338033-4604-45es-0004-05 (stainless steel heat exchangers - technical specification).pdf

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Technical Specification

Stainless Steel Heat ExchangersProject No:

338033

338033/4604-45ES-0004Rvision Date

Page 1 of 1305 15/10/2013


Stainless SteelHeat Exchangers

CLIENT: National Iranian Copper Industries Company

PROJECT: Sarcheshmeh Sulphuric Acid Plant Renovation &

Development Project Eng.

SIGNATURE

PREPARED BY : E. Mirbaha

Responsible

CHECKED BY : Y. SadeghinejadEngineering Management

APPROVED BY : M. KianifardProject Manager

19/10/2013


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0515/10/2013

. SNC Italy0209/04/20132,3,5,6,7,9,10,11

0308/05/20133,5,6,7,9,10,11

0403/06/20131,6,10

0515/10/20137,8,10,11,12,13

: /


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REVISION INDEX

Revision Pages Revised Remarks

# By App. Date

02 Y. SadeghinejadM.

Kianifard09/04/2013 2,3,5,6,7,9,10,11 IFR


Kianifard08/05/2013 3,5,6,7,9,10,11 IFT


Kianifard08/05/2013 1,6,10 IFC

05 E.MirbahaM.

Kianifard15/10/2013 7,8,10,11,12,13 IFC

05 E.MirbahaM.

Kianifard17/10/2013 AFC

INSTRUCTION TO PRINT CONTROL (Indicate X where applicable)

Issued for Tender.

Issued for Approval.

Issued for Comment.

Issued for Information.

Approved for Tender.

Approved for Design.

X Approved for Construction.


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TABLE OF CONTENTS

ITEM DESCRIPTION PAGE

1.0 SCOPE ...............................................................................................................................................4

2.0 GENERAL ..........................................................................................................................................5

3.0 MATERIALS......................................................................................................................................5

4.0 WELDING..........................................................................................................................................7

5.0 FABRICATION...................................................................................................................................8

5.1 General .........................................................................................................................................8

5.2 Shell.............................................................................................................................................95.3 Baseplate.....................................................................................................................................95.4 Tubesheets and Baffles.............................................................................................................10

6.0 TUBE INSTALLATION....................................................................................................................10

7.0 FLANGED AND DISHED HEADS...................................................................................................10

8.0 TOLERANCES.................................................................................................................................11

9.0 TESTING..........................................................................................................................................11

9.1 General .......................................................................................................................................11

9.2 Radiography ...............................................................................................................................119.3 Dye Penetrant Inspection ...........................................................................................................129.4 Pneumatic Testing.....................................................................................................................12

10.0 LEAKS.............................................................................................................................................12

11.0 INSPECTION...................................................................................................................................12

12.0 PROTECTION & SHIPPING............................................................................................................13

13.0 IDENTIFICATION.............................................................................................................................13

14.0

QUALITY CONTROL .......................................................................................................................13

1.0 SCOPE


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1.1 This specification covers the requirements for furnishing all materials, equipment, tools,accessories, labor and supervision for the fabrication and testing of the Stainless Steel Gas

to-Gas Heat Exchangers.

1.2 The extent of the work is defined in the Scope of Work Specification 338033/4604-45EW-0002.

2.0 GENERAL

2.1 Fabricator shall furnish all material as shown on the drawings, except as noted.

2.2 Fabrication shall be to C.E approved drawings, stamped "Issued for Construction".

2.3 If the exchangersphysical dimensions are within the allowable limits for shipping, it shall be

completely shop fabricated and tested before shipment.

2.4 The exchangersshall have lifting lugs designed by the Fabricator. Lifting lugs shall be

permanent attachments and the vessel clearly marked with net weight. If vessel is fabricated

in sections, each section must have a set of lifting lugs.

2.5 Special Note

C.E shall not assume the responsibility for searching out deviations in the Fabricator's

drawings. All deviations must be clearly noted on approval drawings.

2.6 Fabricator shall not sublet work to others without the written approval of MC/Client.

3.0 MATERIALS

3.1 All plates used in the execution of this work shall be new, clean stock free from surface

laminations or other physical imperfections.

3.2 All materials shall be identified throughout fabrication. Material certification shall be provided

to C.E or Inspector upon request.

