MCOP11

PETRONAS/UCC JV MALAYSIA PROJECT
TECHNICAL STANDARD
MECHANICAL HEAT EXCHANGERS GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS
MCOP-11
SEPTEMBER 1998
MECHANICAL HEAT EXCHANGER
PETRONAS/UCC JV - MALAYSIA PROJECT Revision 2
MCOP-11 PAGE 0 OF 70 SEPTEMBER 1998
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS
NOTE:
Revisions in subsequent issues will be noted on Page 0 of this standard. REVISION A 0 DATE 1-Dec-97 27-Feb-98 PAGE(S) REVISED Review and Comments Issue for Engineering (Pre-Endorsement) Issue for Engineering (Endorsement Issue) Revised Para. 25.2.1.2 Per comment from UCC.
06-Apr-98
15-Sept-98
PMC APPROVAL SIGNATURE ON FILE Name: Title: Originating Engineer/Engineering Manager Title: (PMC) PMT AUTHORISATION SIGNATURE ON FILE Name: Title: Skills Area Lead Engineer (Union Carbide Corporation) Title: SIGNATURE ON FILE Engineering Representative (PETRONAS) SIGNATURE ON FILE Engineering Representative (PMT)
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS TABLE OF CONTENTS 1. GENERAL 1.1. 1.2. 1.3. 1.4. 1.5. 2. Scope Exceptions Policy Design Requirements Vessel Specifications Definitions
1.6. Bid Proposals REFERENCE CODES AND STANDARDS 2.1. 2.2. ASME Code TEMA Standards
3.
2.3. Other Codes 2.4. Effective Dates 2.5. Laws of Malaysia WORKING DRAWINGS AND CALCULATIONS 3.1. Information Required 3.2. Special Notes 3.3. Language 3.4. CONTRACTOR/OWNER Review 3.5. Units 3.6. Calculations MATERIALS 4.1. Unspecified Materials 4.2. Tubing 4.2.1. Tubing Thickness 4.2.2. Welded Tubing 4.2.3. Stainless Steel Welded Tubing 4.3. Flange Gaskets 4.3.1. Service Gaskets 4.3.2. Test Gaskets 4.3.3. Spare Gaskets Solution Anneal
4.
4.4. 5.
FABRICATION DETAILS 5.1. Backing Strip Removal 5.2. 5.3. 5.4. Weld Metal 5.2.1. Clad Materials Nozzle Attachment Welds Nozzle Location
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 5.4.1. Examination Of Intersected Weld Joints Segmental Nozzle Reinforcing Pads Nozzle Reinforcing Pad Test Nozzles For Safety Relief And Drainage Bore Of Welding Neck Flanges Flange Drilling Grounding Clip Gasket Contact Surfaces 5.11.1. Surface Finish 5.11.2. Flatness Tolerance 5.12. 5.13. 5.14. 5.15. Thickness Of Fixed Tubesheets Heat Treatment Of Expanded Joints Tolerances Welding 5.15.1. Welders and Welding Procedures 5.15.2. Subcontracted Fabrication Work Welding Or Grinding Prevention Of Stress Raisers In Impact Tested Materials Postweld Heat Treatment 5.18.1. Exchangers In Ammonia Service 5.18.2. Welding After Heat Treatment 5.18.3. Alternative PWHT
5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11.
5.16. 5.17. 5.18.
6.
5.19. Flanged Joint Assembly 5.20. Painted Components That Will Be Inaccessible After Assembly NONDESTRUCTIVE EXAMINATION 6.1. Applicable Code 6.2. 6.3. Examination After Heat Treatment Miscellaneous Examinations 6.3.1. Weld Examination 6.3.2. Welded Pressure Joints That Will Be Inaccessible After Assembly 6.3.3. Base Material Examination 6.3.4. Tube-To-Tubesheet Joints 6.4. Examination Of Repairs HYDROSTATIC TESTING 7.1. 7.2. 7.3. 7.4. 7.5. Vertically Mounted Exchangers Horizontally Mounted Exchangers Individual Compartment Tests Stacked Exchangers Expansion Joints
7.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 7.6. 7.7. 7.8. 7.9. 7.10. 7.11. Holding Time Metal Temperature Water Quality Blind Flanges For Test Leakage During Test Retesting Repaired Exchangers
7.12. Disassembly Of Flanged Joints After Testing 7.13. Painting 8. 7.14. Shot Peening NAMEPLATES Manufacturer's Nameplate 8.1.1. Mounting Clip 8.2. OWNER'S Nameplate REQUIRED INFORMATION 9.1. Retention 9.1.1. Retention of Radiographs 9.2. Reports 9.3. Calculations CLEANING, PAINTING, AND SHIPPING PROTECTION 10.1. Drying And Cleaning 10.2. Painting 10.3. Machined Surfaces 10.3.1. Assembled Joints 10.3.2. Exposed Surfaces Exchanger Openings Warning Signs 10.5.1. Heat Treated Exchangers 10.5.2. Fragile Components 10.6. Welded Attachments REFERENCES 11.1. 11.2. 11.3. 11.4. 11.5. 11.6. American Society Of Mechanical Engineers (ASME) American National Standards Institute (ANSI) Military Specifications OWNERs Engineering Standards: Not Used Welding Research Council (WRC) 8.1.
9.
10.
10.4. 10.5.
11.
11.7. Laws of Malaysia 11.8. Attachments 11.8.1. Figure 2 - Expanded Tube to Tubesheet Joint
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 11.8.2. Figure 3 - Expanded and Seal Welded Tube to Tubesheet Joint ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED DESIGN CRITERIA 20.1. Equivalent Design Pressure 20.1.1. Equivalent Design Pressure For Shop-Fabricated And ShopTested Exchangers Design Temperature 20.2.1. Maximum Design Temperature 20.2.2. Minimum Design Temperature Operating Liquid Head Allowable Stress Values 20.4.1. Low Allowable Stress Designing For Vacuum Service 20.5.1. Internal Pressure Rating of Exchangers Designed for Vacuum Service 20.5.2. Stiffening Rings Butt Joints Required Radiographic Examination 20.7.1. Seams In Formed Heads Corrosion Allowance 20.8.1. Tubes 20.8.2. Nonpressure Parts Common Components
12. 13. 14. 15. 16. 17. 18. 19. 20.
20.2.
20.3. 20.4. 20.5.
20.6. 20.7. 20.8.
20.9.
20.10. Clad Components 20.11. Wind Or Earthquake Loads 20.11.1. 20.11.2. Wind Loads Earthquake Loads
20.11.3. Article Not Used 20.11.4. Wind Excitation 20.12. Design Pressure And Additional Loadings 20.12.1. 20.12.2. Design Loads Load Combinations
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 20.13. Torispherical Heads 20.14. Local Shell/Formed Head Stresses 20.15. Combined Primary Stress For Elevated Temperature Service (>427C) 21. 20.16. Exchangers In Cyclic Service HYDROSTATIC TEST (SEE ARTICLE 7) 21.1. Test Pressure Determination 21.1.1. Test Pressure 22. 23. PNEUMATIC TESTS NONDESTRUCTIVE EXAMINATION 23.1. Magnetic Particle And Liquid Penetrant Examination 23.1.1. ASME Code Categories A and B, and Categories C and D ButtType Joints 23.1.2. ASME Code Categories C and D Non-Butt-Type Joints 23.1.3. Corner Joints 23.1.4. Nonpressure Attachment Welds Ultrasonic Examination
23.2.
24.
23.2.1. Rolled Plate 23.2.2. Forgings 23.2.3. Integrally-Bonded Clad Plate 23.2.4. Reports MATERIAL SELECTION 24.1. Carbon And Low-Alloy Steels 24.2. 24.3. 24.1.1. Restriction of Code Provision Other Than Carbon Or Low Alloy Steels Pressure Bolting 24.3.1. Piped Nozzle Flanges 24.4. 24.5. 24.3.2. Swing Bolts Exchanger Supports Attachments To Pressure Parts 24.5.1. Internal Attachments 24.6. 24.5.2. External Attachments Welded Parts Of Dissimilar Metals 24.6.1. External Nozzle Reinforcing Pads for Austenitic Stainless Steel Exchangers 24.6.2. External Nonpressure Attachments, Excluding Exchanger Support Skirts, Welded to Austenitic Stainless Steel Exchangers 24.6.3. Support Skirts Welded To Austenitic Stainless Steel Exchangers 24.6.4. Nozzle Necks For Clad And Unclad Steel Exchangers 24.6.5. External Stiffening Rings Welded to Austenitic Stainless Steel Exchangers
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 24.6.6. Tubesheets Welded To A Carbon Steel Shell Flanged Joints Of Dissimilar Metals
24.7. 25.
MISCELLANEOUS DESIGN REQUIREMENTS 25.1. Flanged Pressure Joints 25.1.1. Confined Joints 25.1.2. Gasketed Pass-Rib Joints 25.1.3. Unconfined Joints 25.1.4. Lap Joints 25.1.5. Limitations On The Use Of Slip-On Flanges 25.1.6. Asbestos Gaskets 25.1.7. Spiral-Wound Gaskets 25.1.8. Gasket Selection, Design Factors, and Contact Width 25.1.9. 3-Ply and Single-Ply Corrugated Metal Gaskets 25.1.10. External Moments 25.1.11. Flange Rigidity 25.1.12. Minimum Bolt Size 25.1.13. Bolt Spacing Factor 25.1.14. Indicator-Type Bolting 25.1.15. Additional Flange Design Criteria For Elevated Temperature (>427C) Tubesheets 25.2.1. Minimum Tubesheet Thickness 25.2.2. Cladding Thickness 25.2.3. Stationary Tubesheets for Removable Tube Bundles 25.2.4. Tubesheet-to-Shell Weld Joints 25.2.5. Tube-to-Tubesheet Joints 25.3. Tubes 25.3.1. Minimum Wall Thickness 25.3.2. Plain Ends for Low-Finned Tubes Expansion Joints 25.4.1. Design Basis 25.4.2. Type of Construction 25.4.3. Location 25.5. 25.4.4. Other Considerations Vapour Belts 25.5.1. Design Basis 25.5.2. Type of Construction 25.6. 25.5.3. Use as Expansion Joint Baffles And Support Plates
25.2.
25.4.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.6.1. Minimum Thickness 25.6.2. Baffle Cuts 25.6.3. Drain or Vent Notches 25.6.4. Slides for Removable Tube Bundles 25.6.5. U-Tube Bundles 25.6.6. Tie Rods And Spacers 25.7. Channels, Covers, And Bonnets 25.7.1. Pass Partition Plates 25.7.2. Mitered Reducing Elbows 25.7.3. Flanged Joints 25.8. Nozzles And Manways 25.8.1. Projection 25.8.2. Minimum Manway Size 25.8.3. Integral Reinforcement 25.8.4. Type Of Nozzle Connection 25.8.5. Nozzle Flanges 25.8.6. Minimum Nozzle Neck Thickness 25.8.7. Pipe Tap Connections 25.8.8. Studding Outlets 25.8.9. Gussets 25.8.10. Shell Side Nozzles and Vents and Drains 25.8.11. Flange Connections 25.8.12. Nozzles in or Passing Through Skirts 25.8.13. Tubesheet Vents and Drains 25.8.14. Manway Davits Internal Parts 25.9.1. Clad Exchangers 25.9.2. Integrally-Clad Plate 25.9.3. Weld Overlay 25.9.4. Loose Lining 25.10. Exchanger Supports 25.10.1. 25.10.2. 25.10.3. Design Stresses Skirt Supports Saddle Supports
25.9.
25.11. Anchor Bolting 25.11.1. Design Stresses 25.11.2. 25.11.3. 25.12. Lifting Lugs Spacing and Location Supplier
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.12.1. 25.12.2. Exchanger Lifting Lugs Lugs for Removable Parts
25.12.3. Tailing Lugs 25.13. Flow-Induced Tube Vibration
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS PREFACE MCOP-11 (OWNER Technical Standard) publication reflects the views, at the time of publication, of: PETRONAS /UNION CARBIDE Malaysia Joint Venture It is based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate in MCOP11 is based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice applied by OWNER in oil and gas production facilities, oil refinery, gas processing, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation. When CONTRACTORS or Manufacturers use MCOP-11, they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the OWNER will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the MCOP-11. If in doubt, the CONTRACTOR or Manufacturer/SUPPLIER shall, without detracting from his own responsibility, consult the OWNER or its technical advisor. The right to use MCOP-11 rests with three categories of users: 1) 2) 3) OWNER and its affiliates. Other parties who are authorised to use MCOP-11 subject to appropriate contractual arrangements. CONTRACTORS / subcontractors and Manufacturers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or -generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, OWNER disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company with the use, application or implementation of any MCOP-11 combination of MCOP-11 or any part thereof. The benefit of this disclaimer shall inure in all respects to OWNER and/or any company affiliated to OWNER that may issue MCOP-11 or require the use of MCOP-11. Without prejudice to any specific terms in respect to confidentiality under contractual arrangements, MCOP-11 shall not, without the prior written consent of OWNER, be disclosed by users to any company or person whomsoever and MCOP-11 shall be used exclusively for the purpose it has been provided to the user. MCOP-11 shall be returned after use, including any copies which shall only be made by users with the express prior written consent of OWNER. The copyright of MCOP-11 vests in OWNER. Users shall arrange for MCOP-11 be held in safe custody and OWNER may at any time require information satisfactory to OWNER in order to ascertain how users implement this requirement.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 1. GENERAL 1.1. Scope This standard designates general requirements for design and construction1 of welded shell-and-tube heat exchangers having maximum allowable working pressures (MAWP) greater than 1.034 barg but not exceeding 138 barg, and those subject to external pressure, or for vacuum service (internal pressures less than atmospheric pressure). Special requirements are covered in the Vessel Specification (see Article 1.4). This standard does not provide coverage of air- cooled heat exchangers (see Engineering Standard MCOP-12). Shell-and-tube heat exchangers within the scope of this standard satisfy all applicable requirements of the ASME Boiler and Pressure Vessel Code including inspection and Code symbol stamping. 1.1.1. The technical intent of this standard is to establish minimum "base case" requirements for the construction1 of shell-and-tube heat exchangers, irrespective of specific service fluid-related requirements. The bases/sources for the statements are regulatory requirements, safety, environmental protection, and recognised and generally accepted good engineering practices for exchangers in chemical service. 1.2. Exceptions Policy Any exception to or deviation from any statement of this standard and the referenced documents herein, and which meets the technical intent of the standard, requires written approval by the OWNER, who shall be responsible for interpreting the technical intent of the statement. Exceptions or deviations to the statements which have been properly approved and listed in the Vessel Specifications (see Article 1.4) shall be the Manufacturers authorisation to deviate from the statements in this Standard. Otherwise the Manufacturer shall not deviate from this Standard and the referenced documents herein without written approval by the OWNER (see Article 1.5). 1.3. Design Requirements Exchangers or exchanger parts shall comply with applicable parts of the Design Requirements of Articles 20 through 25. Mechanical design provided in the Vessel Specifications shall not relieve Manufacturer of his ASME Code-defined responsibility regarding Code construction1. 1.4. Vessel Specifications The term "Vessel Specifications" shall be understood to include any drawings, specifications, data, and listings of approved deviations (see
1
Construction is an all-inclusive term comprising materials, design, fabrication, examination, inspection, testing, certification and pressure relief.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS Article 1.2) designated by OWNER (see Article 1.5) for a particular exchanger or group of exchangers. In case of disagreement between the Vessel Specifications and MCOP-11, Article 1.2 applies. 1.5. Definitions The OWNER is the party which initiates the project and ultimately pays for its design and construction. The OWNER will generally specify the technical requirements. The OWNER may also include an agent or consultant, authorised to act for the OWNER. The CONTRACTOR is the party which carries out all or part of the design, engineering, procurement, construction and commissioning for the project. The OWNER may sometimes undertake all or part of the duties of the CONTRACTOR. The Manufacturer is the party which manufactures or supplies equipment and services to perform the duties specified by the CONTRACTOR. 1.6. Bid Proposals All quotations shall be submitted in strict accordance with this standard and/or the Vessel Specifications. Proposed exceptions or alternatives to these requirements may be quoted as options for OWNER's consideration provided such exceptions or alternatives are clearly and completely described in the proposal. 2. REFERENCE CODES AND STANDARDS 2.1. ASME Code Exchangers shall be constructed1 in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1 (hereafter referred to as the ASME Code). Each ASME Code U-symbol- stamped exchanger shall be registered with the National Board of Boiler and Pressure Vessel Inspectors. National Board registration is not applicable for exchangers stamped with the ASME Code UM-symbol. 2.2. TEMA Standards Exchangers shall comply with the mechanical standards of the Tubular Exchanger Manufacturers Association (TEMA) for Class "B" exchangers, except as otherwise or additionally specified herein or in the Vessel Specifications.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 2.3. Other Codes Requirements for exchangers constructed in accordance with rules other than specified in Articles 2.1 and 2.2 shall be by written agreement between OWNER and Manufacturer. 2.4. Effective Dates References to codes, standards, and other specifications are to the latest edition or addenda issued at the date of the exchanger purchase contract award. 2.5. Laws of Malaysia Factories and Machinery Act 1967 (Act 139) & Regulations and Rules (As at 25th January 1997). 2.5.1. Exception 2.5.1.1.Paragraph 61, Item 2 (Factories and Machinery (Steam Boilers and Unfired Pressure Vessel) Regulations, 1970, Part III) "The distance between any two supports of any horizontal unfired pressure vessel shall not be greater than sixteen feet and each support shall extend over not less than one-third of the circumference of the vessel except where authorised in writing by the Chief Inspector" Exception: Article 25.10.3.3 of this standard "Saddle Design" shall be used as an approved exception to Paragraph 61, Item 2 of the Factories and Machinery Regulations, 1970.
