jeres-e-004 design criteria of shell & tube heat exchangers

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JERES-E-004 Design Criteria of Shell and Tube Heat Exchangers Revision 1 Responsibility JER Engineering Division 14 May 2008 Jubail Export Refinery Engineering Standard

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Design Criteria of Shell & Tube Heat Exchangers

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Page 1: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

JERES-E-004 Design Criteria of Shell

and Tube Heat Exchangers

Revision 1

Responsibility JER Engineering Division

14 May 2008

Jubail Export Refinery Engineering Standard

Page 2: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 2 of 39

Revision Tracking

Revision Revision Date Scope of Revision

1 14 May 2008 Updating Issued for bid package Rev. 0 to incorporate technical comments.

0 28 April 2008 Issued for bid package.

04 24 April 2008 Revised to incorporate technical audit team comments.

03 31 March 2008 Issued for bid package only for review.

02 18 February 2008 Updated as Indicated.

01 27 April 2007 The first official JERES-E-004 is issued.

00 29 March 2007 First draft issued is based on Saudi Aramco SAES-E-004 “Design Criteria of Shell and Tube Heat Exchangers” issue date 30 March, 2005. Document was modified to incorporate amendments and modifications.

Page 3: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 3 of 39

Table of Contents

Section Contents Page

1 Scope 4

2 Conflicts, Deviations and Clarifications 4

3 References 5

4 Definitions 7

5 Responsibilities 8

6 Basis for Thermal Design 8

7 Basis for Mechanical Design 15

8 Nozzles and Gaskets 24

9 Exchanger Supports 27

10 Material Selection 27

11 Insulation and Surface Coating 28

12 Fireproofing 28

13 Cathodic Protection 28

14 Drawing and Calculations 29

Appendixes

A Nozzle Loads for Metallic Shell and Tube Heat Exchangers 30

B Safety Instruction Sheet 33

Page 4: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 4 of 39

1 Scope

1.1 This standard covers the minimum mandatory requirements for the thermal and mechanical design of new shell and tube heat exchangers (hereinafter referred to as exchangers). It does not cover existing exchangers that undergo repairs or alterations.

1.2 This standard is intended to establish a standard for thermal and mechanical design and to assist the Design Engineer in the selection and specification of exchangers.

1.3 The requirements in this standard shall be used by the Design Engineer for the completion of the shell and tube heat exchanger data sheet (hereinafter referred to as data sheet).

1.4 This standard shall not be attached to or made a part of purchase orders.

1.5 This standard may not be applied to the design of non-TEMA exchangers that are used with or as parts of packaged equipment like motors, compressors, pumps and turbines oil coolers.

Commentary Note:

These exchangers have small heat transfer surface with a typical shell diameter of up to 150 mm and tube length of up to 1220 mm.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

Page 5: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 5 of 39

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 Company References

Company Engineering Standards

JERES-A-112 Meteorological and Seismic Design Data

JERES-A-301 Materials in Wet H2S Service

JERES-B-006 Fireproofing for Plants

JERES-C-101 Basic Design Data for Jubail Export Refinery

JERES-H-001 Coatings Selection & Application Requirements for Industrial Plants & Equipment

JERES-J-600 Pressure Relief Devices

JERES-L-109 Selection of Pipe Flanges, Stud Bolts and Gaskets

JERES-N-001 Basic Criteria for Industrial Insulation

JERES-N-100 Refractory Systems

JERES-X-500 Cathodic Protection of Vessel and Tank Internals

Company Materials Specifications

JERMS-E-3207 Manufacture of Shell and Tube Heat Exchangers

JERMS-D-3231 Manufacture of Clad Vessels and Heat Exchangers

JERMS-D-3233 Manufacture of Low Alloy Vessels and Heat Exchangers 2 ¼ Cr - 1 Mo and 2 ¼ Cr - 1 Mo-V

JERMS-D-3232 Manufacture of Low Alloy Vessels and Heat Exchangers 1 ¼ Cr - ½ Mo

Company Forms and Data Sheets

Page 6: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 6 of 39

JEREF-2713 Safety Instruction Sheet - Shell and Tube Heat Exchangers (see appendix B)

Company Standard Drawings (JERSD)

2271-AAA-STC-0690-000 Standard Construction drawings for shell and tube heat exchangers

