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TABLE OF CONTENTS PAGE

IX. SECTION 6 - FABRICATION 23

6.1 Shells 236.2 Pass Partition Plates 236.3 Connection Junctions 23

6.5 Welding 23

6.6 Heat Treatment 23

6.8 Gasket Contact Surfaces Other than Nozzle Flange Facings 246.10 Assembly 24

X. SECTION 7 - INSPECTION AND TESTING 25

7.1 Quality Assurance 25

7.2 Quality Control 257.3 Pressure Testing 26

7.4 Nameplates and Stamping 27

XI. SECTION 8 - PREPARATION FOR SHIPMENT 27

XII. SECTION 9 - SUPPLEMENTAL REQUIREMENTS 28

APPENDIX I: SHELL & TUBE EXCHANGER ANCHOR LOCATION 29

APPENDIX II: PREPARATION OF ROLLED JOINTS IN TUBESHEETS > 4" (thick) 30


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SHELL AND TUBE HEAT EXCHANGERS

I. SCOPE

A. This Standard, together with applicable Industry Standards, covers the minimumrequirements for shell and tube exchangers used in general refinery andpetrochemical services.

B. This Standard does not cover double pipe exchangers, tank heaters, surface

condensers (partially covered), and standard off-the-shelf accessory exchangersnormally furnished with packaged equipment, such as small lube or seal flush

coolers on rotating equipment.

C. Where conflicts exist between this Engineering Standard and other Polaris

Engineering Standards and/or applicable codes or regulations, the more stringent

requirement shall govern. All conflicts shall be brought to clients attention forresolution. client shall be the sole arbiter of any conflicts.

II. REFERENCES

This Polaris Standard is to be used in conjunction with the latest revision of the standards

and codes listed below, unless specifically noted. The terminology latest revision shall

be interpreted as the revision in effect at the time of contract award. This PolarisStandard may reference specific sections of some of these codes and standards. The

revision of the codes and standards being referenced is noted below in parenthesis. This

information is provided to identify the subject matter being referenced. Changes or

exceptions made to the referenced code or standard shall apply to later revisions asapplicable.

A. American Petroleum Institute (API) Standards

660 Shell-and-Tube Heat Exchangers for General Refinery Services

(6th

Edition, 2001)

B. Standards of the Tubular Exchanger Manufacturer's Association (TEMA) (8th

Edition, 1999)

C. Polaris Engineering Standards

1. 140.10 General Welding, Fabrication and Inspection

2. 150.1 Equipment Purchases, General Engineering Requirements

3. 170.1 Positive Material Identification (Alloy Materials)


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4. 415.1 Design Loads for Structures and Equipment

5. 500.1 Pressure Vessels - Carbon and Low Alloy Steel

6. 500.2 Pressure Vessels - Alloy Lined Steel

7. 592.2.2 Standard Nozzle Details for Clad and Lined Vessels

8. 592.2.1 Nameplate Bracket Details

9. 596.1.7 Grounding Lug Details

10. 1400.1 Painting Process Equipment and Piping

11. 1500.2 Hydraulic Stud Torquing

D. American Society of Mechanical Engineers (ASME) Standards:

1. B16.5 Pipe Flanges and Flanged Fittings NPS through NPS 24

(1998)

2. B16.20 Metallic Gaskets for Pipe Flanges, Ring-Joint, Spiral-

Wound and Jacketed (2000)

3. B16.47 Large Diameter Steel Flanges NPS 26 through NPS 60

(1998)

4. B46.1 Surface Texture (1995)

5. Section I Rules for Construction of Power Boilers (2001)

6. Section VIII Division 1 Rules for Construction of Pressure Vessels

(2001)

III. GENERAL REQUIREMENTS

A. Shell and tube heat exchangers covered by this Standard shall be designed,

fabricated, inspected and tested in accordance with API Standard 660except asmodified in this Standard, the Polaris Engineering Standards and individual datasheets listing specific operating conditions and special requirements, and TEMA.

The order of precedence is:

1. Data Sheet

2. This Standard3. Polaris Engineering Standards

4. API Standard 660

5. TEMA R

B. Paragraph numbers referenced in this standard refer to paragraph numbers


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in API Standard 660. Reference is made only to those paragraphs where

an exception is taken, an option exercised, or supplementary information

is added. Each paragraph is identified by the heading shown below whichdenotes what action has been taken regarding the subject matter of the

corresponding paragraph of API Standard 660.

HEADING ACTION

Decision A decision has been made where required by the

corresponding paragraph.

Exception An exception has been made to the corresponding

paragraph. Such exception does not invalidate the entiresubparagraph, but only that portion of the paragraph to

which the exception applies.

Substitution A substitution has been made for the corresponding

paragraph in its entirety.

Modification An amplification, rewording, or addition has been made tothe corresponding paragraph, but not a substitution

invalidating the paragraph.

New A new subparagraph, which does not appear in API

Standard 660, which is to be inserted in numerical order in

API Standard 660 adding supplemental requirements to the

same main paragraph subject matter.

Deletion A statement that is to be completely removed from thestandard.

IV. SECTION 1 - GENERAL

1.2 General

1.2.1 Modification - Exchangers shall conform to Class R requirements, of theTEMA Standards (latest edition and addenda). In addition ASME Section

I of the ASME Code may be mandated in lieu of Section VIII, Division Iwhen required. Where conflict occurs with regulatory and/or insuranceagencies concerning full Section I stamping, it is incumbent on the Vendor

to advise the Purchaser of the circumstances immediately.


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1.2. 4 Decision - All exchangers shall be ASME Code stamped and registered

with the National Board of Boiler and Pressure Vessel Inspectors.

V. SECTION 2 - PROPOSALS

2.2.8. New - The vendor shall guarantee the exchanger against defectiveworkmanship or materials, improper design, freedom from vibration either

mechanical or acoustical, and failure to perform as specified at design

conditions. The guarantee period shall be as stated in the Purchase Order

Terms and Conditions. If the exchanger does not perform satisfactorily ordefects occur during this period, the vendor shall make necessary repairs,

alterations, or replacements at no cost to Polaris. If shipment or receipt of

the completed exchanger is delayed by the purchaser or by factors outsidethe control of the vendor or purchaser, extension of the guarantee period

shall be subject to negotiation with Polaris.

