180530-00-me-spc-0010-a

PETROM SA EXPLORATION &

PRODUCTION DIVISION

PROJECT NO: 180530

DOC NO: 180530–00–ME–SPC-0010-A PAGE 1 OF31

REV. DATE DESCRIPTION BY CHK APP’D CLIENT 0 28/02/08 ISSUED FOR INTERNAL REVIEW SH PC PC 1 27/03/08 ISSUED FOR CLIENT REVIEW SH PC PC A 04/04/08 APPROVED FOR DESIGN SH PC PC

ENGINEERING SPECIFICATION

DOCUMENT TITLE: SHELL AND TUBE HEAT EXCHANGER SPECIFICATION

PROJECT DESCRIPTION: FEED AND PRE-FEASIBILITY STUDY FOR SURFACE PRODUCTION SYSTEMS IN OIL AND GAS

ORIGINATOR: S. HODDER

DATE: 27 FEB. 08


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PROJECT NO: 180530


REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

A 3.5

A 4.8

A 4.9

A 7.2

A 10.2

Hold No. Para. Description of Hold


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CONTENTS

1. EXECUTIVE SUMMARY .......................................................................6

1.1 Project Outline.......................................................................................6

2.0 SCOPE...................................................................................................7

2.1 Definitions..............................................................................................7

2.2 Units ......................................................................................................7

3.0 REGULATIONS AND CODES...............................................................7

3.1 Equipment Directive ..............................................................................7

3.2 Statutory Regulations ............................................................................8

3.3 Design and Fabrication Code................................................................8

3.4 Alternative codes...................................................................................8

3.5 Standards ..............................................................................................8

3.6 Project Specifications ..........................................................................10

4. DESIGN ...............................................................................................10

4.1 Hazard Analysis ..................................................................................10

4.2 Design Life ..........................................................................................10

4.3 Sour Service........................................................................................10

4.4 Shell and Head Layout ........................................................................10

4.5 Design Pressure and Temperature .....................................................11

4.6 Exchanger Covers...............................................................................11

4.7 Shell Supports .....................................................................................11

4.8 Floating Heads ....................................................................................12

4.9 Tube Bundles ......................................................................................13

4.10 Tubesheets..........................................................................................14

4.11 Nozzles and Connections....................................................................14

4.12 Flanged Girth Joints ............................................................................15

4.13 Gasket Contact Surfaces other than Nozzle Flanges..........................17

4.14 Handling Attachments .........................................................................17

4.15 Kettle Type Reboilers ..........................................................................18

4.16 Gaskets ...............................................................................................18

4.17 Bolts ....................................................................................................18


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4.18 Test Rings ...........................................................................................19

5.0 MATERIALS ........................................................................................19

5.1 Alternative Materials............................................................................19

5.2 Material Essential Safety Requirements..............................................19

5.3 Castings ..............................................................................................19

5.4 Pressure Parts in Sour Service ...........................................................19

6.0 FABRICATION ....................................................................................20

6.1 Welded Joints......................................................................................20

6.2 Preparation for Welding.......................................................................21

6.3 Preheat................................................................................................21

6.4 Welding ...............................................................................................21

6.5 Pass Partition Plates ...........................................................................22

6.6 Reinforcing Pads and Wear Plates......................................................22

6.7 Tube-to-Tubesheet Joints....................................................................22

6.8 Post Weld Heat Treatment ..................................................................24

6.9 Hot Forming.........................................................................................24

7.0 INSPECTION, REPAIRS, TESTING AND REJECTION......................24

7.1 Inspection/Examination – Generation Requirements ..........................24

7.2 Radiography ........................................................................................25

7.3 Surface Examinations .........................................................................25

7.4 Chemical Analysis ...............................................................................26

7.5 Ultrasonic Examination........................................................................26

7.6 Hardness Testing ................................................................................26

7.7 Leak Testing........................................................................................27

7.8 Pressure Testing .................................................................................27

7.9 Repairs of Defective Welds .................................................................28

7.10 Rejection .............................................................................................28

8.0 CODE STAMPING ...............................................................................28

9.0 PAINTING ............................................................................................29

9.1 General................................................................................................29

10.0 MARKING, PACKING AND SHIPPING...............................................29


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10.1 Marking................................................................................................29

10.2 Packaging and Shipping......................................................................30


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CONTENTS

1. EXECUTIVE SUMMARY

PETROM have issued a reimbursable engineering contract to WorleyParsons to provide a Front End Engineering Design (FEED) and EPC ITT documentation for the Central and East Region OSPS Facilities consisting of 284 Parks contained within 23 Projects (22 in Central Region and 1 in the East). In addition, Pre-feasibility Studies leading to future FEED design work are to be carried out on 92 Parks (contained within 15 Projects) for the Western Region as well as for 45 Tank Farms in the three regions (2 in the Eastern Region; 38 in the Central Region; and 5 in the Western Region).

1.1 Project Outline

The Project Scope is comprised of the modernisation or abandonment of existing Park facilities. Modernisation consists of complete replacement of the existing Park facilities, sized to present production capacities. The Park facilities will be designed to be of modular construction, the modules to consist of PETROM design for manifold only (PMAN) or one of five metering point (MP) designs as put forward by PETROM. In addition, there are five Metering Point Production (MPP) designs covering 20 Park facilities in the Central and East Regions that are to be evaluated for abandonment, modernising, upsizing or downsizing in addition to others in the Eastern Region that are to be identified. Given the size and complexity of these facilities, only partial modularisation is expected. Work on the West Region Parks will culminate in a Pre-feasibility Study following a detailed data gathering exercise and verification of the same. There are 92 Parks contained in 15 Projects that will be assessed for upgrade or abandonment. The 45 Tank Farms are to be examined for upsizing, downsizing, modernisation or abandonment and will also culminate as a Pre-feasibility Study.

The scope of work begins at the manifold inlet to the Park facilities and continues through to the delivery points of the Tank Farms or MPP’s; i.e. pipelines and wellheads upstream of the manifolds are not considered. However, interconnecting and delivery pipelines will have to be considered in the overall assessment of the project.


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2.0 SCOPE

This specification covers the minimum requirements for the design, materials, fabrication, testing, inspection and documentation of shell and tube heat exchangers.

2.1 Definitions

• The Contractor is the party who carries out all or part of the design, engineering, procurement, construction, commission or management of the project, or operation or maintenance of a facility.