2271-AAA-STC-0490-000 Construction standards for pressure vessels

3.2 Industry Codes and Standards

American Society of Civil Engineers

ASCE 7 Minimum Design Loads for Buildings and Other Structures

American Society of Mechanical Engineers

ASME SEC II Material Specifications Parts A, B and D

ASME SEC VIII D1 Rules for Construction of Pressure Vessels

ASME SEC VIII D2 Rules for Construction of Pressure Vessels, Alternative Rules

ASME B16.11 Forged Steel Fittings, Socket-welded and Threaded

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring-Joint, Spiral-Wound, and Jacketed

ASME B16.21 Non-Metallic Gaskets for Pipe Flanges

ASME B16.47 Large-Diameter Steel Flanges NPS 26 inch through NPS 60 inch

American Petroleum Institute

API STD 660 Shell and Tube Heat Exchangers for General Refinery Services

Tubular Exchangers Manufacturers Association

TEMA Standards of the Tubular Exchanger Manufacturers Association

Welding Research Council

WRC 107 Welding Research Council Bulletin: Local Stresses in Spherical and Cylindrical Shells Due to External Loadings

Page 7: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 7 of 39

WRC 297 Welding Research Council Bulletin: Local Stresses in Cylindrical Shells Due to External Loadings on Nozzles Supplement to WRC Bulletin No. 107

4 Definitions

4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Amine Services: All amine solutions including MDEA, DEA, MEA, DGA and ADIP.

Auto-Refrigeration Temperature: Auto-refrigeration temperature is the temperature resulting from adiabatic vaporization at atmospheric pressure of the process fluid. The value of this temperature shall result from a process simulation.

Caustic Services: All sodium hydroxide solutions at all temperatures and concentrations.

Cyclic Services: Services that require fatigue analysis per AD-160 of ASME SEC VIII D2. This applies to Division 1 and Division 2 of ASME SEC VIII.

Design Engineer: The Engineering Company responsible for specifying the thermal and mechanical design requirements for exchangers.

Exchanger Manufacturer: The Company responsible for the manufacture of exchangers.

High Alloy Steels: Steels with a total alloying content more than 5%.

Page 8: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 8 of 39

Hydrogen Services: Process streams containing relatively pure hydrogen and component streams containing hydrogen with a partial pressure of 350 kPa abs and higher.

Lethal Services: Process streams containing a concentration of hydrogen sulfide in excess of 20% by volume shall be considered as lethal service.

LODMAT: The lowest one-day mean ambient temperature equal to 0°C

Low - Alloy Steels: Steels with a total alloying content equal or less than 5% but more than specified for carbon steels.

Nominal Thickness: The value of the design thickness required to withstand all primary loads, and includes allowance for corrosion.

Shock Chilling Effect: The rapid decrease in temperature of a component caused by a sudden flow of fluid colder than -20°C and at a temperature lower than the initial temperature of the component by 40°C, regardless of pressure.

Thick Wall Exchanger: An exchanger course or dished head with nominal thickness greater than 50 mm.

Utility Services: Water, steam, air and nitrogen services

Wet Sour Service: As defined by JERES-A-301.

5 Responsibilities

5.1 The Design Engineer is responsible for specifying the thermal and mechanical design requirements and completing the data sheet in accordance with this standard. The Design Engineer shall carry out the thermal design except for special application.

5.2 The Exchanger Manufacturer is responsible for the thermal design (rating) and verification of the Design Engineer's thermal design, if required. The Exchanger Manufacturer is responsible for the manufacture of exchangers, which includes the complete mechanical design, Code and structural calculations, supply of all materials, fabrication, nondestructive examination, inspection, testing, surface preparation, and preparation for shipment, in accordance with the completed data sheet and the requirements of JERMS-E-3207 and JERMS-D-3231.

6 Basis for Thermal Design

Page 9: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 9 of 39

6.1 General

6.1.1 This section covers the basic design considerations which shall be used when selecting, sizing and specifying exchangers.

6.1.2 The exchanger nomenclature in TEMA shall be used when specifying exchangers, including sizes and types.

6.1.3 The Design Engineer shall utilize API STD 660, Annex B "Shell and Tube Heat Exchanger Checklist" when completing the exchanger data sheet.

6.2 Thermal Design

6.2.1 The exchanger size shall be based with due consideration for maintenance requirements. Following are the recommended maximum limits for removable bundles. Larger bundles may be used with prior agreement from the Company.