2.5.1.2.Paragraph 72. (Factories and Machinery (Steam Boilers and Unfired Pressure Vessel) Regulations, 1970, Part III) (1) "Every steam boiler and unfired pressure vessel shall, before being put into service for the first time, be subjected to a hydrostatic test a) of twice the authorised safe working pressure where such pressure is not more than one hundred pounds per square inch: and
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS b) of one and a half times the authorised safe working pressure plus fifty pounds where such pressure exceeds one hundred pounds per square inch". Pressure Vessels conforming to this standard, shall be hydrostatic tested in accordance with Article 21.
Exception:
3.
WORKING DRAWINGS AND CALCULATIONS 3.1. Information Required Manufacturer shall provide certified assembly and working drawings and applicable design calculations (see Article 3.6) for all exchangers. Drawings shall be complete and shall include, but not necessarily be limited to, the following information: 1. 2. OWNER's item number, purchase order number, work order number, and property number. Reference to specifications. Manufacturer shall include on his drawings a reference to all applicable codes, ASME Code Cases, standards, and specifications, including date of issue. References shall include all applicable OWNER specifications and standards, and any applicable Manufacturer standards. When reference is made to Manufacturers own standards, copies of such standards shall be included with the submitted working drawings. Applicable ASME Code paragraphs for impact test exemption [e.g., UG-20(f), UCS-66(a), UCS-66(b), UCS-66(c)] or for impact test requirements (such as UHA-51 or UHT-6). National Board registration number (U-symbol stamped exchangers; see Article 2.1). Maximum allowable working pressures (MAWP) for shell side and tube side and coincident maximum design temperature (see Article 20.2). (Internal and external if applicable). Minimum design metal temperatures (MDMT) for shell side and tube side and coincident maximum allowable working pressure (see Article 20.2). Design specific gravity (see Article 20.3). Joint efficiency for each butt welded joint (or seamless equivalent) in the exchanger, including nozzles and communicating chambers. A joint efficiency map may be required. Corrosion allowance. If none, so state. Relevant fabrication, inspection, nondestructive examination, testing, and painting requirements, including postweld heat treatment, degree of radiographic or other nondestructive examinations, etc. Hydrostatic or pneumatic test pressures for the shell side and the tube side, as applicable:
3.
4. 5.
6.
7. 8.
9. 10.
11.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS a. Horizontal position (referenced to compartment centreline) b. Vertical position (referenced to top of compartment) Minimum permissible test temperature and holding times for the shell side and the tube side. Sensitive leak tests, if any. Estimated weight of exchanger, empty, operating, full of water, and erection weight with platforms, insulation, piping, and other attachments which will be in place during the erection. Also show estimated weight of removable tube bundles. Capacity of shell side (or each compartment) and tube side, in litres. 2 Gross tube surface area on shell side, in mm . Thickness of all components. For formed heads, the specified minimum thickness after forming shall be shown. Tube bending schedule for u-tube bundles. (Center-to-centre dimensions of bends.) Material specifications for all components (including ASME standard specifications for product forms, as applicable). Weld details including weld contour requirements, if applicable. All welds shall be either detailed or identified by use of the standard welding symbols of the American Welding Society, ANSI/AWS A2.4. Surface preparation and painting or other protective coating specifications. All pertinent dimensions, including location of weld seams, nozzle location and projection, location of exchanger supports, insulation supports, and any other information necessary for a complete description of the exchanger. Manufacturer's drawings shall have the same designation for nozzles, manways, and skirt openings as shown in the Vessel Specifications. For nozzles located normal to a cylindrical shell, the exchanger assembly drawings shall include dimensions from the centreline (axis) of the shell to the nozzle faces. Complete description of all exchanger flanges (including both standard and custom design), pressure bolting, and gaskets. Facsimiles of Manufacturer's and OWNER's nameplates as stamped by Manufacturer. Special service notes (e.g., "for cyclic service" followed by a description of the cyclic loadings and number of cycles used in the design). Exchanger support details.
12. 13. 14.
15. 16. 17. 18. 19. 20.
21. 22.
23.
24. 25. 26.
27.
3.2.
Special Notes Manufacturer's drawings shall also include the following notes as applicable: 1. Stainless Steel or Nickel-Alloy Exchangers The following note: "Zinc-coated (galvanised or painted) components shall not be in contact (welded, bolted, or loose) with any alloy parts of the exchanger." Hastelloy, Monel, Nickel, or Nickel-Alloy Exchangers The following note: "Substances containing sulphur (e.g., lubricants to aid machining) shall not be applied to alloy parts of the exchanger." All Exchangers The following note: "Substances containing chlorine or which will decompose to hydrogen chloride (e.g., coatings to prevent adhesion of weld spatter) shall not be applied to any part of the exchanger." Clad-Steel Exchangers Drawing notes shall specify whether or not the thickness of cladding metal has been included in the design calculations for strength. Inclusion of cladding requires OWNER's approval (see Article 20.10). Balance Point Location For horizontal exchangers, the balance point location shall be noted and dimensioned from a permanent reference point (e.g., main shell flange, tubesheet, etc.). Exchangers for which Fatigue is a Controlling Design Requirement The following note: "Each shell section shall be corrected for peaking of the longitudinal seam(s) prior to assembly to mating shell sections or other components."
2.
3.
4.
5.
6.
3.3.
Language The language of all drawings and calculations shall be English or the English translation of the language used shall also be shown.
3.4.
CONTRACTOR/OWNER Review Manufacturer's drawings shall be reviewed by CONTRACTOR prior to start of fabrication unless release to proceed is obtained from CONTRACTOR in writing. OWNER may also require review/audit of Manufacturers drawings.
3.5.
Units Dimensions, pressure, stress, volume, temperature and area shall be in the following metric units: Dimensions Stress Temperature mm kg/cm
o 2
Pressure Volume Area
bar litre mm
2
3.6.
Calculations Calculations are required for each item in sufficient detail to demonstrate compliance with the requirements of this standard and the referenced documents (see Article 9.3).
4.
MATERIALS 4.1. Unspecified Materials Materials not completely defined in the Vessel Specifications shall conform to the requirements of the ASME Code. 4.2. Tubing 4.2.1. Tubing Thickness Average wall tubing (tubing with a plus-or-minus variation from specified wall thickness) may be used provided the undertolerance will not permit wall thicknesses less than the required minimum for design conditions. The tolerance for average wall tubing shall not be more than the smaller of the allowable tolerance for average (nominal) wall given in the applicable tube specification or plus-or-minus 10% of the specified wall thickness. Tubes having a wall thickness different than specified in the Vessel Specifications shall not be substituted without OWNER's approval. 4.2.2. Welded Tubing Welded tubing shall be examined by the electromagnetic (eddy current) nondestructive examination technique after final heat treatment in accordance with applicable ASME Boiler and Pressure Vessel Code material specifications.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 4.2.3. Stainless Steel Welded Tubing The weld metal of molybdenum bearing grades of stainless steel welded tubing shall be cold worked prior to final heat treatment in accordance with applicable ASME Boiler and Pressure Vessel Code material specifications. 4.3. Flange Gaskets Gaskets shall be continuous, except that metal gaskets made integral by welding (e.g., single or 3-ply corrugated gaskets) and GRAFOIL GTTMH grade tape gaskets (or surface treatment for single or 3-ply corrugated gaskets) with overlapped ends are acceptable. Means shall be provided for positioning (centring) the gasket during joint make-up. Gaskets cut from sheet stock shall be 1.6 mm thick. 4.3.1. Service Gaskets When service gaskets are designated to be furnished by Manufacturer (e.g., for main shell joints, manways, blind flanged nozzles), the gaskets shall be as specified in the Vessel Specifications (see Article 25.1.6). 4.3.2. Test Gaskets Any flanged joint for which the service gasket is to be furnished by Manufacturer and which will not be disassembled after testing shall be tested with the specified service gasket (see Article 4.3.1). If the joint is to be disassembled after testing and employs flanges per ASME/ANSI B16.5, the test gasket may be selected by Manufacturer subject to the limitations in Article 4.3.2.1. If the joint is to be disassembled after testing, employs non-standard flanges (other than ASME/ANSI B16.5), and the service gasket is not specified, the test gasket shall be approved by OWNER. 4.3.2.1.Limitations In no case shall the nominal thickness of sheet or laminate gasketing be greater than 1.6 mm. No joint sealing compound, gasket adhesive, or lubricant shall be used unless specified for the service condition. 4.3.2.2.Flanged Joints Disassembled After Testing Flanged joints specified to be furnished with service gaskets (e.g., main shell joints, manways, blind flanged nozzles) and which are disassembled following tests shall be reassembled using new service gaskets. If such joints are shipped unassembled, new service
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS gaskets for field installation shall be suitably packaged, marked, and shipped with the exchanger. 4.3.3. Spare Gaskets For flanged joints specified to be furnished with service gaskets, a spare gasket (in addition to any required for initial field assembly in Article 4.3.2.2) shall be furnished and suitably packaged, marked, and shipped with the exchanger for the following joints: Flanged joints having other than ASME/ANSI B16.5 flanges with other than commercially available sheet or laminate gaskets. 4.4. Solution Anneal All formed heads fabricated from austenitic (Type 304 and Type 316 only, including low-carbon and stabilised grades) or duplex stainless steel shall be solution annealed, per SA-480 of ASME Boiler and Pressure Vessel Code Section II, Part A, after forming. 5. FABRICATION DETAILS 5.1. Backing Strip Removal Permanent weld joint backing strips are not permitted (see Article 20.6). 5.2. Weld Metal Deposited weld metal shall be essentially of the same strength, ductility, and chemical composition as the material joined. 5.2.1. Clad Materials For weld joints in clad material, the final pass on the clad side shall be of the same nominal composition as the cladding. The weld shall not be ground smooth or flush unless specified in the Vessel Specifications. Corrosion resistant weld overlay shall be in accordance with Engineering Standard MMOC-616. 5.3. Nozzle Attachment Welds Non-butt joints connecting nozzles (includes manways, couplings, studding outlets, and sight glasses) to exchanger wall (ASME Code Category D joints) shall be full penetration welds. Unless otherwise approved by OWNER, all Category D joints shall be full penetration welds extending through the entire thickness of the exchanger wall. Reinforcing pads shall not be located on the inside surface of the vessel. Nozzles designated to extend beyond the inside surface of the exchanger wall shall have a fillet weld at the inside corner.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 5.4. Nozzle Location Nozzles or other openings shall be located so that no part of the nozzle, added reinforcement, or attachment welds intersects any welded joint in the exchanger wall, except, if necessary, they may be located in ASME Code Category B joints. They shall not be located in other exchanger joints. 5.4.1. Examination Of Intersected Weld Joints Welded joints in the exchanger wall which are to be intersected shall be radiographed using acceptance standards as set forth in ASME Code Paragraph UW-51 for full radiography. When the welded joint is to be covered by a reinforcing pad, the weld shall be radiographed and ground flush before pad attachment. Except as required by ASME Code Paragraph UW-14 for small openings, the length of weld seam to be radiographed shall be the greater of the nozzle inside diameter each side of the axis of the nozzle or the portion of the weld seam to be covered by a reinforcing pad and its attachment weld plus 25 mm on each side. 5.5. Segmental Nozzle Reinforcing Pads Nozzle reinforcing pads constructed in segments shall have the segments joined with full penetration butt welds, the location of which shall be at least 45 from the longitudinal axis of the exchanger (see ASME Code Figure UG37). 5.6. Nozzle Reinforcing Pad Test External nozzle reinforcing pads shall have one NPT 1/4 telltale hole in each pad segment. The pad shall be tested with 1.724 barg dry air or nitrogen and application of a bubble forming solution (soaps, detergents, and/or industrial compounds that are designed specifically to be used as cleaning agents are not permitted) to all pad welds and accessible surfaces of inside nozzle-to-exchanger wall weld. Telltale holes shall be plugged with a room temperature vulcanising (RTV) silicone sealer. 5.7. Nozzles For Safety Relief And Drainage Nozzles intended for use with a safety relief device and nozzles serving as exchanger drains shall be trimmed flush inside the exchanger wall. 5.8. Bore Of Welding Neck Flanges The bore of welding neck flanges shall match the inside diameter of the attached pipe.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 5.9. Flange Drilling Bolt holes in all fixed flanges and studding outlets shall straddle the natural centrelines. For nozzles in heads, the bolt holes shall straddle centrelines parallel to or coincident with the natural exchanger centrelines. Bolt holes in flanges shall be 3.2 mm larger than the diameter of the bolts. 5.10. Grounding Clip Provide each exchanger with a grounding clip in accordance with Engineering Standard MEQ-19. 5.11. Gasket Contact Surfaces For all tubesheets, shop-fabricated flanges, and lap rings, the gasket contact surface shall be checked and machined as required after completion of all operations that can affect flatness tolerance. 5.11.1. Surface Finish Except for ASME/ANSI B16.5 flanges and factory-made lap-joint stub ends, the gasket contact surface shall be 3.175 - 6.350 microns with spiral or concentric circular serrations. 5.11.2. Flatness Tolerance When specified in the Vessel Specifications, the gasket contact surface flatness tolerance, in both the radial and circumferential directions, shall be 0.152 mm total indicator reading. Measurement shall be made by a dial indicator after all other operations with regard to the fabrication of the tubesheet, flange, or lap ring and its attachment to the shell or nozzle neck have been completed. The total circumferential tolerance shall not occur in less than 20 degrees of arc. 5.12. Thickness Of Fixed Tubesheets Tubesheet thickness in excess of 3.2 mm greater than the specified thickness is not acceptable for fixed tubesheets. 5.13. Heat Treatment Of Expanded Joints Expanded tube-to-tubesheet joints shall be rolled (expanded) after any required postweld heat treatment in which the temperature of the expanded joint exceeds 204C. 5.14. Tolerances Dimensional tolerances shall apply to the completed exchanger after final pressure test, and shall conform to Engineering Standard MEQ-182. For