• The Manufacturer/Supplier is the party who manufactures or supplies equipment

and services specified by the Contractor / Company

• The Company is the party who owns and operates the equipment.

• The Notified Body is the inspection body with the responsibility for ensuring that the European pressure directives (PED) requirements are met.

• The word shall indicates a requirement.

• The word should indicates a recommendation.

2.2 Units

The S.I. (System International) system of units shall be used as the official units throughout all documentations with the exceptions as shown on data sheets and piping specifications.

3.0 REGULATIONS AND CODES

All work specified shall be in accordance with the applicable sections of the latest

editions of the Regulations, Codes and Standards (and their current amendments), listed below or referenced in this specification, except where modified or supplemented by requirements noted in this specification.

3.1 Equipment Directive

All pressurised equipment including piping shall fulfil the requirement of the Pressure Equipment Directive (PED) 97/23/EC. The requirements listed below are additional requirements, which in any case shall be fulfilled. The Supplier shall clarify actual requirements with Notified Body and inform Contractor regarding final requirements. Any


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additional requirement concluded by Notified Body to meet the directives shall be Supplier’s responsibility (cost, schedule, technical).

3.2 Statutory Regulations

EU Directive 97/23/EC Pressure Equipment Directive (PED) EU Directive 94/9/EC ATEX PT C 4/1 Technical prescription for erection, installation,

exploitation, repairing and testing of the metallic pressure vessels

PT C 4/2 Guide for designing, fabrication, construction and repairing of the metallic pressure vessels

3.3 Design and Fabrication Code

Heat exchangers shall be designed and manufactured in accordance with:

• TEMA Tubular Exchanger Manufacturers Association • SR EN 13445 Unfired pressure vessels

3.4 Alternative codes

Alternative codes can be used if there is a proven economical incentive. To use alternative code will require written acceptance by Company.

Alternative Codes: • PD5500 Unfired Fusion Welded Pressure Vessels, British code • ASME VIII Boiler and Pressure Vessel Code, section VIII Div. 1 & 2, American code

In all cases the alternative Design Code shall be complied with fully in addition to the requirements stated in EU Directive 97/23/EC.

3.5 Standards

ASME B-16.5 - Steel Pipe Flanges and Flanged Fittings ASME B16.47 - Large Diameter Steel Flanges

ASME B 31.3 - Process Piping ASME VIII - Boiler and Pressure Vessel Code section VIII Div. 1&2 ASTM A 143 - Safeguarding against Embrittlement of Hot Galvanized Structural Steel


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Products

ASTM A 153 - Zinc Coating (Hot Dip) on Iron and Steel Hardware ASTM A 388 - Ultrasonic Examination of Heavy Steel Forgings ASTM A 435 - Straight-Beam Ultrasonic Examination of Steel Plates for Pressure

Vessels ASTM A 578 - Straight-bream Ultrasonic Examination of Plain and Clad Steel Plates for

Special Applications API 660 - Shell-and-Tube Heat exchanger for general refinery service SR EN 286-1:2001+A2: 2006

- Simple Unfired Pressure Vessel to contain air and Nitrogen

SR EN 287:2004+A2: 2006

- Approval testing of welders - Fusion welding

EN473:2003+ A1:2006

- Qualification and certification of NDT personnel. General principles

SR EN ISO 14731:2007

- Welding coordination. Task and responsibilities

SR EN 970:1999

- Non-destructive examination of fusion welds. Visual examination

SR EN 1289:2002

- Non-destructive examination of welds. Penetrant testing of welds. Acceptance levels

SR EN 1435:2001

- Non-destructive examination of welds. Radiographic examination of welded joints

SR EN 1712:2002

- Non-destructive examination of welds. Ultrasonic examination of welded joints. Acceptance levels

SR EN 1714:2000+A2:2004

- Non destructive testing of welded joints. Ultrasonic testing of welded joints

SR EN 10021:2007

- Technical delivery requirements for steel & iron products

SR EN 10028:2002

- Flat steel products for pressure vessels

SR EN ISO 3834:2006 (repl. EN 279)

- Quality requirements for fusion welding of metallic materials.

SR EN ISO 6506-1

- Metallic materials - Brinell hardness test - Part 1: Test method

SR EN 13445 - Unfired pressure vessels - Part 1, 2, 3, 4, 5 & 6 SR EN 13480 - Metallic Industrial Piping – Part 1, 2, 3, 4 & 5 SR EN ISO 15609 (replacing EN 288)

- Specification and qualification of welding procedures for metallic materials. Welding procedure specification. Part 1- Arc welding

SR EN ISO 15614 (replacing EN 288)

- Specification and qualification of welding procedures for metallic materials Part 1 – Arc and gas welding of steel and welding of nickel and nickel alloys

SR CR 13576: - Implementation of EN 729 on quality requirement for fusion welding of metallic materials


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SR EN ISO 16812

- Petroleum and natural gas industries Shell-and-tube heat exchangers

WRC 107 & WRC 297

- Welding Research Council Bulletins 107 & 297.

3.6 Project Specifications

180530-00-IN-PHL-0001 - Instrumentation Philosophy 180530-00-ME- PHL-0001 - Sparing Philosophy 180530-00-ME-SPC-0001 - Pressure Vessel Specification 180530-00-ME- SPC -0003 - Painting and Coating Specification 180530-00-ME- SPC -0004 - Insulation Specification 180530-00-ME- SPC -0005 - Nozzle Loads 180530-00-ME- SPC -0007 - Heat Tracing Specification 180530-00-ME-SPC-0009 - Welding Specification 180530-00-ML-DEG-0001 - Material Selection Guide

4. DESIGN

4.1 Hazard Analysis

The Manufacturer shall perform a hazard analysis in accordance with EU Directive 97/23/EC, Essential Safety Requirements, Preliminary observations

4.2 Design Life

The design life shall be at least 25 years, or as specified in the equipment data sheet.

4.3 Sour Service

Heat exchangers in sour service shall be subject to additional design and inspection requirements defined in this specification and on the equipment data sheets.