VI. SECTION 3 - DRAWINGS AND OTHER REQUIRED DATA

3.1 Outline Drawings

3.1.1 Modification Vendor shall submit drawings for approval as required by

the purchase order. All drawings and other documentation shall be in

English and shall be prepared using US customary units for all dimensionsand data. Vendor shall furnish one reproducible copy of qualified welding

procedures and other documents, required by Polaris Engineering

Standard 140.10 for review and approval prior to start of fabrication. No

welding shall be done prior to the clients and/or Polaris writtenacceptance of the procedures. Vendor shall ensure that all sub-vendors are

also in complete compliance with this standard.

3.2 Information Required After Drawings Are Reviewed

3.2.1 Modification - Vendor shall furnish certified outline drawings inaccordance with the Purchase Order.

3.2.3 Modification - Vendor shall furnish one reproducible copy of qualifiedwelding procedures and other documents, required by Polaris Engineering

Standard 140.10 for review and approval prior to start of fabrication. Nowelding shall be done prior to the clients and/or Polaris writtenacceptance of the procedures.

3.2.4 Modification - After receipt of Purchaser's comments on the outline

drawings the Vendor must send calculations with detail drawings as

described in Paragraph 3.2.5. Failure by the Vendor to includecalculations with detail drawings can result in contract delay.


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3.2.5 Modification - Vendor shall prepare and submit, for review, one

reproducible copy of calculations to accompany the detail approval

drawings. They are to represent complete mechanical design.Calculations must have a cover sheet with the following information:

a. Identification: Item number, purchase order number, Vendor's shoporder number and project name and location.

Where design calculations are computer generated, input data shall

be included along with necessary explanatory notes forinterpretation. Output data shall include the applicable formulas

with the proper values shown as a part of those formulas along

with the results. The exchanger fabricator is responsible for theaccuracy of all computer programs used for the analysis.

b. Design pressure and design temperature.

c. Corrosion allowances.

d. TEMA size and type.

e. Number of passes

f. Maximum allowable working pressure (hot and corroded) and

limiting component

g. Maximum allowable working pressure (new and cold) and limitingcomponent

Detailed calculations, for approval and record, are required for the design

of all components and appurtenances of the exchanger. These shall

include:

a. Weight calculation: fabricated, operating, and full of water.

b. Thickness of shell, head, tubesheets, etc.

c. Compliance with Charpy test requirements per ASME code basedon material, thickness and minimum design metal temperature(MDMT)

d. Reinforcement requirements for nozzles, manways, etc.

e. Saddle supports based on Zick analysis


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f. Wind and earthquake analysis

g. Local stress analysis for external loads on nozzles and attachments.

h. Lifting and tailing devices including their effects on the exchanger.

i. Drawings of any required test rings shall be furnished. Drawings

shall be submitted of the "code" nameplate and the supplementary

nameplate. Information provided on the supplementary name plate

will include the following:

1) Exchanger Service and Item Number

2) P.O. Number

3) Maximum Allowable Working Pressure - MAWP (Newand cold) and shop test pressure.

4) Field Hydrostatic Test Pressures on each side based on

MAWP (hot and corroded)

5) Any test or operating limits such as differential pressure.

6) Number, size and gauge of tubes, (Birmingham Wire Gage

- BWG specified minimum or average wall), length, and

square feet of surface area.

7) Minimum design metal temperatures and specified vacuum

service and temperature.

8) If Post Weld Heat Treatment (PWHT), a warning should

specify that the equipment is stress relieved and welding is

not permitted.

3.3 Final Records

Modification - The Vendor shall maintain records of the following for at least five

(5) years:

(a) Certified material test reports or certificates of compliance.

(b) Temperature-Recorder charts made during PWHT.

(c) A complete set of radiographs and records as described in UA-51 ofSection VIII of ASME Code; except for time retention.


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VII. SECTION 4 - DESIGN

4.1 Design Temperature

4.1.4 New - For design temperatures of 800oF and higher, the design details fornozzles, supports and other attachments to the exchanger shall be free ofhigh local stress concentrations. Design details using fillet welds shall be

avoided unless welds are ground to a smooth radius.

4.1.5 New- Unless otherwise specified exchangers shall be designed for fullvacuum at 300 F on shell and tube sides.

4.2 Cladding for Corrosion Allowance.

4.2.1 Modification - Unless indicated otherwise on the exchanger data sheet, the

minimum thickness of applied liners or cladding shall be the greater of 1/8inch or the specified corrosion allowance

4.2.2 Modification - Unless indicated otherwise on the exchanger data sheet, the

minimum thickness of applied liners or cladding shall be the greater of 1/8inch or the specified corrosion allowance

4.2.3 New - Shellside corrosion allowance shall be applied to tube bundlebaffles.

4.2.4 New - The specified minimum thickness of corrosion-resistant lining or

cladding shall be applicable to all exposed surfaces including sides andbottom of partition grooves and other gaskets grooves. See Polaris

Engineering Standard 592.2.2..

4.2.5 New - For sleeve lining or strip lining refer to Polaris Engineering

Standard 500.2 and Section 5 of this Standard.

4.3 Shell Supports

4.3.1 Modification - The fixed shell support and anchor bolt size are to bedesigned to withstand a longitudinal force twice the bundle weight.

Minimum anchor bolt size is 1 inch diameter. Refer to Appendix I, thesaddles with slotted holes are to be at the saddles closest to the channelend.

4.3.3 Modification - The lower shells of stacked removable-bundle heat

exchangers shall be designed to carry the superimposed load without

suffering distortion that could cause binding of the tube bundles. Thecorrosion allowance shall be deducted before investigating such external

loading. Differential thermal expansion between shells shall be

considered.


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4.3.6 New - Projection distance of upper and lower intermediate supports

between stacked exchangers shall provide a minimum of 12" clearance

between adjacent body flanges.

4.3.7 New - All exchangers weighing 30,000 lbs. or more (full of water) shallhave supports designed in accordance with L.P. Zick's paper "Stresses inLarge Horizontal Cylindrical Pressure Vessels on Two Saddle Supports".