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS exchangers for which fatigue is a controlling design requirement, the allowable peaking distortion, shall be specified by OWNER. 5.15. Welding 5.15.1. Welders and Welding Procedures All welds, including those attaching non-pressure parts to pressure parts, shall be made by welders (or welding operators) and welding procedures qualified under the provisions of Section IX of The ASME Boiler and Pressure Vessel Code. 5.15.2. Subcontracted Fabrication Work Approval must be obtained from CONTRACTOR before any welding or preparation for welding is subcontracted to another shop or supplier. Such approval shall require knowledge by CONTRACTOR of the qualifications of the subcontractor who is performing the work. 5.16. Welding Or Grinding Welding or grinding (including cosmetic grinding) will not be allowed on the pressure resisting components of exchangers after pressure testing and ASME Code symbol stamping unless approved in writing by OWNER. 5.17. Prevention Of Stress Raisers In Impact Tested Materials Special care shall be taken to prevent stress raisers which might cause low impact strength due to notch effect or abrupt change in section. Reference lines shall not be stamped on the material. Welder's and welding operator's symbols may be stamped on the material in accordance with the provisions of ASME Code Paragraph UW-37, provided that a round-nose stamp is employed and the symbol is located at least 25 mm from the edge of the weld. 5.18. Postweld Heat Treatment When postweld heat treatment is required, a sufficient number of thermocouples shall be firmly attached to the exchanger to assure that it is being heated and cooled evenly during the heat treatment operations. A multi-point recording type instrument shall be used to record the temperatures during the heat treatment cycles. (See Article 5.13 for expanded tube joints.) 5.18.1. Exchangers In Ammonia Service Ferritic steel exchangers in anhydrous ammonia service shall be postweld heat treated.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 5.18.2. Welding After Heat Treatment No welding shall be performed on the exchanger after postweld heat treatment. 5.18.3. Alternative PWHT Requirements of Code Table UCS-56.1 for carbon and low alloy steels shall not be employed.
5.19.
Flanged Joint Assembly 5.19.1. Joints shall be assembled and tightened in accordance with the following: 1. All "working" surfaces must be cleaned and inspected before assembly is started. a) Clean gasket seating surfaces to remove all grease and dirt. Gasket seating surfaces shall be free from any scratches, nicks, burrs, weld spatter, and similar defects. b) External and internal threaded surfaces of fasteners shall be inspected for damage: replace questionable parts. c) Inspect nut bearing surfaces for scores, burrs, etc.: Remove protrusions, spot face if required. Place new gasket in position following examination for defects or damage. Handle gaskets carefully to avoid damage. Do not remove any gasket shipping/handling protector until ready to use the gasket. Make sure that the gasket is in proper alignment with the gasket surfaces on the flanges or lap joint stub ends. Liberally coat all external and internal threaded surfaces of fasteners with the lubricant specified in the Vessel Specification. If the lubricant is not specified in the Vessel Specification, the lubricant shall be approved by OWNER. Align flange or stub end faces carefully before bolting up. Fasteners shall fit loosely in bolt holes. Do not use fasteners to spring flanges for alignment. Install fasteners with nuts hand tight, then snug up at 1.38 to 2.77 kg-m. Tighten fasteners carefully using a cross-bolting technique and incremental tightening to increase loading about 1/4 to 1/3 of total preload per step.
2.
3.
4.
5. 6.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 5.19.2. Joints requiring custom assembly procedures shall be as required by the Vessel Specification. 5.20. Painted Components That Will Be Inaccessible After Assembly The surfaces of painted components that will be inaccessible after assembly shall be non-destructively examined and painted prior to assembly and hydrostatic testing (see Articles 6 and 10.2). 6. NONDESTRUCTIVE EXAMINATION 6.1. Applicable Code When weld examination by the magnetic particle (MT), liquid penetrant (PT), or ultrasonic (UT) method is required, the examination shall be in accordance with Appendix 6, 8, or 12, respectively, of the ASME Code. 6.2. Examination After Heat Treatment When completed welds are required to be examined by the MT, PT, or UT method and the exchanger or part is to be postweld heat treated, the examination shall be made after heat treatment for the following: 1. 2. 3. 4. 6.3. Carbon or low-alloy steel exchangers for which impact testing is required. Welds joining non-impact-tested low-alloy steels over 32 mm thick. Welds joining carbon steels over 51 mm thick. When required by the ASME Code.
Miscellaneous Examinations 6.3.1. Weld Examination The root pass, after back-chipping to sound metal, and all accessible surfaces of the completed weld shall be examined by MT or PT for the following: 1. 2. Category A, B, C, and D butt-type joints when joint thickness exceeds 51 mm. Category C and D nonbutt-type joints when design is based on a joint efficiency of 1.00.
6.3.2. Welded Pressure Joints That Will Be Inaccessible After Assembly Welded joints that will be inaccessible after assembly shall be examined by PT (see Article 6.1), and repaired as required, prior to painting and assembly as follows: 1. Examine the root pass and its opposite side after backchipping to sound metal.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 2. Examine the finished surfaces of the weld, after any required machining or grinding, with the following additional requirement: all indications on the finished weld surfaces shall be removed by grinding or welding prior to the required pressure test.
6.3.3. Base Material Examination When nozzles are attached with a full penetration weld through the nozzle wall, the cut edge of the openings in exchanger walls thicker than 13 mm shall be examined by MT or PT before nozzle attachment and, when accessible, after attachment. 6.3.4. Tube-To-Tubesheet Joints Any specified sensitive leak testing of seal-welded or strengthwelded tube-to-tubesheet joints shall be performed prior to any tube-to-tubesheet joint rolling or hydrostatic testing. 6.4. Examination Of Repairs When an examination reveals an unacceptable imperfection, it shall be repaired and the repair shall be examined by the same method, to the same extent, and by the acceptance criteria that revealed the condition. Additionally, all repairs made by welding shall be made prior to any required postweld heat treatment. 7. HYDROSTATIC TESTING 7.1. Vertically Mounted Exchangers Vertical exchangers shall be tested in their operating position if practicable. If a vertical exchanger is shop-tested in the horizontal position, Manufacturer shall be responsible for determining the need for and providing any temporary supports to prevent distortion or other damage to the exchanger during the test. All supporting lugs, rings, legs, or other permanently attached supports shall be attached to the vessel before the test. 7.2. Horizontally Mounted Exchangers Horizontal exchangers shall be tested on their operating supports without additional temporary supports or shoring. The saddles or other permanently attached supports shall be attached to the exchanger before the test. 7.3. Individual Compartment Tests The shell side and tube side shall be given a separate and individual test with atmospheric pressure in the adjacent compartments (see Article 20.9).
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 7.4. Stacked Exchangers Stacked exchangers with integrally connected nozzles shall be assembled and tested as a single unit by Manufacturer. 7.5. Expansion Joints Temporary ties or supports which restrict the normal movements of expansion joints shall be removed or loosened during hydrostatic tests. 7.6. Holding Time The test pressure shall be maintained for one hour per 25 mm of maximum shell or formed head thickness, with a one hour minimum and a five hour maximum. 7.7. Metal Temperature The exchanger metal temperature, for the entire duration of the test, shall not be colder than the minimum design metal temperature (MDMT) plus 17C (see Article 20.2). 7.8. Water Quality Unless otherwise approved by CONTRACTOR in writing, the hydrostatic test liquid shall comply with the following: 1. 2. Hydrostatic test liquid shall be potable water, condensate, or demineralised water. Hydrostatic test liquid shall have a chloride content not greater than 250 ppm. For exchangers with austenitic stainless steel or aluminium components, the chloride content shall not exceed 50 ppm unless the vessel is drained and rinsed with condensate or demineralised water having a chloride content less than 50 ppm. Hydrostatic test liquid shall not remain in contact with exchanger components longer than 72 hours.
3. 7.9.
Blind Flanges For Test Manufacturer shall furnish all blind flanges, gaskets, and bolting (or other types of blanking covers as may be required) necessary for testing. For connections not specified to be furnished with blind flanges, the blind flanges and bolting (or other type covers) may be removed after testing and remain the property of Manufacturer (see Article 10.4 for shipping covers).
7.10.
Leakage During Test Except for leakage that might occur at temporary test closures for those openings intended for weld connections, leakage is not allowed during the duration of the test (see Article 7.6). Leakage form temporary seals shall be directed away so as to avoid masking leaks from other joints.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 7.11. Retesting Repaired Exchangers Repairs to eliminate rejectable imperfections revealed during pressure testing shall be tested by reapplying the original pressure test(s). 7.12. Disassembly Of Flanged Joints After Testing Main shell joints, manways, and nozzles specified to be furnished with blind flanges shall be left undisturbed and assembled after testing if practicable. If necessary to disassemble for shipping, drainage, or other purposes, new gaskets shall be furnished as specified in Article 4.3.2.2. 7.13. Painting Except for surfaces to be painted but which will be inaccessible after assembly (see Article 10.2), painting shall be performed after the Code pressure test (and any sensitive leak test) has been completed. 7.14. Shot Peening Unless approved by OWNER in writing, controlled shot peening and other similar methods, which are intended only to enhance surface properties of exchangers or exchanger parts, shall be performed after the Code pressure test (and any sensitive leak test) has been completed. 8. NAMEPLATES 8.1. Manufacturer's Nameplate Each exchanger shall be furnished with a Manufacturer's nameplate in accordance with ASME Code Paragraph UG-119. Where stamping directly on the exchanger in lieu of a nameplate is unavoidable, a round-nose stamp or punch shall be employed. Nameplate stamping directly on impact tested material is not permissible. For exchangers designed for vacuum operation, the nameplate shall also include the maximum allowable external pressure and coincident maximum temperature. 8.1.1. Mounting Clip Material, style, and projection for mounting clips shall be the same as shown on Engineering Standard MEQ-15A for the OWNERs nameplate (see Article 8.2). Engineering Standard MEQ-15A provides for mounting the Manufacturer's nameplate and the OWNER nameplate on the same clip where adequate exchanger space is available. 8.2. OWNER'S Nameplate Each exchanger shall be furnished with a separate OWNERs standard nameplate for the shell side and the tube side. The nameplate(s) will be
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS furnished by CONTRACTOR for stamping and installation by Manufacturer. Stamping shall be per Engineering Standard MEQ-16, and attachment to the exchanger per Engineering Standard MEQ-15A. 9. REQUIRED INFORMATION 9.1. Retention Copies of drawings, calculations, reports, and other pertinent data required by this standard and the referenced documents shall be submitted by CONTRACTOR to OWNER. 9.1.1. Retention of Radiographs All radiographs (full RT only), including the location marker map when location markers are not permanently marked on the exchanger, shall be forwarded to CONTRACTOR. Radiographs and location marker maps shall be identified by the equipment purchase order and exchanger item number. 9.2. Reports Manufacturer shall furnish CONTRACTOR with a minimum of four copies of each of the following data as applicable: 1. Manufacturer's Data Report (U-symbol stamped exchangers; see Article 2.1). For exchangers which are designed for overpressure protection by system design, Manufacturer shall include the following statement in the Remarks section of the Manufacturer's Data Report: "Code Case 2211; Prior jurisdictional acceptance of this Code Case may be required." Manufacturer's Certificate of Compliance (UM-symbol stamped exchangers; see Article 2.1). Certified mill test reports or certificates of compliance for materials used, including forgings to other than the dimensional and identification marking requirements of an ASME/ANSI flange or fitting standard. Charts of recorded heat treatment temperatures. Rub-offs of Manufacturer's and OWNERs nameplate stampings.
2. 3.
4. 5. 9.3.