4.4 Shell and Head Layout

Seams in horizontal exchangers shall not be located coincident with or across saddle supports. Plate layouts shall be arranged so that to the maximum extent possible, longitudinal and circumferential weld seams clear all nozzles, manways and their reinforcing pads (if permitted) by 50mm minimum measured weld edge to weld edge. When nozzles must penetrate, or when nozzle reinforcing pads must cover weld seams, the seam shall be ground flush and 100% radiographically examined before welding the

https://ukprojects.worleyparsons.com/hydrocarbons/petrom_osps/5%20Approved%20Deliverables/F1.1%20Standards%20and%20Specifications/180530-00-ME-PHL-0001-A%5b1%5d.pdf







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nozzle. The seam shall be radiographed for a distance of 152mm beyond the OD of the nozzle or 152mm beyond the OD of the reinforcing pad, whichever is greater. The cladding or weld overlay thickness in clad or overlayed components of exchangers shall be considered as corrosion allowance and not considered in strength calculations.

4.5 Design Pressure and Temperature

Exchanger components common to both the shell and the tube sides shall not be designed for differential pressure. The design temperature for bolting at the shell and channel joint shall be the most severe of the shell side or tube side design temperatures. Pass rib thickness shall be designed for the greater of 69kPa or 1.5 times the total tube side allowable pressure drop. When longitudinal baffles are specified, they shall be designed for 1.5 times the shell side pressure drop. Total deflection shall be no greater than ½ the clearance between the adjacent row of tubes and the longitudinal baffle. Calculations shall be submitted to the Contractor.

4.6 Exchanger Covers

When TEMA Type “B” channels are required on the exchangers with removable tube bundles, the following requirements apply: a. The tubesheet shall be the same outside diameter as the connecting flanges. b. One piece collar bolts shall be used to maintain the gasket seal on the shell side of

the tubesheet with the channel removed. Collar bolts shall be installed in 25 percent of the bolt holes (four minimum).

c. The extended portion of the tubesheet shall be designed to consider shell side hydrostatic test pressure.

4.7 Shell Supports

The lower fixed support of stacked exchangers shall be designed for bundle pulling loads for removal of the upper bundle. Exchangers greater the 762mm inside diameter shall have the saddle supports designed and stresses in the exchanger shell checked in accordance with SR EN 13445, Part 3, 16.8 of Clause 16. Calculations shall be submitted to the Contractor. Seismic loadings shall be included when applicable. Stacked exchangers shall have the lower shell(s) designed to withstand the superimposed load of the upper exchanger(s) full of water without distorting the shell and causing binding of tube bundle(s).


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When two or more exchangers are stacked, the entire stack shall be shop-assembled and checked for accuracy of saddle and nozzle fit-up. A 12mm thick shim pack one 6mm and two 3mm shall be supplied between intermediate supports. The shims shall be one piece construction the same size as the saddle base plate. Lug-supported exchangers with an inside diameter of 762mm and greater shall have stresses in the shell evaluated for the effects of local loadings from the support lugs in accordance with SR EN 13445, part 3, Clause 16. Supplier shall furnish bolts, nuts and washers for saddle to saddle connections between stacked exchangers. These components shall be shipped bolted in place on the lower intermediate supports. For the design of saddles for horizontal exchangers, the following coefficients of static friction shall be used to determine the friction forces at the sliding surfaces of the exchangers: a. Steel on steel 0.30 b. Steel on concrete 0.50 c. Teflon on Teflon 0.10 d. Lubrite on lubrite 0.10 Saddles for horizontal exchangers with removable bundles shall be designed to withstand a longitudinal bundle pulling load equal to 50% of tube bundle weight or 1000kg whichever is greater.

4.8 Floating Heads

Floating heads shall be designed and dimensioned in accordance with SR EN 13445, Part 3, Figure 12-1 of Clause 12. Pass rib in contact area is to be considered in accordance with TEMA RGP-RCB-11.7. Floating heads, including flanges, shall be designed for the most severe design temperature (internal or external). Metal temperatures may be used only if calculations for metal temperatures are submitted to Contractor. Floating head flange to floating tubesheet gasket shall be solid flat metal. Nubbins shall not be used over 370ºC design temperature. Floating heads shall be designed with corrosion allowance applied to the inside and outside of the floating head flange. Corrosion allowance on the outside diameter of the flange may be included in the recommended edge distance for the selected bolt size.


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4.9 Tube Bundles

The minimum bend diameter of U-tubes shall not be less than 3 times the nominal tube O.D. U-tubes shall be of one piece construction. The special close-fit tolerances for tube holes as stated in TEMA shall be mandatory for: a. Austenitic tubes with expanded and grooved tube-to-joints b. Tubes with seal welded or strength welded tube-to-tubesheet joints.

When baffle cuts include a portion of the inlet and outlet knockout areas, the baffles shall be cut to prevent by-pass of the shell-side fluid. Cross baffles shall have a thickness not less than twice the shell side corrosion allowance. Tube holes in baffles for finned tubes shall be drilled 0.4mm larger than the tube diameter regardless of the baffle spacing. Support plates and baffles in horizontal exchangers shall be provided with 12mm x 90 degree notches in the bottom for draining. TEMA Type “S” and “T” exchangers shall have a floating head support plate located 101mm to 152mm from the inside face of the floating tubesheet. Seal strips or dummy tubes are not required for shell side isothermal boiling, isothermal condensing or for kettles. For other services, seal strips are provided as follows: a. Seal strips are required when the diametrical clearance between the shell and the outer tubes exceeds 32 mm. b. Dummy tubes shall be provided for U-tube pass partitions which are parallel to the shell-side flow. c. Seal strip thickness shall be I0mm. For vertical cut baffles, seal strips shall not extend

into the inlet or outlet baffle spaces. For horizontal cut baffles, seal strips shall extend from the stationary tubesheet to the floating head support plate. Seal strips or dummy tubes shall be welded to each baffle. Each weld shall be 25mm minimum length. Dummy tubes shall be sealed at one end only.

d. One pair of seal strips or one dummy tube shall be provided for each 5 tube rows between baffle cuts. Minor adjustments may be made to suit actual tube layout.

Exchangers with removable tube bundles weighing 9100 kg or more shall have bundle skid/guide bars. a. The skid/guide bars shall be welded with a continuous fillet weld to each cross baffle

(when possible), support or stationary tubesheet. The bars shall extend from the


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stationary tubesheet to floating head support plate (or the end baffle for U-tube exchangers).

b. When the skid/guide bars interfere with nozzle openings, they shall be terminated at the baffle or support plate adjacent to the nozzle. A tie rod/spacer of adequate strength to carry the bundle pulling load, shall be located close to the tube field and within 75mm of the bar and shall extend from the tubesheet or baffle/support plate on one side of the nozzle to the baffle/support plate on the other side of the nozzle.

c. A minimum of two skid/guide bars shall be provided. The bars shall be 12mm minimum thickness by 38mm minimum height flat bar. The outer edge shall be ground to match the baffle/support outside diameter. The bars shall be located no more than 30 degrees from the vertical centreline.