The calculations shall be submitted for review.

4.3.8 New - When stacked exchangers are used, the Fabricator shall investigatepotential thermal expansion problems of the intermediate connecting

nozzles and supports, caused by vertical and horizontal differential

expansion forces.

4.3.9 New - All exchangers with an I.D. of 36 inches or greater or weighing

more than 30,000 lbs. full of water, shall have the shell evaluated for theeffect caused by loading on support lugs. Calculations shall be made with

the shell cylinder in the corroded condition and the exchanger full of

water. The calculations shall be submitted for review.

4.3.10 New - The Fabricator shall locate all welded joints on shop drawings

submitted for approval. Longitudinal joints in adjacent shell courses shall

be offset.

4.3.11 New - Wherever possible, nozzles, reinforcing pads for nozzles, and other

attachments shall not be located over longitudinal and circumferential

weld joints. If this is unavoidable, approval must be obtained from theclient and/or Polaris and the welded joint shall be ground smooth and

radiographed for its entire covered length, plus 1 inch on each side.

4.3.12 New - The maximum shell diameter shall be 44 inches I.D. unless

otherwise approved by the client and/or Polaris.

4.3.13New - Exchanger supports shall be located per Appendix I, of this

Standard, unless otherwise noted.

4.3.14 New Exchangers shall be designed for the wind load and seismic loads

specified in Polaris Engineering Standard 415.1.

4.4 Stationary Head (Channel)

4.4.4 New - Unless otherwise specified channel covers shall be removable(flanged).

4.4.5 New - Drain holes shall not be provided in pass partition plates unlessapproved by the client and/or Polaris.

4.4.6 New - When using TEMA the maximum allowable flat channel cover


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deflection for all diameters shall be 0.03125 inches. The thickness used

for the channel cover will be the greater of the ASME Sect. VIII

calculation or TEMA R.

4.5 Floating Head

4.5.6 New - Floating head flanges and bolting shall be designed for the most

severe design temperature (Internal and External). Metal temperatures

may be used only if calculations for metal temperatures are submitted to

the client and/or Polaris for review.

4.5.7 New - Gasket seating area of pass ribs shall be considered in the design of

floating head flanges.

4.5.8 New - For internal flange bolting, when the shell material is higher alloy

than carbon steel, the bolts and nuts shall be equal to or better than theshell material with regard to chemical and mechanical properties.

4.5.9 New - Where a single pass floating head design is required and approved

by the client and/or Polaris, a bellows type internal expansion joint shallbe used for the floating head nozzle connection.

4.5.9.1 New - The expansion joint shall be designed for full internal andexternal design pressure applied independently, and jointly.

4.5.9.2 New - The expansion joint shall be designed to accommodate the

maximum design temperature, including steam-out conditions.

4.5.9.3 New - There shall be an internal sleeve welded to the upstreamend.

4.5.9.4 New - The expansion joint shall be "cold set" during assembly

for the design movement so that it will be in the neutral positionwhen at the normal operating temperature.

4.5.9.5 New - Provide permanent external stiffening stays to preventdamage to the expansion joint during maintenance.

4.5.9.6 New - Minimum design cycle life shall be 5000 cycles.

4.5.10 New - The Vendor is expected to expose the floating tubesheet tube-jointsduring the testing process for verification of leakers or seepers. If the

client has not ordered a test head, the Vendor shall use a head from

inventory suitable for a low pressure test of at least 50 PSI. If the clienthas ordered a test head, a full test pressure is expected. Care should be

taken by the Vendor to avoid work-hardening tube ends at this joint. The

painting system on the test head shall be per Polaris Engineering Standard

1400.1, system I.A. on all surfaces (internal and external). The gasket


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surfaces shall be coated with a rust inhibitive.

4.6 Tube Bundle

4.6.1 Tubes

4.6.1.1 Substitution - The minimum tube outside diameter shall be 3/4

inches.

4.6.1.2 Substitution - 3/4 inch O.D. tubes and 1 inch O.D. tubes shall beused and if 12 BWG minimum wall or thicker is required due to

frequent cleaning, such as residual oil service, then 1 inch O.D. is

required. The required minimum values of tube diameter andwall thickness are as follows:

MaterialTubeO.D.

B.W.G.(Min. Wall)

B.W.G.(Avg. Wall) Thickness

Copper and

Copper Alloys

3/4 16 NA 0.065

1 14 NA 0.083

Carbon Steel, Aluminum

and Aluminum Alloys

3/4 NA 12 0.109

1 NA 10 0.134

Stainless Steel and Other

Alloys

3/4 NA 14 0.083

1 NA 14 0.083

Notes:a) Average wall tubes of one BWG thicker may be used in place of

the specified minimum wall tubes.

b) Tubes specified from Copper & Copper Alloys shall be

minimum wall tubes. Tubes from all other materials shall be

average wall tubes.

c) Carbon Steel tubes must be seamless. Stainless Steel tubes may

be seamless or autogenous fusion welded, with clients approval.

All other alloy tubes shall be seamless unless approved by client.

4.6.1.5 New - Unless otherwise specified on the individual data sheet

and approved by client, U-Bends in U-Tube bundles shall be in avertical plane.

4.6.1.6 New - The nominal length of tubes for removable bundles shallbe a maximum of 20 feet.

4.6.1.7. New - Where yield strengths of tubes used in an Exchanger shellexceed 10% variation due to heat or mill differences, the Vendor

will advise the client and/or Polaris immediately and also provide

an "as-built" tubesheet drawing locating the groups of tubes to

assist the client in future re-rollings when confronted with such


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variation. In such instances, data requested on Appendix II will

be completed by the Vendor and furnished to the client.

4.6.1.8 New Square pitch shall be used on exchangers in high fouling

services with a shell side fouling factor over 0.002 Hr Ft2F/Btu.

4.6.1.9 New A minimum in-tube velocity based on liquid normal flow

rate with a fouling factor of:

0.002 Hr Ft2F /Btu shall be minimum 3.3 fps

0.003 Hr Ft2F /Btu shall be minimum 4 fps

0.004 Hr Ft2F /Btu shall be minimum 4.5 fps

4.6.2 Tube Sheets

4.6.2.4 Exception - The Fabricator is expected to calculate a fulldiameter tubesheet using formulae from ASME Section VIII,

Division I, Paragraph UG-34, and TEMA 1999, Paragraph

RCB7.134, and use the thicker tubesheet. Both calculations are

to be shown on Vendor submittal.

