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BGS-ME-002 Rev B3

Borouge Project

DOCUMENT No: REV. No: DATE: PAGE OF

BGS-ME-002 B3 15 September 2009 1 43

BOROUGE PROJECT

BOROUGE GENERAL SPECIFICATION

Shell and Tube Heat Exchangers

BGS-ME-002

REV DATE DESCRIPTION BY CHK APPROVED BOROUGE

DISC PROJ

B3 15 Sep 2009 Issued for B3 Project Execution MAE BOV MAB AJ

B2 24/11/06 Issued for Project Execution CM BR BR RBT OL

PROPRIETARY INFORMATION

THIS DOCUMENT CONTAINS INFORMATION BELONGING TO BOROUGE. NEITHER THE DOCUMENT,

NOR ANY OF IT’S CONSTITUENT PARTS, MAY BE REPRODUCED OR DISCLOSED WITHOUT THE PRIOR

WRITTEN AUTHORISATION OF BOROUGE.

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Borouge ProjectBOROUGE GENERAL SPECIFICATION


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CONTENTS

1.0 PURPOSE ............................................................................................................................... 3

2.0 DEFINITIONS AND ABBREVIATIONS ........................................................................... 3 2.1 DEFINITIONS ............................... ........................................... .................................... .................... 3 2.2 ABBREVIATIONS ......................................... ...................................... ...................................... ...... 3 2.3 EXCEPTIONS ............................... ........................................... .................................... .................... 4

3.0 CODES AND STANDARDS ................................................................................................ 4

4.0 REFERENCE DOCUMENTS .............................................................................................. 5

5.0 DOCUMENTATION REVIEW ........................................................................................... 7

6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ......................................... 7

7.0 QUALITY CONTROL ......................................................................................................... 7

8.0 DOCUMENTATION ............................................................................................................ 7

9.0 SERVICE CONDITIONS ..................................................................................................... 8

10.0 SPARE PARTS ...................................................................................................................... 8

11.0 PAINTING ............................................................................................................................. 8

12.0 PACKING, SHIPPING AND STORAGE ........................................................................... 8

13.0 DESIGN .................................................................................................................................. 8 13.1 GENERAL ........................................................................................................................................ 8 13.2 AMENDMENTS / SUPPLEMENTS TO TEMA STANDARDS ............................. .................. 11

14.0 MATERIALS ....................................................................................................................... 31

15.0 FABRICATION ................................................................................................................... 32

16.0 TESTING.............................................................................................................................. 33

APPENDIX 1 WELDING OF TUBE-TUBESHEET CONNECTIONS ................................... 35

APPENDIX 2 TUBE - TUBESHEET CONNECTION .............................................................. 39

APPENDIX 3 EXAMINATION OF PROCEDURE AND WELDING

QUALIFICATION TEST PIECES ..................................................................... 41

APPENDIX 4 RECOMMENDED ALTERNATIVE DETAILS OF WELD

STRENGTH TESTS ............................................................................................. 43

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1.0 PURPOSE

The purpose of this document is to define the technical requirements for the mechanical

design of TEMA type shell and tube exchangers on the Borouge Project. It is providedto the CONTRACTOR for the specification and definition of the COMPANY’S

minimum requirements for the WORKS.

Any references to VENDOR define the requirements to be imposed on the VENDOR by

the CONTRACTOR.

2.0 DEFINITIONS AND ABBREVIATIONS

2.1 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

COMPANY – means Abu Dhabi Polymers Company Limited (Borouge) and itssuccessors in interest.

CONCESSION REQUEST – refers to a technical or other deviation requested by theCONTRACTOR or VENDOR to COMPANY. Its submission is often linked to an

authorization to modify the design, to use, repair, recondition, reclaim, or release

materials, components or equipment already in progress or completely manufactured but

which does not meet or comply with COMPANY requirements. A CONCESSION

REQUEST is subject to COMPANY approval.

CONTRACTOR – means a party contracted to COMPANY to carry out work or services

to the Project.

GOODS – means any and all things, including but not limited to materials and equipment

(including spare parts) required to be incorporated in the WORK.

PROJECT – means the Borouge Project at Ruwais, Abu Dhabi, UAE.

VENDOR – means any and all persons, firms, partnerships, companies, bodies, entities

or a combination thereof including sub-vendors and suppliers, who are providing

GOODS, and the successors and assigns of such persons, firms, partnerships, companies,

bodies, entities or a combination thereof.

VENDOR/MANUFACTURER - has same meaning as VENDOR, it has been used when

referring to TEMA paragraph which uses the term MANUFACTURER.

SHALL AND MUST– indicate a mandatory requirement.

In addition, supplementary definitions are contained in Article 1 of the AGREEMENT.

Note, where definitions given here conflict with those given in Article 1 of the

AGREEMENT, ARTICLE 1 DEFINITIONS shall take precedence.

2.2 ABBREVIATIONS

ASME American Society of Mechanical Engineers

HTFS Heat Transfer and Fluid Flow Services

HTRI Heat Transfer Research Institute

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NDE Non Destructive Examination

MT Magnetic Particle Testing

PMI Positive Material Identification

PPM Parts Per Million

PT Liquid Dye Penetrant Testing

PWHT Post Weld Heat Treatment

RT Radiograph Testing

TEMA Tubular Exchanger Manufacturers Association

2.3 EXCEPTIONS

This Specification does not apply to Double Pipe Heat Exchangers, Plate Type Heat

Exchangers, Brazed Aluminum Fins Type Heat Exchangers, and Water Cooled Surface

Condensers. For other special applications and equipment, only part of this Specification

may be relevant, subject to mutual agreement between VENDOR and COMPANY/ CONTRACTOR.

3.0 CODES AND STANDARDS

It shall be the CONTRACTOR’S responsibility to comply with the requirements of all

Codes and Standards which are applicable to meet the Specification.

The following Codes and Standards form a part of the Specification:

Tubular Exchanger Manufacturers Association (TEMA) Standard

Eighth edition.

American Petroleum Institute (API)

Standard 601 Metallic Gaskets for Raised-Face Pipe Flanges and Flanged Connections(Double-Jacketed Corrugated and Spiral-Wound)

American Society of Mechanical Engineers (ASME):

Section II Boiler and Pressure Vessels Code, Material Specifications

Section V Boiler and Pressure Vessels Code, Nondestructive Examination

Section VIII,Div. 1

Boiler and Pressure Vessels Code, Rules for Construction of PressureVessels

Section IX, Boiler and Pressure Vessels Code, Welding and Brazing Qualifications

American Society for Testing and Materials (ASTM)

A-450 Specification for General Requirements for Carbon, Ferritic Alloy, and

Austenitic Alloy Steel Tubes

A-578 Standard, Straight-Beam Ultrasonic Examination of Plain and Clad Steel

Plates for Special Applications

European Committee for Standardisation (EN)EN 10204 Types of Inspection Documents - Metallic Products

Heat Transfer Research Institute (HTRI) - Computer Programs

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(Xchanger suit, Xist).

International Organisation for Standardisation (ISO)

ISO-9001:2000 Quality Management Systems - Requirements

ISO-9004:2000 Quality Management Systems – Guidelines for Performance

Improvements

The edition or revision of the Codes and Standards shall be the edition current at theEFFECTIVE DATE of the AGREEMENT.

CONTRACTOR shall advise COMPANY of any changes to Codes and Standards after

the EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction to

comply with any changed Codes and Standards.

CONTRACTOR shall advise of conflict among any referenced Codes and Standards andany technical specification, and COMPANY will determine which shall govern.

4.0 REFERENCE DOCUMENTS

The following Reference Documents form a part of this Specification.

Project Specifications

BGS-CU-002 Structural Engineering Design Criteria

BGS-MD-007 Requirements for Manufacturing Data Report for Pressure Vessels

BGS-ME-001 Shell and Tube Heat Exchangers Design Criteria

BGS-MD-001 Vessel Design Basis

BGS-MD-002 Pressure Vessels - General

BGS-MN-100 Thermal Hot Service Insulation

BGS-MU-002 Preservation and Export Packing

BGS-MU-003 Spare Parts

BGS-MU-013 Criticality Rating System

BGS-MU-014 Minimum Shop Inspection and Certification Requirements

BGS-MU-016 Thickness Measurements for Pressure Vessels, Heat Exchangers,Tanks and Piping

BGS-MW-001 Welding, NDE and Prevention of Brittle Fracture of Pressure

Vessels and Heat Exchangers

BGS-MW-004 Materials and Fabrication Requirements for Carbon Steel Piping

and Equipment in Severe Service

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BGS-MW-005 Materials and Fabrication Requirements for Cr-Mo Alloy Steel

High Pressure Equipment

BGS-MW-006 Positive Material Identification of Equipment and Piping

BGS-MX-001 Painting

BGS-LU-005 Piping Flexibility Analysis

BGS-LU-009 Bolt Torquing / Tightening Procedure for Flanged Joints

PPM-GG-B3-001 Document Numbering Procedure

PPM-DU-B3-005 Procedure for Document and Drawing Format

PPM-GG-B3-009 Procedure for Concession Requests

PQP-GG-B3-002 Quality Management Requirements for Contractor

PGS-GG-B3-001 Basic Engineering Design Data

Standard Drawings

BTD-MD-00017 Bolting for Nonstandard Flanges

BTD-MD-00020 Nozzles to Apparatus

BTD-MD-00022 Typical Details for Bush-Lined, Overlay Welded and Clad Steel

Nozzles

BTD-MD-00024 Nameplate with Bracket for Vessel and Heat Exchanger

Equipment

BTD-MD-00040 Earthing Clips for Tanks, Vessels and Supporting Structures

BTD-ME-00001 Bracket for Standard Vertical Reboilers, Nom. Dia. 350 mm

up/incl. 1100 mm

BTD-ME-00002 Sacrificial Anodes for Tubulars

BTD-ME-00003 Steel Sacrificial Plates for Tubulars 350 mm Nom. Dia. and

Larger

BTD-ME-00004 Bottom Part For 14”-16” and 18” Diameter Reboiler with Floating

Head with Expansion Joint of Nominal Diameter 100

BTD-ME-00005 Bottom Part For 20”-24” and 26” Diameter Reboiler with FloatingHead with Expansion Joint of Nominal Diameter 100

BTD-ME-00006 Bottom Part For 24”-26”-30”-32” and 36” Diameter Reboiler with

Floating Head with Expansion Joint of Nominal Diameter 200

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BTD-ME-00007 Bottom Part For 30”, 32”, 36”, 40”, and 44” Diameter Reboiler

with Floating Head with Expansion Joint of Nominal Diameter

300

BTD-ME-00008 Saddles for Horizontal Shell and Tube Heat Exchangers

The edition or revision of the Reference Documents shall be the edition current at the

EFFECTIVE DATE of the AGREEMENT.

