metric coarse screw threads shall be used. Girth flange boltings shall be of stud bolt type, threaded full length, and at least M16 for flange of 600 mm and smaller inside diameter and at least M20 for over 600 mm inside diameter flange.

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Hydraulic bolt tensioner with all accessories shall be supplied for bolt sizes M64 and over. Required torque shall be furnished for the same.

3.6.2 The hardness of metal gaskets shall not exceed the values in the following table. VENDOR shall confirm these hardness are lower than those of gasket contact surface.

Gasket Materials Brinell Hardness Soft iron, Low Carbon Steel and Nickel 120 5 % Cr - 1/2 % Mo Steel 140 Austenitic Stainless 160

Asbestos gasket is not permitted, Non-asbestos type gasket shall be used.

3.6.3 Threads of bolts and nuts shall be coated before installation with anti-galling agent.

3.7 Supports

3.7.1 Saddles or lugs for exchangers shall be as per the tables in Vessel Standard. For exchangers which meet all the conditions stipulated in the tables such as maximum weight or saddle height, strength calculations may not be submitted to the CONTRACTOR.

3.7.2 Units which are to be stacked shall be provided with the required additional intermediate supports and liners for elevation adjustment.

3.7.3 Supports for low temperature horizontal exchangers with the operating temperatures -20 C or below shall be provided with wooden pillows according to Vessel Standard.

3.8 Miscellaneous

3.8.1 To facilitate breaking gasketted joint of main girth flanges, jack screws shall be provided.

3.8.2 Guide rails shall be provided for kettle type exchangers and the horizontal exchangers with the removable bundle weighing 100 kN and over.

3.8.3 Each channel, channel cover and shell cover shall be provided with plate type welded-on lifting lug with 25 mm diameter hole.

3.8.4 Tapped holes for insertion of eyebolts shall be provided on the outer face of tubesheets of removable bundles and floating head cover flanges.

3.8.5 Alignment marks shall be provided to prevent mis-assembly of channel covers, channel flanges, shell flanges, shell cover flanges and floating heads.

3.8.6 According to the CONTRACTORs information, VENDOR shall check the strength of the heat exchangers during transportation and field erection, and provide necessary reinforcements prior to shipment. The shock factor of 1.25, as minimum, shall be considered in these design, VENDOR shall submit such strength calculation to the CONTRACTOR.

3.8.7 For vertical heat exchangers, plate type lifting lugs shall be provided in general. Trunnion type lifting device needs the CONTRACTORs prior written approval. Lifting lugs shall be designed taking account of heat exchanger weight and lifting method, etc. The shock factor of 1.25, as minimum, shall be considered in the design of lugs and shell.

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3.8.8 In general, exchangers shall be provided with two earth lugs.

4. FABRICATION

4.1 Plate Layout

4.1.1 Shell plates shall be laid out so that there will be a minimum of welded seams.

4.1.2 Longitudinal and circumferential welded seams shall not interfere with nozzle openings, reinforcement plates and saddle pads, as far as possible. If the seam is covered with reinforcement plates or saddle pads under the CONTRACTORs approval, they shall be ground flush with shell surface and radiographically examined in full length prior to welding of plates or pads.

4.1.3 Longitudinal welded seams on adjacent shell segments shall be separated by at least 4 times the wall thickness of the thicker plate but not less than 100 mm.

4.1.4 Longitudinal and circumferential welded seams shall be kept out of the internal welds insofar as practical, and shall be so located that they can be easily inspected with internals in place.

4.2. Forming

4.2.1 Selection of hot or cold forming of materials may be made by VENDOR, but heat treatment after forming shall conform to the requirements of applicable material specifications.

4.2.2 Despite of Par. 4.2.1, austenitic stainless steel including clad plate shall generally be subjected to cold forming. Hot forming shall not be employed unless otherwise approved by PMC.

4.2.3 A formed head shall generally be made of single plate.

4.2.4 When temporary attachments are required during the forming work, they shall be welded to the shell plate using the same welding procedures as for the main seams. After removing these attachments, the surface shall be ground flush and examined by magnetic particle method. In case of high alloy steel or non ferrous materials, liquid penetrant method can be substituted.

4.3 Welding

4.3.1 VENDOR shall obtain the CONTRACTORs approval for start of welding.

4.3.2 As a rule, exchangers shall be welded by fusion arc process. Electrogas or electroslag welding shall be subject to the CONTRACTORs approval.

4.3.3 Welding procedures and welders shall be qualified in accordance with the specified code or standard.

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4.3.4 Pressure holding seams shall normally be full-penetration double-welded butt joints. Single-welded butt joints which ensure full-penetration shall be used, where double-welded butt joints are impractical. Butt joint with backing strip needs to obtain PMCs prior written approval.

4.3.5 Welding electrodes and wires shall have chemical compositions and mechanical properties equal to or of higher grade than the base material.

4.3.6 Welding procedures shall be selected to minimize the residual stresses insofar as practical.

4.3.7 Preheating shall be carried out for carbon and low alloy steel welding where required. Preheating temperature shall be kept uniform from the start to the end of welding.

4.3.8 Welding procedure for any dissimilar metal welds of stainless steel to carbon steel or low alloy steel shall be presented in full detail to the CONTRACTOR for approval.