4.6.2.5 New - In the case of TEMA Type "B" stationary heads only; the

stationary tubesheets on removable bundles shall be of "fulldiameter" design, with shoulder studs to retain the tube sheet to

shell joint when bonnet is removed. Tubesheet extension shall

be strong enough to allow hydrotesting of bundle on both sides

when bolted separately to channel or shell. Allowable strengthfor this purpose only may be three-fourths of yield.

4.6.2.5.1 Where solid stainless steel tube sheets are used with

a design pressure over 600 psig, the requirement of

4.6.2.5 may be modified with clients approval to a

design the tubesheet for a 300-450#+ differentialpressure with a warning plate. This is typical for

HDS combined feed service.

4.6.2.6 New - Tubesheets for fixed tube sheet exchangers shall be

designed per the requirements of TEMA with the followingexception: The stress value of the tube sheet shall be based onthe maximum design temperature of the shell side or tube side

design temperature, whichever is greater. The modulus ofelasticity and the mean coefficient of thermal expansion for the

shell cylinder, tubes and tube sheet are to be based on calculated

metal temperatures.

4.6.2.7 New - Tubes in expanded joints shall be expanded for the full

thickness of the tubesheet less 1/8 inch on the shellside face up to

the tubesheet thickness of four tube diameters. If the tubesheet is


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thicker than four tube diameters, rolling shall cover a width of

three tube diameters from the tubeside face and one tube

diameter from the shellside face to within 1/8 inch of theshellside face. For thick tubesheets involving the latter

procedure, the Fabricator will provide data to the client describedin Appendix II.

4.6.3 Transverse Baffles and Support Plates

4.6.3.1 Modification - The shell side corrosion allowance shall beapplied to the bundle baffles and support plates. TEMA Table

RCB-4.41 (1999 Edition) thicknesses will be increased

accordingly.

4.6.3.3 New - Baffle material shall be the same pressure vessel quality

plate as the shell. If the shell is clad or weld overlaid, the baffleswill be the same material as the overlay.

4.6.3.4 New - Baffle cuts of single-segmental baffles for sensible heat

transfer service on the shell side shall be between 15% and 30%of the shell diameter. The first baffle shall be located as close to

the tube sheets as possible, consistent with the specified baffle

spacing. In this regard, the floating head support shall be asclose to the floating tube sheet as possible. Baffles shall not be

located between the inlet and outlet nozzle and the respective

tube sheet unless a deflector baffle is provided to direct flow

across the tube sheet.

4.6.3.5 New - When maximum baffle cuts are required with U-tubeconstruction having horizontal bends, consideration must be

given to the addition of extra tie-rods on the vertical centerline to

give added rigidity to the two bundle halves.

4.6.3.6 New - Special consideration shall be given to ensure adequate

support of tubes in inlet and outlet flow zones and of U-bends to

prevent vibration.

4.6.4 Impingement Protection

4.6.4.1 Substitution - Where impingement protection of the tube bundle

is required per TEMA RCB-4.61, a solid plate shall be used.Slotted or perforated plates shall not be used without the

approval of client. Swaged inlet nozzles where the impingement

plate is located in the nozzle shall not be used. Vapor belts maybe used at the Manufacturer's option.

4.6.4.2 Substitution The diameter of impingement plates shall be equal

to the nozzle I.D. plus 2 inches (minimum). It shall be attached


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to the tube bundle and may be any shape. There shall be at least

1/16 inch clearance between the bottom of the plate and the top

of the tubes.

4.6.4.4 Substitution - The impingement plate shall not be less than 1/4inch nominal thickness for carbon or 3/16 inch nominal thicknessfor non-ferrous or high alloy materials.

4.6.4.5 Modification - Impingement baffle plates shall be attached in a

manner providing at least two parallel edges for support.

4.6.5 Bypass Sealing Devices

4.6.5.1 Substitution - Bypass sealing devices are required in peripheral

bypass lanes when the radial distance from the outermost tube of

the tube bundle and the shell inside diameter exceeds one inch.Internal bypass sealing devices are required in the bypass lane

between the innermost tube row of U-tube bundles when the pass

partition lane is not parallel to the baffle cut. The number of

seals in each bypass lane shall be determined as follows: (Referto API 660 Figure 1)

1. A minimum of two pair of seals shall be located in theperipheral bypass lane with one pair at the top and one pair

at the bottom of the tube bundle.

2. A minimum of one pair of seals shall be located in theinternal bypass lane. If the requirement for the minimum

pairs cannot be physically met, single seals shall be locatedat the centerline of the tube bundle.

3. Outermost seal plates in peripheral or internal bypass lanes

shall be located between one and three inches from theedge of baffle cuts.

4.6.5.4 Modification - Continuous tube lanes shall be maintained for allsquare and rotated square pitch arrays.

4.6.5.8 New - Baffle window areas which are void of tubes shall besealed with baffle "ears," except where "no-tubes-in window"

designs are intentional.

4.6.6 Bundle Skid Bars

4.6.6.1 Modification - Bundles shall be provided with skid bars when

bundle weight exceeds 12,000 lbs. As a minimum two bars, 1-

inch high by 2 inches wide, mounted 15 degrees each side of the

bottom centerline shall be provided. The bars shall be adequate


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to permit handling the bundle with a cable sling without

damaging the tubes or baffles. Weld bars to intersecting baffles.

4.7 Nozzles and Other Connections

4.7.1 Substitution - All nozzles must be flanged, raised face. The inlet andoutlet stream connections shall be faced and drilled to the rating specified

on the data sheets.

a. Minimum nozzle size shall be 1 1/2 inch for exchanger designtemperatures up to 750 F.

b. Minimum nozzle size shall be 2 inches for exchanger designtemperatures exceeding 750 F.

c. With the exception of hill side or long projection nozzles, nozzlesizes 2 inches and under shall be long welding necks.

d. The minimum exchanger nozzle rating for sizes 2 inches and less

shall be 300 lbs.