Perforated or slotted impingement plates shall not be used. Multiple exchangers of the same TEMA size, type and material either stacked or parallel, shall have interchangeable components to the maximum extent possible. Supplier shall verify that the density times the velocity squared is less than 5950 kg/m.s (TEMA RCB-4.62) at all points on the shell side. When impingement plates are required they shall be round with a surface area equal to 1.1 times the cross sectional area of the inlet nozzle.

4.10 Tubesheets

Fixed tubesheets shall be designed in accordance with SR EN 13445, Part 3, 13.5 of Clause 13. Calculations by the Supplier shall be submitted with the mechanical design calculations for Contractor approval. Expansion joints for fixed tubesheet exchangers shall be designed in accordance with TEMA RCB-8.

4.11 Nozzles and Connections

When external piping loads are supplied by the Purchaser, the Supplier shall indicate the external loads on the Supplier's Setting Plan in addition to determining the effect on the adjacent components. As an option the Supplier may show a reference to the loads and include the loads on an additional sketch to be included with the Supplier drawings. The Supplier shall provide the point of load application (loads at face of nozzle, loads at OD of cylinder, etc.) and the reference axis. Flanges for nozzles NPS 24 and smaller shall be in accordance with ASME B16.5 for the rating and type of facing specified. Flanges for nozzles NPS 26 through NPS 60 shall be in accordance with ASME B16.47 Series B. Raised face flanges shall be furnished with standard ASME B16.5 gasket surface finish.


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Threaded connections shall be Class 6000 full couplings with NPT threads conforming to ASME B1.20.1. Each coupling shall be furnished with a 75mm long hex head forged plug. Threaded connections are not permitted in Hydrogen Service. When Hydrogen Service is specified on the Heat Exchanger Specification Sheet, all connections shall be flanged. Flanges for nozzles shall be one of the following: a. Forged welding neck with pipe, plate or integrally reinforced neck. b. Forged long welding neck. c. Slip-on flanges may be used when the design conditions do not exceed ASME B16.5,

Class 150 nozzle rating in non-cyclic, non-hydrogen services and with design temperatures less than 343ºC.

Bolts for flanges of mating connections between stacked exchangers shall be removable from the top side without moving the exchanger. Bolt removal shall not be obstructed by insulation of adjacent exchanger components. TEMA standard thermowell and pressure gauge connections are not required. Integral reinforcement of all nozzle openings is mandatory under the following conditions: a. Cyclic service or thermal shock. b. Wall thickness of the component to which the nozzle is attached is 50mm or greater. c. Openings 914 mm in diameter and greater with design temperature of 398ºC or

higher. d. Design temperature exceeds 450°C e. Design pressure exceeds 100 barg. f. Design temperature exceeds 350°C and the design pressure exceeds 30 barg. g. Nozzle NPS 1.5 and smaller. In Hydrogen Service the vent and drain nozzles shall be flanged connections furnished with blinds, bolts, and gaskets. The Supplier shall furnish bolts and gaskets for nozzles with blinds or covers. The Supplier shall furnish bolting (studs and nuts) and gaskets for flanges of mating connections between stacked exchangers.

4.12 Flanged Girth Joints

Girth flanges shall be of the forged hub type with through bolting. Ring flanges may be used when the design conditions do not exceed ASME B16.5, Class 150 in non-cyclic, non-vacuum, non-hydrogen services and with design temperatures less than 343ºC.


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Pass rib contact area is to be considered in accordance with TEMA RGP-RCB-11.7. A minimum clearance of 3mm shall be provided between flange faces. An 8mm by 45 degree bevel shall be provided at the corner formed between the flange O.D. and the flange face of all flanges, covers, and tubesheets where applicable. When selecting gaskets for girth flanges, if 2y (where y is the minimum gasket seating stress) exceeds the gasket-surface material yield stress (flange, tubesheet, or cover), the term 2y shall be replaced with the yield stress of the material used for the flange, tubesheet, or cover in the equation for Nmin: Nmin = Ab x Sa / π x G x sy where Sy is the specified material yield stress at ambient temperature. Girth flanges shall satisfy the deflection (rigidity) criteria in accordance with SR EN 13445. Flanges with studs M36 diameter and greater are to have the studs tightened with hydraulic bolt tensioners. Each stud shall be provided with hardened flat washers. The studs shall extend at least one stud diameter beyond the nut. The residual stress in the studs after bolt-up shall not be less than 1.5 times the Code allowable bolt stress at ambient temperature. A complete Bolt Tensioning Procedure for each flanged joint shall be prepared by the Supplier and submitted with the Supplier's drawings for acceptance. Flanged joints with bolting that requires tensioning shall be indicated on the Supplier's setting plan drawing. The Supplier shall provide a reference to the applicable Bolt Tensioning Procedure on their setting plan for each flanged joint requiring tensioning. The differential radial thermal growth of gasketed joints with dissimilar materials shall be calculated by the Supplier. The permissible radial differential expansion strain at the gasket reaction load diameter "G" shall not exceed 0.03175mm per mm. Studs shall be spaced more than 75mm apart. The number of studs in main girth flanges may be divisible by 2 if the stud diameter exceeds 38 mm. The studs must straddle the vertical centreline of the exchanger. The cross-sectional area of the bolts (AB) shall not be less than (AB,min x 1.05), where (AB) and (AB,min) are defined in SR EN 13445, Part 3, 11.3 of Clause 11.


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4.13 Gasket Contact Surfaces other than Nozzle Flanges

Gasket contact surfaces shall have a 3.2 to 6.3 micrometer Ra finish. The use of a straight edge to determine flatness is acceptable Exchangers in Hydrogen Service and applications specified by the Contractor shall meet the flatness tolerances given in a. and b. below: a. The flatness tolerance on peripheral gasket contact surfaces shall be as shown in

Table 1. Measurement shall be made with a dial indicator.