Calculations Manufacturer shall furnish CONTRACTOR with complete certified exchanger design calculations (see Article 3.6).
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 10. CLEANING, PAINTING, AND SHIPPING PROTECTION 10.1. Drying And Cleaning The exchanger shall be completely drained and immediately dried after the hydrostatic test. It is preferred that the residual water be wiped from the interior of the exchanger heads; however, blowing with nitrogen, or dry air if an adequate source of nitrogen is unavailable, is acceptable provided that the gas pressure in the exchanger is not greater than essentially atmospheric pressure. 10.2. Painting Surfaces that are required by the Vessel Specification to be painted and which will be inaccessible after assembly (e.g., mating surfaces between lapjoint flanges and nozzle necks, shells, lap rings or stub ends, bolt holes, and welded joints) shall be painted prior to assembly and hydrostatic testing. Welded joints that will be inaccessible after assembly shall be examined by PT, and repaired as required, prior to painting (see Article 6). 10.3. Machined Surfaces All gasket seating, threaded, or other machined surfaces shall be protected for shipment as follows: 10.3.1. Assembled Joints Main shell joints, manways, blind-flanged nozzles, plugged couplings, and other connections specified to be furnished with service covers shall be shipped assembled if practicable (see Article 4.3.2.2). 10.3.2. Exposed Surfaces For carbon and low alloy steels, all exposed machined or threaded surfaces shall be cleaned with solvent and coated with temporary rust preventive grease conforming to Military Specification MIL-G-10924. The following products meet this designated specification; other equivalent products are acceptable: Ashland Oil-Tectyl 858C, Sanchem No-Ox-Id-A, Exxon-Beacon 325, Houghton-Rust Veto Heavy. Furnish shipping covers per Article 10.4. 10.4. Exchanger Openings Openings shall be covered with durable and damage-resistant covers (e.g., wood or metal) to prevent entrance of dirt, water, and debris. Protect machined and threaded surfaces from damage.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 10.5. Warning Signs The following types of exchangers shall be conspicuously marked on opposite sides of the exchanger identifying the need for caution: 10.5.1. Heat Treated Exchangers Exchangers which have been postweld heat treated shall be so identified and marked with a notice prohibiting the welding of any attachments. 10.5.2. Fragile Components Exchangers having fragile parts (e.g., glass lining, HAVEG, KARBATE) shall be so identified and marked with the need for careful handling. 10.6. Welded Attachments Welding attachments to exchangers for shipping purposes is not permitted (see Article 10.5.1). 11. REFERENCES This standard contains references to the following documents (see Article 2.2): 11.1. American Society Of Mechanical Engineers (ASME) ASME Boiler and Pressure Vessel Code Section II, Part A, Ferrous Material Specifications Section II, Part B, Non-ferrous Material Specifications Section VIII, Division 1, Pressure Vessels Section IX, Welding and Brazing Qualifications ASME Code for Pressure Piping B31.3, Chemical Plant and Petroleum Refinery Piping B1 Screw Threads (formerly ANSI B1) ASME/ANSI B1.1, Unified Inch Screw Threads (UN and UNR Thread Form) B16 Standardisation of Valves, Flanges, Fittings, and Gaskets (formerly ANSI B16) ASME/ANSI B16.5, Pipe Flanges and Flanged Fittings ASME/ANSI B16.9, Factory-Made Wrought Steel Buttwelding Fittings
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS ASME/ANSI B16.47, Large Diameter Steel Flanges B18 Standardisation of Bolts, Nuts, Rivets, Screws, Washers, and Similar Fasteners (formerly ANSI B18) ASME/ANSI B18.2.2, Square and Hex Nuts (Inch Series) 11.2. American National Standards Institute (ANSI) American Society of Civil Engineers (ASCE) ANSI/ASCE 7, Minimum Design Loads for Buildings and Other Structures American Welding Society (AWS) ANSI/AWS A2.4, Symbols for Welding, Brazing, and Nondestructive Examination 11.3. Military Specifications MIL-G-10924, Grease, Automotive and Artillery 11.4. OWNERs Engineering Standards: MEQ-15A, Nameplate Mounting Clip for OWNERs Nameplate. MEQ-16, OWNERs Nameplate for Process Vessels. MEQ-19, Grounding Clip for Process Vessels. MEQ-180, Locking Studs for Stationary Tubesheets. MEQ-182, Fabrication Notes and Dimensional Tolerances for Shell-andTube Heat Exchangers. MCOP-12, General Requirements for Design and Construction of Air-Cooled Heat Exchangers MMOC-615, Application of XYLAN 1014 Coating to Carbon Steel and LowAlloy Steel Threaded Fasteners MMOC-616, Corrosion Resistant Overlays on Steel Base Metal 11.5. 11.6. Not Used Welding Research Council (WRC) Bulletin 107, Local Stresses in Spherical and Cylindrical Shells due to External Loadings
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS Bulletin 297, Local Stresses in Cylindrical Shells due to External Loadings on Nozzles 11.7. Laws of Malaysia Factories and Machinery Act 1967 (Act 139) & Regulations and Rules (As at 25th January 1997). 11.8. Attachments 11.8.1. Figure 2 - Expanded Tube to Tubesheet Joint 11.8.2. Figure 3 - Expanded and Seal Welded Tube to Tubesheet Joint 12. 13. 14. 15. 16. 17. 18. 19. ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED ARTICLE NOT USED
DESIGN REQUIREMENTS LIMITATIONS The design of shell, tubes, tubesheets, and expansion joints (if used) for fixed tubesheet exchangers having any of the following design conditions shall either be performed by OWNER, or Manufacturer's proposed design shall be reviewed by OWNER prior to purchase: 1. 2. 3. Tube side design pressure exceeding 42 barg. Shell side design pressure exceeding 69 barg. Shell inside diameter larger than 1219 mm with carbon steel, low-alloy steel, or clad tubesheet material; or larger than 762 mm with high-alloy or non-ferrous tubesheet material. Any exchanger requiring a shell expansion joint(s). DESIGN CRITERIA 20.1. Equivalent Design Pressure FOREWORD These design requirements for determining exchanger thicknesses are based on the criteria that exchangers shall be designed to withstand, in the corroded condition if a corrosion allowance is required, the more severe of the following design conditions: 1. The "Equivalent Design Pressure" at 38C. This design condition provides for full hydrostatic test of all pressure components of shopfabricated vertical exchangers while in the horizontal position, and permits future hydrostatic testing of vertical exchangers in the operating position. Article 20.1 defines the design procedure to be used for the "Equivalent Design Pressure" condition for ASME Code exchangers (see Article 2.1). The design pressure plus any applicable additional loadings (e.g., wind pressures, seismic loadings) at both the maximum and minimum design metal temperatures (considering: start-up and start-up following an emergency shutdown; normal, temporary, and emergency operation; and, normal and emergency shutdown).
4. 20.
2.
In addition to the requirements of Articles 20.2 through 20.13, the thickness of all pressure components shall be further checked and increased, if necessary, to conform to the following requirements: 20.1.1. Equivalent Design Pressure For Shop-Fabricated And ShopTested Exchangers The thickness of all pressure components (before any corrosion allowance is added), regardless of elevational position in the exchanger, shall be adequate to withstand the larger of the
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS equivalent design pressures PED or PET determined by formulas (1) and (2) below. In computing thickness required to withstand equivalent design pressures, the ASME Code allowable tensile stresses at 38C and the applicable welded joint efficiency shall be used, and no additional loadings other than those inherent in the equivalent design pressure formulas need be considered. For the purpose of computing equivalent design pressures only, where two ASME Code allowable stress values are given for a material, the higher value shall be used (see Article 20.4). S PED = a ( PD + HO + V ) Sd PET = Sa Sd ( PD + V ) + 2HT 3 (1)
(2)
where: PED =
Equivalent design pressure at 38C based on design (operating) liquid head, in barg Equivalent design pressure at 38C based on test liquid head, in barg Internal design pressure at top of compartment in its operating position at maximum design temperature (nameplate rating), in barg Hydrostatic head at the bottom of the compartment in its operating position when filled to its maximum operating depth with a liquid having a specific gravity equal to the greater of that of the operating liquid or 1.0, in barg. Exchangers, except those in noncondensing gas service, shall be assumed to operate completely filled with liquid Hydrostatic head at the bottom of the compartment in its operating position when completely filled with water, in barg = Highest ratio (for each of the materials of which the main exchanger shell sections and formed heads are constructed) of the ASME Code allowable tensile stress at 38C (Sa) to the ASME Code allowable tensile stress at design temperature (Sd). Tubesheets and tubes shall not be included in the calculation of this ratio
PET =
PD
HO =
HT
Sa/Sd
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS V = Design vacuum on adjacent chamber, if any, in barg
20.2.
Design Temperature The shell side and the tube side shall have both maximum and minimum design metal temperature ratings, and both shall be marked on the exchanger nameplates. Except when specified in the Vessel Specifications, maximum and minimum design temperatures shall be determined as follows: 20.2.1. Maximum Design Temperature Exchangers for warm service (0C to 400C, inclusive) shall have a maximum temperature rating at least equal to the maximum anticipated temperature (considering: start-up and start-up following an emergency shutdown; normal, temporary, and emergency operation; and, normal and emergency shutdown) plus 14C, but in no case less than 66C. 20.2.2. Minimum Design Temperature Exchangers shall have a minimum design metal temperature rating equal to or lower than the minimum anticipated temperature (considering: start-up and start-up following an emergency shutdown; normal, temporary, and emergency operation; and, normal and emergency shutdown), but in no case warmer than minus 1C. For exchangers whose metal temperature in normal service is dependent on ambient temperature, the minimum design metal temperature shall be minus 1C..
20.3.
Operating Liquid Head The hydrostatic head considered to apply in addition to and coincident with the design pressure shall be the hydrostatic pressure on each component when the compartment is filled to its maximum operating depth with a liquid having a specific gravity equal to the greater of that of the operating liquid or 1.0. Exchangers, except those in non-condensing gas service, shall be assumed to operate completely filled with liquid, unless otherwise specified in the Vessel Specifications.
20.4.
Allowable Stress Values Allowable design stress values for all operating temperature conditions shall be taken at the maximum nameplate (rated) temperature for the component under consideration. 20.4.1. Low Allowable Stress Where two allowable stress values are given in the ASME Code for a material, use the lower value only in the design of
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS tubesheets and gasketed flange joints or other applications where slight distortion can cause leakage or malfunction. 20.5. Designing For Vacuum Service Exchangers subjected to partial vacuum operating pressures of 0.259 barg or more shall be designed and ASME Code stamped for full vacuum. Maximum design temperature shall be per Article 20.2. 20.5.1. Internal Pressure Rating of Exchangers Designed for Vacuum Service Exchangers designed primarily for vacuum service shall be designed for an internal pressure rating not less than 1.724 barg at the maximum design temperature specified for the vacuum rating. 20.5.2. Stiffening Rings Stiffening rings for shells under external pressure shall have a thickness not less than 9.5 mm and a ring width-to-thickness ratio no greater than 10. Stiffening rings shall be located on the outside of the exchanger and shall be attached with a continuous fillet weld on both sides of the ring. 20.6. Butt Joints Required Welded joints of ASME Code Categories A and B, and when used, butt-type Categories C and D, shall be Type No. (1) of ASME Code Table UW-12. Butt welds with one plate edge offset [ASME Code Figure UW-13.1(k)] and permanent weld joint backing strips are not permitted (see Article 5.1). See Article 25.10.2.3 for butt welded joints in vessel support skirts. 20.7. Radiographic Examination The minimum degree of examination of welded butt joints shall be spot radiography per ASME Code Paragraph UW-52. In applying the rules of Paragraph UW-52, the increments of weld shall be selected so as to include all Category A, B, and C butt welds, except Category B or C butt welds in nozzles and communicating chambers that exceed neither 254 mm nominal pipe size nor 28.6 mm wall thickness may be excluded. 20.7.1. Seams In Formed Heads The flat plate from which formed heads are made shall be either seamless or made equivalent to seamless ; i.e., all Category A welds shall be Type No. (1) and fully radiographed per ASME Code Paragraph UW-51. After forming, the spin hole, if it remains in the final exchanger construction, shall be repaired with a metal plug which is butt-welded in place with a Type No. (1)
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS weld and radiographed to meet the requirements of the Vessel Specifications and the design basis. 20.8. Corrosion Allowance Add corrosion allowance specified in Vessel Specifications to all pressure parts in contact with the service fluid. 20.8.1. Tubes Corrosion allowance shall be added to tubes only when specified in the Vessel Specifications. 20.8.2. Nonpressure Parts Design welded-in, nonpressure, internal components of noncorrosion resistant materials to include a corrosion allowance on all wetted surfaces of 75% of that for pressure parts to permit the components to function in the corroded condition. Removable nonpressure, internal parts of noncorrosion resistant material shall include a corrosion allowance on all wetted surfaces of 50% of that for pressure parts.. 20.9. Common Components Tubesheets, tubes, and other components subjected to both shell side and tube side conditions shall be designed for the most severe combinations of pressure, temperature, and other loadings which may occur during operation and test conditions. Design solely on the basis of simultaneous loading of internal pressure in adjacent compartments is not acceptable. 20.10. Clad Components Except for austenitic stainless steel and nickel alloy clad components (this exclusion does not apply to clad tubesheets), the thickness of cladding metal (includes weld overlay) shall not be included in the design calculations for strength. 20.11. Wind Or Earthquake Loads Exchangers shall be self-supporting and designed to resist the specified wind pressures. 20.11.1.Wind Loads Design wind loads shall be the greater of those determined in accordance with ANSI/ASCE 7(95), using data for classification Category II, Exposure C structures, or other code or standard if invoked by jurisdictional regulation. The basic wind speed at 10m shall be 40.3 m/sec.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS See Article 20.11.4.2 for force coefficients to be used for the length of vertical exchangers for which spoilers are added. Apply wind load to the total projected area of the exchanger including insulation, ladders, platforms, attached piping, and other appurtenances. 20.11.2.Earthquake Loads Earthquake loads are not a design consideration for this project. 20.11.3.Article Not Used 20.11.4.Wind Excitation Vertical exchangers having a height-to-diameter ratio (h/d, where "h" is the total exchanger height and "d" is the exchanger diameter measured to the mid-thickness of the exchanger wall) of 15 or greater and which do not have a significant number of effective external exchanger attachments (attachments such as ladders and piping where the maximum circumferential distance between them is not greater than 108) shall be investigated for dynamic behaviour due to wind excitation. [One paper covering the analysis of vessels for vibration due to vortex shedding is "Dynamic Response of Tall Flexible Structures to Wind Loading" by Joseph Vellozzi, PhD, P.E.; available through the National Institute of Standards and Technology (formerly the National Bureau of Standards)]. 20.11.4.1.Wind Spoilers - Corrective Action When it has been determined that an exchanger may vibrate and the attributes of the exchanger (e.g., normal attachments) cannot be changed such that vibration will not occur, wind spoilers in accordance with one of the following shall be added to the upper third of the exchanger: 1. Helical Spoilers Use a three-start system of spoilers in a helical pattern. An optimum configuration consists of spoilers with an exposed width (beyond insulation, if applicable) of 0.09d and a pitch (height of one helical wrap) of 5d, where "d" is the exchanger diameter at the top. The spoiler system may be interrupted to provide clearance at exchanger attachments. Vertical Spoilers Use a three-start system of short vertical spoilers arranged in a helical pattern. An optimum