CONTRACTOR shall advise COMPANY of any changes to Reference Documents afterthe EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction to

comply with any changed Referenced Documents.

CONTRACTOR shall advise of conflict among any Reference Documents and any

technical specification, and COMPANY will determine which shall govern.

5.0 DOCUMENTATION REVIEW

The CONTRACTOR shall notify the COMPANY of any apparent conflict between thisSpecification, Codes and Standards, Referenced Documents and any other applicabledocumentation (ie Datasheets, AGREEMENT).

The CONTRACTOR shall prepare a tabulated list of discrepancies between any of these

documents for review with the COMPANY. Resolution of any conflict shall be obtained

from COMPANY in writing before proceeding.

6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to this Specification shall be sought by the CONTRACTOR

only through the CONCESSION REQUEST procedure. Refer to PPM-GG-B3-009 -Procedure for Concession Requests.

COMPANY will review and consider all proposed CONCESSION REQUESTS.

Approval may be granted at COMPANY’S discretion. No proposed technical deviationshall be implemented prior to approval being granted. Technical deviations implemented

prior to approval shall be subject to rejection.

7.0 QUALITY CONTROL

CONTRACTOR and VENDOR shall comply with the requirements of PQP-GG-B3-002-

Quality Management Requirements for CONTRACTORS.

The Criticality Rating (CR) System outlined in Project Specification BGS-MU-013 shall

be used by CONTRACTOR to develop the design checking levels and minimum

requirements for shop inspection, testing and material certification given in Project

Specification BGS-MU-014.

Regardless of the Criticality Rating CONTRACTOR shall review the VENDOR’Sdocumentation to ensure compliance with the requirements of the AGREEMENT.

CONTRACTOR shall develop a list of Criticality ratings for all equipment items.

8.0 DOCUMENTATION

CONTRACTOR and VENDOR shall comply with the requirements of the PPM-DU-B3-

005 - Procedure for Document and Drawing Format, PPM-GG-B3-001 - Document

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Numbering Procedure.

9.0 SERVICE CONDITIONS

In addition to requirements stated in this specification and related documents, the BasicEngineering Design Data (BEDD) – PGS-GG-B3-001 shall be used in the design andconstruction of this Equipment.

10.0 SPARE PARTS

The CONTRACTOR shall ensure that the requirements of the Specification BGS-MU-003, Spare Parts are met.

11.0 PAINTING

The CONTRACTOR shall ensure surfaces are prepared and painted in accordance with

Specification BGS-MX-001, Painting.

12.0 PACKING, SHIPPING AND STORAGE

As a minimum, the CONTRACTOR shall ensure that items are packed for shipment in

accordance with the requirements of BGS-MU-002 - Preservation and Export PackingProcedure.

The CONTRACTOR shall ensure that detailed and specific instructions for thepreservation and maintenance of equipment while stored at the construction site, from

receipt at site to operational start-up, shall be delivered to construction site with the

equipment. Such instructions shall include as a minimum the preservation and

maintenance schedule, preservative materials, lubricants to be used etc.

Exchangers shall be thoroughly cleaned inside and outside and shall be free of grease,weld spatter, scale, slag, rust and all other foreign matter.

After inspection and test, equipment shall be completely free of water and dry before

start of preparation for shipment.

For Kettles (type “K”) a “hold” angle shall be provided, placed above the tube bundle, tokeep bundle in place during shipment and handling. It is to be located directly above andclose to the floating head flanges (type “T”) or the full support plate (at u-bend) when u-

tube construction is used.

13.0 DESIGN

13.1 GENERAL

13.1.1 Data Sheets

When specifying a heat exchanger, the applicable Data Sheets shall be used and filled out

accordingly.

In all cases the mechanical design code and equipment design standard shall be stated onthe Data Sheets.

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13.1.2 Design Rules

The principal mechanical design code shall be ASME Section VIII, Div. 1.

Shell and tube heat exchangers shall be considered to be pressure vessels. Only

requirements for shell and tube heat exchanger additional to those in the ASME Code,are stated in this Specification.

The principal design standards shall be TEMA standards, as referenced in thisSpecification.

13.1.3 Special Applications

For special applications the equipment design, fabrication, and testing shall also be inaccordance with Project Specifications BGS-MW-004 and BGS-MW-005, as applicable.

13.1.4 Corrosion Protection

When specified on Data Sheets, corrosion protection by means of sacrificial

anodes/plates shall be provided. They shall be in accordance with Project Standard

Drawings BTD-ME-00002 or BTD-ME-00003, as appropriate. Sacrificial anode/plate

shall not obstruct tube side flow.13.1.5 Units of Measurement

The Project unit system has been applied in this Specification, but where considered

necessary, the Project units are followed by their Imperial equivalents in brackets.

On VENDOR data, listing of Imperial Units as supplementary information in brackets is

acceptable.

It shall always be indicated whether absolute pressure or gauge pressure is intended. Theunit of pressure shall be followed by (A) or (G), whichever is applicable.

13.1.6 End Flanges

For the purpose of this Specification, “end flanges” shall be defined as stationary head

flanges, shell flanges, shell cover flanges and floating head cover flanges.

13.1.7 TEMA – Sections 8 and 9

The paragraphs/clauses in the TEMA Standards not referred to in this Specification

remain valid, except that:

Section 8 of TEMA Standards ("Physical Properties of Fluids") is not applicable to thisProject. Project specific data (shown on equipment Data Sheets or otherwise) shall be

followed.

Section 9 of TEMA Standards ("General Information") is valid only in terms of Imperial

units of measurement.

13.1.8 Selection of Type

Unless specified on the Project equipment Data Sheets, the selection of a type of heat

exchanger shall be in accordance with BGS-ME-001.

13.1.9 Code Stamp

Exchangers with a criticality rating of 1 or 2, as calculated in accordance with BGS-MU-

013, shall be specified as requiring ASME “U” stamp.

13.1.10 TEMA Class

All exchangers for the Project shall be in accordance with TEMA Class R.

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13.1.11 Bolting and Bolt Pattern

All bolting up to and including 25.4 mm (1 inch) shall be UNC, for 28.5 mm (1-1/8 inch)

and above UN-8 threads series bolting shall be used.

Bolting material SA 193-B7 and SA 194-2H shall be restricted to design temperatures upto and including 450°C. For design temperatures above 450°C and up to 525°C, SA 193-

B16 and SA 194-4 shall be used.

Low alloy steel bolting SA 193-B7 and SA 194-2H or SA 193-B16 and SA 194-4 used to

connect stainless steel flanges shall be limited to the operating temperature of 400°C.

For flanges operating above 400°C, SA 453 shall be used, when stainless steel bolting

SA 194-B8 and SA 194-8 cannot provide required torque loads.

The required bolt area for stainless steel bolting shall be checked for hydrostatic test

condition.

Refer to Paragraph 12.0 of this Specification for bolt coating requirements.

Bolts coated with zinc or cadmium shall not be used.

Flange bolt holes shall straddle the natural centrelines.

13.1.12 Nameplate

All exchangers shall have a nameplate in accordance with the Project Standard DrawingBTD-MD-00024. VENDOR may choose to add its standard nameplate as a supplement,

but nameplate and bracket materials shall be in accordance with the Project Standard.

Mounting bracket for nameplates shall protrude at least 40 mm (1.5 inch) beyond theoutside of the shell (noninsulated) or outside of insulation (insulated).

On insulated equipment nameplate brackets should be attached to a non-pressure part of

the vessel, e.g. the saddle.

13.1.13 Nozzle Loads

To allow for easy removal of channels or shells (after disconnecting the piping lines),

piping shall not rest on exchanger nozzles, and sufficient clearances between exchangernozzles and piping flanges shall be assured.

During operation, the process nozzles shall be able to withstand piping nozzle loads in

accordance with the Project Specification BGS-LU-005.

13.1.14 Structural Design

All exchangers shall be designed in accordance with Project SpecificationBGS-CU-002 and this Specification.

13.1.15 Earthing

Each saddle/support of horizontal/vertical exchangers shall have one earthing clip in

accordance with the Project Standard Drawing BTD-MD-00040.

13.1.16 Insulation

Insulation thickness shall be specified on the Data Sheets.

13.1.17 Electric Heaters

The shellside of an electric heater shall be in accordance with this Specification.

13.1.18 Bolting and Non-Standard Flanges

Bolting of nonstandard flanges shall be in accordance with Project Standard Drawing

BTD-MD-00017.

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13.2 AMENDMENTS / SUPPLEMENTS TO TEMA STANDARDS

The content of paragraph 13.2 amends TEMA Standards. For ease of reference

paragraph and section numbers as listed in TEMA standards are maintained.

SECTION 1 - HEAT EXCHANGER NOMENCLATUREN-1.11 NOMINAL DIAMETER

Delete this clause and replace with:

Nominal diameters shall be listed in millimeters and shall be in accordance with

paragraph RCB-3.11 of this Specification. For kettles, port diameter shall be stated first,followed by shell diameter.

N-1.12 NOMINAL LENGTH

Delete first sentence of paragraph and replace with:

The nominal length shall be the straight tube length in millimeters.

N-1.3 TYPICAL EXAMPLES

Insert new text:

In conformity with the use of Project units of measure for this Specification, the

nomenclature with size indication used in the typical examples N-1.31 through N-1.35 is

not applicable.