TABLE l Flatness Tolerance on Peripheral Gasket Contact Surfaces

NOMINAL EXCHANGER DIA. (mm) TOLERANCE (mm)

Less than 381 0.076 Over 381 to 736 0.127

Over 736 to 1117 0.254 Over 1117 0.305

b. For exchangers without internal pass partition covers, the flatness tolerance on individual pass partition grooves shall be 0.8 mm.

The girth flange flatness tolerance shall be measured after the flange is attached to the component cylinder or the bonnet and after any post weld heat treatment. The flatness of the tubesheet gasket contact surface shall be measured after the tube-to-tubesheet joints are expanded or welded.

4.14 Handling Attachments

Handling lugs for exchanger components shall be provided in accordance with Figure 1 and the following requirements: a. Lug orientation shown on top exchanger shall be used for exchangers that are not

stacked. b. Handling lugs shall be located above the centre of gravity of the parts to which they

are welded. d. Handling lugs shall be of the same material as the part they are welded to or shall be

carbon steel welded to pads of the same material as the part to which they are welded.

e. Holes in handling lugs shall be 38mm minimum diameter, drilled not burned.


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f. The centreline of the hole in lifting lugs shall be a minimum of 120mm from the

component to which it is welded. Lifting attachments shall be designed using a 1.50 impact factor.

FIGURE 1 – LOCATION OF LIFTING LUGS

4.15 Kettle Type Reboilers

If a weir plate is required, the weir plate shall be continuously welded to the shell inside diameter, shall contain no drain holes and shall be of sufficient height to flood the top row of tubes with a minimum of 50mm of process fluid. Fixed tubesheet kettle type exchangers shall have a 75mm minimum length cylindrical section between the tubesheets and conical transitions. Any crevice between the tubesheet and cylindrical section shall be seal welded. The angle of the conical section of kettle type exchangers shall be 30 degrees.

4.16 Gaskets

Asbestos gaskets shall not be used.

4.17 Bolts

All bolts shall be fully threaded. Bolt length shall be measured from first thread to last thread. Three threads shall be exposed.


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4.18 Test Rings

Test rings shall be provided for each exchanger unit or group of identical exchanger units except kettle type. Floating head rings shall be provided for all floating head units. Channel rings shall be provided only for units designed so that the tube ends cannot be seen when the channel cover is removed.

5.0 MATERIALS

5.1 Alternative Materials

Materials of construction shall be as specified in the equipment data sheets. Materials other than those specified may be proposed as an alternate when accompanied by their advantages and/or cost savings. Proposed alternative materials are to be approved by the Contractor.

5.2 Material Essential Safety Requirements

Materials shall be suitable for the minimum design temperature stated on the equipment data sheet and shall be in accordance to SR EN 13445 Part 2. The Manufacturer shall document compliance with the material specifications of the EU Directive 97/23/EC, Essential Safety Requirements, sec. 4, Materials.

5.3 Castings

Castings shall not be used for pressure containing parts without the prior written agreement of the Contractor.

5.4 Pressure Parts in Sour Service

For exchangers which are identified on the equipment data sheet as being in sour service, the pressure parts, welded attachments to the pressure parts and internals (including bolting) shall comply with the requirements stated on the equipment data sheet and equipment purchase requisition and all requirements of NACE MR 0175/ISO 15156 (latest edition) shall be applied.

Supplementary Requirements for Materials in Sour Service:

1) Plate materials

The following limitations on chemical composition shall apply: a) the maximum carbon content shall be 0.23% carbon equivalent

CE (formula indicated in 6.5) shall not exceed 0.43% plates having a thickness of 10mm and above shall be ultrasonically tested for laminations in accordance with ASTM A 578, level 1

The following limitations on chemical composition shall apply: a) Sulphur content: maximum 0.007% (ladle analysis), 0.009% (check analysis). b) Phosphorus content: maximum 0.015 % (ladle analysis), 0.020% (check

analysis).


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c) Rare earth metal are not permitted

1) Hardness

a) The maximum hardness of parent metal and welds shall be 235 HBN b) Hardness measurements shall be made on the internal welds. A minimum of one

reading (including base metal, weld and HAZ shall be made on each circumferential weld and on each longitudinal shell course weld.

3) Pipes and fittings

Because of the significantly greater risk of crevice corrosion in sour service, the use of socket- welded fittings, screwed couplings or any other weld detail which could result in a crevice on the process side is not permitted. The use of ERW pipe is not permitted.

Composition for Carbon and Carbon Manganese Steel Exchangers and attachments The carbon content shall be 0.25% maximum and the carbon equivalent (C.E.) shall be 0.45% maximum.

Where C.E. = C + Mn + Cr + Mo + V + Cu + Ni 6 5 15 6.0 FABRICATION

6.1 Welded Joints

a. Pressure retaining shell, head, and transition section seams shall be full penetration double-welded joints except as noted in c.

b. Nozzles and manways shall fully penetrate through the exchanger wall and shall be full

penetration double welded joints except as noted in c. Set-on connections can only be used if accepted by the Purchaser.

c. When sound back-welding is not feasible due to inaccessibility, single-welded joints

which utilize a Gas Tungsten Arc Welding or Gas Metal Arc Welding root pass shall be used. Permanent backing strips shall not be used.

d. Temporary backing strips may be used. After welding, they shall be removed and the

surface shall be conditioned to meet visual examination criteria. The surface shall be magnetic particle (MT) or liquid Penetrant (PT) examined prior to any radiographic examination or heat treatment.

e. Flanges using diaphragm gaskets shall have a 6mm minimum thickness (after

machining) high alloy or non-ferrous weld overlay deposited on the flange face so that field replacement of the diaphragm may be made without post weld heat treatment.


PRODUCTION DIVISION

PROJECT NO: 180530


f. Heads having more than one piece shall consist of the minimum possible number of

pieces. All seams shall be fully radiographed before forming and MT tested after forming.

6.2 Preparation for Welding

On clad plates, the cladding shall be stripped back from the weld bevel at least 6mm on both sides of seam edge preparation. Weld metal shall not be used to build up the edges of plates that are too short or those that contain large cavities. Edges to be welded shall be prepared by machining or automatic oxy-acetylene, followed by grinding. Shear cutting is allowed only for carbon steel plates thinner than 12mm. Manual oxy-acetylene cutting is allowed only if nozzles or manholes are to be inserted, provided that grinding is subsequently carried out. Oxy-acetylene cutting is not permitted on Cr-Mo steel with chrome content 2% or higher unless approved by the Purchaser. If approved by the Purchaser, then a finishing by machining or grinding shall subsequently be prepared to remove all hardened areas within the heat affected zone back to the nominal hardness of the parent material.