2.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS configuration consists of spoilers with an exposed width (beyond insulation, if applicable) of 0.09d and a pitch of between 5d and 11d. There should be a minimum of 8 spoilers over the pitch distance (each complete helical wrap) and a minimum of 1.5 helical wraps over the top third of the exchanger. The spoiler system may be interrupted to provide clearance at exchanger attachments. 20.11.4.2.Additional Sail Area When spoilers as described in Article 20.11.4.1 are added to a exchanger, the column projected area normal to the wind, Af, and the corresponding force coefficient, Cf, for very rough surfaces for the column height where spoilers have been added shall be used in the calculation of the overturning load when designing the exchanger and supporting structure. The column projected area shall be calculated using the projected diameter taken at the outside edge of the spoilers times the height of the section under consideration. 20.12. Design Pressure And Additional Loadings The shell side and tube side shall be designed to withstand the specified design pressure at both the maximum and minimum design metal temperatures, including any additional loadings as specified in Paragraph UG-22 of the ASME Code, and as required by this standard and the Vessel Specifications. The design pressure applies to the top of the exchanger in its operating position, and in its corroded condition when a corrosion allowance is required by applicable codes or the Vessel Specifications. 20.12.1.Design Loads Design loads are defined and classified as follows: 1. Dead Load (L1) - Dead load is the installed weight of the exchanger including internals, catalyst, platforms, insulation, piping, and other permanent attachments. Operating Live Load (L2) - Operating live load is the weight of the liquid at the maximum operating level. Pressure Load (L3) - Pressure load is the MAWP (internal or external at the coincident maximum or minimum design metal temperature) load, including the pressure drop through the exchanger. See Article 20.9 and ASME Code Paragraph UG-19(a). Thermal Loads (L4) - Thermal loads are the loads caused by the restraint of thermal expansion/contraction of the
2. 3.
4.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS exchanger and/or its supports and connected piping or other equipment. Test Load (L5) - Test load is the weight of the test medium, usually water. Wind Load (L6) - Wind load shall be determined in accordance with Article 20.11.1 and 20.11.4.2. Piping Loads (L7) - Loads caused by piping other than the dead load shall be considered as applicable.
5. 6. 7.
20.12.2.Load Combinations Exchangers and their supports shall be designed to meet the most severe of the load combinations below. Except as permitted in Item 5 below, ASME Code allowable stresses and factors [see Paragraph UG-23(d) of the ASME Code] shall be used for exchangers and attachments such as supports outside the scope of the ASME Code (see Article 20.4). 1. L1 + (0.11)L6 Lift condition with 33% of design wind velocity (11% of design wind load). L1 may be reduced for weight of materials not installed at the time of lift. L1 + L6 Erected condition with full wind load. L1 + L2 + L3 + L4 + L6 +L7 Design condition with full wind load [include both full and zero pressure conditions (L3) for check of maximum longitudinal tensile and compressive stress]. L1 + L2 + L3 + L4 + L7 Design condition with seismic load [include both full and zero pressure conditions (L3) for check of maximum longitudinal tensile and compressive stress]. L1 + (F)L3 + L5 + (0.25)L6 Future test condition with 50% of design wind velocity (25% of design wind load). "F" is the required design pressure or MAWP multiplier for a hydrostatic test, defined as 1.5(Sa/Sd), where (Sa/Sd) is defined in Article 20.1.1. For exchangers having a corrosion allowance, L1, (F)L3, and L5 shall be based on the exchanger in the corroded condition.
2. 3.
4.
5.
20.13. Torispherical Heads For the prevention of internal pressure-induced plastic buckling or axisymmetric yielding of large diameter, thin, formed (torispherical) heads (diameter-to-thickness ratio greater than 300), a design check of the ASME Code required thickness shall be performed. One acceptable method (among several that have been published) is by G. D. Galletly, Design Equations for Preventing Buckling in Fabricated Torispherical Shells Subjected to Internal Pressure, published in Proceedings, Institute of Mechanical Engineers, London, Volume 200, No. A2.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 20.14. Local Shell/Formed Head Stresses When there is concern that an overstress condition may exist, the local membrane and surface stresses due to local loads, such as piping loads, platform loads, etc., shall be determined using the WRC-107. For local loads and internal pressure, the allowable stresses are 1.5Sd for local primary membrane stress and 3.0Sd for primary membrane plus secondary bending stress, respectively at the design temperature. 20.15. Combined Primary Stress For Elevated Temperature Service (>427C) For evaluating the effect of external loads on exchanger appurtenances, (nozzles, clips, etc.) and other discontinuities (cone/cylinder junctions having half-apex greater than 30, etc.), as permitted by ASME Code Paragraph U2(g), combined local membrane stress plus primary bending stress shall be limited to 1.25 Sd for temperatures greater than 427C. 20.16. Exchangers In Cyclic Service The required service for all exchangers shall include consideration of cyclic service. When an exchanger is identified in the Vessel Specifications as being in cyclic service, the applicable cyclic conditions provided in the Vessel Specifications shall be used to perform a fatigue analysis. 21. HYDROSTATIC TEST (SEE ARTICLE 7) 21.1. Test Pressure Determination Test pressures for the shell side and the tube side shall be determined as follows: 21.1.1. Test Pressure For testing in the horizontal position, the test pressure referenced to the centreline of the compartment shall be 1.5 times (the larger of PED or PET) minus (the hydrostatic head of the testing liquid below the compartment centreline). If a vertical exchanger is tested in a vertical position (as for a field test), the test pressure referenced to the top of the compartment shall be 1.5 times (the larger of PED or PET) minus HT (see Article 20.1.1). 22. PNEUMATIC TESTS Except for preliminary low-pressure leak tests (e.g., see nozzle reinforcing pad test in Article 5.6), pneumatic tests (air, nitrogen, etc.) shall be performed only when specified in the Vessel Specifications.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 23. NONDESTRUCTIVE EXAMINATION This Article defines the minimum degree of nondestructive examination required in addition to radiographic examination specified in Article 20.7. Additional nondestructive examination may be required by the ASME Code and the Vessel Specifications. All nondestructive examination shall be performed in accordance with ASME Code methods (see also Article 6.2 for postweld heat treated exchangers). 23.1. Magnetic Particle And Liquid Penetrant Examination Examine the following weldments by magnetic particle or liquid penetrant examination: 23.1.1. ASME Code Categories A and B, and Categories C and D ButtType Joints When the joint thickness exceeds 2 inches (51 mm), examine the root pass and all accessible surfaces of completed weld. 23.1.2. ASME Code Categories C and D Non-Butt-Type Joints Except as required in Article 15.1.2.1 for tubesheet-to-shell joints, when the exchanger shell sections and heads have been designed on the basis of a joint efficiency of 1.00, examine all Category C and D non-butt type joints, including those in nozzles and communicating chambers, as follows: 1. 2. After back-chipping or gouging root pass to sound metal, examine the back-chipped or gouged surface. All accessible surfaces of completed weld.
23.1.2.1.Joints Attaching Tubesheets For exchangers larger than 610 mm nominal diameter, or for any size having design pressure on the tubesheet attachment side exceeding 20.68 barg, nonbutt-type joints attaching tubesheets shall be examined as follows: 1. 2. Before welding, examine the cut surfaces per ASME Code Paragraph UG-93(d)(4). For joints per ASME Code Paragraph UW13.2(f), (j), or (k), examine the deposited groove weld surfaces after machining weld flush with tubesheet. For double-welded joints, after back-chipping the reverse side of weld metal first deposited and before additional welding, examine the backchipped surfaces.
3.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 4. 5. Examine all accessible surfaces of completed weld. After welding, re-examine all cut edges examined per Item 1 above that remain exposed.
23.1.3. Corner Joints For nozzles and communicating chambers attached with a full penetration weld through the nozzle or communicating chamber wall (see Article 5.3), examine the cut edge of the openings in exchanger walls thicker than 13 mm. The examination shall be made before nozzle attachment, and a re-examination made after attachment when accessible. 23.1.4. Nonpressure Attachment Welds Examine accessible surfaces of completed welds attaching nonpressure parts to pressure parts as follows: 1. 2. 3. 23.2. All welds (internal and external) when the thickness of the pressure part exceeds 51 mm. Welds attaching exchanger supports (e.g., skirts, lugs, legs, etc.). Welds attaching exchanger lifting (erection) lugs.
Ultrasonic Examination Examine the following materials ultrasonically in accordance with the ASME material specifications shown: 23.2.1. Rolled Plate Rolled plate for flat covers and blind flanges (blind flanges per ASME/ANSI B16.5 excluded) exceeding 76 mm in thickness shall be examined after cutting to final size per SA-578, acceptance level I. Rolled plate for tubesheets exceeding 76 mm in thickness shall be examined after cutting to final size per SA-578, acceptance level I, supplementary requirement S1. Note: This Article shall apply to carbon, low alloy, and high alloy steel plates. 23.2.2. Forgings Forgings exceeding 76 mm in thickness (flanges per ANSI/ASME B16.5 excluded) shall be examined per SA-745 with the following requirements. Note: This Article shall apply to carbon, low alloy, and high alloy steel forgings: 1. Quality levels for straight beam examinations from flat surfaces shall be: Thickness, mm Quality Level
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS over 76 through 203 QL-2 over 203 through 305 QL-3 over 305 QL-4 Quality level for straight beam examinations from curved surfaces shall be QL-5. Quality level for all angle beam examinations shall be QA1. Notch depth shall be per QA-1 or 6.4 mm, whichever is less.
2. 3.
23.2.3. Integrally-Bonded Clad Plate Except as provided in Article 23.2.3.1, clad plate, excluding tubesheets, for exchangers designed for vacuum service and for exchangers whose design calculations include the cladding (see Article 20.10) shall be examined per SA-578, acceptance level I, supplementary requirement S6. Clad plate for tubesheets shall be examined per SA-578, acceptance level I, supplementary requirement S7. 23.2.3.1.Manufacturer's Specifications Where the clad plate Manufacturer's specifications include ultrasonic examination which differs from that in Article 23.2.3 (e.g., proprietary explosion-bonded clad), such specifications shall be submitted for OWNER's review. 23.2.4. Reports A report of examination results shall be CONTRACTOR and shall include the following: 1. 2. 3. 4. 5. 6. 7. 8. submitted to
Component identity. Drawing, purchase order, and Manufacturers serial numbers (if applicable). Examination equipment used (including couplant). Instrument settings and calibration data. Location and dimensions of reportable and unacceptable indications. Location of areas not inspected due to geometric configuration. Names and certification levels of examination personnel. Date of examination.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 24. MATERIAL SELECTION 24.1. Carbon And Low-Alloy Steels Except as required in Article 24.1.1, impact testing exemptions for carbon and low-alloy steels shall be established in accordance with ASME Code requirements. 24.1.1. Restriction of Code Provision When Paragraph UCS-66 of Section VIII, Division 1 of the ASME Code is used to establish impact testing exemptions, all welded attachments shall be considered essential to the structural integrity of the exchanger and shall also be in compliance with rules of ASME Code Paragraph UCS-66. 24.2. Other Than Carbon Or Low Alloy Steels Materials other than carbon steel or low alloy steel shall be as specified or approved by CONTRACTOR. 24.3. Pressure Bolting Except as required in Article 24.3.1 bolting materials for pressure-resisting flanged joints shall be selected from Table 1. Bolting shall be studs with one nut at each end unless otherwise specified in the Vessel Specifications. For exchangers with maximum nameplate temperature ratings 232 C, low alloy steel bolting shall be coated per Engineering Standard MMOC-615 TABLE 1
(1)(9)
Materials For Pressure Bolting (2) ASME Boiler and Pressure Vessel Code Material Design Temperature Range Specification (4)(5)(6) Minimum Maximum Bolting Nut Material
(3)
-40C -40C -29C -101C -101C -198C -198C -198C
399C 427C 538C 204C 371C 260C 538C 621C
Material FERRITIC STEELS SA-193, Gr B7 SA-194, Gr 2 or 2H SA-193, Gr B7 SA-194, Gr 3 or 4 SA-193, Gr B16 SA-194, Gr 3 or 4 SA-320, Gr SA-194, Gr 7, Suppl. Requirement S4 (7) L43 SA-320, Gr L7(7) SA-194, Gr 7, Suppl. Requirement S4
(8)(9)
AUSTENITIC STEELS SA-193, Gr B8, SA-194, Gr 8 or 8A Cl 2 SA-453, Gr 660 Same as bolting