4.3.9 Dissimilar metal welding of stainless steel to carbon steel or low alloy steel in pressure retaining butt weld shall be carried out in the following manner.

(1) Filler metal of Inconel 182 : For joints where PWHT is required or design temperature over 350 C

(2) Filler metals of E309, E309L : For first layer of joints where no PWHT is required 309Mo, 309MoL and design temperature is less than 350 C

Note: The welding method and welding parameters of the dissimilar weld overlay shall be carefully selected to control the dilution and micro-structure of weld deposit to avoid any cracks. 20 000 J/cm is allowable maximum heat input for the first layer of pressure retaining dissimilar butt weld.

4.3.10 The minimum bead length for low alloy and high alloy steel shall be 80 mm.

4.3.11 When joining alloy-clad plate, the alloy layer shall be stripped for a minimum distance of 8 mm from the bevel to assure the sound weld joint of base materials. If VENDOR would propose other procedure, the details of it to assure the sound weld joint of the base material shall be referred to PMC for approval. The thinning of base metal due to this clad stripping is not necessary to consider in the shell thickness calculation if the thinning is within the smaller of 1.0 mm or 10 % of the base metal nominal thickness.

4.4 Heat Treatment

4.4.1 Heat treatment after bending of U-tubes shall be carried out prior to bundle assembling for the following conditions:

(1) Carbon steel U-tubes in caustic service or amine service

(2) Austenitic stainless steel U-tubes when stress corrosion cracking may be expected

(3) Al-killed steel U-tubes of which mean bending radius is less than or equal to 5 times the tube outside diameter in low temperature service

(4) Cr-Mo steel U-tubes in all services

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4.4.2 Unless otherwise stated, post weld heat treatment shall be carried out in accordance with the applicable codes or standards.

4.4.3 No welding shall be performed on heat exchangers after the final post weld heat treatment without the CONTRACTORs approval.

4.4.4 When clad steel or dissimilar metal welded parts are heat treated, the heat treatment procedure shall be submitted for the CONTRACTORs approval.

4.4.5 The gasket faces of shell and channel girth flanges shall be machined after final heat treatment.

4.4.6 When fixed tubesheet exchanger bundles are heat treated, the heat treatment procedure shall be submitted for the CONTRACTORs approval.

4.5 Hardness

Hardness of base metal, weld metal and heat affected zone shall not exceed the limits given below, unless otherwise specifically specified by LICENSER or PMCs specific job requirements.

Material (P-Number) Brinell Hardness Carbon Steel (P-1) 225 Low Alloy Steel (P-3, 4) 225 Low Alloy Steel (P-5, 6, 7, 9) 235

4.6 Miscellaneous

4.6.1 Materials for heat exchangers shall be carefully stored at shop not to be heavily rusted or damaged. Stainless steel shall be stored under roof and protected from the contamination of any harmful substances such as chloride and zinc.

4.6.2 All the QA plans, NDT procedures & WPS/PQR shall be reviewed and approved by the CONTRACTOR/third party and then submitted to PMC for approval/review/information as the case may be. Third party approval of these documents and PMC approval of QA plan is mandatory before proceeding for work.

5. INSPECTION AND TESTS

5.1 All heat exchangers shall be inspected and tested (stage & final) in accordance with the applicable local regulations, applied code, and Appendix B, Inspection Requirement, unless otherwise specified on CONTRACTORs drawings .

5.2 Vender shall submit a detailed procedure of inspection and test for the CONTRACTORs approval.

5.3 The CONTRACTOR and his designated representative shall have the right to witness inspection and test to be performed by Vendor.

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6. NAMEPLATE, PAINTING AND MARKING

6.1 Nameplate

A nameplate as shown in the Vessel Standard shall be mounted on each exchanger. Mounting on the removable parts is prohibited.

6.2 Painting

6.2.1 As a rule, all external surface of vessels shall be painted in accordance with Painting specification O-301, except the following.

A. Surface of Stainless Steel and high alloy steels; Not painted. B. Gasket seating surface; See Par. 6.2.2

6.2.2 All flange faces and other machined surfaces shall be coated with a readily removable rust preventive paint.

6.2.3 Weld bevels on the ends of carbon steel and low alloy steel nozzles which are to be welded at site shall be coated on the inside and outside for a distance of 75 mm from the end of the nozzle with Deoxyaluminite, Taseto Silver or equivalent.

6.2.4 VENDOR shall submit a detailed procedure of applicable painting system (Painting Specification) for the CONTRACTORs approval.

6.3 Marking

Each Heat Exchanger and its parts shall be marked in accordance with D-123M, Vessel Standard.

7. PACKING AND SHIPPING

7.1 General

Packing and shipping shall be in accordance with Engineering Specification for Packing and Transportation and the following additional requirements.

7.2 Packing and Preparation for Shipping

7.2.1 All exchangers shall be dried up by draining and air blowing, thoroughly cleaned inside and outside and free of all dirt and loose foreign materials before shipping.

7.2.2 All flanged openings shall be provided with bolted steel cover of minimum 5 mm thickness with gaskets. Number of bolting is one fourth of the service bolt but not less than 4 sets.