1) Bundle weight: 18000 kg

2) Bundle diameter: 1525 mm

3) Straight tube length 7320 mm

Commentary Note:

Longer tube lengths and larger bundle diameters can reduce the number of shells for the same duty. However, this will require availability of lifting equipment capable of removing heavy tube bundles for maintenance.

6.2.2 Tube-side fluid shall generally be the higher ranking of the following:

1) Cooling water.

2) Fouling, erosive, corrosive or less viscous fluid.

3) The higher pressure fluid.

4) The smaller flow rate.

6.2.3 The log mean temperature difference (LMTD) correction factor shall not be less than 0.8.

6.2.4 The LMTD for kettle reboilers and the recirculating thermosyphon reboilers shall be based upon isothermal boiling at the outlet temperature.

Page 10: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 10 of 39

6.2.5 The LMTD calculation for vertical thermosyphon reboilers shall take into account the suppression of the boiling point along the tube length due to the effect of static head.

6.2.6 The surface area in the 'U' bends shall be excluded from the heat transfer calculations except for tubes in kettle reboilers and stab-in type bundles.

6.2.7 Triangular pitch shall be limited to those services that are clean such that they do not require mechanical cleaning. Tube pitches shall generally be specified as follows:

1) Triangular pitch (30 degree) for all services with shell-side fouling resistance up to and including:

0.00035 m² °K/W (0.002 hr °F ft²/Btu)

2) Square pitch (90 degree) for all services with shell-side fouling resistance above:

0.00035 m² °K/W (0.002 hr °F ft²/Btu)

3) Rotated square pitch (45 degree) for shell side reboilers and shell-side laminar flow regimes, in preference to square pitch.

Recommendation:

For reboilers 45° pitch is preferred and recommended over a 90° pitch. This is based on refinery experience, and the fact that controlling a reboiler duty with a 90° pitch can lead to a step control (with the tube rows) and not a linear continuous control.

6.2.8 a) For square and rotated square pitches, a minimum of 6.3 mm shall be provided between adjacent tubes. Cleaning lanes shall be continuous through the bundle.

b) For triangular and rotated triangular pitches, a minimum of 6.3 mm shall be provided between adjacent tubes.

6.2.9 For strength welded tube to tubesheet joint, a minimum of 6.3 mm shall be provided between adjacent tubes.

6.2.10 Fouling resistances shall be in line with the individual plant's operating experience in similar service and as per process licensor's recommendations/specifications, where applicable. In the absence of such information, the fouling resistance shall be selected from the values recommended by TEMA. The following are the exceptions to this:

Page 11: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 11 of 39

1) Fouling resistance for sea water shall be 0.00035 m² °K/W (0.002 ft² hr °F/Btu).

2) Fouling resistance for untreated well water for water temperature up to 52°C shall be 0.000528 m² °K/W (0.003 ft² hr °F/Btu) and 0.00088 m² °K/W (0.005 ft² hr °F/Btu) for water above this temperature.

3) Fouling resistance for soft cooling water shall be 0.00034 m² °K/W (0.00195 ft² hr °F/Btu)

4) Fouling resistance for steam shall be 0.00017 m² °K/W (0.00098 ft² hr °F/Btu)

5) Fouling resistance for demineralised water shall be 0.00034 m² °K/W (0.00195 ft² hr °F/Btu)

6) Fouling resistance for BFW shall be 0.00017 m² °K/W (0.00098 ft² hr °F/Btu)

7) Fouling resistance for condensates shall be 0.00034 m² °K/W (0.00195 ft² hr °F/Btu)

8) Fouling resistance for Auxiliary cooling water 0.0006 m² °K/W (0.00346 ft² hr °F/Btu)

6.2.11 The Design Engineer shall consider providing spare exchangers for critical services where severe fouling can be expected and which would result in un-scheduled shutdowns.

6.2.12 The Design Engineer shall include provisions for blocking and bypassing streams where required by the process design. For example, the effect of bypassing heat transfer streams in a crude preheat exchanger train shall be fully investigated on the downstream exchangers.

6.2.13 For single phase shell-side services, the baffle cut shall be horizontal. Vertically cut baffles shall generally be specified for shell-side condensing and vaporizing services and for fluids containing suspended solids.

6.2.14 The value for the calculated pressure drop in the clean condition is to be specified on the data sheet.

6.2.15 When minimum wall tubes are specified, the tube-side pressure drop shall be based on 110% of the selected tube wall thickness.

6.2.16 The inlet operating cooling water temperature to be used in the design of heat exchangers utilizing seawater shall be in accordance with JERES-C-101.