6.3 Preheat

The Supplier shall include in the WPS the preheating temperatures and, where relevant, the inter-pass temperatures required for welding. The preheating temperatures shall be taking into consideration the composition, thickness of the metal being welded, the welding process being used and the arc parameters.

6.4 Welding

Fabrication involving welding shall not be sublet to others without prior acceptance. Attachments of non-pressure parts by welds which cross existing main welds or for which the minimum nominal distance between the toe of the attachment weld and the toe of the existing main welds or branch weld is less than the smaller of twice the thickness of the pressure part or 50mm, should be avoided. For Cryogenic systems this se

paration shall be at least 150mm. See below:


PRODUCTION DIVISION

PROJECT NO: 180530


If such welds cannot be avoided, on all but cryogenic systems, they should cross the

ain weld completely rather than stop abruptly near the main or branch weld in order to void stress concentrations in these areas. All such intersecting welds shall be non- estructive tested regardless of code piping class requirements. All fillet welded ttachments on exchangers in Hydrogen Service shall be vented to prevent entrapment f hydrogen.

ongitudinal and circumferential weld seams on the inside of the shell which may terfere with bundle removal shall be ground smooth and flush with the inside wall.

shall be removed from weld deposits.

6.5

a shall

6.6

ach nozzle reinforcing pad, or each segment if more than one segment is used, shall . Welds in segmented two-piece

inforcing pads on cylinders and cones shall be in the exchanger's circumferential

ted tractor for review before start of fabrication.

tubes ith the Suppliers weld procedure; the fifth hole shall be p shall be cut through the centreline of the five tube

gure 2

madao Lin Temporary attachment welds and arc strikes on pressure retaining parts shall be removed. The surfaces shall be properly conditioned to eliminate stress risers. Such surfaces shall be MT or PT examined. Any defects found shall be repaired and re-examined. Welding slag Pass Partition Plates

ass partition plates for channels and floating heads shall have full penetration weldsPminimum of 50mm from the gasket face of each flange. The balance of the length be continuously welded on both sides of the plate. Reinforcing Pads and Wear Plates

Ehave a NPS ¼ NPT threaded hole for venting/testingredirection. Each saddle wear plate and similar type pad attachments, or each segment if more thanone segment is used, shall have two 6mm diameter holes for draining/venting.

6.7 Tube-to-Tubesheet Joints

For strength welded tube-to-tubesheet joints the proposed method of fabrication, including complete sequential joint preparation, overlay (when required), cleaning, assembly, welding, tube expansion, testing and other inspection procedures, together with a representative mock-up sample of the tube-to-tubesheet weld shall be submito the Cont The mock-up shall consist of five (5) tube holes, drilled and prepared for welding of the ame size and tube pitch that will be used for production welding. Four adjacents

shall be welded in accordance wleft open. The tubesheet mock-uholes, polished, etched and submitted for Contractor’s acceptance according to Fibelow.


PRODUCTION DIVISION

PROJECT NO: 180530


The thickness of the mock-up tubesheet shall be at least as thick as the production tubesheet, but need not be greater than 38mm.

Strength welds shall be in accordance with SR EN 13445, Part 4. The Supplier shall use a "J" - Groove in lieu of single bevel. The ends of the tubes shall be free of deposited weld metal. The Supplier shall include the calculations for the strength weld sizing in accordance with SR EN 13445, Part 4 with the mechanical design calculations. The minimum shear length of the weld parallel to the tube wall shall be noted on the weld map submitted to the Contractor. Tube joints shall be expanded the full depth of the tubesheet. The expanding operation shall not extend past the back face of the tubesheet or into a weld. Final expanding

the tube-side face of the tubesheet (channel side, floating side).

The tube-to-tubesheet joint shall be welded if: a. The design temperature is lower than -10°C or higher than 300°C. b. The exchanger is U-tube type with design pressure exceeding 150 kg/cm2g c. The exchanger is floating head type or fixed tubesheet type with design pressure

exceeding 40 kg/ cm2g. d. The exchanger has cladding on

e. High reliability of the joint is required, for example, because of lethal substance product quality or hazards of intermixing.


PRODUCTION DIVISION

PROJECT NO: 180530


6.8

N

oc rformed without prior acceptance.

erature of normalized and tempered or quenched and t least 50°C higher than the minimum post weld heat

When post weld heat treatment of the shells of fixed tubesheet exchangers is required, to

eat eatment and is subsequently heat treated, welding to buttered weld metal deposit may

elding is used for tube-to-tubesheet joints with low alloy steels, e weld shall be post weld heat treated after completion of welding and before final tube

6.9 ot Forming

7.0

7.1

completely radiographically examined after the completion of the

he production welds attaching welding pins or studs for external insulation or reproofing supports shall be tested by tapping with a light hammer.

he roundness of the inside diameter of exchanger shells shall be checked by using a ks having an outside diameter apart. The template shall pass

completely through the shell without binding.

Post Weld Heat Treatment

Post weld heat treatment where required shall be performed in accordance with SR E13445-4.

Post weld heat treatment is required for channels and floating head covers fabricated from carbon and low alloy steels with four or more tube passes.

al post weld heat treatment shall not be peL The minimum tempering temptempered materials shall be atreatment temperature.

the fabrication procedure and the post weld heat treating procedure shall be submittedthe Purchaser. If material is "buttered" by depositing weld metal that does not require post weld htrbe done without further post weld heat treatment with prior acceptance. When seal or strength wthexpansion. The Supplier shall submit the post weld heat treatment procedure and the proposed location of thermocouples to the Purchaser for review. H

Hot forming is not permitted for austenitic stainless steel with the exception of forgings. INSPECTION, REPAIRS, TESTING AND REJECTION

Inspection/Examination – Generation Requirements

elds which are subjected to severe working (ratio of thickness to local radius greater Wthan 5%) shall beworking. Tfi Ttemplate consisting of two concentric, rigidly mounted disequal to the baffle outside diameter and spaced 457 mm


PRODUCTION DIVISION

PROJECT NO: 180530


7.2

um requirement, exchangers shall be spot radiographed and shall be in

(Deleted)

Radiography

s a minimAaccordance with EN 1435.

adiographic film shall be fine grain, high definition, high contrast filmR type

7.3

Weld surface examination shall be conducted in accordance with Table Ill and for visual N 970 on all accessible surfaces after any required post weld heat

ethod for austenitic materials.