SECTION 2 - HEAT EXCHANGER FABRICATION TOLERANCES

F-3 TUBESHEETS, PARTITIONS, COVERS AND FLANGES

Add to this clause:

The alternate tongue and groove joint arrangement shown in Figure F-3 is not permitted.

The plus tolerance on dimension R4 shall be 5 mm, see Note 1 to Figure F-3.

Unconfined joints are not permitted.

SECTION 3 - GENERAL FABRICATION AND PERFORMANCE INFORMATION

G-3.2 PURCHASER’S NAMEPLATE


See paragraph 10.1.12 for requirements. Nameplates are part of VENDOR’S/

MANUFACTURER’S scope of supply.

G-3.4 ASSET NUMBER PLATE (New clause)

If required by the COMPANY, an asset number plate of corrosion-resistant metallicmaterial shall be provided, attached to the exchanger alongside the VENDOR’Snameplate.

When a spare tube bundle forms part of the supply, an asset number plate shall also be

provided and fixed to the tubesheet.

The asset number plate shall show the text 'ASSET No.' in lettering 6 mm high, followedby a space 15 mm (5/8 inch) by 65 mm (2 1/2 inch) for the asset number.

G-4.1 DRAWINGS FOR APPROVAL AND CHANGE

Add to this clause:

VENDOR/MANUFACTURER drawings shall be supplied in accordance with Section

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8.0 of this Specification.

G-4.2 DRAWINGS FOR RECORD

Delete this clause and replace by:

Final “as-built” drawings shall be supplied in accordance with the requirements of Section 8.0 of this Specification and shall be part of the VENDOR’S/

MANUFACTURER’S final documentation compiled for each exchanger. The specific

format and content of the VENDOR/MANUFACTURER data report shall be inaccordance with the Project Specification BGS-MD-007.

G-5.1 GENERAL

Add to this clause:

VENDOR/MANUFACTURER is ultimately responsible for the thermal and hydraulicdesign or rating of the Shell and Tube Heat Exchangers based on the information shown

on the Project equipment Data Sheets and shall guarantee the thermal and hydraulic

performance of the equipment. VENDOR/MANUFACTURER may choose to guarantee

the design by certifying the Project Data Sheets or by supplying its own Data Sheets,along with statement of guarantees.

G-5.21 THERMAL PERFORMANCE TEST

If the thermal performance rating is not guaranteed by the VENDOR/

MANUFACTURER and such occurrence is approved by the COMPANY, test conditions

and procedures shall be selected by agreement between the

COMPANY/CONTRACTOR and the party who performed the thermal design.

G-6.2 DRAINING

Delete last sentence.

G-7.11 HORIZONTAL UNITS

Delete paragraph 2 and replace with:

The fixed support of removable bundle type heat exchangers shall be designed towithstand a longitudinal force of 200% of the bundle weight, referenced to the

exchanger’s centerline. The shear stress shall not exceed 40% of the yield strength of the

material used.

Delete paragraph 5 and replace by:

Support saddles shall be in accordance with data shown on the equipment Data Sheets

and Project Standard Drawing BTD-ME-00008.

VENDOR shall be responsible for verification of all thicknesses in saddle design,especially the thickness of the baseplate, at the point of interface with foundation design.

Saddle bearing plates shall be of the same material as shell and shall be continuously

welded to the shell.

Sliding saddles shall be designed to allow thermal expansion and contraction duringservice.

The sliding saddle shall be have slots oriented in the direction of thermal movement.

VENDOR is responsible for verification of size and number of openings shown on theProject equipment Data Sheets.

The holes for anchor bolts shall be provided in the fixed saddle. VENDOR is responsible

for verification of size and number of openings shown on the Project equipment Data

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Sheets.

For stacked exchangers, the saddles shall be continuous over the shell circumference,except for the top shell.

Saddle supports for stacked exchangers shall be designed to carry the superimposed loadswhich occur during operations and during shutdown for maintenance, e.g. pulling of tube

bundles, without distorting the lower shell.

For stacked heat exchangers where the nozzles on the shellside and channel side aredirectly connected, a set of shim plates of corrosion-resistant material, with a total

thickness of 11 mm (7/16 inch), shall be provided for inserting between the upper andlower saddle supports. The shim plates shall not be permanently attached to the saddles.

Bolting of flanges of mating connections between stacked exchangers shall be removable

without moving the exchangers.

Baseplate of saddle mounted on concrete shall not exceed temperature of 100° C.

To ensure correct alignment of stacked exchangers, a trial assembly shall be carried out

at VENDOR works, using the specified gaskets between the intermediate nozzle flanges.

Saddles shall protrude beyond the bottom process nozzles and/or drain nozzle by at least50 mm (2 inches) to prevent damage to flange facings during transport, storage and

maintenance.

The minimum size of anchor bolts shall be 19 mm (3/4 inch).

G-7.12 VERTICAL UNITS


Support brackets shall be in accordance with Project Standard Drawing BTD-ME-00001and equipment Data Sheets.

G-7.2 LIFTING DEVICES

Add to first paragraph:Where welded plate type lugs are used, these shall be welded on with a full penetration

weld.

For cast components the lugs shall be integrally cast with the casing.

The hole diameter shall be 28 mm diameter minimum.

The integrity of the lugs in supporting the required load shall be demonstrated bycalculation.

Stationary tubesheets shall have two or more holes UNC threaded to take eye bolts for

removing the tube bundles from the shells. Floating head covers shall have one holeUNC threaded to take an eye bolt. The position of eye bolts in stationary tubesheets shall

be suitable for a hydraulic bundle pulling device.

Removable threaded plugs shall be provided to protect the eye bolt holes duringoperation; they shall be of a material equivalent to that of the part concerned. For clad

tubesheets the eye bolt shall be the same material as the cladding then seal welded.

Removable threaded plugs of material equivalent to that of the cladding shall be provided

to protect the eye bolt holes of the insert during operation.

Add to this clause:

All the necessary eye bolts shall be provided, and they shall be of SA 307 B material.

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NOTES: 1) The required size and length of thread for the insert and for the eye

bolt shall be calculated to resist the force of tube bundle removal. The

threads shall be well formed and be a tight fit for maximum grip.

2) Attention shall be given to the possibility of pulling out the insert and

stripping the cladding when using force to remove the tube bundleparticularly when the material of the cladding is nonferrous.

Jack bolts shall be provided in heat exchanger end flanges.

Removable channel covers, channel shells, bonnets, and shell return covers shall have a

permanent lifting lug(s). The actual weight of the component shall be indicated on theVENDOR/MANUFACTURER detail drawings and also stamped in minimum 10 mm

high letters on the side of the lug.

Channel covers of exchangers located in the area with no crane access or liftingprovisions for cover removal shall be provided with a davit. CONTRACTOR shall

identify such cases on the Project Data Sheets.

Wherever possible, the lug shall be located at the top of component, above the center of gravity; otherwise two lugs shall be provided, located approximately 45 degrees apart.The lifting lugs shall be designed for 200% of the weight of the component.

SECTION 4 - INSTALLATION, OPERATION AND MAINTENANCE

E-2.12 FOUNDATIONS

Add to this clause:

VENDOR shall adhere to the location and number of anchor bolts shown on the Project

equipment Data Sheets. Any correction necessary shall be immediately brought to theCOMPANY’S/CONTRACTOR’S attention.

E-2.13 FOUNDATION BOLTS

Delete this clause and replace by:The saddle design shall provide for free thermal expansion of the heat exchanger in thelongitudinal direction. Anchor bolts, with exception of bolts used for stacked exchangers

(top to bottom shell attachment), are not part of VENDOR’S scope of supply.

E-2.32 TEST CONNECTIONS

Add to this clause:

Test connections in heat exchanger nozzles are not allowed, with exception of thefollowing:

• For vertical reboilers with tubeside nozzle directly attached to the column,

temperature indicators or pressure indicators connections on the tubeside nozzle are

permitted.

• For horizontal stacked exchangers, when necessary for process reasons,

temperature indicators or pressure indicators connections are permitted on the topnozzles of the bottom shell.

• Vent and drain connections shall be provided on the shellside inlet and outletnozzles for purging during maintenance, when nozzles are blinded. Threaded

connections are not permitted for vents and drains.

E-3.25 RECOMMENDED BOLT TIGHTENING PROCEDURE

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Add to this clause:

The use of hydraulic bolt tensioning equipment is required for all bolts over 25mm

diameter. The force at a specified temperature shall be stated on the drawing.

NOTE: When the application of bolt-tensioning equipment is anticipated in the designstage, due attention shall be given to the clearance required to accommodate the

tensioning tools.

E-4.2 TUBE BUNDLE REMOVAL AND HANDLING


During removal of a tube bundle from a shell, a pulling cable shall be attached to eye

bolts screwed into the tubesheet. The bundle shall be supported on the tube baffles,

sliding strips, supports or tubesheets to prevent damage to the tubes. Contact surfaces

shall be protected. See G-7.2 of this specification. When tube bundle pulling equipmentis used which requires special provisions, this shall be stated on the equipment Data

Sheets and on “as-built” VENDOR drawings, as part of the MANUFACTURER’S datareport.

E-4.33 POST CLEANING PRECAUTIONS (New clause)

After cleaning, tube bundles shall be placed in a self-draining position.

E-4.5 GASKET REPLACEMENT

Add to this clause:

When a heat exchanger is dismantled for any cause, it shall be reassembled with new

gaskets.

The use of a nubbin to decrease the gasket seating width is not permitted.

E-4.6 SPARE AND REPLACEMENT PARTS

Delete the last sentence from this clause and add the following:

Two complete sets of start-up spare gaskets shall be supplied for each exchanger. This

includes gaskets to girth flanges, test rings, blind flanges and intermediate processnozzles for stacked exchangers. Ten percent (10%) of start-up spare bolting of each sizeused shall also be supplied. Spare Parts and Interchangeability Records shall be

completed for each exchanger/service. For instruction how to complete the form andrequired documentation, refer to Project Specification BGS-MU-003.