Page 12: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 12 of 39

The maximum cooling water outlet temperature shall not exceed the temperature defined in JERES-C-101.

6.2.17 Where untreated well water is used as the cooling fluid, the design cooling water inlet temperature shall be based on actual water reservoir data.

6.2.18 Exchangers utilizing sea or untreated well water or cooling tower water as cooling medium shall have a minimum water velocity of 1.2 m/s. The maximum permissible water velocity varies with the tube material as shown below:

Materials m/s

Admiralty Brass (inhibited) 1.5

Carbon Steel (only with fresh water) 1.8

Aluminum Brass or Aluminum Bronze 1.8

70/30 Cupro-nickel 3.0

90/10 Cupro-nickel 3.0

Nickel - Copper Alloy (Monel) 3.7

AISI 316 Stainless Steel (fresh water only) 4.6

Titanium unlimited

6.2.19 Kettle reboilers shall be sized such that no more than 0.5 weight percent liquid is entrained in the outlet vapor. A minimum of 450 mm shall be provided as the height above the highest liquid level. Design engineer to provide vapour velocity at the vapour space in reboilers for review to Company Representative.

6.2.20 The Design Engineer shall ensure that the exchanger design is free of any damaging flow induced tube vibration including the effect of acoustic vibration.

6.2.21 The Design Engineer shall provide the completed data sheet, and thermal design calculations (including tube vibration) for review by the Company Representative.

If the design is done using computer programs, the relevant input and output data shall be submitted.

The data sheet shall contain fluid physical properties used in the design, including non-linear condensing and boiling heat release profiles and weight fraction vapor curves, where applicable. For vaporizing services, critical pressure of the boiling fluid and the relevant vapor liquid equilibrium data shall also be provided.

Page 13: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 13 of 39

The Design Engineer shall include a sketch on the data sheet, showing both the shell and the tube side flow arrangements. For stacked exchangers, it shall also show the stacking arrangement.

6.2.22 The number of stacked exchangers shall not be more than three.

6.2.23 For water-cooled exchangers, the cooling water should preferably circulate upwards. This means that the cooling water supply enters at the bottom of the exchanger.

6.2.24 As a general rule, the cold inlet and outlet streams should enter and exit the exchanger at the bottom side and the hot inlet and outlet streams should enter and exit the exchanger at the top side.

6.2.25 For the design of exchanger on lubricating oil for critical equipment, the cooling water pressure shall be lower than the oil pressure.

6.3 Selection of TEMA Types

6.3.1 The service is considered clean when fouling resistance of the stream is not greater than 0.000176 m² °K/W (0.001 hr °F ft²/Btu). Fouling resistance in excess of this means that the service is fouling.

6.3.2 Generally, exchangers shall either be a floating head type (TEMA type AES or AET) or 'U' tube type.

6.3.2.1 Floating head type is required when both the shell and the tube sides are considered fouling, and require mechanical cleaning. 'T' type (pull through) is used when shell design pressure is equal or higher than 5 MPa(g) and for exchangers of the “Kettle” type. ‘S’ type is used when shell design pressure is lower than 5 MPa(g).

6.3.2.2 'U' tube bundles shall only be specified for use in clean tube-side services, or when tube-side can be chemically cleaned or when specified by the process licensor.

With fouling resistance between 0.000176 m2 °K/W and 0.0003 m2°K/W, ‘U’ tube may be used with written approval of Company after verifying that the possible deposit forming in the tube can be removed chemically or with high pressure water.

6.3.3 Fixed tubesheet type shall only be specified in shell- side clean and non-fouling services or when specified by the process licensor. Fixed tubesheet specified by the licensor in fouling service required the prior written approval of Company.

However, fixed tubesheet type is not acceptable in shell-side wet sour services.

Page 14: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 14 of 39

6.3.4 Fixed tubesheet exchangers without the expansion joint are acceptable up to a maximum differential temperature of 28°C between tube wall temperature in any one tube pass and average shell temperature. However, when shell and tube materials have different thermal expansion coefficients, the differential stresses shall be analyzed even when the temperature difference is less than 28°C. Designs with shell expansion joint are not allowed except for special case with written approval of Company Representative.

6.3.5 For fixed tubesheet exchangers, the Design Engineer shall analyze and specify (on the data sheet) the mean shell and tube wall temperatures which give the maximum temperature differential. The conditions of normal operating, start-up, shut-down, process upset, emergency, and steam-out shall be investigated to determine the maximum differential.