7.2.3 All beveled openings shall be covered or capped to protect the inside from rust and moisture. The welded cover or cap shall be so designed to protect the weld bevel and to be removed easily at site.

y

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7.2.4 Nitrogen filling or volatile corrosion inhibitor such as DICHAN* shall be applied for carbon or low alloy steel heat exchangers. In case of equipment shipped by sea, the same shall be filled with Nitrogen at 1.25 kg/cm2g pressure and fitted with N2 cylinder, valve and pressure gauge.

* Dicyclohexylammonium nitrite

7.2.5 Spare parts shall be packed separately from the exchangers.

7.2.6 Tell-tale holes on the outside of exchangers shall be greased up. Plugging of holes is prohibited.

7.2.7 Demisters shall be free of wire pieces in so far as possible.

7.2.8 Unless otherwise specified on the CONTRACTORs document, girth flanges shall not be loosed after final hydrostatic test and shipped as it is, provided service gasket is used for the hydrostatic test.

7.3 Shipping

7.3.1 Templates and foundation bolting shall be shipped separately from the exchangers according to the CONTRACTORs instruction. The CONTRACTOR shall indicate in purchase order delivery time for supply of template & anchor bolts to site.

7.3.2 No exchangers shall be released for shipment from VENDORs shop until it have been approved by the CONTRACTORs inspector.

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Appendix A Basic Design Requirements

This appendix describes the basic requirements of the design of the shell and tube heat exchangers and are reflected into the CONTRACTORs drawing or data sheet, in general. When the CONTRACTOR issues only the duty specification and the basic design is executed by VENDOR, in such a case of heat exchanger in package units, the requirements of this appendix shall be followed in addition to the body of this specification.

A.1 Type Selection A.2 Basic Dimensions A.3 Design Temperature (Minimum) A.4 Corrosion Allowance A.5 Material Selection A.6 Gasket Selection A.7 Minimum Shell Thickness A.8 Pipe Shell A.9 Minimum Nozzle Size A.10 Nozzle Flange Design A.11 Nozzle Protrusion A.12 Girth Flange Design A.13 Support Design of Vertical Heat Exchangers A.14 Fire Proofing A.15 Extent of Radiographic Examination

A.1 Type Selection

A.1.1 TEMA Standard type shell and tube heat exchangers shall be used except for high pressure & temperature or other special services.

A.1.2 Normally, heat exchangers shall be designed with corrosive or fouling fluid in the tube side.

A.1.3 Fixed tubesheet exchangers shall be used for little-fouling service on the shell side, or when chemical cleaning device is provided. Special considerations must be given to fixed tubesheet exchangers that are in dry-out or steam-out conditions.

A.1.4 U-tube exchangers shall be used for little-fouling service (fouling factor is less than 0.0003 m2 C/W) on the tube side, or when fixed tubesheet or floating head exchangers are not practicable.

A.1.5 In case of cooling water or fouling fluid (fouling factor is equal and larger than 0.0003 m2 C /W) on the tube side, removable flat covers (TEMA Type A) shall be provided on the channel.

A.2 Basic Dimensions

A.2.1 Nominal shell inside diameters shall be selected on every 50 mm, and limited, except for kettle type exchangers, to the maximum of 2000 mm, as a rule.

A.2.2 Tube lengths will be selected from 3000, 5000, 6000, 7200, 9000 and 12000 mm. However Preferable lengths are 3000 mm, 6000 mm, 9000 mm and 12000 mm. For removable bundles, a tube length of 7200 mm shall be the maximum as a rule.

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A.2.3 Standard tube outside diameters and tube pitches shall be as follows:

Tube Outside Diameter (mm)

Pitch (mm)

19.05 25.0 25.4 32.0

A.2.4 Standard tube patterns shall be of triangular and square. Triangular pattern shall not be used when mechanical cleaning is required on the shell side.

A.2.5 Standard tube thickness shall be as follows:

Tube Thickness (mm) Tube Outside

Diameter (mm)

C.S. & Low Alloys

(Min. Wall) High Alloys (Avg. Wall)

Copper & Copper Alloys

(Avg. Wall) 19.05 2.11 1.65 1.65 25.4 2.77 1.65 1.65 31.8 2.77 2.11 2.11 38.1 2.77 2.11 2.11

A.2.6 The effective heat transfer surface shall be defined as the outside surface of the tubes between the inner faces of tubesheets. Bent portions shall not be considered as the heat transfer surfaces in U-tube exchangers.

A.2.7 When plate thicknesses are to be governed by the minimum thickness stipulated in TEMA in inches, the nearest thickness in millimeters normally available in the market shall be used.

A.3 Design Temperature (Minimum)

A.3.1 The minimum design metal temperature (MDMT) shall be determined for each heat exchanger in accordance with UG-20 of ASME Boiler and Pressure Vessel Code Section VIII, Div.1

A.4 Corrosion Allowance

A.4.1 The necessity and the values of corrosion allowances shall be determined depending on the material, inside fluid characteristics, operating conditions and applicable codes and standards.

A.4.2 Corrosion allowances for pressure parts made of carbon steel and low alloy steel shall be 1.0 mm minimum. Unless otherwise specified, corrosion allowances are not required for high alloy and non-ferrous metals.