4.7.2 Substitution - Welded connections shall not be used.

4.7.3 Substitution Nonflanged or threaded connections shall not be used. All

connections shall be flanged per paragraph 4.7.1.

4.7.4.c. Deletion

4.7.5 Substitution - Slip-on flanges and couplings are not allowed. N.P.T.connections are not allowed.

4.7.6 Modification - Flanges 24 inches nominal size and smaller shall be in

accordance with the dimensions and ratings of ASME B16.5. Unlessapproved by the client and/or Polaris, flange nominal sizes 26 to 60

inclusive, shall be in accordance with the dimensions and ratings of

ASME B16.47 Series B(formerly API 605). Contractor shall verify thatASME B16.47 Series B flanges are suitable for the intended application.

Other sizes shall be calculated in accordance with the applicable code andshall be approved by the client and/or Polaris. Lap-joint flanges requirethe client and/or Polaris approval. If allowed, the stub end shall be

equipped with stops to prevent falling when bolting is loosened.

4.7.9 Decision Clearance shall be provided for stud tensioning in accordance

with Polaris Engineering Standard 1500.2.

4.7.11 New - The inner edge of all nozzles shall be rounded to 1/8 inch radius.

All nozzles shall be flush with the inside surface of the exchanger unless

noted otherwise.


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4.7.12 New - Nozzle necks larger than 10 inches may be made of built-up

construction using formed plate necks and welding neck flanges whenseamless pipe is not readily available and such construction is approved by

the client and/or Polaris. Nozzle necks 10 inches and smaller shall bemade with seamless pipe and welding neck flanges. In any sizes, longwelding necks are preferred.

4.7.13 New - The corrosion allowance for nozzles and manways shall be at least

equal to the corrosion allowance specified for the exchanger side in whichthey are located.

4.7.14 New - Each nozzle shall be adequately reinforced for new and cold as wellas corroded condition in accordance with code requirements. Nozzle

reinforcement shall not limit maximum new and cold maximum allowable

working pressure. Reinforcement for 2 inch nozzles shall be checked forcorroded condition.

Each reinforcing pad or section thereof shall have at least one test hole

tapped 1/4 inch NPT. The weld of each pad shall be given an air and soapsolution test (5 psig minimum), in the presence of the client's Inspector

before post weld heat treatment. After the test, the hole shall be filled with

corrosion inhibiting grease. The hole shall not be welded or plugged. Ifthe pad is fabricated in two parts the weld shall be oriented in the

circumferential direction. All rectangular and square reinforcing pads

shall have rounded corners with 3 inches minimum radius.

4.7.15 New Nozzle flange facings shall be machine finished as noted below for

spiral-wound gaskets, and a fine serrated finish for smooth metal gaskets.The exchanger fabricator shall specify the type of finish to be furnished.

Welding neck flanges shall have the same bore as the nozzle necks to

which they are attached.

4.7.16 New All RF flanges shall have a flange surface finish range of 125 Ra

minimum to 250 Ra maximum. Finishes shall be judged by visual

comparison with AARH Standards, ASME B46.1.

4.7.17 New - External nozzle bolting shall be supplied by the exchangerfabricator and shall be a minimum of ASTM A-193 Gr. B7 stud-bolts,complete with two ASTM A-194 Gr. 2H semi-finished oil-quenched

heavy hex nuts each. For bolt metal temperatures over 800 F, boltingshall conform to ASTM A-193 Gr. B16 stud-bolts with ASTM A-194 Gr.

4 nuts.

4.7.18 New - Gaskets shall be furnished as specified on the data sheets.

Dimensions of raised face gaskets shall be in accordance with ASME

B16.5. Flexitallic type "CG" (type "CGIU" for flanges over 24 inches

diameter) or equal shall be used for all hydrocarbon services. All


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gasketing and packing, including test gaskets, shall be commercial quality

fabricated from asbestos-free material suitable for the process

environment. The Fabricator shall ship additional gaskets, shippedseparately with proper protection and identification, as follows:

a. For nozzles sizes up to and including 24 inches diameter, ship onegasket new and unused for each nozzle having a cover.

b. For nozzle sizes larger than 24 inches diameter, ship two gaskets,

new and unused, for each nozzle having a cover.

4.7.19 New - Kettles: Level control, level glass, alarm and shutdown device

connections may be individual 1-1/2 inches (2 inches for over 750 Fdesign temperature) nozzles or on a bridle arrangement with 2 inch

nozzles (the bridle arrangement is preferred); however, alarm and

shutdown device connections shall not be combined on the same bridlewith level and gauge glasses.

4.7.20 New - On vertical exchangers: level glass, level control, alarm and

shutdown device connections shall have their own individual connections.

4.7.21 New - All level instrument connections shall be jig set.

4.7.22 New - For alloy nozzles or alloy lined nozzles (the client and/or Polaris

approval required prior to use) refer to Polaris Engineering Standard

500.2, Pressure Vessels, Alloy-lined steel.

4.7.23New - All process nozzles of heat exchangers shall be provided with

pressure and temperature connections as prescribed in TEMA R, B-10.32and RB-10.33. For stacked exchangers the instrument connections may be

omitted from one of the two mating connections as per TEMA R, B-10.4.

The connections shall have one (1) 1-inch and one (1) 1 inch long weld

neck flanged connection with blind flange, Flexitallic type stainless steelgasket and appropriate bolting provided. Pressure rating of these

connections is to be consistent with the design of the heat exchanger, but

in no event less than 300 lb. The projection of these nozzles shall be longenough to clear the insulation to allow for installation and removal of

bolts.

4.7.24 New - Process nozzles in the corroded condition shall be capable of

withstanding the moments and forces in Table 1 below. The forces act asshown in TEMA Figure RGP-RCB-10.6 (1999 Edition).