3.3 Materials of construction shall be as follows. In the event of conflict between this specification

and design drawings, design drawings govern the requirements.

3.4 Non-Tubing Materials


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3.4.1 Platework & Structural Members

The entire vessel including all internal and external attachments and also including the gas

inlet and outlet stub nozzles is to be fabricated from stainless steel to ASTM-A-240 Type 304

with a minimum yield strength of 210 MPa.

Notes:

*a) Stainless steel types 304L and N are not acceptable.

* Special Note:

Type 304H may be considered if pricing advantage exists. No premium will be paid

for 304H material.

Prior approval is required from C.E

Do not mix materials.

b) Carbon content to be in the range of 0.04 to 0.08%.

3.4.2 Tubesheet Support Posts

To be welded or seamless stainless steel pipe to ASTM A-312, Grade TP304.

* Grades TP304L or N are unacceptable.

Minimum carbon content to be in the range of 0.04 to 0.08%.

3.4.3 Expansion Joint

Same material as Item 3.4.1

3.4.4 Nuts & Bolts

All sizes: Stud bolts, stainless steel to ASTM A-193, Gr. B8M, complete with heavy, semi -finished

hex nuts to ASTM A-194 Gr.8M.

3.4.5 Gaskets

Spiral wound 316 S.S. metal rings with ceramic filler, 3 mm thick, complete with bolt holes to

suit ANSI 150 Ibs. flat face flange.

The bolt hole diameter will be specified on the drawings if different from the ANSI standard.


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All sizes: Garlock FLEXSEAL style RW or approved equal.

3.4.6 Bearing Plate Assemblies

The base plate welded to the support column shall be stainless steel per paragraph 3.4.1.

The bearing (sole) plate is to be fabricated from carbon steel to ASTM A36 or ST37-2.

Slide bearings are to be Fluorotemp Type "A" high load bearings, as manufactured by

Fluorocarbon, Pine Brook, New Jersey, U.S.A., or approved equal.

The bearing pads shall be supplied for the following condition:

Bearings shall be designed for a sulphuric acid plant type environment.

The coefficient of friction between bearing plate and carbon steel plate shall be no

greater than 0.10.

Vendor to supply installation instructions with plate shipment to job site.

3.5 Tubing

a) Exchangerstubes, both working and dummy, shall be stainless steel to ASTM A-249

Grade TP304 (Grades TP304 L and N are unacceptable) ERW carbon content 0.04 to

0.08% and shall be 13 Gauge (BWG).

b) Tolerances for tube OD.shall be to specification ASTM A-450. Tubes will be ring

gauged at random to ensure that the OD.tolerances are met.

c) The maximum deviation from straightness over the full tube length shall not exceed 3

mm. Tolerances of the overall tube length will be +5 mm - 0 mm.

4.0 WELDING

4.1 All welding procedures and welders shall be qualified in accordance with Section IX of the

ASME Boiler and Pressure Vessel Code, 2010 edition.

All welding shall conform to the requirements specified herein and also to the requirements of

the American Welding Society Standards of (D1.1 2010 edition for welds not covered herein. All

welding shall be identified by AWS symbols on the shop drawings. Symbols shall include all

pertinent information, such as location, type, size and extent of grinding, if required.

4.2 All welding (including tack and intermittent) shall be free of visible imperfections, such as:cracks, excessive undercuts (0.8 mm) and surface slag inclusions.

4.3 Complete penetration and complete fusion of all platework joints is required, unless noted


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otherwise on drawings.

4.4 The deposited weld metal shall have properties equal to or better than the parent metal and

shall be "full strength" for the thinner plate connected.

4.5 All fillet welds shall be with equal legs. The leg of each weld shall be equal to or greater than

the thickness of the thinnest plate being joined, except as noted on a drawing approved by C.E.

4.6 Weld heat must be properly controlled to eliminate dimpling of the plates.

4.7 In assembling and joining parts to the members, the procedure and sequence shall such as

will minimize distortion and shrinkage.

4.8 All attachments to the heat exchanger shall have continuous welds unless otherwise noted.

4.9 No lap or skip welds will be allowed.

4.10 Slag between passes shall be removed.

4.11 Platework shall be welded by any or all of the processes covered under Section IX of the

ASME Boiler and Pressure Vessel Code:

4.12 Welding electrodes within the carbon content range of 0.04 to 0.08%shall be used and the

following electrodes are acceptable: E308H, E308-16, E308-15, ER308, E308T-3.