A.5 Material Selection

A.5.1 Materials shall be selected from those listed in ASTM/ASME Standards considering the inside fluid characteristics, design conditions and applicable codes and standards. However, considering the availability in the market, equivalent materials of country of origin may be selected with the CONTRACTORs approval.

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A.5.2 Unless otherwise specified girth flanges and flat covers shall be forged steel. Plate construction shall be subject to the CONTRACTORs approval.

A.5.3 Materials for the low temperature service shall be selected considering the impact properties of the material and MDMT specified for the heat exchanger. The requirements of the impact test shall be as specified in UCS-66 of ASME Boiler and Pressure Vessel Code Section VIII, Div.1.

A.5.4 A283 Gr.C may be used for pressure retaining parts when all of the following conditions are met.

(1) Design pressure does not exceed 10 kg/cm2 (1,000 kPa) (2) Design temperature, both maximum and minimum, are from 10 C up to 350 C (3) Utility services such as cooling water, steam, steam condensate, air, N2, etc. (4) Shell plate nominal thickness is equal or less than 16 mm

A.5.5 Seamless type tubes only shall be used.

A.6 Gasket Selection

A.6.1 Gaskets for girth flange shall be determined depending on the inside fluid characteristics, design conditions and applicable codes and standards. As a rule, spiral wound with carbon steel inner ring shall be selected except that non-asbestos sheet gasket may be used when all of the following conditions apply.

(1) Flange inside diameter does not exceed 1200 mm (2) Design pressure does not exceed 10 kg/cm2 (1,000 kPa) (3) Design temperature, both maximum and minimum, is from 0 C up to 180 C (4) Utility services such as cooling water, steam, steam condensate, air, N2, etc.

A.6.2 When spiral wound gasket is used, spiral wound gasket with inner ring shall be used for confined type flange, and spiral wound gasket with outer ring shall be used for raised face flange.

A.7 Minimum Shell Thickness

A.7.1 The minimum nominal shell thickness including corrosion allowance shall be in accordance with TEMA including RECOMMENDED GOOD PRACTICE.

A.8 Pipe Shell

A.8.1 When shell diameter is less than 600 mm, pipes may be used.

A.9 Minimum Nozzle Size

A.9.1 In general, nozzles shall be flanged and minimum 3/4 inch nominal size.

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A.10 Nozzle Flange Design

A.10.1 Nozzle flange shall be of welding neck type except slip-on type may be adopted for nozzles of all of the following conditions are met.

(1) Material of nozzle is carbon steel, high alloy or non-ferrous (2) Flange rating is class 150 and under for process and instrument nozzle (3) Flange rating is class 300 and under for manhole, handhole and blind flange (4) Design temperature, both maximum and minimum, is from -10 C up to 350 C (5) Nozzle size is 2 inch and larger

A.10.2 Nozzle flanges equal and larger than 26 inch nominal shall be of welding neck type.

A.11 Nozzle Protrusion

A.11.1 Nozzle protrusion shall be decided considering the minimum clearance of 50 mm between the bottom of bolt to the surface of the shell or surface of the insulation cover. PMCs Vessel Standard VS-49 shall be referred.

A.11.2 For the nozzles to be connected to piping, the distance of the flange face to the center of the heat exchanger shall be rounded up to each 10 mm by adjusting the nozzle protrusion.

A.12 Girth Flange Design

A.12.1 All girth flanges shall be of welding neck construction.

A.12.2 For low alloy or clad shells, welding neck flanges shall be adopted.

A.13 Support Design of Vertical Heat Exchangers

A.13.1 Vertical heat exchangers shall generally be supported by lugs.

A.14 Fire Proofing

A.14.1 fire proofing shall be provided for the heat exchangers installed in the fire hazardous area in the following manner. Application of fire proofing to heat exchangers installed on elevated structure shall be decided for each case.

For lug type support, fire proofing shall not be provided. For leg type support, fire proofing shall be provided for legs of all length. For saddle type support, fire proofing shall not be provided.

A.15 Extent of Radiographic Examination

A.15.1 The extent of radiographic examination of the shell, shell cover and channel seams shall be spot examination, as minimum. In case of dished ends and conical sections ,

radiography shall be full.

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Appendix B Inspection Requirements

B.1 Material

B.1.1 Ultrasonic Examination of the base metal shall be done in accordance with the following criteria.

(1) Plate material and thickness over 50 mm ASME A435 (2) Forging material, plate-like one such as tube sheet, ASME A578 Level II forging shell and thickness over 100 mm (3) Forging material, not included in B above, and thickness ASME A508 Par. 7.3

Over 100 mm (4) Cladding material, any thickness ASME A578 Level S6

B.1.2 Charpy impact test shall be done in accordance with the Code, based on MDMT specified on the CONTRACTORs engineering drawings or data sheet. For carbon steel and low alloy steel, when the nominal thickness of plate or forging exceeds 100 mm., charpy impact test as specified in Table B-1 is mandatory.

Table B-1

Item CRITERIA Sampling - Min. 1 set from each heat

- Min. 3 specimen in 1 set - Sampling from 1/4T (Thickness) depth

Test Temperature 0 C or MDMT whichever is lower Absorbed Energy ASME Div.1, Fig. UG-84.1

B.1.3 Integrally cladding material shall conform to ASTM A263, A264 or A265 whichever applicable, and shear test is mandatory.