(8)(9)
NICKEL ALLOY
(10)
SB-637
Same as bolting
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS NOTES: (1) (2) (3) Bolt coating (e.g. galvanised or fluoropolymer coated), shall be per Article 24.3. Exchanger nameplate temperature rating. Both ends of studs shall have a flat and chamfered point. Stud length shall be measured from first thread to first thread. Studs 25 mm and smaller shall be coarse-thread series and studs over 25 mm shall be 8-pitch thread series. All studs shall have ASME/ANSI B1.1 Class 2A threads. Nuts shall conform to the dimensions of Heavy Hex Nuts per ASME/ANSI B18.2.2. Nuts produced from sintered, powder metal are not acceptable. Washers specified for use with these nut materials shall be through-hardened and shall meet the chemical and mechanical property requirements of ASTM F-436 for temperatures not exceeding 204C. For temperatures greater than 204C, washers shall be in accordance with SA-540 of ASME Section II [any grade having a 2 minimum yield strength of 8437 kg/cm or higher]. For diameters 50.8 mm and smaller, the impact requirements of SA-320 of ASME Section II may be applied. For diameters larger than 51 mm, the requirements of ASME Code Paragraph UG-84 shall apply. Austenitic stainless steel and nickel alloy bolting shall be lubricated with one of the following products, or with a Buyer-approved equal: Stainless Steel Nickel Alloy Lubricant Maximum Temperature Maximum Temperature Jet-Lube 550 288C 260C GRAFOIL Tape 454C 260C TEFLON Tape 204C 204C Jet-Lube is manufactured by Jet-Lube, Inc., Glendale, CA. For temperatures exceeding 454C, lubricants shall be approved by OWNER. Because of possible incompatibility, bolt lubricants shall not be used on internal components exposed to process fluids. ASME Code Case 1993. 24.3.1. Piped Nozzle Flanges Bolting for piped nozzle flanges, if furnished by Manufacturer, shall be according to applicable Valve and Piping Materials Specifications. 24.3.2. Swing Bolts Swing bolts (eye bolts) shall be of one-piece construction without welding. Hinge pins shall be solid (not rolled) and of the same material as the swing bolts. 24.4. Exchanger Supports All components of skirts, saddles, lugs, legs, and other exchanger supports shall be ASME Code approved material.
(4) (5) (6)
(7)
(8)
(9) (10)
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 24.5. Attachments To Pressure Parts Attachments welded to pressure parts shall be ASME Code approved material (see Item 3 of Article 9.2). Carbon and low-alloy steel materials shall be selected per Article 24.1. 24.5.1. Internal Attachments Internal attachments shall be of the same type material as the pressure part to which attached. 24.5.2. External Attachments External attachments shall be of the same type material (ASME Code P-Number) as the pressure part to which attached, except as provided in Article 24.6. When austenitic stainless steel external welded attachments are required, any 300-series stainless steel may be used. 24.6. Welded Parts Of Dissimilar Metals Pressure parts or attachments welded to pressure parts shall be of a material having essentially the same coefficient of expansion as the exchanger material, except as permitted in Articles 24.6.4, 24.6.5, 25.1.5 Item 4, and as follows: 24.6.1. External Nozzle Reinforcing Pads for Austenitic Stainless Steel Exchangers External nozzle reinforcing pads for austenitic stainless steel exchangers may be of carbon steel provided that: 1. 2. The maximum design temperature is not greater than 232C . The minimum design metal temperature is not colder than minus 29C and the carbon steel material satisfies the requirements of Article 24.1. The total number of cycles in which the range of temperature fluctuation exceeds 69C does not exceed 5000. The exchanger is not postweld heat treated. The exchanger is not for lethal service.
3.
4. 5.
24.6.2. External Nonpressure Attachments, Excluding Exchanger Support Skirts, Welded to Austenitic Stainless Steel Exchangers External nonpressure attachments, excluding exchanger support skirts, welded to austenitic stainless steel exchangers may be of carbon steel subject to the limitations specified in Items 1 through
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 4 of Article 24.6.1. Exchanger support skirts shall be per Article 24.6.3. 24.6.3. Support Skirts Welded To Austenitic Stainless Steel Exchangers Support skirts welded to austenitic stainless steel exchangers shall be of austenitic stainless steel, except as follows: 1. For exchangers having a design temperature between minus 29C and 66C, and having a height-to-diameter ratio of 5 or less, the entire skirt may be carbon steel subject to the requirements of Article 24.1. For exchangers having a design temperature greater than 66C but not exceeding 232C, the skirt shall be stainless steel for a minimum distance of 1.5 Rt (where R = mean skirt radius, and t = skirt thickness) below the attachment weld, but not less than the dimensions shown below. The remainder of the skirt below this stainless steel portion may be carbon steel. Minimum Dimension Exchanger Diameter 203 mm up to 1981 mm, inclusive 305 mm over 1981 mm through 3505 mm 457 mm over 3505 mm For exchangers having a design temperature greater than 232C, the minimum length of stainless steel skirt below the attachment weld shall be 457 mm.
2.
3.
24.6.4. Nozzle Necks For Clad And Unclad Steel Exchangers Nozzle necks for steel exchangers clad with austenitic stainless steel shall be of similarly clad material for nozzles larger than NPS 12 nominal diameter. For unclad steel exchangers and for steel exchangers clad with austenitic stainless steel, nozzles NPS 12 nominal diameter and smaller may be of solid stainless steel subject to the limitations specified in Items 1 through 4 of Article 24.6.1. Weld overlay in accordance with Engineering Standard MMOC-616 in lieu of clad may be used. Loose liners shall not be used. 24.6.5. External Stiffening Rings Welded to Austenitic Stainless Steel Exchangers External stiffening rings welded to austenitic stainless steel exchangers may be of carbon steel for exchangers designed for full vacuum and a maximum internal pressure rating of 1.724 barg at a minimum design metal temperature not colder than minus 12C and a maximum design temperature not exceeding that permitted by Figure 1, but in no case greater than 232C. Use of carbon steel rings on stainless steel exchangers outside these
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS limitations or geometries not covered by Figure 1 shall be justified by a complete stress analysis and approved by OWNER. Additionally, the material for carbon steel rings shall satisfy the requirements of Article 24.1.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS FIGURE 1: Maximum Permissible Temperature Carbon Steel Stiffening Ring On Austenitic Stainless Steel Shell
D (Shell ID) t Stiffening Ring
C L
tR
460 450 440 430 420 410 400 390 380 370 360 350 340 330 320 310 300 40
MAXIMUM PERMISSABLE TEMPERATURE F
Q=5
232 227 Q=15 Q=20 204 Q=30 193 Q=40 182 171 160 149 216
Q=10
Q=(tR x H)/t 2
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
D/t
Note: Maximum permissible temperature is equal to the lesser of the temperatures determined for both the corroded and non-corroded conditions, but shall in no case be greater than 232C. 24.6.6. Tubesheets Welded To A Carbon Steel Shell Tubesheets welded to a carbon steel shell shall be of carbon steel or clad carbon steel except that solid stainless steel tubesheets may be used provided: 1. The intended use of tubesheets of stainless steel (or other materials having a coefficient of expansion which differs from that of the shell material by more than 15%) is justified by a complete stress analysis and approved by
400
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS OWNER, or the tubesheet is welded to a relatively short shell section of the same material and the junction of the alloy and carbon steel shell sections is justified by a complete stress analysis and approved by OWNER. The tubesheet material is approved by OWNER.
2. 24.7.
Flanged Joints Of Dissimilar Metals Austenitic stainless steel or non-ferrous alloy flanges may be bolted to carbon steel flanges provided that the differential diametrical expansion will not result in diametrical interference of recessed (e.g., tongue and groove) joints and does not exceed 0.80 mm. Bolting joining a carbon steel flange to a stainless steel or non-ferrous alloy flange shall be of low-alloy steel (see also Article 24.3).
25.
MISCELLANEOUS DESIGN REQUIREMENTS 25.1. Flanged Pressure Joints 25.1.1. Confined Joints For any of the following conditions, gasketed flange joint designs (main shell and nozzle joints) larger than 610 mm nominal diameter shall provide outer confinement of the gasket: 1. 2. 3. 4. 5. Design pressure 20.68 barg or higher. Design temperature hotter than 260C. Design temperature colder than minus 29C. Joint requires metallic gasket. 3-ply and single-ply corrugated metal gaskets are exempted. Cyclic pressure or temperature service.
25.1.2. Gasketed Pass-Rib Joints Confining grooves shall be provided for gasketed pass-rib joints where the nominal diameter of the joint exceeds 305 mm, or the maximum anticipated differential pressure across the pass partition exceeds 2.07 barg. 25.1.3. Unconfined Joints Flanges for unconfined gasket joints shall have a raised face of at least 1.6 mm, except that a raised face is not required on a tubesheet mating with a lap-joint type flange. 25.1.4. Lap Joints In exchangers having a nameplate temperature rating greater than 300F, flanged joints for stainless steel and non-ferrous alloy shells or nozzle necks shall be of the lap-joint type with carbon or
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS low-alloy steel flanges (see Article 24.7). Flanges for aluminium lap joint stub ends shall be galvanise. Except for ASME/ANSI Class 150 NPS 12 and smaller and Class 300 NPS 8 and smaller, modified slip-on welding flanges shall not be substituted for ASME/ANSI B16.5 lapped flanges. This note shall appear in all Vessel Specifications that permit lap-joint flanges. 25.1.4.1.Lap Ring Dimensions The nominal outside diameter of shop-fabricated laps shall correspond to ASME/ANSI B16.9 standard diameters when used with ASME/ANSI standard flanges. When shop-fabricated laps are to be used with custom designed flanges, the nominal outside diameter of the lap shall not exceed the flange bolt circle diameter minus one bolt diameter, and the finished radial width of the lap shall comply with the following: Minimum Radial Exchanger OD (mm) Lap Width(1) (mm) up to 914.4, inclusive 38 over 914.4 through 1524 44 over 1524 51 Radial lap width shall be measured from the toe of the lap-to-shell attachment weld to the outer edge of the lap ring (see Article 25.1.8.5).
(1)
25.1.4.2.Lap Ring Thickness The minimum finished thickness of shop fabricated lap rings shall be the nominal thickness of the shell to which it is attached plus 4.8 mm. The lap rings shall be machined after welding on both the front and back surfaces in one "set-up" so that the planes of the two surfaces are parallel after machining. 25.1.4.3.Lap-Type Flange To Shell Clearance The difference between the flange ID and the OD of the shell shall not exceed: 1. 2. 3. 1.6 mm for nominal diameters up to NPS 12, inclusive. 3.2 mm for nominal diameters over NPS 12 through 1219 mm OD. 4.8 mm for nominal diameters over 1219 mm OD.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.1.4.4.Flange Bevel And Lap Ring Weld The fillet weld attaching the lap ring to the shell shall be an equal leg fillet weld with the leg dimension equal to the nominal shell thickness (+1.6 mm, -0 mm). The flange bevel for lap ring-to-shell weld clearance shall be 45 x 1.6 mm greater than fillet weld leg size. 25.1.4.5.Stop Rings Where needed to hold the lap-joint flange in position for bolt-up (such as lap-joint type manways), three small, equally spaced flange stops shall be used below the flange. 25.1.5. Limitations On The Use Of Slip-On Flanges Slip-on type flanges are limited to use under the following conditions: 1. ASME/ANSI standard forged flanges for design pressures and temperatures not exceeding the pressure-temperature ratings for Class 150 standard flanges as specified in ASME/ANSI B16.5. Custom designed flanges per ASME Code Mandatory Appendix 2, Fig. 2-4 (8), (8a), (9), (9a), (10), or (10a) for design temperatures not exceeding 343C; and for flange thickness not exceeding 76 mm. Corrosion allowance does not exceed 1.6 mm. In special cases and when approved by OWNER, slip-on flanges may be considered for corrosion allowance exceeding 1.6 mm, or for use on necks of clad material; however, in such cases, the flanges shall be provided with a telltale hole drilled radially through the flange. The hole shall be tapped from the outside NPT 1/8 for flange sizes NPS 4 and smaller; NPT 1/4 for larger flange sizes. Carbon or low-alloy steel flanges attached to solid highalloy necks are limited to sizes NPS 12 and smaller, and to design temperatures no greater than 232C; unless a higher temperature is justified by a complete stress analysis and approved by OWNER. Minimum design metal temperature is not colder than 29C. Exchanger is not for lethal service. Exchanger is not for cyclic pressure or temperature service; or subjected to cyclic loadings from associated equipment.
2.
3.
4.
5. 6. 7.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.1.6. Asbestos Gaskets Gaskets containing asbestos are not acceptable. Compressed asbestos-substitute gaskets shall not be used without OWNERs approval, except as permitted in Article 4.3.2 for test gaskets only. 25.1.7. Spiral-Wound Gaskets 25.1.7.1. Spiral-wound gaskets shall not be used in custom designed flanges. 25.1.7.2. All spiral-wound gaskets for raised face or other unconfined gasket joints shall be furnished with an inner and an outer compression limiting ring. 25.1.7.3. Spiral-wound gaskets shall not be used for joints larger than 610 mm nominal diameter. 25.1.8. Gasket Selection, Design Factors, and Contact Width 25.1.8.1.Pass-Rib Area The total gasket area in contact with pass partitions shall be included in the gasket area used in flange joint design calculations. 25.1.8.2.Gasket Selection Gaskets for main shell joints, custom designed flanges, and blind flanged nozzles shall be as specified in the Vessel Specification. 25.1.8.3.Gasket Design Factors Gasket design factors "y" and "m" shall be according to the ASME Code or, if not listed in the Code, in accordance with manufacturer's recommendations. Factors for GRAFOIL gaskets and corrugated metal gaskets with GRAFOIL tape on both sides shall be as follows: GASKET MATERIAL/TYPE TM GRAFOIL, Grade GH E, 1.6 mm