SECTION 5 - MECHANICAL STANDARDS TEMA CLASS R

Add new paragraph:

All heat exchangers for the Project shall be in accordance with TEMA Class R. Clauses

pertaining only to Classes C or B are not applicable.

RCB-1.21 DESIGN PRESSURE

Add to this clause:

The most unfavorable combination of design pressures on shellside and tubeside shall beused in calculations for tubesheets, floating heads and tubes.

See Project Specification BGS-ME-001 for additional requirements.

RCB-1.42 DESIGN TEMPERATURE OF HEAT EXCHANGER PARTS

Add to this clause:

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For exchangers in series, but with individual shells having different design temperatures,

measures shall be taken to prevent incorrect line-up. A Minimum Design MetalTemperature of +15°C shall be used unless otherwise specified on Data Sheets.

RC-1.54 LINING, CLADDING AND WELD OVERLAYS (New clause)

The requirement of corrosion-resistant lining or cladding specified in the Project

equipment Data Sheets shall apply for all exposed (wetted) surfaces including the surfaceof pass partition plates and the side and bottom of gasket grooves, but excluding thetubes.

RCB-1.62 EXTERNAL PACKED JOINTS

This clause is not applicable to this specification.

RCB-2.1 TUBE LENGTH

Add to this clause:

Unless specified on the Project equipment Data Sheets, the selection of tube length shall

be in accordance with Project Specification BGS-ME-001.

RCB-2.21 BARE TUBES

Delete this clause and Table RCB-2.21 and replace by the following clause:

Unless specified on the Project equipment Data Sheets, the selection of tube diametersand gauges shall be in accordance with Project Specification BGS-ME-001.

During check rating of design, the Standard Wire Gauge (SWG) of the same gauge

number as Birmingham Wire Gauge (BWG) may be used. The standard used shall be

identified.

RCB-2.22 INTEGRALLY FINNED TUBES

Add to this clause:

For additional information refer to Project Specification BGS-ME-001.

RC-2.23 LONGITUDINALLY-FINNED TUBES (New clause)

Longitudinally-finned tubes are not permitted.

RCB-2.3 U-TUBES

Insert new text:

Only seamless U-tubes are acceptable for U-tube bundles. Welded bends are not

permitted.

RCB-2.31 U-BEND REQUIREMENTS

Add to this clause:

Bends with radius R < 1.5 (one and a half) times nominal tube OD are not permitted.

RCB-2.321 CENTER-TO-CENTER DIMENSION

Add to this clause:

The tolerance of the center-to-center distance between the parallel legs of the U-tubes

shall be within the following:

• ± 1.0 mm; when the distance is less than 5 times the nominal tube OD.

• ± 1.5 mm; when the distance is more than 5 times the nominal tube OD.

RCB-2.33 HEAT TREATMENT

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Add to this clause:

U-tube bends, except for titanium tubes, shall be stress-relieved when the colddeformation exceeds 5%.

U-tubes shall be totally heat-treated when the application of local heat treatment to thebent portion only would possibly induce embrittlement or susceptibility to stress

corrosion in the transition zones between the straight legs of the U-tube and the bend.

Postweld Heat Treatment shall be implemented when required by ASME Code SectionVIII, Div. 1, this Specification, other Project Specifications referenced on Data Sheets, or

when specified on Data Sheets.

R-2.5 TUBE PITCH

Add to this clause:

Unless specified on Project equipment Data Sheets, the selection of tube pitch shall be inaccordance with Project Specification BGS-ME-001 and the following additional

requirements:

• The minimum nominal ligament shall be 6.35 mm (1/4 inch) for tubes with anominal tube OD of less than 25.4 mm (1 inch)

• The minimum tube pitch over the pass partition lane, for straight tubes with a tube

pattern of 30 or 60 degrees, is determined by the nominal tube OD and the width of the pass partition plate gasket groove, see RCB-6.4 of TEMA standards

• The difference between the thickness of the partition plate (at the tapered end) and

the width of the gasket groove shall result in a clearance of 3.2 mm (1/8 inch) with

a tolerance of + 0.5 mm

• The minimum distance between the edge of the gasket groove and the tube holeshall be 1.6 mm (1/16 inch) for expanded tube-to-tubesheet joints, and 3.2 mm

(1/8 inch) for strength-welded tube-to-tubesheet joints

In other cases an even greater distance may be required.

R-2.6 TUBE LAY-OUT (New clause)

The tube lay-out shall ensure that the allowable stresses in the tubes are not exceeded dueto temperature differences between tubes in adjacent passes.

For shellside heat transfer and the mechanical construction of the pass partition plates, a

minimum of two tube rows per pass are required.

RCB-3.11 SHELL DIAMETERS

Add to this clause:

Shell diameters shall be stated on Project equipment Data Sheets.

Up to nominal diameter DN 500 mm (20 inches) seamless pipe should be used.

For shells rolled from plate, the nominal shell diameter is the shell inside diameter.

A list of dimensions for TEMA type R heat exchangers, using pipe for the shell, is shown

in Table R-3.11:

TABLE R-3.11 DIMENSIONS FOR CARBON STEEL PIPE

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Nominal Shell Diameter Shell Inside Diameter Wall Thickness Schedule No.

mm inch mm mm

150 6 146.3 10.97 80

200 8 193.7 12.7 80

250 10 254.5 9.27 40

300 12 303.2 10.31 40

350 14 336.6 9.53 30

400 16 387.4 9.53 30

450 18 438.2 9.53 -

500 20 489.0 9.53 20

RCB-3.13 MINIMUM SHELL THICKNESS

Add to this clause:The minimum wall thickness of any pressure containing part shall be 6.0 mm plus

corrosion allowance.

Delete first Paragraph and replace with:

Shell thickness is determined by the Code design formulas plus corrosion allowance, but

in no case shall the nominal thickness be less than shown in the table R-3.13. Claddingshall not be considered part of the minimum thickness. Cladding can be considered as

corrosion allowance.

RCB-3.2 SHELL COVER THICKNESS

Add to this clause:

Shell cover heads shall be of true semi-ellipsoidal shape, ratio 2 : 1.

RCB-4.1 TYPE OF TRANSVERSE BAFFLES

Add to this clause:

Unless specified in Project equipment Data Sheets, the baffle selection shall be in

accordance with Project Specification BGS-ME-001 and the following additionalrequirements:

• For single-phase fluid flow, horizontally cut baffles shall be used. For two-phasefluid flow, baffles with a vertical cut shall be used.

• For draining heat exchanger shells, all baffles and support plates shall have a V-

notch, 20 mm wide and 17 mm high, at the lowest point. All baffles and support

plates used in two-phase or vapor flow shall have same size notch on top as well, to

allow venting.

RCB-4.3 TRANSVERSE BAFFLE AND SUPPORT CLEARANCE

Add to first paragraph:

The clearances given in Table RCB-4.3 shall only be exceeded if specified on the Project

equipment Data Sheets.

RCB-4.41 TRANSVERSE BAFFLES AND SUPPORT PLATES

Add to this clause:

The minimum thickness shall not be less than twice the specified shellside corrosion

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allowance.

Full support plate for u-tube bundles shall have the minimum thickness of twice thevalues specified in TEMA, with exception of full support plate at u-bend for u-tubebundles used in kettles (type “K”) which shall have minimum thickness of 16 mm.

R-4.42 LONGITUDINAL BAFFLES

Add to this clause:

In type F shells, longitudinal baffles shall only be applied if welded into the shell and to

the tubesheet.

RCB-4.52 MAXIMUM SPACING

Replace first sentence:

Tube support plates shall be so spaced that the unsupported tube span does not exceed

0.8 times the value indicated in Table RCB-4.52 for the tube material used.

RCB-4.61 SHELLSIDE IMPINGEMENT PROTECTION REQUIREMENTS

Add to this clause:

Unless specified on Project equipment Data Sheets, shellside impingement protectionshall be in accordance with Specification BGS-ME-001 and the following:

• Impingement protection shall take the form of either:

• At least two rows of impingement rods at a lay-out angle of 30 or 45 degrees with

the following rod diameters:

Rod diameter [mm]

Grid Layout Angle Rod Pitch [mm]

[deg] 25.4 31.75

30 16 19

45 22 25

or

• A nonperforated plate, which may be rectangular, square or circular, extending atleast 25 mm beyond the projection of the nozzle bore, and having a thickness of not

less than 6 mm.

RCB-4.63 TUBE SIDE


During check rating of design defined on the Project equipment Data Sheets,consideration shall be given to the need for special devices to prevent erosion of the tube

ends for gases and vapors when the ρV2 in the tubes exceeds 7000 kg/m-s2

(4700 lb/ft-s2).

For water, the maximum velocities as specified in Project Specification BGS-ME-001

shall be adhered to.

For liquids other than water, the ρV2

shall not exceed 8900 kg/m-s2

(5980 lb/ft-s2).

For two-phase flow, the ρV2 in the tubes shall be checked carefully against the danger of

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erosion of the tube ends. In such a case, the velocity and density shall be based on a

homogeneous gas/liquid mixture.

V is the linear velocity in m/s (ft/s) and ρ is the density in kg/m3 (lb/ft3).

RCB-4.7 TIE RODS AND SPACERSAdd to this clause:

Unless specified on the Project equipment Data Sheets, tie rods and spacers shall be

equally divided around the circumference of the baffles.

Additional tie rods may be required in order to prevent internal bypassing through

partition lanes.

In shellside hazardous service, spacers are not permitted.

R-4.71 NUMBER AND SIZE OF TIE RODS

Delete this clause and Table R-4.71 in the TEMA Standards and replace by :

Unless specified on Project equipment Data Sheets, tie rods shall be selected in

accordance with Table R-4.71 below:

NOTE: The screw threaded connection of the tie rod in the tubesheet shall have adiameter which is significantly not less than the diameter of the tie rod.

TABLE R-4.71 TIE ROD STANDARDS

NominalShell

Diameter

Tie Rod Diameter

Tube OD of 19.05 mm(3/4 in.)