B.2 Welds

B.2.1 Welding edge shall be inspected by MT or PT when any of the following conditions met.

(1) Carbon steel and thickness of base metal is 75 mm and over. (2) Low alloy steel (Cr-Mo) and thickness of base metal is 50 mm and over. (3) Low alloy steel (Ni) and thickness is 38 mm and over. (4) Dissimilar welding, any material and any thickness

B.2.2 Welding backchip surface shall be inspected by MT or PT when any of the following condition met.

(1) Carbon steel and thickness of base metal is 50 mm and over. (2) Carbon steel and MDMT -10 C and thickness of base metal is 25 mm and over. (3) Low alloy steel (Cr-Mo) and thickness of base metal is 25 mm and over. (4) Low alloy steel (Ni), any thickness (5) Austenitic stainless steel and thickness is 25 mm and over. (6) Dissimilar welding, any material and any thickness

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B.2.3 All butt weld joints shall be inspected by UT after PWHT when any of the following conditions met.

(1) Carbon steel and thickness of base metal is 50 mm and over (2) Low alloy steel (Cr-Mo) and thickness of base metal is 50 mm and over. (3) Low alloy steel (Ni) and thickness is 38 mm and over. (4) Dissimilar welding

B.2.4 Welding surface shall be inspected by MT or PT after Hydrostatic test, when any of the following conditions met. Inspection shall be done on all accessible interior and exterior surface.

(1) Carbon steel and thickness of base metal is 38 mm and over, or Full RT(100 %) is specified.

(2) Low alloy steel (Cr-Mo),any thickness include attachment welds (3) Low alloy steel (Ni), any thickness include attachment welds (4) High alloy steel, any thickness (5) Welds in lining or cladding metal and weld overlay surfaces, include attachment welds (6) Welds of tube to tubesheet (7) Dissimilar welding, any material and any thickness (8) Fillet welds of intermediate heads

B.2.5 All area where temporary attachment was welded and is removed shall be examined by MT or PT.

B.2.6 The extent of radiography is specified on the CONTRACTORs drawings. When Full RT (100 %) is specified on the CONTRACTORs drawings, all length of butt

weld joint, including Category B seam, shall be RT. When Full RT( -- %) is specified, RT shall be done in accordance with UW-11 of ASME Div.1.

B.2.7 When Spot RT is specified, each intersection of longitudinal and circumferential welding seams in the shell and heads shall be radiographed. An acceptance standard for spot radiography is in accordance with UW-51 of ASME Div.1.

B.2.8 RT shall be done before final PWHT.

B.2.9 Acceptance criteria of MT, PT and UT is ;

(1) MT Appendix 6 of ASME Div.1 (2) PT Appendix 8 of ASME Div.1 (3) UT Appendix 12 of ASME Div.1

B.3 Hardness Test

B.3.1 Hardness of base metal, weld metal and heat affected zone shall be checked as follows.

(1) For Non-PWHT vessel : One point per one vessel (2) For PWHT vessel : Two points per one of circumferential welds, and One point per one of longitudinal welds, and One point per each nozzle weld

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B.4 Dimensional Inspection

B.4.1 Main dimension of vessels shall be checked after PWHT. Unless otherwise specified, tolerances for pressure vessel shall be in accordance with Fig. B-1, B-2.

B.4.2 Thickness of pressure retaining parts shall be checked after forming, at least one point of every 1 m2.

B.4.3 Vessels to be field assembled shall be pre-assembled at shop, and miss-alignment, which shall be less than those specified in UW-33, shall be reported.

B.4.4 The gap between interconnecting nozzles of stacked type heat exchangers shall be checked and reported to the CONTRACTOR. Tolerance of the gap shall be 0.8 mm.

B.5 Hydrostatic Test

B.5.1 Hydrostatic test shall be done prior to painting at weld and/or coating.

B.5.2 Hydrostatic test shall be done by water and at the temperature of at least 16 C above MDMT.

B.5.3 The hydrostatic test pressure shall be held at least 30 minutes.

B.5.4 When carbon and low alloy steel materials are exposed to test water, chloride content in the water shall be less than 100 ppm. Corrosion inhibitor such as 500 ppm NaNo2 shall be dosed to the test water.

B.5.5 When austenitic stainless steel materials are exposed to test water, chloride content of water shall be less than 30 ppm.

B.6 Leak Test

B.6.1 Reinforcing pads shall be leak tested at least 10 kPa with air before hydrostatic test.

B.6.2 Sleeve type nozzle shall be leak tested at least 10 kPa with air after hydrostatic test.

B.6.3 When tube to tubesheet joint is expanded and not welded, leak test shall be done with the pressure specified on the CONTRACTORs drawing.

B.6.4 Stacked type heat exchangers having interconnecting nozzles shall be leak tested in the stacked condition.

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B.7 Inspection and Test Records

B.7.1 Inspection and test records for each vessel shall be supplied by Vender.