AA, equivalent or better). Film density shall be within a range 2.0 to 3.5 as determined by film density specimens or by calibrated densitometer. Surface Examinations

examination with Etreatment using the following methods:

a. by either the MT or the PT method for ferritic materials. b. by the PT m

TABLE III - EXAMINATION OF WELD SURFACES

NOTES TO TABLE Ill: 1. The level of radiography which is specified for longitudinal and circumferential welds. 2. Nozzle welds include the welds between nozzle and the reinforcing pad, exchanger and the reinforcing pad, and the nozzle and exchanger under the reinforcing pad. Welds under the reinforcing pad shall be examined before the pad is attached. 3. Attachment welds include structural support, external clips, and saddle attachment When PT examination is required, surface preparation shall be in accordance with EN 1289.


PRODUCTION DIVISION

PROJECT NO: 180530


y manual or automatic procedures, shall be PT examined in ccordance with the methods described in EN 1289. When the overlay involves two or

the

7.4

s of production weld overlay shall be taken to confirm chemical analysis to the

ion (e.g. each

nalysis shall report all elements for which specific values are .

ion of specified in SR EN 13445-2.

7.5

f

repair of such defects shall be cause for rejection of the item.

7.6

rinell hardness testing shall be performed in accordance with EN ISO 6506-1 as follows s testing equipment:

ayed. utside surfaces when the inside surfaces are clad or

d metal of each longitudinal seam and 1 reading in each heat.

Weld overlay, whether baspot examined (no less than 10% of the surface) after heat treatment. Tube-to-tubesheet strength welds shall be PT examined on the finished surface beforeand after tube expansion. All tube-to-tubesheet seal welds shall be PT examined onfinished surface after expanding. Chemical Analysis

ampleSrequired depth. Samples shall be taken as follows to represent both manual and automatic overlay welding: . one sample from each automatically overlayed exchanger part/secta

shell ring, head, nozzle, cone, etc.). b. two samples from each manually overlayed exchanger part/section and each

manually overlayed seam (longitudinal, girth and nozzle welds). A quantitative chemical agiven in SR EN 13445-2 Acceptance criteria shall be that the deposited overlay has the chemical compositthe applicable filler metal as Ultrasonic Examination

Ultrasonic examination shall be performed in accordance with EN 1714 and for acceptance levels with EN 1712. Defects detected during ultrasonic examination exceeding the acceptance standards othe applicable code ultrasonic examination specification may be repaired. Failure to btain acceptance prior too

Hardness Testing

Busing portable macro hardnes a. Testing shall be done on accessible inside surfaces that are not clad or overl. Testing shall be done on the ob

overlayed. c. Testing shall be done after post weld heat treatment when PWHT is required. d. Frequency and location of testing: i. 1 reading in the wel affected zone (HAZ)


PRODUCTION DIVISION

PROJECT NO: 180530


ii. 1 reading in the weld metal of each circumferential seam and 1 reading in each HAZ for exchangers 1219mm ID and smaller; 2 readings 180 degrees apart for

xchangers over 1219mm ID.

ll be n the mock-up samples required by Paragraph

ser the maximum allowable values for the proposed method. Test

7.7

dry ir. hanger shall be inspected during the test. Test

7.8

ode required test pressures shall be held at least one hour.

ll be stainless steel and shall not have

lly tested with potable water only; salt, brackish, or raw used. Testing of exchangers or components made with austenitic ls shall be conducted with water containing no more than 30 ppm

d by blowing with warm air at 49°C maximum.

eiii. 1 reading in the weld metal of nozzle-to-exchanger welds and 1 reading in each HAZ, in 50 percent of the nozzles. The hardness of the tube-to-tubesheet weld and HAZ of strength welded tubes shameasured by micro hardness testing o The Supplier shall submit the proposed testing method to the Purchaser. The Purchawill advise the Supplier ofresults shall be included with the sample. Leak Testing

Each nozzle reinforcing pad or each segment thereof shall be tested at 1.5 bar with All welds inside and outside the exca

holes in pads shall be left open after the test.

ube-to-tubesheet strength welds shall be bubble tested with 1.5bar air test pressure Tbefore final tube end expansion. Pressure Testing

C Before the pressure test of the exchanger, internal surfaces shall be cleaned so the exchanger will be free of any loose scale and other debris. Cleaning agents shall be compatible with the materials of construction and shall be neutralized, if required. Wire

rushes used on austenitic stainless steel shabbeen used on other materials.

xchangers shall be hydrostaticaEriver water shall not bestainless steel materiachloride and the pH controlled between 6 and 9. The metal temperature during hydrostatic test shall be at least 17°C greater than theMDMT stamped on the nameplate. After hydrostatic testing, the exchangers shall be drained and dried. Any remaining [standing water may be remove Stacked exchangers shall be hydrotested in the stacked position. Exchangers with bellows type expansion joints in the shell shall be hydrotested with the expansion joint shipping braces removed.


PRODUCTION DIVISION

PROJECT NO: 180530


Bellows expansion joints shall be hydrotested at the joint Supplier's shop.

7.9 epairs of Defective Welds

surface shall

gers, or materials containing defects originating n, materials, or workmanship; or that are not in complete

d.

ection and acceptance of the plier of responsibility to comply

PING

g

st pressure . Purchase Order Number

limitations.

de ameplate for all fixed tubesheet type exchangers which shall be worded and stamped

R

Welds with defective areas shall have: a. the defect removed . confirmation of defect removal by MT or PT examination b

c. repair welding using qualified welding procedures d. re-post weld heat treatment if originally required. The finished weld-repair shall be radiographed if originally required and thee re-examined by MT or PT examination. b

7.10 Rejection

Completed exchangers, parts of exchanwith the Supplier's desigcompliance with the requirements of the Order will be rejecte

pDiscovery of conditions warranting rejection, after insxchanger by the Purchaser, does not relieve the Supe

with the Order.