Tube OD of 25.4 mm(1 in.) and larger

Minimum

Numberof

Pipe OD Pipe OD Tie Rods

Solid Sched 80 Solid Sched 80

mm (inch) mm mm mm mm

150-375 (6-15) 13 17.15 13 17.15 4

400-700 (16-27) 16 17.15 16 17.15 6

710- 850 (28-33) 16 17.15 20 21.34 6

860-1230 (34-48) 16 17.15 20 21.34 8

1240-1540 (49-60) 19 21.34 22 26.67 10

1550-2540 (61-100) 19 21.34 22 26.9 12

RCB-4.8 SEALING DEVICES

Add to this clause:

Unless specified on the Project equipment Data Sheets, the following shall be adhered to:

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• Sealing and sliding devices should be located in such a way as to minimize the

force exerted by the hoisting band on the outer tubes of the bundle.

• Sealing strips shall be provided for all shell and tube exchangers, except in the case

of fixed tubesheet and U-tube bundles with a diametric bundle to shell clearance of

less than 19 mm (3/4 inch).

• Sealing strips may be counted as tie rods when properly seated in the baffles and

secured with a complete seal weld of length 'a' > 4 mm and attached to thestationary tubesheet with a full penetration weld.

• For floating head bundles, one pair of sealing devices shall be provided for every 5

to 6 rows of tubes in the cross flow area.

• The sealing strips shall not protrude beyond the periphery of the baffles.

• The sealing devices shall not obstruct the tube lanes or pass partition lanes for tube

patterns of 45 or 90 degrees.

• Sealing strips shall be a minimum 6mm thick continuously welded and not split

design.

R-4.10 SLIDING STRIPS (New clause)

Unless specified on the Project equipment Data Sheets, the following shall be adhered to:

• Sliding strips shall be provided to facilitate pulling the tube bundle. Sliding strips

may be counted as tie rods when properly seated in the baffles and secured with acomplete seal weld of length 'a' > 4 mm and attached to the stationary tubesheet

with a full penetration weld. To avoid damage to the baffles during bundle pullingand replacement, the sliding strips shall protrude 1 to 2 mm beyond the periphery of

the baffles.

• For vertical exchangers, four sliding strips shall be provided evenly divided around

the circumference of the bundle.

• The sliding strips shall not obstruct the tube lanes or pass partition lanes for tube

patterns of 45 and 90 degrees (or hinder the liquid inflow to the center tube rows ina kettle-type reboiler).

• Kettle type exchangers shall be provided with “riding rails” (or tracks), fully

welded to shellsides, to support and guide the tube bundle.

• The sliding strips shall be rigged to ensure their functioning during bundle

handling. Table R-4.10 shows the minimum required size of the sliding strips.

TABLE R-4.10 MINIMUM SLIDING STRIP SIZE

Nominal Shell Diameter Height Thickness

mm (inch) mm mm

150-375 (6-15) 30 9.5

400-700 (16-27) 40 9.5

710-850 (28-33) 50 12.7

860-1230 (34-48) 60 12.7

1240 - (49 - ) 75 15.8

RCB-5 FLOATING END CONSTRUCTION

Insert new text:

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The nominal wall thickness of floating head covers shall be at least equal to the

minimum wall thickness of the appropriate nominal shell diameter given in paragraphRCB-3.13.

Packing boxes are not acceptable.

For internal bellows used in reboilers with a floating head, see Project Standard

Drawings BTD-ME-00004, 00005, 00006, 00007, as applicable.

RCB-5.16 FLOATING HEAD NOZZLES


Packed floating head nozzles and packing boxes are not permitted.

RCB-5.2 OUTSIDE PACKED FLOATING HEADS (Type P)

Paragraphs RCB-5.21 through RCB-5.25 of the TEMA Standards are not applicablesince Type P is not permitted.

RCB-5.3 EXTERNALLY SEALED FLOATING TUBESHEET (Type W)

Paragraphs RB-5.31 through RCB-5.34 of the TEMA Standards are not applicable sinceType W is not permitted.

RCB-6 GASKETS

Insert new text:

RCB-6.1 through R-6.5 of this specification refer solely to gaskets for end flanges (girthflanges).

Gaskets for intermediate process nozzles of the stacked exchangers shall be in

accordance with the Project Data Sheets.

RCB-6.1 TYPE OF GASKETS

Add to this clause:

Only gaskets containing nonasbestos materials are permitted.In cooling water service, gaskets shall be same material as the tubesheet, but in the fullysoft condition.

The type of gasket used shall be selected from those listed in Table RCB-6.1 below.

TABLE RCB-6.1 TYPE OF GASKETS

Type Description Minimum

Width

Minimum

Thickness

mm mm

1 Corrugated double jacketed 304/316, graphite

filled12.7 3.2

2 Solid flat metal 5 Cr-0.5 Mo SA 357, maximum

hardness Brinell 1606.35 2.4

3 Solid flat metal 316, maximum hardness Brinell

1606.35 2.4

4 Spiral-wound 316 with graphite filler (flexicarbon)1) 1) 3)

5 Grooved metal 316 with graphite layer 12.7 3.0

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2) 3)

1. To avoid overstressing of the spiral-wound gasket, an inner and/or centering ring willbe required. For nominal shell inside diameters 150 mm to 600 mm, gaskets shall be

in accordance with API 601. For nominal inside diameters of more than 600 mm, thewidth of the gasket shall be 25 mm, the thickness 7.2 mm and it shall have a 4.8 mm

thick inner and/or centering ring with a width of 16 mm minimum.

2. Thickness is exclusive of graphite layer. For shell diameters above 1000mm theminimum thickness shall be 4mm

3 For sea water applications materials other than graphite filler or graphite layer should

be considered.

R-6.2 GASKET MATERIALS

Delete this clause and replace by :

GASKET SELECTION

The gasket type and material shall be indicated on the Project equipment Data Sheets,otherwise the following applies for “end flanges”.

The selection of gaskets depends on the design temperature and pressure and the

corrosive conditions of the service to which the flange and gasket are exposed.

For design temperatures and pressures and service conditions other than those given in

the tables, gasket selection shall be as agreed between COMPANY/ CONTRACTOR andVENDOR/MANUFACTURER.

When two gasketed joints are compressed by the same bolting, gasket selection and area

of gasket facing shall be such as to ensure effective sealing of both joints without

crushing of the gasket under the required bolt load. This shall be demonstrated with

calculations and submitted for approval by CONTRACTOR.

TABLE R-6.22 SELECTION OF TYPE OF GASKET(For a description of the gasket type, see Table RCB-6.1)

Condition

DesignTemperature

[°C]

DesignPressure

[kg/cm2(G) ]

Preferred

Type

Alternative

Type

All services, except

hydrogen

up to 450 up to 31.6 1 4,3

All services up to 550 up to 105.0 4 21)

All services, except

hydrogen

up to 550 up to 105.0 3 4

Hydrogen service up to 550 105.0 up to 214.0 2 --

NOTE: 1. Substitute Type “2” for “4” in hydrogen service.

2. For conditions outside of range specified, the selection shall beapproved by COMPANY.

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RC-6.31 GASKET MINIMUM WIDTH


The minimum width of peripheral ring gaskets shall be in accordance with Table

RCB-6.1 of this specification for the type of gasket selected.R-6.34 GASKET CONTACT SURFACE (New clause)

The arithmetic average roughness, Ra, which determines the flange face surface finish

required for each type of gasket and flange size is given in Table R-6.33 below.

See Table RCB-6.1 of this specification for a description of the gasket type.

TABLE R-6.33 GASKET CONTACT SURFACE FINISH

Gasket type

From Table RCB-6.1 Ra value µm

4 3.2 - 6.3

1, 2, 3 0.8 - 1.6

R-6.5 GASKET JOINT DETAILS

Delete note of figure RCB-6.5 and replace by:

For dimensions and tolerances, see paragraph F-3.

RCB-7 TUBESHEETS

Insert new text:

All removable bundles with a B-type front head shall have the stationary tubesheet

outside diameter (OD) equal to the OD of the shell flange (Extended Tubesheet).

Extended stationary tubesheets are also required when the bundle weight exceeds 10,000kg, applicable to all shell and tube exchangers with removable bundles.

When extended stationary tubesheets are required, they shall be provided with a

minimum of 4 collar stud bolts to maintain the tubesheet in place when the channel is

removed.

The design shall comply with Paragraph UG-34 of ASME Code, Section VIII Div. 1.

Divided floating heads are not permitted.

Where the tubesheet forms a flange or is directly welded to the shell, it shall be specified

as a forging.

RCB-7.141 OUTSIDE PACKED FLOATING HEAD (Type P)

Paragraph RCB-7.141 and sub-paragraphs RCB-7.1411 and RCB-7.1412 of TEMAStandards are not applicable. Type P is not permitted.

RCB-7.142 PACKED FLOATING TUBESHEET WITH LANTERN RING (Type W)

Paragraph RCB-7.142 of TEMA Standards is not applicable. Type W is not permitted.

RB-7.44 TUBE HOLE GROOVING

Add to this clause:

Tube hole grooves shall be square edged, concentric and free from burrs.

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The distance from the center line of the first groove to the cover side of the tubesheet

should be 9.5 mm. The distance between groove center lines should be 9.0 mm.

For tubesheets constructed of integrally clad plate or with applied corrosion-resistant

facings, one groove shall be in the center of the cladding/facing material layer. For the

minimum clad thickness of 10 mm, the centerline of the first groove shall be 6.0 mmfrom the tubesheet’s face and the distance between the centerlines of grooves shall be 9.0

mm.

Tube holes shall be in accordance with table RCB 7.41 column (a) (standard fit) for

strength welded tube to tubesheet joints.

RB-7.513 TUBE PROJECTION


Unless otherwise specified on Data Sheets, tubes shall extend between 3 mm and 5 mmbeyond the face of the tubesheet, except in special cases when tube ends are required to

be flared.