B.7.2 Inspection and test records shall include (where applicable);

(1) Manufacturers Data Report (2) As-built sketch or tabulation for identification of the materials showing the location (3) Certified Material Test Report, including data of impact tests and records/certificates of

non-destructive examination required for the materials (4) Records of production weld tests (5) Time-temperature charts of post weld heat treatment, and records of other heat

treatments (6) Records/certificates of non-destructive examination, such as radiographic, ultrasonic,

magnetic-particle and liquid-penetrant examination (7) Data/results of dimensional inspection (8) Certificates of hydrostatic test, pneumatic test or other pressure tests (9) Rubbing of nameplates

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Fig. B TOLERANCES FOR HEAT EXCHANGERS

[EXTERNAL DIMENSIONS, NOZZLE AND SUPPORT LOCATIONS] Standard tolerances for the external dimensions of heat exchangers and for nozzle and support locations are shown in Fig. B-1. All dimensions to flange faces are to the gasket surface.

Fig. B-1 3 (+6, -3)

3(5)

6

3 (5)3 (5)

3 (5)

3 (5)

3(5)

3(5)

3

3(5)(5)

6

15

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3(5)

3(5)

3(5)

3(5)

3(5)

3(5)

3(5)

3(5)

3(5)

3(5)

G

CONNECTION NOZZLE ALIGNMENT AND SUPPORT TOLERANCES

Nominal Nozzle Size, (in.) G Max. 2 - 4 Inclusive 1.5 6 - 12 Inclusive 2.5 14 - 36 Inclusive 5 Over 36 Inclusive 6

Note: This table applies to nozzles connecting to external piping only.

Allowable CenterlineRotation

True Centerline

1

ROTATIONAL TOLERANCE ON NOZZLE FACES

NOTES TO Fig. B-1: 1. Tolerances given in parenthesis ( ) shall apply only to

heat exchangers with inside diameters exceeding 1 500 mm.

2. For heat exchangers with inside diameters not exceeding 1 500 mm, this figure gives the same tolerances as TEMA Standards (Six Edition).

3. Tolerances of the inside diameters shall be as follows: (1) Pipe Shells: The inside diameter of pipe shells shall be in

accordance with the applicable pipe specifications. (2) Plate Shells: The inside diameter of any plate shell shall not

exceed the design inside diameter by more than 3 mm (4 mm: See Note 1) as determined by circumferential measurement.

4. For any pair of nozzles for liquid level gauge, additional tolerances shall be applied as follows:

a Difference in nozzle length : Max. 1

b Distance between nozzles : 2

c Difference in location from reference centerline: Max. 2

d Alignment of flange face : 1/4

a

b

d

c

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[TUBESHEETS, PARTITIONS, COVERS AND FLANGES] The standard clearances and tolerances applying to tubesheets, partitions, covers and flanges are shown in Fig. B-2.

Fig. B-2

R2R1

D1R4

t

A

t t

R1

W3 W1

0.8

W2=(W1+3)

R4R4

t

t

0.4

D4=(D1+3)

D=I.D. DESIGND5=(D3+3)

D1

R1t

A D3

D2

t

t t t

R1 R1R2

A AA

t

D6=(D2+3)

D1

R1t

t

D2=(D1+3)

R4

t

STANDARD CONFINED JOINT CONSTRUCTION

R3

t

t t t t t t

R4

A

D1 D1D3AW3

D2D=I.D. DESIGN

R3t t

t

t

tA

AAD1

t

STANDARD UNCONFINED PLAIN FACE JOINT CONSTRUCTION

R2 R2R1R1

t t t

D1 W1

D4=(D1+3)W2=(W1+3)

ALTERNATE TONGUE AND GROOVE JOINT

DIMENSIONS TOLERANCES A +6, -3 D1, D2, D3, D4, D5, D6

0.8

t 1.5 (R1=5) +0, -0.8 (R2=6, R3=1.5) +0.8, -0 (R4=5) -0.8 (Note 1) W1, W2, W3 0.8

NOTES TO Fig. B-2: 1. This figure is not intended to

prohibit unmachined tubesheet faces and flat cover faces. Therefore no plus tolerance is shown on R4.

2. Negative tolerances shall not be construed to mean that final dimensions can be less than that required by design calculations.

3. For peripheral gaskets, Confined means Confined on the O.D..

4. Details are typical and do not preclude the use of other details which are functionally equivalent.

NOTES: 1. Unless otherwise stated, all dimensions and tolerances are given in (mm). 2. Tolerances are not cumulative. 3. Tolerances indicated on Vessel Drawing shall govern. 4. This appendix shall be used in conjunction with TEMA Standards.

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Appendix C Special Design Code Requirements

C.1 Application of ASME Boiler and Pressure Vessel Code Section VIII, Div.2 or AD Merkablatt or BS 5500 shall be considered for construction of pressure vessel when any of the following conditions are met;

(1) Design Pressure exceeds 100 kg/cm2 (10,000 kPa) (2) Plate thickness exceeds 38 mm (3) If specified in data sheet

C.2 When a vessel unit consists of more than one independent pressure chamber, different code may be applied to each chamber. In such a case, only the combination of ASME Boiler and Pressure Vessel Code Section VIII, Div.1 and Div.2 is acceptable.