TM
y 2500
m 2.0 2.0 3.5 2.75
2500 GRAFOIL, Grade GH R, 1.6 mm 3-ply corrugated stainless steel with GRAFOIL 6500 overlay 1-ply corrugated stainless steel with GRAFOIL 3700 overlay
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.1.8.4.Gasket Seating Stress The design of all custom flanges shall include the following check: After designing the flange per ASME Code rules, the actual seating stress over the full seating area of the gasket, based on 11/2 x allowable bolt stress at ambient temperature (11/2 x Sa), shall be equal to or greater than the "y" value, but shall not 2 exceed 2460 kg/cm . If it is not, then bolting and/or gasket width adjustments shall be made and the flange redesigned. 25.1.8.5.Gasket Contact Width The minimum gasket contact width for gaskets in custom designed joints shall not be less than the following: Minimum Gasket Vessel OD (mm) Contact Width(1).(mm) up to 914, inclusive 25 over 914 through 1524 32 over 1524 38 (1) Gasket contact width is the recommended width of the gasket in contact with both flange or lap faces. Note: For 3-ply corrugated metal gaskets, the gasket OD shall be a minimum of 6.4 mm smaller than the gasket contact facing OD. For all other gaskets, the contact OD shall be the gasket contact facing OD. 25.1.9. 3-Ply and Single-Ply Corrugated Metal Gaskets 3-ply and single-ply metal corrugated gaskets, when required, shall be as specified in the Vessel Specifications. 25.1.10.External Moments The design of custom and ASME/ANSI B16.47 flanges (other than flanges per ASME/ANSI B16.5) shall include the effects of external moments. When calculating the required bolt loads for the operating condition, the hydrostatic end force, H, shall be modified as follows:
16M H = 0.785G2 P + G3
Where:
P and G are as defined in ASME Code Appendix 2, Paragraph 2-3 and M = moment applied across full section at flange, in.-lb.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS Note: Experience has shown that axial forces resulting from a properly designed piping system have no significant effect on the flange design and hence are not included in the equivalent pressure.
25.1.11.Flange Rigidity The rigidity of custom flanges and flanges per ASME/ANSI B16.47 (other than flanges per ASME/ANSI B16.5) shall be checked, and redesigned if necessary, in accordance with ASME Code Appendix S, Paragraph S-2. KI shall be 0.30 and KL shall be 0.20. 25.1.12.Minimum Bolt Size The diameter of bolts for custom designed pressure-resisting joints (other than flanges per ASME/ANSI B16.5 or B16.47) shall not be smaller than 19 mm. 25.1.13.Bolt Spacing Factor The design of custom flanges and flanges per ASME/ANSI B16.47 (other than flanges per ASME/ANSI B16.5) shall include the effect of bolt spacing in accordance with the following: 1. 2. Maximum bolt spacing = 2a + 6t m + 0.5
If bolt spacing exceeds (2a + t), the design moment (MO) BS acting on the flange shall be multiplied by 2a + t MO, and m are as defined in ASME Code Appendix 2, Paragraph 2-3; a = nominal bolt diameter; BS = actual bolt spacing, and t = minimum finished flange thickness, exclusive of corrosion allowance.
where:
25.1.14.Indicator-Type Bolting Flanged joints requiring 51 mm diameter and larger bolting (also see Item 6 in Article 25.1.15) shall be furnished with bolts having an indicator rod through the bolt centre for measuring installed bolt elongation (using a depth gauge). Every bolt in the joint assembly shall be an indicator-type bolt. The indicator rod material for low alloy steel bolting shall be nickel alloy UNS 10276. The indicator rod for other bolting materials shall be the same as the bolts or a material having essentially the same coefficient of expansion and a composition suitable for welding to the bolts. All bolts in the assembly shall have a through-hardened
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS flat washer under each nut. Engineering Standard MEQ-1B). (see Table 1, Note 6 and
25.1.15.Additional Flange Design Criteria For Elevated Temperature (>427C) The use of flanged joints in high temperature service shall be avoided when possible. When flanged joints are required, the following requirements shall be met: 1. 2. 3. 4. The flange type shall be lap-joint construction with wrought flanges. Integral type flanges shall not be used. The coefficients of expansion of flange and bolting materials shall be nominally the same. The required gasket for custom designed flanges is a 3ply corrugated metal gasket. External pipe reactions on flanged joints shall be held by CONTRACTOR to a minimum practical value (see Article 25.1.10). Flanged joints that are designed on the basis of no insulation require administrative controls to assure that insulation will not be added during their use in the future. These joints shall be provided with a shield to protect them from thermal shock due to rain. The design of rain shields and personnel protection cages shall be such that the design temperature will not be exceeded. Indicator-type bolting shall be used when the bolt size is 38 mm diameter or larger. Buyer shall be involved in the preparation of a joint assembly and bolt tightening procedure when indicatortype bolting is required.
5.
6. 7.
25.2.
Tubesheets 25.2.1. Minimum Tubesheet Thickness 25.2.1.1. The effective tubesheet thickness shall not be less than 25 mm. 25.2.1.2. For all fixed tubesheet exchangers greater than 762 mm ID, the Manufacturer shall calculate the value of Xa as defined in ASME Code Paragraph AA-2.4. These calculations shall be submitted with the mechanical design calculations. If the value of Xa is less than 3.0, then the tubesheet shall be designed in accordance with ASME Code, Appendix AA rules, or the methods provided in the references in TEMA, RGP-RCB-7. For values of Xa equal to or greater than 3.0, the tubesheet may be designed in accordance with TEMA, ASME Code, or the RGP-RCB-7
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS references. Tubesheets exceeding the scope of TEMA shall be designed in accordance with ASME Code Rules or RGP-RCB-7 references regardless of the value of Xa. 25.2.2. Cladding Thickness The minimum thickness of cladding, when required, shall be the greater of 4.8 mm or that required to provide 3.2 mm cladding under pass partition and gasket grooves. 25.2.3. Stationary Tubesheets for Removable Tube Bundles Stationary tubesheets for removable tube bundles shall have a diameter and bolt hole drilling to match the mating flange. The tubesheet shall be designed to permit hydrostatic test of the shell side with the channel removed; and test of the tube side with the bundle removed from the shell. 25.2.3.1.Locking Studs Flanged joints for stationary tubesheets for removable tube bundles shall be furnished with locking studs per Engineering Standard MEQ-180. 25.2.3.2.Pulling Eyes The stationary tubesheet of exchangers with removable tube bundles shall be provided with at least two tapped holes in the tube side face for pulling eyes. Furnish service plugs of a material similar to the tubesheet material. 25.2.4. Tubesheet-to-Shell Weld Joints Except as required in Article 25.2.4.1, or by the ASME Code (for lethal service), tubesheet-to-shell (or channel) weld joints may be any full penetration weld permitted by ASME Code Figure UW13.2 [excluding Figures (d) and (i)] that does not employ a permanent backing strip. 25.2.4.1.Limiting Design Conditions Exchangers having any of the following design conditions shall employ tubesheet-to-shell (or channel) weld joints per ASME Code Figure 13.2 (a), (f), or (k); 1. 2. 3. Tube side design pressure exceeding 42 barg. Shell side design pressure exceeding 69 barg. Design temperature colder than minus 29C.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 4. High-alloy tubesheet or adjoining shell (or channel) material with the weld joint exposed to process fluid. Shell inside diameter larger than 1219 mm with carbon steel, low-alloy steel, or clad tubesheet material; or larger than 762 mm with high-alloy or non-ferrous tubesheet material.
5.
25.2.4.2.Determination of Weld Sizes For the purposes of determining required weld sizes in accordance with ASME Code requirements, a tubesheet shall be considered supported (not less than 80% of the pressure load is carried by the tubes, stays, or braces) if:
AtEt 4 AsEs
where:
At
total cross-sectional metal area of 2 tubes, in mm modulus of elasticity of tube material at design temperature, in 2 kg/cm cross-sectional metal area of shell based on actual thickness less 2 corrosion allowance, in mm modulus of elasticity of shell material at design temperature, in 2 kg/cm
Et
As
Es
25.2.4.3.Clad Tubesheets Remove cladding from clad tubesheets as required to permit welding directly to the base material. After completion of the strength weld, exposed base material shall be covered with weld overlay of the same composition and thickness as the cladding. 25.2.5. Tube-to-Tubesheet Joints Tube-to-tubesheet joints for single tubesheets shall be as follows. When the type of tube joint is not designated in the Vessel Specifications, expanded joints shall be used for tubesheets of solid material; expanded and sealed-welded tube joints shall be
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS used for tubesheets having integrally-clad material on the outer face: 1. 2. Expanded tube-to-tubesheet joints per Figure 2. Expanded and seal-welded tube-to-tubesheet joints per Figure 3.
25.2.5.1.Strength Welded Tube Joints Requirements for strength welded joints with the total tube load carried by the weld shall be as specified in the Vessel Specifications or otherwise approved by OWNER. 25.2.5.2.Double Tubesheets Requirements for tube joints for double tubesheets shall be as specified in the Vessel Specifications or otherwise approved by OWNER. 25.3. Tubes 25.3.1. Minimum Wall Thickness Except as provided in Articles 25.3.1.1 and 25.3.1.2, tubing shall have an average wall thickness (see Article 4.2.1) not less than 16 BWG (1.65 mm). 25.3.1.1.Titanium Tubes Tubes of titanium material for welded tube-totubesheet joints shall have an average wall thickness not less than 20 BWG (0.89 mm). 25.3.1.2.Low-Finned Tubes The wall thickness under the fin of low-finned tubes shall be not less than 18 BWG (1.25 mm) average wall. 25.3.2. Plain Ends for Low-Finned Tubes Plain ends for low-finned tubes shall have a wall thickness not less than 16 BWG (1.65 mm) average wall and a length not less than 102 mm or the tubesheet thickness plus 25 mm, whichever is greater.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.4. Expansion Joints 25.4.1. Design Basis The need for and design of expansion joints shall be based on the following design conditions: 1. 2. 3. Operating or upset temperatures rather than nameplate temperatures. Metal temperatures rather than process fluid temperatures. Design (nameplate) pressures rather than operating pressures.
25.4.2. Type of Construction Expansion joints shall be of the external type constructed of flanged-and-flued or flanged only heads. Bellows type joints shall not be used without Buyer's approval. 25.4.3. Location The expansion joint-to-shell weld shall not be located less than 2.5 Rt from the back of the tubesheet; where R = outside radius of the shell and t = actual thickness of shell less corrosion allowance. 25.4.4. Other Considerations The flexibility of the joint(s) shall be considered in the design of the exchanger shell, tubes, and tubesheets. 25.5. Vapour Belts 25.5.1. Design Basis The design of vapour belts shall include the effect of pressure loads and loads resulting from expansion contraction. For exchangers of other than fixed tubesheet type, the design shall also consider the hydrostatic end load under both the operating and test conditions. 25.5.2. Type of Construction Vapour belts shall be constructed of flanged-and-flued or flanged only heads.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.5.3. Use as Expansion Joint Vapour belts may be used as expansion joints provided all requirements of Article 25.4 are met. Whether or not vapour belts are used as expansion joints, their flexibility shall be considered in the design of exchanger shell, tubes, and tubesheets. 25.6. Baffles And Support Plates 25.6.1. Minimum Thickness The minimum thickness of carbon steel traverse baffles and support plates shall be 1.6 mm greater than required by TEMA, Class B. 25.6.2. Baffle Cuts Segmental traverse baffles shall be cut on the centreline of a row of tubes. For tubes on a triangular pitch, the baffle cut shall not bisect the apex angle of the pitch. 25.6.3. Drain or Vent Notches Traverse baffles shall not be furnished with drain or vent notches. 25.6.4. Slides for Removable Tube Bundles Removable bundles for exchangers larger than 610 mm nominal diameter shall be furnished with slides or runners welded to the baffles and tubesheet. 25.6.5. U-Tube Bundles The baffle adjacent to the tube bends shall be located in the straight portion of the tubes not more than 51 mm from the tangent line of the bends. 25.6.6. Tie Rods And Spacers Peripheral tie rods and spacers for positioning baffles shall be located so that the outside of the spacers coincides with the outer periphery of the baffles. The inside diameter of the spacer shall not be larger than the tie rod diameter plus 3.2 mm. 25.7. Channels, Covers, And Bonnets 25.7.1. Pass Partition Plates Pass partitions shall be designed for the maximum anticipated differential pressure across the partition and coincident