RCB-7.52 WELDED TUBE-TO-TUBESHEET JOINTSAdd to this clause:

Tubes shall be welded to the tubesheet only when specified on the Project equipment

Data Sheets.

Strength welding with light expansion (between 3% and 5% of original wall thickness) isrequired for all tube to tubesheet joints. Welding shall be in accordance with Attachment

1 of this specification. Detail and calculation for weld shall however be in accordancewith ASME UW20 (C).

RCB-7.521 SEAL WELDED JOINTS


Seal-welded joints are not permitted.

RCB-7.522 STRENGTH WELDED JOINTS

Add to this clause:

When specified on Data Sheets, tubes shall be welded to the tubesheet in accordance

with Attachment 1 of this Specification.

RCB-7.53 EXPLOSIVE BONDED TUBE-TO-TUBESHEET JOINTS


Explosive bonding and/or explosive expanding of tubes to the tubesheet is not permitted.

RB-7.8 CLAD AND FACED TUBESHEETS

Delete this clause and replace with:Tubesheets with nonferrous or alloy cladding for corrosion protection shall meet the

following requirements:

• The cladding shall be integrally and continuously bonded to the base material.

• All surfaces exposed to the corrosive medium, excluding gasket seating surfaces,

shall have at least a 10 mm thickness of cladding when tubes are expanded only (to

allow a groove within the cladding thickness) and at least a 5 mm thickness for astrength-welded connection.

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• Bonding the cladding to the tubesheet with solder is not permitted.

• Integrally clad tubesheets and tubesheets with linings applied by overlay welding

shall be ultrasonically tested to check the integrity of the bonding in accordance

with ASTM A 578, with an acceptance level of S7.

• Where titanium tubes are required, then tubesheet shall be titanium clad. Cladding

shall be explosively bonded to base metal, and tube to tubesheet joint shall be

strength welded.

• Titanium cladding on tubesheet shall be 5mm thick minimum after final machining.

RCB-8 FLEXIBLE SHELL ELEMENTS

Delete this section and replace by:

The application of shell expansion joints for fixed tubesheet exchangers is not permitted.Also refer to Project Specification BGS-ME-001.

RCB-9 CHANNELS, COVERS AND BONNETS

Insert new text:

Stationary head (Type B) shall consist of bonnets equipped with true semi-ellipsoidal

shape, ratio 2:1.

RCB-9.13 PASS PARTITION PLATES

Insert new text:

Drain holes are not permitted in pass partition plates.

RCB-9.132 PASS PARTITION PLATE FORMULA

Add to this clause:

For the pressure drop across the plate, the full pressure drop over the heat exchanger shall

be taken.

RCB-9.133 PASS PARTITION WELD SIZE

Add to this clause:

The first 50 mm of the weld from the joint face of the partition plate shall be full

penetration.

R-9.135 ALIGNMENT (New clause)

The free edge of pass partition plates shall be recessed with 0.2 mm maximum measured

from the joint face of the head flange, in order to allow full tightening of the flange

bolting.

RCB-10.1 NOZZLE CONSTRUCTION

Add to the clause:

All nozzles and their minimum projections shall be in accordance with Project Standard

Drawing BTD-MD-00020.

All nozzles flanges shall be “Raised Face” (RF) and “Smooth Finish” (SF), unlessspecifically indicated otherwise on the Data Sheet. “Smooth Finish” shall be as defined

in Project Standard Drawing BTD-MD-00020.

Nozzle necks of DN 200 (8 inch) pipe size and smaller shall be minimum of schedule 80

seamless pipe. Larger nozzles shall have a minimum thickness of 12.7 mm (1/2 inch).

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Minimum nozzle size is DN 50 (2 inch).

All DN 50 (2 inch) connections, including vents and drains shall be braced in two

directions.

Reinforcing pads are not allowed on shellside nozzles, if their use will increase the inletor outlet baffle spacings by moving the nozzles’ location away from the body flanges.

Set-in connection shall be used. In exceptional cases, when set-in connection is not

practicable, set-on connections may be used, but subject to prior COMPANY’S/ CONTRACTOR’S approval.

Stubbed, socket welded, pad type or built-up, single fillet welded and screwedconnections are not permitted.

Cladded connection shall be formed from integrally clad plate or weld overlay.

Nozzle necks may be of seamless pipe, rolled plate, or integrally forged with the flanged

connection. Rolled plate nozzle necks and all plate reinforcing pads shall be the same

grade of material as specified for the shell or head to which they are attached.

Reinforcing pad thickness shall not exceed 40 mm or the channel thickness, whichever isthe lesser.

RCB-10.31 VENT AND DRAIN CONNECTIONS

Add to this clause:

All connections shall be flanged. The minimum connection size shall be DN 50(2 inches).

For stacked floating head type heat exchangers, drain of the top exchanger and vent of

the bottom exchanger shall be elbowed out 90 degrees.

Minimum rating for vents and drains shall be Class 300.

R-10.32 PRESSURE GAUGE CONNECTIONS

Delete R-10.32 and replace by:

If required, pressure gauge connections shall be specified on equipment Data Sheets.

Pressure gauge connections in heat exchanger nozzles are not permitted, except asdefined in paragraph E-2.32 of this Specification.

RB-10.33 THERMOMETER CONNECTIONS

Delete RB-10.33 and replace by:

TEMPERATURE INSTRUMENT CONNECTIONS

If required, temperature instrument connections shall be specified on Project equipment

Data Sheets. Temperature instrument connections in heat exchanger nozzles are not

permitted, except as defined in paragraph E-2.32 of this Specification.

RC-10.34 CLEANING CONNECTIONS (New clause)

When exchangers require in service cleaning with hot water, steam, solvents or other

chemical methods, suitable flanged nozzle connections of DN 50 (2 inch) minimum sizeshall be provided on the shell. Cleaning connections are not permitted on exchanger

nozzles; however, they may be located on the connecting piping.

RC-10.35 SAFETY/RELIEF VALVE CONNECTIONS (New clause)

Flanges for safety/relief valve nozzles shall have a minimum pressure/temperature rating

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of Class 300.

RCB-11 END FLANGES AND BOLTING

Add to this Clause:

All bolting shall comply with requirements of paragraph 13.1.11 of this Specification.

Nuts shall have a height equal to the bolt diameter.

RCB-11.24 BOLT ORIENTATION

Delete the last sentence from this clause.

RCB-11.4 BOLT TYPE

Add to this clause:

For sizes over 63.5 mm (2-1/2 in.), reduced diameter ("necked") stud bolts shall be used.

SECTION 6 - FLOW INDUCED VIBRATION

V-1 SCOPE AND GENERAL

Insert new text:

The computer programs used for the thermal design or rating of the heat exchangers

contain routines to check the likelihood of mechanical and/or acoustic vibrations. The

thermal designer should analyze the vibration warnings generated by the program and

incorporate the appropriate measures into the design of exchangers to avoid or minimizevibration.

V-2.5 ACOUSTIC VIBRATION

Add to this clause:

Where a detuning baffle (parallel to the flow) is considered to change the acousticfrequency, this detuning baffle shall extend at one side of the bundle as far as possible to

the shell wall.SECTION 7 - THERMAL RELATIONS

T-1.1 SCOPE

Add to this clause:

The thermal design and rating of shell and tube heat exchangers shall be based on designmethods which have been proven in practice. In this respect, the design procedures and

computer programs published by the Heat Transfer Research Institute (HTRI), and HeatTransfer & Fluid Flow Service (HTFS) are considered proven design methods.

In the event of inadequate performance, the HTRI calculation procedure shall be used as

the basis for reassessing the thermal performance rating. This involves the following

computer programs:

1. Shell and Tube Heat Exchanger Program : ST

2. Shell and Tube Condenser Program : CST

3. Kettle and Horizontal Thermosyphon Reboiler Program : RKH

4. Vertical Thermosyphon Reboiler Program : RTF

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5. Mean Tubewall Metal Temperature Program : TWL

The print-out of the computer runs shall correspond to the input data. Introducingchanges or deviations between submitting the program and printing the results is not

permitted.

Special requirements for the thermal design or rating shall be recorded appropriately

and/or shown on drawings and/or Data Sheets.

T-1.6 DETAILED INSTRUCTIONS TO COMPUTER PROGRAMS (New clause)

The physical properties of the fluid shall be as specified in Project equipment Data

Sheets. In the event that the data thus provided is considered by the designer or theVENDOR to be insufficient for design purposes, it is his responsibility to request further

information from the COMPANY/CONTRACTOR.

T-1.61 TUBE VIBRATIONS (New subclause)

A check for potential tube vibration shall be made for shell and tube heat exchangers.

T-1.62 BAFFLE-TO-SHELL CLEARANCE (New subclause)

For viscous fluid on shellside, with a dynamic viscosity above 2 cP at the inlet or outlet

temperatures, the heat transfer coefficient shall be calculated with the baffle-to-shellclearance taken as ‘large’ to allow for wear and tear. The shellside pressure drop,however, shall be calculated with the baffle-to-shell clearance taken as

“standard/average.”

T-1.63 PRESSURE DROP (New subclause)

In order to design a heat exchanger with a minimum area requirement, the allowable

pressure drop of the controlling heat transfer side should be fully utilized.

T-1.64 TUBE LAYOUT/SHELL DIAMETER (New subclause)

The design shall ensure that the number of tubes resulting from the computer calculationwill fit into the shell.

The maximum number of tube passes shall be 16 for any given exchanger.

The tubesheet layout drawing, whether in Data Sheets or generated by VENDOR, shallindicate the following, as a minimum:

• Tube pattern

• Number of tubes per pass

• The provision (or otherwise) of impingement protection

• The provision (or otherwise) of sliding strips

•

The provision (or otherwise) of sealing devices• Baffle cut and orientation

• Support plates

• Tie rods

• Drain notch

• Nozzles

• The main dimensions in millimeters (including outer tube limit).

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The tubesheet layout drawing shall show at least one half of the tubesheet (if symmetrical

to the other half). Otherwise the complete tubesheet layout drawing shall be provided.