C.3 When the equipment is fabricated by ASME Boiler and Pressure Vessel Code Section VIII, Div.2, Vender shall have the Certificates of authorization for use of ASME U2 Code Symbol Stamp, although code stamping is not required for the equipment, as a rule.

C.4 When the design code is not ASME Boiler and Pressure Vessel Code Section VIII, Div.1 or Div.2, Vender shall check the consistency of the code requirement and the requirement of the spec. D-102M and E-102M, and shall inform of any inconsistency to the PMC.

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Appendix D Wind Load Calculation

Wind load shall be calculated in accordance with Indian Standard IS 875-1987 Part 3 as follows;

Wind load (kg) F = C x Ae x Pd

Where

C : Shape factor for cylinders = Refer to Table D-2 (Table 23 IS 875)

Ae : Effective Area = D x H (m2)

D = Maximum of (1.2Do or Do+0.6) (m) Do = Outside diameter of insulated shell (m) H =Height of the section (m)

Pd : Design Wind Pressure at height H = Refer to Table D-1 (kg/m2)

Table D-1

Height (m) Pd (kg/m2)

0 to 10 150 >10 to 15 161 >15 to 20 170 > 20 to 30 180 > 30 to 50 196 > 50 to 100 216

Table D-2 : Shape factor is depended upon Length / Diameter (L /D)

L / D

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Appendix E Requirements for Earthquake Design

Please refer to Design Specification for Seismic Document No. A-6235-110-007

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Appendix F Requirements for Cathodic Protection

F.1 SCOPE

Whenever specified in data sheets, channels and floating head covers of heat exchangers shall be provided with Cathodic Protection as per the procedure given below.

F.1.1 FORWARD

The mild steel partition plate and certain metallic surfaces of a condenser are subject to excessive corrosion in a refinery service or petrochemical industry. One of the principal reasons for the corrosive action is the galvanic effect, if the tubes and tube sheets are made of copper or nickel alloys/stainless steel (solid or clad). The present specification recommends a method of controlling corrosion by application of paint and if necessary by additional installation of zinc alloy anodes.

The anodes system alone can also be used in cases where only the tubes are of brass and corrosion is experienced in the tube sheets, channels and covers.

F.1.2 CATHODIC PROTECTION OF PARTITION PLATE AND FLOATING HEAD

F.1.2.1 Dimension of Anode

The zinc alloy anode (part 1 & 3 of attached sketch with composition conforming to ASTM B-418-95A Type II) shall be of dimension of 150mm dia and 50mm thickness with a galvanized mild steel insert cast in situ.

F.1.2.2 Number of Anodes

One anode shall be fitted in each compartment of the channel, and floating head cover.

F.1.2.3 Painting of one surface of the Anode

Two coats of paint detailed in para 1.4 of this specification shall be applied on part of the anode surface as shown in sketch enclosed, prior to the mounting of the anode.

F.1.2.4 Location of the anode

Each anode shall be located approximately centrally on the surface to be protected.

F.1.2.5 Mounting of the Anode

The anode is designed for bolting directly to the surface as shown in the sketch, using galvanized mild steel washers and double nuts. Anodes (part 3) in sketch can be fitted on the partition plate using a common stud (part 4) in sketch, whereas the anode (part 1) in sketch on the floating head can be fitted by welding the stud (part 2) as shown in sketch. In case of difficulties in fitting anodes with common stud on partition plates, two studs can be fitted on both sides of the partition plate and the anodes can be fitted in on both sides similar to scheme-1 in the sketch.

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F.1.2.6 Electrical Contact

In the installation of each anode, good metal to metal contact must be ensured by proper supervision. The galvanized steel insert end of the anode should be ground of surrounding anode material for good metal to metal contract with the washer.

F.1.2.7 Approval of Anodes

Acceptance tests as given at the end of this specification para 1.6 should be conducted under the supervision of the CONTRACTOR on anodes and test report reviewed by the CONTRACTOR/PMC for approval.

F.1.3 OVERLAYING WITH BRONZE / STAINLESS STEEL

The face of the channel flange and partition plate coming against the brass/stainless steel tubesheet should be overlayed with bronze/stainless steel welding rod and machined.

F.1.4 PAINTING

F.1.4.1 Area to be painted

Paint shall be applied on the tubesheet on the water side, channels, partition plate, head covers and one surface of the anode.

F.1.4.2 Surface Preparation

The areas to be painted shall be completely freed from any loose material, old paint and corrosion products. Carbon steel surface shall be cleaned by hard wire brushing followed by degreasing with an aromatic solvent. The brass and other non-ferrous surfaces should be cleaned with bristle brush and degreased. The surface preparation should conform to SSPC SP 2.

F.1.4.3 Paint System

(I) For non ferrous surfaces (tube sheet and one surface of anode)

Following paint system is recommended for application on non-ferrous surfaces. (a) One coat of wash primer @ 10 microns DFT.

Type : Two pack polyvinyl butyral resin medium cured with phosphoric acid solution pigmented with zinc tetroxy chromate.