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS temperature during operation and test conditions, but in no case shall the pressure be less than 2.07 bar. 25.7.2. Mitered Reducing Elbows Mitered 90 reducing elbows for thermosyphon reboiler outlet heads shall conform to the following requirements: 1. The minimum number of section shall be 5, with not less than 3 changes in direction at the inside and outside contour. Meridianal (change of direction) angles between adjacent sections shall be approximately equal for gradual flow transition. The general contours shall be similar to those of commercial forged reducing elbows. Cyclic loading is not a governing design requirement.
2.
3. 4.
25.7.3. Flanged Joints Removable channels or bonnets, channel covers, and floating head covers shall be attached with through-bolted flanged joints. (see Article 25.2.3.1 for required locking studs for removable tube bundles.) 25.8. Nozzles And Manways 25.8.1. Projection The minimum distance from the outside of the exchanger wall to the nozzle face shall be: 1. 2. 152 mm for nozzles up to NPS 3, inclusive. 203 mm for nozzles larger than NPS 3.
25.8.2. Minimum Manway Size Manways, when required, shall be no smaller than 610 mm nominal size. 25.8.3. Integral Reinforcement Nozzles and manways shall be integrally reinforced for the following conditions: 1. 2. 3. 4. When located in shells greater than 51 mm thick. The exchanger is designed for cyclic service. The maximum design metal temperature is hotter than 399C. Radial nozzles exceeding the limits in ASME Code Paragraph UG-36(b)(1). The design shall comply with
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS ASME Code Appendix 1-7(a) & (b). Code Case 2236 shall not be used without written approval by OWNER. 25.8.4. Type Of Nozzle Connection External nozzles NPS 1-1/2 nominal size and larger shall be flanged-type connections. Couplings shall neither be less than Class 6000 nor smaller than NPS 3/4. 25.8.5. Nozzle Flanges External nozzle flanges for nozzle sizes NPS 24 and smaller shall be per ASME/ANSI B16.5. Threaded flanges and socket-weld type flanges shall not be used. 25.8.6. Minimum Nozzle Neck Thickness For nozzle sizes NPS 2 and smaller, the nominal neck thickness shall not be less than Schedule 80 or 80S. 25.8.7. Pipe Tap Connections Pipe tap connections per TEMA B-10.32 and RB-10.33 (pressure and temperature) shall not be located on nozzle necks unless specified in the Vessel Specifications. 25.8.8. Studding Outlets The use of studding outlets is discouraged. However, if studding outlets must be used, they shall have tapped bolt holes, thread relief on studs, and coated bolts and studs as specified in the Vessel Specifications. A spacer ring of the same material as the nozzle flange shall be provided for each studding outlet. The thickness of the spacer ring shall be sufficient to provide an effective stud bolt stretching length equal to or greater than that resulting from a through-bolted joint of two identical nozzle flanges. 25.8.9. Gussets The use of gussets on nozzle necks to increase external load capacity is prohibited. Alternatives such as thicker exchanger wall, reinforcing pads, and larger or thicker nozzles shall be considered.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.8.10.Shell Side Nozzles and Vents and Drains 25.8.10.1.Location Shell side nozzles or vent and drain couplings when required for horizontal exchangers shall be located on the top and bottom of the shell. 25.8.10.2.Minimum Distance from Tubesheets Shell side nozzles shall not be closer to integral tubesheets than tn+t or 1.5 Rt , whichever is greater; where R = mean radius of the shell; t = thickness of shell; and tn = thickness of the nozzle. 25.8.10.3.Vents and Drains Shell and channel vents and drains shall be NPS 1 Class 6000 couplings with plugs. The couplings shall be omitted for lethal or hydrogen-rich services, or CSC Class II and III services as specified in the Vessel Specifications. 25.8.11.Flange Connections Flanged connections shall not be located within the confines of the exchanger skirt. 25.8.12.Nozzles in or Passing Through Skirts Nozzles (including attached piping) within or passing through exchanger support skirts shall be adequately supported for the operating conditions and for protection during shipping and handling. 25.8.13.Tubesheet Vents and Drains Three or four tubesheet vents/drains are required for vertical exchangers to permit venting and draining of the shell side. 25.8.14.Manway Davits When required by Vessel Specifications, exchanger manways shall be provided with davits for the cover plates in accordance with Engineering Standard MEQ-206. 25.9. Internal Parts Internal nonpressure parts attached to exchanger wall shall be welded with continuous fillet welds all around the part. The size of weld shall include
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS allowance for corrosion when a exchanger corrosion allowance is required (see Article 20.8.2). 25.9.1. Clad Exchangers Pass partitions, sealing strips, and other parts shall normally be welded directly to the cladding. Unusual conditions requiring removal of cladding for welding to the base metal (e.g., heavily loaded parts) shall be reviewed with OWNER. 25.9.2. Integrally-Clad Plate All integrally-clad plate, whether cladding is included in design calculations or not (see Article 20.10), shall satisfy the requirements of ASME Code Paragraph UCL-11 for shear and bond strength. 25.9.3. Weld Overlay Weld overlay shall be in accordance with Engineering Standard MMOC-616. Weld overlay alloy designation shall be as specified in the Vessel Specifications. 25.9.4. Loose Lining Loose type applied lining material shall not be used, except as a liner for flat cover plates and blind flanges. Plug welds shall not be used to attach liners to blind flanges. 25.10. Exchanger Supports The type of exchanger support (skirt, legs, saddles, lugs) shall be as specified in the Vessel Specifications (see Article 25.11 for anchor bolting). 25.10.1.Design Stresses Except as provided in Article 25.10.1.1, allowable design stresses for all exchangers support components shall be the same as specified in the ASME Code for pressure parts. The total longitudinal compressive stress due to the combined action of overturning moment and weight in a cylindrical support skirt shall not exceed that permitted in ASME Code Paragraph UG-23 for cylindrical shells. 25.10.1.1.Anchor Rings Stresses resulting from direct bending in anchor ring base plates shall not exceed 1.5 times the ASME Code allowable tensile values. Compressive stresses in anchor ring gussets and other compression
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS members shall not exceed 1.25 times the Code tensile values. 25.10.2.Skirt Supports Support skirts for vertical exchangers with either a torispherical, semi-ellipsoidal, or toriconical bottom head shall be welded to the bottom head with a continuous weld sized so as to provide for the maximum imposed loadings. 25.10.2.1.Access Openings Skirt supports shall be provided with two round access openings spaced 180 degrees apart. The openings shall not be smaller than the following: Opening Diameter Exchanger OD mm mm 610 through 762, inclusive 203 over 762 through 914 254 over 914 through 1219 381 over 1219 through 1524 457 over 1524 610 Skirt access openings for exchangers less than 610 mm OD shall be as specified in the Vessel Specifications.
(1)
(1)
25.10.2.2.Vent Openings Skirt supports shall not be provided with vent openings. 25.10.2.3.Weld Joints All welds within the skirt shall be Type No. (1) of ASME Code Table UW-12. Alignment tolerance at plate edges shall be per ASME Code Paragraph UW-33. Skirts made up of two or more courses shall have the centres of the welded longitudinal joints of adjacent courses staggered or separated by a distance of at least five times the thickness of the thicker plate. 25.10.3.Saddle Supports Exchangers to be horizontally installed shall be mounted on two saddle-type supports. Supports shall extend over at least onethird (120 degrees) of the circumference of the exchanger shell. Wear plates shall be provided and shall have radiused corners, be welded to the shell with a continuous fillet weld, and be provided with two telltale holes. The holes shall be plugged with
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS a room temperature vulcanising (RTV) silicone sealant. The bottom of the supports shall extend at least 25 mm below nozzles or other projecting exchanger components. 25.10.3.1.Slide Plates One of the two saddles shall be designated as the fixed saddle and holes shall be provided to receive the anchor bolts. The other saddle shall be designated as the sliding saddle and slotted holes of sufficient length to permit the maximum anticipated expansion or contraction shall be provided. Except where greased slide plates are permitted, TFE [(Teflon) limited to 107C] or graphite slide plates shall be furnished (by CONTRACTOR) under all sliding saddles. The design static coefficient of friction for the slide plate shall be taken as 0.1 for TFE and 0.15 for graphite. Greased slide plates may be used when all of the following apply: 1. 2. 3. 4. Exchanger does not exceed 610 mm OD. Support load does not exceed 3400 kg. Outside shell-to-base plate of saddle does not exceed 356 mm. Operating temperature does not exceed 107C.
25.10.3.2.Clearance Of Shell Seams The minimum distance from the toe of fillet welds attaching either saddle or lug-type supports, or their wear plates, to the centreline of either a longitudinal or circumferential shell seam shall be Rt (where R = shell inside radius and t = shell thickness exclusive of corrosion allowance). 25.10.3.3.Saddle Design The effect of the saddles on the shell shall be analysed using the method developed by L. P. Zick and published by John Wiley and Sons, Process Equipment Design by Brownell and Young, 1959, Chapter 11, "Design of Horizontal Vessels with Saddle Supports". 25.11. Anchor Bolting Carbon steel anchor bolts shall not be smaller than 19 mm nor larger than 38 mm. When larger anchor bolts (carbon steel) would be required, low-alloy steel bolts shall be used. The minimum size for low-alloy steel bolts shall be 25 mm. Anchor bolts shall be hot-dipped galvanised per ASTM A 153.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.11.1.Design Stresses Allowable design tensile stresses, as calculated using the tensile stress area of the threaded portion, shall not exceed the following: 1. 2. Carbon steel, 1055 kg/cm 2 Low-alloy steel, 1757 kg/cm for bolt diameters 63.5 mm 2 and smaller, and 1617 kg/cm for bolt diameters over 63.5 mm through 101.6 mm.
2
25.11.2.Spacing and Location Anchor bolts for skirt supported vertical exchangers shall be selected in multiples of four bolts. Orientation will be furnished by CONTRACTOR. The anchor bolt circle shall be selected to provide radial clearance for the bolt tensioning device when lowalloy steel bolting is required. 25.11.3.Supplier Unless otherwise specified in the Vessel Specifications, anchor bolting will be furnished and installed by CONTRACTOR. 25.12. Lifting Lugs Lifting lugs shall be furnished as follows: 25.12.1.Exchanger Lifting Lugs Vertical exchangers having a nominal diameter 1524 mm or larger, or a height greater than 1981 mm shall be furnished with lifting lugs designed to permit erecting the exchanger from a horizontal position. The crevice between the lug and the top head dish surface shall be sealed by a bead of room temperature vulcanising (RTV) silicone sealant after painting. Usually, two ear-type lugs spaced 180 degrees apart and welded to the straight flange portion of the top head and shell are adequate. For unusually tall exchangers, it may be necessary to provide trunnion-type lugs located about two-thirds the height of the exchanger from the base. The effect of handling and erection shall be considered in the design of the exchanger and the lifting lugs. 25.12.2.Lugs for Removable Parts Removable components weighing more than 27 kg shall be provided with lifting lugs.
GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS 25.12.3.Tailing Lugs Provide tailing lugs for vertical exchangers greater than 6000 mm in height and/or greater than 4535 kg in weight. 25.13. Flow-Induced Tube Vibration Flow-induced vibration shall be considered. Damaging vibration (resonance at natural frequency) as a result of fluid-elastic excitation, vortex shedding, acoustic resonance, or turbulent buffeting shall be avoided. The effect of any axial loading on the tubes shall be considered when determining natural frequencies. Regions of high velocity, such as inlet and outlet nozzles, shall be properly considered. Baffle and tube bundle types which reduce or eliminate the potential for flow-induced tube vibration should be selected. Detuning baffles shall be provided when required.
(See drawing MCOP-11.DGN)
(See drawing MCOP-11.DGN)

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PETRONAS/UCC JV MALAYSIA PROJECT

MECHANICAL HEAT EXCHANGER

PETRONAS/UCC JV - MALAYSIA PROJECT Revision 2

MCOP-11 PAGE 0 OF 70 SEPTEMBER 1998

GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS

MECHANICAL HEAT EXCHANGER

PETRONAS/UCC JV - MALAYSIA PROJECT Revision 2

MCOP-11 PAGE 1 OF 70 SEPTEMBER 1998

MECHANICAL HEAT EXCHANGER

PETRONAS/UCC JV - MALAYSIA PROJECT Revision 2

MCOP-11 PAGE 2 OF 70 SEPTEMBER 1998

5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11.

5.16. 5.17. 5.18.

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12. 13. 14. 15. 16. 17. 18. 19. 20.

20.3. 20.4. 20.5.

20.6. 20.7. 20.8.

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25.12.3. Tailing Lugs 25.13. Flow-Induced Tube Vibration

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12. 13. 14.

15. 16. 17. 18. 19. 20.

24. 25. 26.

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GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION OF SHELL-AND-TUBE HEAT EXCHANGERS

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