'L' grades are not acceptable.

5.0 FABRICATION

5.1 General

5.1.1 Shop and field fabrication shall be carried out in accordance with the procedures outlined in

Section 4 (Fabrication) of A.P.I. Standard 620 11th edition, except as modified herein

or on the drawings.

5.1.2 All sharp edges and burrs shall be removed.

5.1.3 All nozzles are oriented horizontally on the true composite orientation plans and vertically on

the vertical sections. Flange face shall be flat and true with tolerance to suit gasket. All welds

shall be ground flush with face of flange.

5.1.4 Vendor shall provide whatever additional treatment such as preheat, post weld heating, which is a

requirement of the material used. The shop drawings must identify such treatments. If stress

relief heat treatment is required, finish machining shall preferably be done after stress relieving.

5.1.5 Set of proper match marks must be provided if items are erected by others.


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5.1.6 In assembling and joining parts to the members, the procedure and sequence shall be suchas will minimize distortion and shrinkage.

5.1.7 During fabrication or field erection, all attachments, brackets, welding lugs, nuts, etc., shall be

kept to a minimum and shall be welded to the vessel with small diameter electrodes.

Attachments shall be removed by chipping rather than being knocked off. Any damage to

plate shall be repaired.

5.2 Shell

5.2.1 At any vertical joint, the misalignment between plates shall not exceed 10% of the platethickness or 2 mm, whichever is smaller.

Any horizontal joint in the upper plate shall not project beyond the face of the lower plate at

any point by more than 20% of the upper plate thickness with a maximum of 3 mm.

5.2.2 Vertical joints in plates of adjoining courses shall be a minimum of 600 mm apart.

5.2.3 The layout of the seams shall be such that longitudinal seams are not behind any obstruction

which prevents inspection of these welds. Circumferential seams shall be located so they do

not fall on an internal ring (40 mm is the nearest a ring can be to a seam). If possible,

nozzles and manholes shall not be located in any seams. If the layouts of the seams result in

a major weld seam being covered, it will prior to covering be 100% radiographed in accordance withASME Section VIII Para. UW-51.

5.2.4 The faces of fabricated plate flanges shall be rough machined after welding. Companion

faces of blind fabricated plate flanges shall be rough machined. All fabricated flanges are to

be of the same material specification as the body of the vessel.

Machined surfaces, which are warped or distorted due to welding, etc., shall be remachined

after these operations are finished.

5.2.5 Flanges will be fixed square to the axis of the vessel with the bolt holes straddling the vessel

centerlines.

5.2.6 Slip-on flanges shall be positioned so that the distance from the face of the flange to the pipe

end shall be equal to the nominal pipe wall thickness, plus approximately 3 mm. The welds

shall be applied in a manner that will not require refacing of the flange.

5.3 Baseplate

5.3.1 The weld on the underside of the baseplate shall be ground flush to allow the stiffeners to sit

flat on the baseplate.

5.3.2 Butt joints shall be used for bottom plates. Back-up strips permitted on the underside only


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with the approval of C.E. Back-up strips permitted shall be shown on shop drawings.

5.4 Tubesheets and Baffles

5.4.1 Tubesheets shall be levelled to a tolerance of plus or minus 3 mm prior to drilling.

5.4.2 Tubesheet holes for tubes shall be drilled and reamed to a diameter of tube OD. plus 0.6 mm

with the tolerance as defined by the TEMA B 9th edition.

5.4.3 Edges and internal surfaces of the tube holes on both tubesheets shall be free of burrs to

prevent cutting of tubes in accordance with the requirements of an AA 250 finish.

5.4.4 Baffle plate holes shall be drilled and reamed to a diameter of tube OD. plus 3 mm.

6.0 TUBE INSTALLATION

6.1 Ends of tubes in contact with the tubesheet must be clean and smooth and free from any

residue or particles. The method of cleaning is optional. Wire brushing is a minimum requirement.

Other methods may be required if corrosion is deep due to poor protection during transit or storage.

Tubes that are pitted shall not be used.