TABLE 1 - MAXIMUM ALLOWABLE NOZZLE LOADS


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NOZZLE

SIZE-INCHES

FORCEPOUNDS

MOMENTSPOUND-FEET

P Vl Vc Mr Ml Mc3 600 600 600 600 600 600

4 1000 1000 1000 1200 1000 1000

6 1800 1500 1500 3000 2700 2700

8 3000 2400 2400 6000 4500 4500

10 4000 3000 3000 6000 5500 5000

12 4500 4000 4000 6000 7000 6000

14 5000 5000 5000 7000 8000 7000

16 5800 5800 5800 7500 9000 8500

18 6500 6500 6500 8300 9800 9300

20 7000 7000 7000 9200 10500 10200

24 7700 7700 7700 10500 12500 11900

None of individual stresses (circumferential, longitudinal shear and

combined stresses) may exceed 2.5 x Sa at nozzle pipe OD for nozzle

without pads, or 1.0 x Sa at nozzle OD for nozzle with pad.

4.7.25 Vents and drains are to be 1 RF LWN blinded conditions with a 300#

minimum flange rating. For heavy oil services, fouling factor of 0.004 HrFt

2F/Btu or higher, 1 1/2 drains shall be provided.

4.8 Flanged External Girth Joints

4.8.2 Substitution - Shell and channel girth flanges are to be of forged steel,

weld neck type or hub type, faced for confined gaskets and have 150 lb.

rating, or higher, and thru-bolt joint construction. Slip-on welding flangesshall not be used.

4.8.7 Decision Clearance shall be provided for stud tensioning in accordance

with Polaris Engineering Standard 1500.2.

4.8.8 New - All fabricated flanges shall conform to the requirements of

Appendix 2 of the ASME Boiler and Pressure Vessel Code Section VIII,

Division I.

4.8.9 New - All pressure boundary forgings, except standard ASME flanges

shall be ultrasonically examined in accordance with the ASME code,


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Section II, SA-388.

4.10 Gaskets

4.10.1 Substitution - Gaskets shall be furnished as specified on the purchaserequisition. Dimensions of raised face gaskets shall be in accordance withASME B16.5, Appendix E. Flexitallic type ("CG" (type) "CGI" for

nozzle flanges over 24 inches diameter) or equal packing, including test

gaskets, shall be commercial quality fabricated from asbestos-free material

suitable for the process environment.

4.10.3 New - Internal floating head gaskets will be of double jacketed non-

asbestos gaskets

4.10.4 New - All solid metal gaskets and inner and outer compression -limiting

rings of spiral-wound gaskets shall be made from a single piece of metalwith no more than one weld. The thickness tolerances specified for the

gasket shall also apply to the weld.

4.10.5 New - Where spiral wound gaskets (flexitallic or equivalent) are used, andpass partitions are required, the gasket for the pass partition shall be a

metal jacketed grafoil-filled strip of the same thickness as the girth gasket.

The ends of the strip shall be pinched together and each end shall bewelded to the spiral-wound gasket

4.10.6 New - All carbon steel or low alloy gaskets containing welds must have

the welds heat treated to remove hard spots.

4.11 Handling Devices

4.11.1 Modification - All lugs shall be completely seal welded to prevent

corrosion behind lugs. Lifting lugs shall be provided on all channels,

removable channel covers, floating head covers and removable shellcovers.

4.11.2 Modification - Attachment welds for lifting lugs that are an abutment, buttwelded to the exchanger, shall be full penetration welds.

4.11.5 New - Jack screws shall be provided to aid in loosening all heads,channels and channel covers.

VIII. SECTION 5 - MATERIALS

5.1 General

5.1 Modification - Bolting - Minimum quality bolting for channel and girth flanges

shall consist of continuously threaded bolts conforming to ASTM A193-B7 with

nuts in accordance with ASTM A194-2H. Material for bolting in units with


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design temperatures below -20 F shall be selected from a suitable grade of

ASTM A-320.

5.1.5 New - Materials which are to be used for a pressure part, or are to be

welded to a pressure part shall be selected from ASME Code section IIpart D when not noted on the data sheet. All materials that are to be usedfor a non-pressure part and are not welded to a pressure part shall meet the

chemistry and mechanical properties of an equivalent ASME Section II

part D material. The selected materials shall be clearly identified on the

Vendor Drawings and MTRs submitted.

5.1.6 New - Use of any foreign materials requires prior approval of the client

and/or Polaris. The Vendor's proposal shall clearly state if any foreignmaterial is quoted and indicate names of foreign manufacturers.

5.1.7 New - Welded non-pressure attachments to pressure parts shall be of thesame material as the base material. For example, pass partition plates,

lifting lugs, saddle pads.

5.1.8 New - When killed carbon steel is specified in H2S service, then onlykilled carbon steel that does not contain aluminum shall be used.

Aluminum killed steel is not acceptable. However traces of aluminum in

the KCS is acceptable. Silicon killed (C.S.-SI killed) shall be specifiedand sulfur content limited to 0.008 per cent maximum.

5.2 Gaskets

5.3 Tubes

5.3.3 New - Carbon Steel tubes must be seamless. Stainless Steel tubes may be

seamless or autogenous fusion welded, with the client and/or Polaris

approval. All other alloy tubes shall be seamless unless approved by the

client and/or Polaris.

IX. SECTION 6 - FABRICATION

6.1 Shells

6.1.3 Decision - Transverse Baffle-to-Shell clearances greater than indicated inTEMA Table RCB-4-.3 shall not be used. Any reduction in thickness of

clad or overlay surfaces in order to meet TEMA tolerance is not permittedwithout written approval of the client and/or Polaris.

6.1.4 New - When a difference in thickness exists between shell plates or platesand heads, the inside diameter shall be held.

6.1.5 New - all bundles and other components are to be trial fit in the shop and

hydrotested in the shell. Should this for any reason not be practical, a


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deviation must be obtained in writing from the client and/or Polaris.

6.2 Pass Partition Plates

Substitution - Pass Partition Plates for forged or welded channels and floatingheads shall be welded full length with full penetration welds.

6.3 Connection Junctions

Modification - Couplings are not permitted. Refer to paragraph 4.7.1

6.5 Welding

6.5.1 Substitution - Welds and welding procedures will conform to Polaris

Engineering Standard 140.10.

6.5.5 Deletion - Backing strips are not permitted.

6.5.11New - Fabrication involving welding shall not be sublet to others without

prior approval of the client and/or Polaris.