T-1.65 BAFFLE SPACING OF END COMPARTMENTS (New subclause)

Except for divided/split flow, baffles and end supports shall be spaced so that they do notobstruct the shellside nozzles.

T-1.66 KETTLE-TYPE REBOILERS AND EVAPORATORS (New subclause)

Refer to BGS-ME-001 for design requirements.

T-1.67 TURBULATORS (New subclause)

The application of turbulators and/or static mixers is not permitted.

T-1.68 MASS ESTIMATE (New subclause)

The mass derived from the computer output sheets and listed on Project Data Sheets is tobe treated as a first estimate only.

SECTION 10 - RECOMMENDED GOOD PRACTICE

RECOMMENDED GOOD PRACTICE (RGP) SECTION

Add to this clause:

For the purpose of this Specification, this section 'Recommended Good Practice' sets outthe requirements which shall be considered as additional to the requirements of the

corresponding paragraphs in the main sections of the TEMA Standards, whether or notamended by this Specification.

RGP-RCB-2 PLUGGING TUBES IN TUBE BUNDLES

Add to this clause:

If tubes have to be plugged, defective tubes shall be cut in accordance with the methodapproved by the COMPANY/CONTRACTOR.

Plugging of faulty tubes for hydrogen and/or very toxic service is not permitted. In these

cases, each tube shall be removed and be replaced by two solid rods. The rods shall be

welded to the tubesheet and shall fill the holes in the baffle plates.

RGP-RCB-4.3 TRANSVERSE BAFFLE AND SUPPORT CLEARANCE

Add to this clause:

The clearance given in Table RGP-RCB-4.3 shall only be exceeded if specified in theData Sheets.

RGP-RCB-4.41 TRANSVERSE BAFFLES AND SUPPORT PLATES

Add to this clause:

The minimum thickness shall not be less than twice the specified shellside corrosionallowance.

RGP-RCB-4.71 NUMBER AND SIZE OF TIE RODS

Delete this clause and Table RGP-RCB-4.71 and replace by:

The following Table RGP-RCB-4.71 shows the minimum number of tie rods and

diameter for various sizes of heat exchanger.

TABLE RGP-RCB-4.71 TIE ROD STANDARDS

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Tie Rod Diameter

Nominal

Shell

Diameter

Tube OD of

19.05 mm (3/4 in)

Tube OD of 25.4 mm

(1 in.) and larger

Minimum

Number of

Tie rods

mm (inch)

Pipe OD

Solid Sched 80

mm mm

Pipe OD

Solid Sched 80

mm mm

1550-2540 (61-100) 19 21.34 22 26.9 12

RGP-T-2.4 DESIGN FOULING RESISTANCES


Typical fouling resistances, with reference to the surface on which they occur, shall be

specified on Project equipment Data Sheets. When specific data for setting properresistances are not stated on the Data Sheets, the COMPANY/CONTRACTOR shall be

consulted.

THIS CONCLUDES AMENDMENT TO TEMA STANDARD.

14.0 MATERIALS

Materials and corrosion allowances shall be selected for equipment design life of 20

years (including tubes). All materials shall be defined with complete ASME designation.Nozzles shall have same corrosion allowance as specified for the shells or heads they are

attached to.

All parts which have been cold formed over 5% shall be subjected to an appropriatenormalizing treatment and, if necessary, a tempering treatment.

Carbon content of carbon and carbon-manganese steels shall not exceed 0.23%, exceptfor forgings and castings, where this may be relaxed to 0.25%. For pressure containing

components the carbon equivalent (CE) shall not exceed 0.43, as given by:

CE=%C+%Mn

6+

%Cr + %Mo+ %V

5+

%Cu +%Ni

15

In accordance with Project Specification BGS-MW-001, Appendix 4, all pressure parts

in low temperature (MDMT <15°C), liquidified gas, and toxic services shall benormalized. All flanges in wet H2S, amine, caustic and criticality "CR-1" services shall

be normalized.

See specification BGS-MW-004 for materials requirements for all pressure containing

components in wet H2S service.

External bolting for design temperature above 450°C and up to 525°C, SA-193 Gr B16and SA-194 Gr 4 shall be used. Bolting materials (both external and internal) shall bespecified on Project vessel Data Sheets/drawings for all other design temperature and

extreme service conditions.

Equipment bolting shall be coated, as applicable, in accordance with Project

Specification BGS-MX-001.

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Vanadium-containing, grade 91 materials are unacceptable and shall not be substituted

for grade 9, 9 Cr-1 Mo components.

VENDOR shall furnish Material Certificates in accordance with the requirements of

EN 10204 (formerly DIN 50049). The type of certificate required “A”, “B” or “C” is

determined by the inspection class assigned to the type of equipment or materials.Component parts of a piece of equipment may require different types of certificates. For

certification requirements, refer to Project Specification BGS-MU-014.

Any contact between galvanized steel and stainless steel shall be avoided.

15.0 FABRICATION

All exchangers shall be fabricated in accordance with the referenced Codes andStandards, amended or supplemented by Project Specifications.

Welding shall be in accordance with the Project Specification BGS-MW-001.

Insulation clips, when specified, shall be in accordance with Project Specification

BGS-MN-100.

When indicated on Data Sheets, fabrication shall also comply with Project SpecificationBGS-MW-004 and BGS-MW-005, as applicable.

For special applications see paragraph 13.1.3 of this Specification.

When “low temperature service” is identified, all pressure containing materials shall beevaluated for possible impact testing requirements and meet material and NDE

requirements of BGS-MW-001, Appendix 4.

All welding of Cr-Mo materials shall be PWHT.

Equipment bolting shall be coated, as applicable, in accordance with ProjectSpecification BGS-MX-001.

Fabrication of welded tube-to-tubesheet joints shall be in accordance with Attachment 1

of this Specification.

When Postweld Heat Treatment is required, the entire vessel shall be treated in anenclosed furnace. Chrome-moly material shall be postweld heat treated in all

thicknesses, unless specified otherwise.

No welding is permitted after postweld heat treatment.

Wherever possible, reinforcing pads for nozzles and other attachments shall not belocated over longitudinal and circumferential welded joints. If this is unavoidable, the

welded joint shall be ground smooth and radiographed for its entire covered length plus25 mm on each side.

The minimum distance between two longitudinal seams in one course and between the

staggered longitudinal seams of two adjacent courses shall be 200 mm or five times the

wall thickness, whichever is larger.

Fabrication of tube bundles with titanium components shall comply with the following

additional requirements:

• All contact with steel shall be minimized throughout fabrication, storage andshipping. Nylon straps shall be used for lifting. Nylon or wooden slats shall be

used to avoid contact with floors. When shipped separately, bundles shall be crated

for shipping. All brushes and tools shall not have had previous use on any other

materials besides titanium. No steel brushes can be used and brushes shall bestainless steels or higher alloys.

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• At the completion of fabrication, the bundle surfaces shall be pickled by flushing or

soaking in a 35 to 5 (or 12 to 1 volume percent) HNO3-HF solution at ambient

temperature for 5 to 10 minutes. This shall be followed by flushing with potablewater.

• Nylon straps shall be a minimum of 25 cm wide and multiple lifting points shall be

used.

• U-bends shall not be stress relieved.

• Rolling shall be done per the tube VENDOR’S recommendations, subject to

CONTRACTOR’S review.

• Tube-to-tubesheet strength welding, if required, shall be done using automated

GTAW processes and the welding procedure shall be submitted to CONTRACTOR

for approval.

• Fabricators shall have previous experience fabricating titanium heat exchanger

bundles and be approved by the CONTRACTOR.

16.0 TESTING

The requirement for PMI and the extent of PMI testing shall be in accordance with the

Project Specification BGS-MW-006.

NDE shall be in accordance with Project Specification BGS-MW-001.

The extent of NDE shall be in accordance with the design/fabrication Code and thefollowing Criticality Rating (CR), as a minimum:

CR 1: Code, but not less than:

100% RT all butt welds

100% MT all completed accessible weld surfaces and root area of all double

welded joints prior to reweld. In case of stainless steel, use PT instead of MT.

CR 2: Code, but not less than:

10% RT all butt welds (including T-junctions).

100% RT all category A+B welds in nozzle necks.100% MT all completed accessible weld surfaces and root area of all double

welded joints prior to reweld. For stainless steel, use PT instead of MT.

CR 3 Code, but not less than:

“SPOT” RT as defined in BGS-MW-001

CR 4 Code, but not less than:

“SPOT” RT as defined in BGS-MW-001

All equipment is subject to inspection by CONTRACTOR’S/COMPANY’S inspector or

nominated representative.

All tubes shall be in accordance with ASTM Standard A-450.

Testing of welded tube-to-tubesheet points shall be in accordance with Attachment 1 of

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this Specification.

All exchangers shall be hydrotested. Stacked exchangers shall be hydrotested in stacked

position, with service gaskets installed.

Sufficient number of tests shall be carried out to fully test the:-a) Tube side

b) Shell side

c) Tubesheets for leakage

Where the internals are designed for design pressure on one side with full vacuum on the

other side, the test pressures on the tube or shellside shall be calculated to test theinternals at least to their full design pressure (including vacuum) multiplied by the Code

factors.

All equipment shall be clean and free of debris, sand, rust, dust, etc. before hydrotesting.Metal and water temperature shall not exceed 50°C during testing, and equipment shall

be immediately drained and dried upon completion of test.

A suitable filter shall be provided in the hydrotest water fill line to remove sand, rust, and

other particles in the test water. The VENDOR shall submit filter requirements, as partof the hydrotest procedure, to the COMPANY for approval.

The test medium for hydrostatic testing shall be clean water containing a suitable wetting

agent to reduce the surface tension. The pH of the water shall be kept between 6 to 8.The use of any other medium shall require approval by CONTRACTOR.

Hydrotest water for austenitic stainless steel shall have chloride contents of 50 ppm or

less. If hydrotest water with a chloride content of 50-200 ppm is used, the exchangershall be immediately flushed with demineralized water with a chloride content of 2 ppm

or less and then drained.