6.2 Tubes shall be rolled into the tubesheets using automatically controlled torque rolling

equipment.

6.3 Tubes shall be lightly rolled to seal and expanded (not beaded) into the tubesheet with tube

projection max 6 mm min 3 mm beyond the tubesheet face, except for the dummy tubes.

6.4 In the actual "rolling in" operation, care shall be taken not to expand the portion of the tube

which projects beyond the tubesheet face. Expansion in this projected portion tends to cause

belling or flaring with accompanying cracking.

6.5 Arrange the expander thrust collar so that the front ends of the rolls do not extend beyond the

inside face of the tubesheet and preferably retracted a small fraction, say 3 mm towards the

front or outside face of the tubesheet.

6.6 Tubes will be rejected if improper rolling technique causes a crack within the tubesheet

thickness area. If the crack develops in the projected part only, the affected area shall be

removed, with the tube end dye penetrant examined to ensure complete removal of defect.

6.7 Reworked or reprocessed tubes are unacceptable.

7.0 FLANGED AND DISHED HEADS


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9.3 Dye Penetrant Inspection

9.3.1 All welds shall be 100% dye penetrant inspected. The welds will be sound and free from

cracks.

9.3.2 Dye penetrant shall be in accordance with Appendix 8 of ASME Boiler and Pressure Vessel

Code, Section VIII, Division 1, 2010 edition.

9.4 Pneumatic Testing

9.4.1 The heat exchanger will be leak tested in the area between the tube sheets by thefabricator prior to shipping. As well, the exchangerare to be leak tested in the field after

installation (by fabricator). All testing is to be in accordance with these specifications.

9.4.2 The testing shall be done with air at a pressure of 173 kPag(from the shell side with soapwater

bubble test prior to expanding the tubes). The pressure shall be maintained on the vessel for the

entire duration of the leak testing.

9.4.3 All welds between the tubesheets on the exchangersshall be checked for leaks during the

air test using a soapwater bubblesolution. No leaks are allowable.

9.4.4 All tubes in the exchangers

shall be checked for leaks at the tube sheets as well as all

tubesheet welds during the air test using a soapwater bubblesolution. No leaks are allowable.

9.4.5 After the last leak is found and repaired, the test air pressure shall be maintained on the

vessel for a minimum period of 60 minutes without loss of pressure.

10.0 LEAKS

10.1 Where leaks are discovered, the welds shall be completely removed, rewelded and retested.

10.2 Thefabricator shall notify C.E/Inspectorregarding any necessary repair work and have writtenapproval before proceeding.

11.0 INSPECTION

11.1 C.E/Inspectorto review mill test certificates for all materials to confirm compliance with materials

ordered to this specification.

11.2 All fillet weld sizes must be checked against design drawings. Convex or concave fillet

welding is not permitted.

11.3 Examine all radiographs which have been taken. Radiographic reports to be reviewed byC.E/Inspector.


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12.0 PROTECTION & SHIPPING

12.1 Before shipment, shop fabricated vessel shall be cleaned internally and externally of shop dirt,

grease, scale, weld spatter, and any other foreign substance.

12.2Adequate crating, skidding, strapping, etc., shall be provided to prevent damage to any part of

the fabricated item being shipped.(Packing Procedure shall be provide by vendor)

12.3 Tubing shall be protected against damage during transit and installation by suitably clamping

the shell expansion joint in a fixed position during fabrication.

N.B. Remove clamps only when the vessel is in an installed position.

During field erection, all attachments, brackets, welding lugs, nuts, etc., shall be kept to a

minimum and shall be welded to the vessel with small diameter electrodes. Attachments shall

be removed by chipping rather than being knocked off. Any damage to plate shall be repaired withcareful welding. All areas where temporary attachments have been removed will be liquid penetrantexamined.

12.4 All open nozzles and flanged connections shall be covered and protected against damageduring transit and installation.

13.0 IDENTIFICATION

Parts sent loose to site will be clearly tagged showing equipment.

14.0 QUALITY CONTROL

Vendor shall provide an inspection and test plan for C.E and inspectorreview detailing all inspectionpoints performed during the manufacturing cycle. This plan shall have an area designated for input ofclient / customer Hold / Witness / Review points.

338033-4604-45es-0004-05 (stainless steel heat exchangers - technical specification).pdf

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