6.6 Heat Treatment

6.6.2 Modification - Stress relieving the bend portion of U tubes is required for

carbon steel, low-alloy steel and copper alloy. If specified, austenitic U-

bends will be stress relieved in accordance with SA-688 Paragraph 7.2.

6.6.3 Modification - The heat treated portion will extend 12 inches beyond the

point of tangency.

6.6.4 Modification - All carbon steel channels, bonnets and floating heads will

be post-weld heat treated.

6.6.5 Modification - PWHT procedures for clad or weld overlaid components,

including temperatures, ramp and holding time shall be submitted for

approval to the client and/or Polaris.

6.6.7 Decision PWHT is required when specified in Polaris EngineeringStandard 140.10 or on the data sheet. Minimum and maximum PWHTtemperatures and minimum holding time shall be as specified in Polaris

Engineering Standard 140.10.

6.6.8 New - All welding, including non-pressure attachments, must be

completed prior to final heat treatment.

6.6.9 New - Materials subject to post weld heat treatment (PWHT) shall be

purchased with mill test reports indicating time necessary to allow at least

one full PWHT cycle in addition to all planned PWHT.


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6.8 Gasket Contact Surfaces Other than Nozzle Flange Facings

6.8.2 Deletion

6.8.3 Substitution

All gasket surfaces will conform to the following flatness tolerances:

a. Peripheral gasket surfaces: plus or minus 0.0025 inches (.064 mm).

b. Cumulative flatness tolerance for two mating gasket surfaces: plus

or minus .004 inches (0.10 mm).

c. For exchangers without internal pass partition covers, the flatness

tolerance on individual pass partition grooves shall be plus orminus .016 inches (0.40 mm).

6.10 Assembly

6.10.3 New - Fabricator is to stamp on all removable components using a metal

punch, the item number, including the shell identifier letter, i.e., E-7001 D,

to assist on re-assembly at turnaround.

6.10.4 New - Tubes will project 1/8 inch (plus or minus 1/16") beyond the face of

the tubesheet on horizontal exchangers. The 1999 TEMA Edition

Paragraph RB-7.513 is to be followed only for vertical exchangers.

6.10.5 New - In sulfur service the tube to tubesheet joint shall be strength weldedin addition to a complete and fully retained rolled joint configuration. This

shall be performed in the shop for all sulfur service equipment due to the

difficulty to weld this type equipment after it has been in service. The

following requirements shall apply:

1. The joint design shall be such that the rolled joint is 100 %

retaining and the strength weld is independently 100% retaining.

2. The tube ends shall extend a minimum of 3/16 minus 1/16 inchplus up to the limits of TEMA RB-7.513.

3. The detail of the cut for the strength weld shall be of a "J" beveldesign. The depth of cut into the tubesheet shall be 0.125 inches or

the thickness of the tube wall, which ever is greater. Alternate

designs may be used if approved by client.

4. Tubes shall be rolled into the tubesheet prior to strength welding.

A preheat to 300F is required. The weld shall consist of two

passes for tempering of the weld, followed by a light contact roll to


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put the weld in compression after the second pass.

X. SECTION 7 - INSPECTION AND TESTING

7.1 Quality Assurance

7.1.7 New - Client's Inspector or Representative will be consulted concerning

repairs and shall, at his option, witness all repair work.

7.2 Quality Control

New - Requirements of Polaris Engineering Standard 140.10, General Welding,

Fabrication and Inspection Specification, shall be followed.

7.2.12 New - Exchangers having a design pressure of 500 psig or greater shall

have all external attachment welds to pressure containing parts examinedby the magnetic particle (DC prod. contact) or liquid penetrant method.

This examination shall be performed after any required postweld heat

treatment and hydrostatic testing.

7.2.13 New - Complete radiography is required, regardless of material, thickness

or service, of any welded seam that has been subjected to severe working

(as defined in the Code Para. UG-79) after welding. Radiography shall becarried out after postweld heat treatment.

7.3 Pressure Testing

7.3.2 Exception - Exchangers and testing medium shall not be less than 70F

during hydrostatic tests. Where the ductile to brittle transition temperatureof the steel is known to be, or suspected of being 40F or higher, it is the

Fabricator's responsibility to raise the temperature of the exchanger and

testing medium to be at least 30F higher than the transition temperature.

7.3.3 Substitution - All exchangers shall be hydrostatically tested at 1.3 times

the maximum allowable working pressure for the new, uncorroded

condition at 60F in accordance with the ASME Code Section VIII,Division I, section UG-99. This test is recorded on the nameplate as "shop

test." The hydrostatic test will be maintained for a minimum of one hourand for no less than one hour per one inch of thickness. The thickness ofthe shell or channel barrels or heads will determine the length of the test

period. When hydrostatic tests are performed either two indicating gagesor one indicating and one recording gage shall be attached to the

exchanger.

A pressure of not less than 100% of the design pressure shall be

maintained for sufficient time to determine if there are any leaks, but not

less than one hour following the application of the hydrostatic test

pressure per UG-99 of the code.


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7.3.4 Substitution - Clean fresh water shall be the primary hydrostatic test

medium unless use of a different medium is approved by the Client orClient's Representative. Hydrostatic testing of exchangers with austenitic

stainless steel internals shall be done with potable quality water having achloride content of not more than 50 ppm (parts per million). If chloridecontent is greater than 50 ppm, up to a maximum of 250 ppm, a sufficient

quantity of sodium nitrate shall be added to provide a test medium of 0.5%

by weight sodium nitrate solution. Water with a chloride content of

greater than 250 ppm shall not be used for hydrotesting. Exchangers shallbe dried thoroughly, immediately after draining, to prevent the possibility

of evaporation and concentration of chlorides. Water may be blown out of

packet by using clean and cold compressed air as alternate.

7.3.11 New - After hydrotest the tubeside shall be air tested by pressuring the

tubeside with air at 25 psig with the shell sloped, full of water, and thetopmost shell nozzle open to observe air bubbles. Bubbles shall be cause

for rejection.

7.3.12 New - Welded attachments shall be tested with 15 psig air and soapsolution before hydrotest of the exchanger. Vent holes shall remain open

during hydrotest. Plug vent holes with stiff grease before shipment.