Volume Solids : 7.8% DFT : 8-10 microns/coat Covering Capacity : 7-8 M2/Litre/coat

(b) One coat of the High Build Zinc phosphate Primer @ 35-50 microns DFT. Type : Single pack synthetic medium pigmented with Zinc phosphate. Volume solids : 40-45%

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DFT : 35-50 microns/coat Covering capacity : 10-12 M2/Litre/coat

(c) Two coats of High Build Chlorinated Rubber paint @ 30 microns DFT per coat. Type : Single pack plasticised chlorinated rubber medium with chemical and weather resistant pigments. Volume solids : 30% (min) DFT : 30 microns/coat (min.) Covering capacity : 100 M2/Litre/coat

(II) Carbon Steel surfaces (a) Two coats of High Build Zinc phosphate primer as in 1.4.3.1 b (b) Two coats of High Build chlorinated Rubber paint as 1.4.3.1 c (c) The paints should be procured form reputed paint manufacturers e.g. Berger paints,

Asian paints, Shalimar paints and Jenson Nicholson.

F.1.5 GENERAL

F.1.5.1 Paint manufacturers instructions for surface preparation, paint application, intercoat interval etc. should be followed.

F.1.5.2 Each coat should have different shades for identification.

F.1.5.3 At each stage of paint application, the painted surface should be inspected for DFT and continuity of paint film.

F.1.6 ACCEPTANCE TEST FOR ZINC ANODES

F.1.6.1 Chemical Analysis

Spectographic analysis of as cast zinc anodes shall be carried out. A total no of 3 cast anodes of different heat nos. shall be selected. Three samples one from each anode should be analyzed.

F.1.6.2 Open Circuit Potential Test

For this purpose 3 samples shall be tested and sampling shall be done as similar to chemical analysis. Each sample should be properly marked with heat nos. Synthetic Sea water conforming to ASTM D1144 at ambient temp. should be the electrolyte in which test shall be done for a duration of 96 hours. Periodic recording of potential of anode samples with reference to saturated calomel electrode at every 24 hours should be recorded.

F.1.6.3 Polarisation Test

Galvanostatic testing using a variable output stabilized constant DC current power source shall be carried on the samples. For this, fresh samples, 3 nos. shall be prepared having appropriate sizes to get desired anodic current density and sampling shall be done as described in 1.6.1 (Chemical Analysis). The anodes shall be tested in parallel/series immersed in synthetic sea water. The circuit shall comprise of the following:

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a) Several anodes in parallel/ series b) One stainless steel cathode c) Resistors of equal magnitude of 1 volt one each in series with one anode d) One copper coulometer and one ammeter connected in series in one leg of circuit

All the resistors should be of close tolerance for to be controlling factor in equalizing the current in each anode circuit.

Test duration shall be of 96 hours (min.) and shall be carried out at an anodic current density of 0.55 mA/cm2 (560 mA/ft2). Anode potential should be recorded at every 1 hr for the initial 4 hours and then every 8 hours for the remaining time. All potentials should be recorded w.r.t saturated calomel electrode or silver/silver chloride electrode in standard KCI solution.

F.1.7 ANODE CAPACITY TEST

a) Fresh test samples shall be prepared similar to that described for polarisation test circuitory and arrangement shall be similar to that of polarisation test. However, for check of total ampere/hour passed over independent copper coulometer and a milli-ampere meter shall be carried out at following current densities: 100, 200, 400 mA/ft2 and duration for test at each specified CD shall be 200 hours. Periodic potential of anode shall also be recorded at 24 hours interval during test period.

Periodic check between ampere hour passed through each anode as measured by two copper coulometers should be made and recorded. A variation of +10% between the, two is acceptable.

b) Observation of corrosion pattern

All the samples after electrochemical testing should be observed visually for pattern of consumption. Any irregular attack or preferential dissolution should be reported. Photographs of selected samples shall also be taken for the anodes samples after tests.

F.1.8 REPORT PREPARATION

All test results shall be submitted in a tabular form alongwith interpretation, if any, in the remarks column.

F.1.9 Chemical composition of zinc Anode conforming to ASTM B-418-95A Type II

Aluminium 0.005% (max.) Cadmium 0.003% (max.) Iron 0.0014% (max.) Lead 0.003% (max.) Zinc Remainder.

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SKETCH SHOWING DETAILS OF ZINC ALLOY ANODES

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Appendix G Requirements for Hydrogen Service

Hydrogen service is considered when hydrogen partial pressure is more than 7 kg/cm2A (690 KpaA) (100 PsiA) or if specified in data sheets issued by PMC/LICENSER

All main body flanges shall confirm to following tolerances: (a) Peripherial gasket surfaces 0.063 (b) Cumulative flatness tolerance for two mating gasket surfaces 0.10 (c) For exchangers without internal pass partition covers, the flatness tolerance on

individual pass partition grooves shall be 0.40 All main body flanges shall have gasket seating surfaces machined after PWHT. Nuts used with SA193GrB7 bolts shall be of SA194Gr4 to minimise hydrogen attack. All seal welded tube to tube sheet joints shall be helium leak tested prior to the final

expansion role. In addition to a hydrostatic test, a shop air test at 3.5 kg/cm2g (350 Kpag) (50 Psig)

shall be applied to all exchangers. All bolted joints and tube to tube sheet joints shall be checked with soap solution. For exchangers subjected to high pressure {more than 105 kg/cm2g (1500 psig)}, helium leak test shall be carried out in addition to shop air test.