8.0 CODE STAM

The nameplate shall be stamped with the design pressure(s) and temperature(s). In addition to required Code information (SR EN 13445-5 Chapter 11), the followin

formation shall be stamped on the nameplate: in a. the Purchaser's equipment item number b. the exchanger service name . shop hydrotec

de. any test or operating Supplier shall supply a supplementary nameplate on the same bracket with the Conas follows:


PRODUCTION DIVISION

PROJECT NO: 180530


C A U T I O N "THE PRESSURES AND TEMPERATURES SHOWN ON THE NAMEPLATE RELATEONLY TO THE PRESSURE RETENTION CAPABILITY OF THlS EXCHANGER. COMPONE

NTS OF THlS HEAT EXCHANGER HAVE BEEN DESIGNED FOR PECIFIC OPERATING CONDITIONS. A CHANGE IN SERVICE OR DEVIATION ROM THE SPECIFIED OPERATING CONDITIONS MAY REQUIRE THAT A ECHANICAL DESIGN CHECK BE MADE TO ASSESS POSSIBLE DAMAGE TO THE EAT EXCHANGER AND PERSONNEL SAFETY."

he nameplates of vertical exchangers shall be located on the shell above the supports. s on horizontal exchangers shall be located on the shell. The Supplier

hall show the nameplate location on the dimensioned outline drawing.

ched e the

9.0

9.1

l be

CKING AND SHIPPING

teels ) which would be

armful to these materials at ambient or elevated temperatures.

xchangers that have been post weld heat treated shall have the following notation nt:

ING OR BURNING PERMITTED ON THlS EXCHANGER The letters shall be approximately 75mm high painted with a contrasting colour.

SFMH TThe nameplates When design based on differential pressure is permitted a warning nameplate attato the exchanger next to the Code nameplate. The warning nameplate shall havmaximum permissible differential design pressure and the maximum permissible differential hydrotest pressure stamped on it. PAINTING

General

Exchangers shall be shop painted in accordance with the requirements of the Purchaser's painting specification Painting and Protective Coatings. Austenitic stainless steel and nickel-iron-chromium alloy material parts shall be kept freeof paints containing zinc to avoid the possibility of embrittlement at elevated operating temperatures. All traces of zinc containing paints which spatter on such parts shalpromptly removed.

10.0 MARKING, PA

10.1 Marking

Marking paint or water insoluble ink for use on austenitic and high nickel alloy sshall contain no substance (e.g., metallic pigments, sulfur or chloridesh Attachments which are removable and are to be assembled by others shall be piece marked and match-marked for assembly. Epainted on the exchanger prior to shipme "NO WELD


PRODUCTION DIVISION

PROJECT NO: 180530


a. On vertical exchangers this sign shall be located on two sides 180 degrees apart. b. On horizontal exchangers the sign shall be located on both sides near the horizontal

152 mm long line and noted as "N". The lines hall be parallel to the exchanger centreline located approximately 304mm above the

.

irth flanges, tubesheets, flat covers, and floating head covers shall be match marked to

the xchanger with a 75mm diameter circle having vertical and horizontal lines through its

10.2 ackaging and Shipping

t

markings shall be in the

parately boxed, shipped, and identified with the exchanger

xchangers subject to damage by water or humidity shall receive additional protection

xchangers shall not be transported by water to the jobsite as above deck cargo without

Spa cleexc

as follows:

The North orientation shall be centre-punched and marked on the outside of each vertical exchanger. The marking shall be asbaseplate of support lugs or the skirt. The marking shall be a contrasting paint colour Gprevent incorrect assembly in the field. Vertical exchangers shall have the centre of gravity marked on opposite sides of ecentre. The marking shall be of a contrasting paint colour. P

The exchanger shall be free of debris, dirt, and foreign matter, and be thoroughly cleaned inside and out before shipment.

he Supplier shall be responsible for suitably packaging each exchanger or componenTto protect it from damage or loss during handling and shipment and any special requirements and the following requirements: a. Packages shall include lifting lugs or designated lifting points. b. Each exchanger, crate, or bag shall be durably marked with the receiving address,

Purchaser's exchanger Item Number, and the complete Purchase Order Number paint stencilled in 75mm minimum high block letters. AllEnglish language.

c. Special tools shall be se item number on which they are to be used, and marked as special tools. Eas required. Components with non-drainable crevices or chambers shall be covered andprotected at all times from the entrance of water and debris. Eprior approval of the Purchaser.

re gaskets shall be labelled, boxed and shipped with the exchanger. They shall bearly labelled as spares with the equipment item number and location on the hanger.

Protection for flange faces, threaded connections, weld bevels, etc., shall be


PRODUCTION DIVISION

PROJECT NO: 180530


a. Machined and threaded surfaces of carbon steel and ferritic alloy steel materials,

except weld bevels, shall be coated with rust preventive approved by the Purchaser.

l and ferritic alloy steel materials shall be coated, after cleaning, on the inside and outside for a distance of approximately 75mm from the

r.

b. Weld bevels shall be free of dirt, oil, grease, scale, rust, and other foreign materials. All weld bevels of carbon stee

end of the weld bevel with a weldable rust preventive approved by the Purchase

nozzles shall be closed with carbon steel weld caps. The weld caps shall be welded to a 10mm minimum thickness carbon steel ring welded to the outside of the

nozzle neck. The weld attaching the cap to the nozzle shall 6mm continuous fillet

d. carbon and low alloy steel nozzle reinforcing pads shall be filled with

vy grease.

e.

ed openings shall be plugged with threaded plugs of the same material as the

g.

ge face and cover. They shall be secured with appropriately sized machine

bolts as follows:

aving 4 to28 bolt holes, a bolt shall be placed in at least every other bolt hole, with a minimum of 4 bolts used.

allo

c. Stub end

nozzle neck so that the cap can be removed at the job site without damage to the

weld.

Vent holes in hea

Socket-weld ends shall be closed with metal protectors that fit either inside or outsideto prevent damage and entrance of foreign materials.

f. Threadopening and sealed with tetrafluoroethylene or graphite tape thread sealant.

Flanged openings, not furnished with permanent blinds, shall be protected with fullsize 4mm minimum thickness steel covers and 3mm thick rubber gaskets betweenthe flan

i. For flanges h ii. For flanges having more than 28 bolt holes, bolts shall be placed in at least

every fourth bolt hole. Nitrogen filling, desiccant or volatile corrosion inhibitor shall be applied for carbon or low

y steel heat exchangers.

180530-00-me-spc-0010-a

Documents

client review sh pc

internal review sh pc

date description

project outline

project specifications

design pressure

design life

surface production systems