7.4 Nameplates and Stampings

7.4.2 Modification - The nameplate shall be made of austenitic stainless steel or

monel and shall be seal welded to the nameplate bracket. The bracketshall be in accordance with Polaris Engineering Standard 592.2.1.

7.4.3 Modification - In addition to the manufacturers serial number being

stamped also stamp the Client's item number to the parts listed. Note in

the case of multiple bundles, identify each, i.e., E-7306 C, stamped

differently from E-7306 D.

7.4.4 New - A supplemental nameplate shall be provided in order to

accommodate Polaris required information in addition to codeinformation, as follows:

1. Exchanger service and item number2. P.O. Number

3. M.A.W.P. (New and cold) and "shop test pressure"4. Field test pressure each side based on M.A.W.P. (hot and

corroded)

5. Any test of operating limits such as differential pressure.6. Tube material, number and size of tubes, BWG minimum or

average wall, length, and square feet of surface area.

7. Minimum design metal temperatures and specified vacuum service

and temperature.


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8. PWHT information and warning of no welding allowed after

PWHT.

9. Year built.

All nameplate data shall be in US customary units.

XI. SECTION 8 - PREPARATION FOR SHIPMENT

8.1.3 Substitution - The following shall be applied to all exchangers:

(a) All exchanger openings shall be made watertight.

(b) All flanged connections which are not furnished with permanentblinds shall be covered with 1/4 inch minimum thickness, full

diameter, steel plate covers. The covers shall be installed with 1/8

inch thick cloth inserted neoprene gasket, and secured with fullbolting. Covers need not be drilled for bolting. Covers need not

be drilled for bolting larger than 3/4 inch diameter bolts and

suitable cut washers if a seal can be maintained.

(c) When the exchanger has surfaces made from austenitic materials

the exchanger fabricator shall provide a positive nitrogen pressure

of 3 psig minimum in the exchanger to provide protection againstpossible chloride attack by the sea water. Protection of outside

surface is required also. Fabricator is invited to submit alternate

methods for consideration. Vessels and exchangers shall be

assumed to be deck cargo. All blinds shall be marked"NITROGEN PURGED - DO NOT OPEN."

(d) Loose items shipped apart from the exchanger shall be crated for

protection against physical damage and sealed in sheet plastic

against water damage.

(e) Protective measures shall be subject to inspection and rejection by

client or clients inspector. All costs occasioned by any rejection

shall be for the account of the Fabricator.

8.1.4 Modification - Machined surfaces and flange faces shall be covered withan acceptable rust preventive grease.

8.1.10 New - Spare gaskets shall be enclosed in a plywood container marked withthe client's purchase order number and equipment number and shipped

with the exchanger.

8.1.11 New - All exchangers shall be provided with a desiccant during shipment.

All desiccant shall be removed by others at the jobsite.

8.1.12 New


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(a) Each exchanger shall be thoroughly cleaned inside and outside and

shall be free from grease, weld spatter, scale, slag, rust and anyother foreign material.

(b) All uninsulated as well as insulated external surfaces of carbonsteel and low alloy exchangers including saddles shall be

sandblasted and primed in accordance with Polaris Engineering

Standard 1400.1, unless noted otherwise. All nozzle faces shall be

adequately protected from damage during sandblasting.

XII. SECTION 9 - SUPPLEMENTAL REQUIREMENTS

9.2 Design

9.2.1 Modification - Refer to paragraphs 4.7 and 6.3 for acceptable connections.


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APPENDIX I

Shell and Tube Exchanger Anchor Location

Note 1: Support spacing = 12 feet for 20 foot tube length (except Type H = 14 feet)

Support spacing = 10 feet for 16 foot tube length (except Type H = 12 feet)


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APPENDIX II

PREPARATION OF ROLLED TUBE JOINTS IN TUBESHEETS >4" (thick)

Fabricator Name:

Polaris P.O. #:

Item # and Service:

Tube Hole Details

(a) Tubesheet Material Stationary ; Floating

(Note 1) (b) Tube Material, Thickness, O.D., Gauge, Length

(c) Tubesheet holes drilled by Radial or N.C. Machine - Describe

(d) Per TEMA Table RCB-7.4.2 (1999 Edition)

Minimum Permissible ligament width =Drill Drift Tolerance @ .0016 x Thickness of Tubesheet =

% of Ligaments Violating Above Values =

Identify on Tubesheet drawing holes outside this value No. =

Tubesheet O.D. before rolling = Stationery Floating

Tubesheet O.D. after rolling = Stationery Floating

Tube Rolling Details:

Lubricant UsedTube Rolling Equipment Used

3 Roll, 5 Roll Expander?

Torque Cut-Off, Roller Speed,Cleaner Used, Roll Angle Relative to Axis,

Output Torque Calibrations Every RollingsType of Dynamometer usedWhich Tubesheet was rolled first?

Were Tubes "set" in second tubesheet? Tool Used


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Apparent % Tube Wall Reduction = (I.D. - (Initial I.D. + Clearance)) x 100

2 x (Measured unrolled Wall Thickness)

Where I.D. = Measured Tube Inside Diameter in.

O.D. = Measured Tube Outside Diameter in.Clearance = Measured Tubesheet Hole Diameter Ins minus O.D. of Tube

Advise Average % Wall Reduction Per Above

Tack & Rolling Sequence

Provide a sketch similar to below giving tacking and rolling procedures used per tubesheet.

The above form is to be completed by the Fabricator, witnessed by Inspector of the client and/orPolaris, and included with "as-built" drawing submittal to the client and/or Polaris.

NOTE 1. Where yield strengths of tubes used in an Exchanger shell exceed 10% variation due toheat or mill differences, the Vendor will complete this form for each heat and provide an "as-

built" tubesheet drawing locating the groups of tubes to assist the client in future re-rollings

when confronted with such variation.

NOTE 2. For background on data revealed by the above, reference is made to a McGraw Hill

Book # ISBN 0-07-072281-1 "A working Guide to Shell & Tube Heat Exchangers" by Stanley

Yokell, Chapter 4, Tube to Tubesheet Joints.

0610.1 - shell and tube heat exchangers.pdf

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