Leak test of reinforcing pads shall be performed in accordance with the ASME CodeSection V. Each reinforcing pad shall have one test hole, tapped for 1/4 inch NPT, and

located at least 45 degrees off the longitudinal axis of the vessel. This applies to eachpad or segment of a multiple piece pad. The welds of each pad or segment shall be given

an air and bubble solution pressure test before the test of the vessel. The test pressureshall be at least 1.05 bar but shall not exceed 1.4 bar. The test holes shall be left open for

use as telltale holes. They shall be filled with corrosion inhibiting grease after testing of exchanger. Do not install a screwed plug.

For insulated vessels in hydrogen service, the VENDOR shall furnish and install pipenipples in the telltale holes. Length of nipple to be approximately 13 mm longer than

insulation thickness. Apply corrosion inhibiting grease in end of nipple after testing of

vessel. Do not install a pipe cap.

After completion of the pressure test, additional welding on the pressure-containing

portion of the exchanger is not permitted without prior approval by CONTRACTOR/ COMPANY.

The VENDOR shall perform material thickness measurements for both shellside and

tubeside in accordance with BGS-MU-016

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APPENDIX 1

WELDING OF TUBE-TUBESHEET CONNECTIONS

A1-1.0 INTRODUCTION

This Attachment is applicable when welded tube/tube sheet connections have been

specified.

The integrity of a heat exchanger greatly depends on the welding methods used to attachtubes to tube plate. Attachment 2 shows weld details.

A1-2.0 PREPARATION OF TUBES AND TUBE PLATES

The ends of the tubes which are to be welded shall be cleaned and degreased with asuitable nonresidue forming solvent, both inside and out, for a length equal to the tube

plate thickness plus not less than 25 mm. The solvent used for degreasing materials

should be chloride free, e.g. acetone. For welding with the GTAW process, the outsideends of the tubes for a minimum distance of 13 mm shall be finished to bright metal, e.g.

by finishing or power brushing. For metal arc welding, the tube ends may be grit blastedprior to cleaning and degreasing as agreed. Tubes with score marks or any other surface

irregularities at the ends shall not be used if considered to be detrimental to theproduction of sound welds.

The tube plates shall be machined and the tube holes bored or drilled as required by the

design; the holes so formed shall be normal to the tube plate surface, parallel, circularand shall have smooth internal surfaces. They shall be free from burrs and the shellside

edges of the tube holes shall be chamfered or rounded to 1.5 mm approximately. Thelimits of tolerance of tube holes shall not exceed those defined by TEMA. Immediately

prior to assembly, the plates shall be thoroughly cleaned and degreased using a

nonresidue forming solvent.

The face of the tube plate, the holes and the tubes shall be free from dirt, grease, scale

and other foreign matter when they are assembled. To avoid possible damage duringassembly or entrapment of contaminants, baffle and support plate holes should be freefrom burrs and effectively cleaned prior to the commencement of tube threading.

A1-3.0 WELDING PROCEDURE QUALIFICATION

A1-3.1 GENERAL

No production welding shall be carried out until the proposed welding procedures have

been evaluated and authorized by the COMPANY/CONTRACTOR in accordance withthe requirements of Attachment 3 and this Attachment.

Any change of major variable, but not a replenishment of any consumable, i.e. gas

cylinder or electrode, shall require requalification of procedure.

A1-3.1.1 Procedure Test Piece

The test pieces shall be in accordance with Attachment 3.

The procedure test shall be welded in the same position as the actual welding shall be

done, i.e. vertical or downhand. Also the welding sequence/configuration shall be part of

the procedure qualification.

All tubes used for procedure testing shall be of the same diameter, wall thickness and

nominal chemical composition as those proposed for production. Plate material to be

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used for the procedure test shall also be of the same nominal composition as that to be

used in manufacture. The thickness of the sample tube plates shall equal that of the plateto be used in production, except that it need not exceed 35 mm thickness. If tube

expansion after welding is specified, it may be necessary for a sample of full plate

thickness to be employed. The test piece shall be at least 25 mm greater in size all roundthan the limits of the tube hole array.

A1-3.1.2 Examination of Test Pieces

The completed test pieces shall be examined as follows:

a. Visual examination

b. Macroscopic examination as shown in Attachment 3, with hardness measurements

where appropriate.

c. The weld quality shall meet the requirements of paragraph 3.2 of this Attachment.

d. Weld strength test, see Appendices 3 and 4.

A1-3.1.3 Welder Qualification

Every welder employed on tube end welding shall demonstrate his competence by

making a test piece in accordance with paragraphs 3.1.1 and 3.1.2 of this Attachment andAttachment 2, using the same tube dimensions, materials and welding procedures as will

be involved in production welding. Welders whose authorized test pieces meet the

requirements of paragraph 3.2 of this Attachment, are qualified for production welding.

When a welder has successfully passed the appropriate qualification tests within the last

6 months and has been regularly employed in this type and size of weld since passing histest, and there is evidence that the welder has continued to make satisfactory welds, he

may be accepted without further qualification at the discretion of the CONTRACTOR’Sinspecting engineer or his nominee.

A1-3.1.4 Weld Quality Requirements

For a summary of tests required, see table below.

Type of Test Required Procedure Qualification Welder Qualification

Visual Examination

Macro Examination

Yes

Yes

Yes

Yes

A1-3.2 WELD QUALITY

The specified tests shall be carried out to the satisfaction of the COMPANY’S Inspecting

Engineer or nominee and the following defects shall be cause for rejection:

(a) cracks NA(b) lack of fusion NA

(c) burn through of the tube bore NA

(d) excessive weld spatter/overhang NA

(e) effective weld thickness of less than 0.7 t NA

NA = not allowed

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A1-4.0 EXAMINATION OF PRODUCTION WELDS

After each weld run, the weld and internal tube surface for at least 3 mm beyond the

fusion zone shall be thoroughly cleaned, wire brushed, and examined. All defects such ascracks, slag, lack of fusion or gross porosity shall be repaired.

When agreed for austenitic materials, each weld run shall be dye penetrant tested using

commercially approved materials and techniques. The soak time for the penetrant shall

not be less than 10 minutes. After dye penetrant testing and before any further welding is

carried out, all traces of dye, developer and solvents shall be removed.

A1-5.0 LOW PRESSURE PNEUMATIC TEST

After welding and before hydraulic testing, the assembly shall be tested for leaks by

applying a pressure of 0.51 bar(G).

While the shell is under pressure a simple soap or detergent test shall be used to indicate

escapes of air from leaks. Generally, 1 to 2% solution by volume of a suitable foaming

agent in water is effective.

When specified, a tracer such as halogen gas/helium may be added to the pressurizinggas, and a suitable detector used to locate leakages.

When specified on the order, leak testing shall be carried out after the completion of each

run in multi-run welds.

All suspect weld locations shall be marked for repair. Since no completely reliable

nondestructive test exists at present to establish weld tightness, defective welds found

during testing shall not exceed 1% of the total number of welds on any tube plate.

A1-6.0 REPAIRS

On completion of a gas leak test required by paragraph 5.0 of this Attachment, any leaks

disclosed shall be repaired and re-tested until all faults are remedied.

Where practical, faulty welds shall be completely removed to sound metal and repaired

using the qualified procedure. Departure from this procedure shall be as agreed by the

CONTRACTOR and may be subject to repair procedure testing.

Minor faults associated with fully automatic GTAW welding with incorrect settings or

tracking, may be rectified by rewelding at corrected settings. If the welds still remaindefective, they shall be removed and repaired manually by the TIG process using

appropriate filler metal addition. When any defects occur, particularly cracking, the cause

shall be established prior to repair.

A1-7.0 EXPANDING AFTER WELDING

Where expansion after welding is specified, it shall not be carried out until after the

successful completion of the low pressure pneumatic test and where postweld heat

treatment is specified after that heat treatment. For services where stress corrosion

cracking may occur, expansion should be carried out before PWHT.

The expansion shall be lightly done with the objective of sealing the back face crevice in

the tube hole. The expanded region shall lie within a zone extending for the various joint

types.

The expanding equipment shall have limiting controls which will ensure that tube wall

thinning is between 3% and 5% of original wall thickness.

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A1-8.0 HYDRAULIC TESTING

The hydraulic test shall be carried out after all welding, pneumatic tests, tube expansion

and heat treatment has been completed.

The complete exchanger shall be hydrotested in accordance with paragraph 16.0 of thisSpecification.

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APPENDIX 2 TUBE - TUBESHEET CONNECTION

Joints for t > 2.5 mm

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TUBE - TUBE SHEET CONNECTION

Joints for t < 2.5 mm

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APPENDIX 3 EXAMINATION OF PROCEDURE AND WELDING QUALIFICATION

TEST PIECES

Test specimen for square pitch. Test specimen for triangular pitch

Macroscopic Examination

Each weld region on one surface of each of the saw cuts A, B and C shall be carefullyprepared by emerying to a minimum 180's grit emery finish, and then etched in a suitable

reagent to reveal the weld structure.

Saw cut D shall be made at a stop/start position.

The effective weld height shall be measured on all sections. Using an electronic

calculator or by plotting the values on probability paper, the average effective weldheight and the 1% minimum weld height can be determined.

A welding procedure can be considered of good quality when average and minimum

weld height values are not much different.

Weld Strength Tests

If a test of weld strength is specified, it is recommended that the tube should be pulled

out through the back of the tube plate and the breaking load recorded (see Attachment 4).

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The minimum acceptable strength shall be as agreed between COMPANY and

VENDOR. Where fracture occurs in the weld, this shall not necessarily be cause forrejection; but the fracture should be examined for any evidence of faulty workmanship.

“Push through” tests, where the tube is pushed from the back and through the face of the

tube plate, are unreliable; they may indicate exceptionally high strength due to thedeformation of the tube under high compression stress, resulting in the tube expandinginto the tube plate and developing a high frictional force in addition to the force required

to cause failure of the weld joint.

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APPENDIX 4 RECOMMENDED ALTERNATIVE DETAILS OF WELD

STRENGTH TESTS