6.3.6 Shells with two passes (TEMA 'F' type) shall not be used unless approved by the Company Representative.

For shells with two passes, the shell-side fouling resistance shall not exceed: 0.000176 m² °K/W (0.001 hr °F ft²/Btu)

'F' type shells shall be limited to a maximum shell-side pressure drop of 70 kPa

6.3.7 Packed floating heads (‘P’ and ‘W’ type) are not permitted unless approved in writing by Company.

6.3.8 Preferred channel covers are TEMA type 'A' (removable flat cover). Type 'B' (integral bonnet) covers may be used when tube-side fluid is non-fouling, and frequent access to the tubesheet is not anticipated.

6.4 Tubes

6.4.1 The minimum tube outside diameter shall be 19.05 mm (0.75 inch) unless otherwise approved by the Company Representative. Preferred tube diameters are 19.05 mm (0.75 inch) and 25.4 mm (1 inch). Other tube diameters shall be approved by the Company Representative.

6.4.2 Unless otherwise approved by the Company Representative, the minimum tube wall thickness shall be specified in accordance with the requirements of API STD 660, modified as follow:

O.D. Inches (mm)

Carbon Steel and Low Alloy, Aluminium and aluminium

High Alloy, copper and copper alloys, other alloys

Page 15: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 15 of 39

alloys

¾” (19.05)

BWG 14 (min. wall) (2.108 mm)

BWG 16 (min. wall) (1.651 mm)

1” (25.40)

BWG 12 (average) (2.769 mm)

BWG 14 (average) (2.108 mm)

Minimum wall tube shall be used for design pressure equal and greater than 7.0 MPa (g).

6.4.3 Preferred tube lengths are the commonly used standard Imperial lengths as given in TEMA. Standard metric lengths such as 5 meters and 6 or 7 meters shall not be used as these give decimal values of Imperial lengths.

6.4.4 Low fin tubes may be used for shell-side non-fouling and low surface tension fluids where their use is justified. Their specification requires prior approval by the Company Representative.

6.4.5 Only seamless tubes shall be used except otherwise agreed by Company Representative.

7 Basis for Mechanical Design

7.1 General

7.1.1 All exchangers shall be mechanically designed in accordance with the rules of the ASME SEC VIII D1 or ASME SEC VIII D2 (herein referred to as the Codes), API STD 660, TEMA and the requirements of JERMS-E-3207 and, if applicable, JERMS-D-3231.

7.1.2 The applicable Division and the edition of the Code to be used for the design of exchangers shall be specified on the data sheet.

7.1.3 ASME SEC VIII D2, shall be specified when economically justified. The following guideline shall be used to determine when Division 2 should be considered:

1) When the thickness of exchanger shell/channel/ heads exceeds 50 mm, irrespective of design pressure, materials, or service.

2) For exchangers with design pressures 7.0 MPa and larger, irrespective of service and materials of construction.

Page 16: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 16 of 39

7.1.4 It is the responsibility of the design engineer, as defined in this standard, to prepare a detailed User Specification for ASME SEC VIII D2 in accordance with paragraph AG-301 of Division 2.

7.1.5 The application of ASME Code Cases to the design of exchangers requires prior approval of the Company Representative

7.2 Design Pressure

7.2.1 Exchangers shall be designed to withstand the maximum internal and/or external pressure conditions, which can occur during normal operation, including startup, shutdown or any unusual operation as shown on the Process Flow Diagram (PFD).

7.2.2 The internal design pressure shall be taken to be at least equal to the maximum operating pressure up rated by the following value:

a) 0.1 MPa for maximum operating pressure below 1 MPa (g). Under no circumstances may the design pressure be less than 0.35 MPa (g).

b) 10 % of the maximum operating pressure when that pressure is between 1 MPa (g) and 7.0 MPa (g) inclusive.

7.2.3 The internal design pressure of exchangers with maximum operating pressure of more than 7.0 MPa shall be a minimum of the larger of 105% of the maximum operating pressure and the maximum operating pressure plus 0.7MPa.

7.2.4 Exchangers in vacuum service shall be designed for a maximum external pressure of 102 kPa

7.2.5 Exchangers that are subject to steam out conditions shall be designed for an external pressure of 50 kPa at 150°C. In case of MP steam use, a 200°C temperature shall be considered.

7.2.6 Exchangers in steam services shall be designed, on the steam side, for an external pressure of 102 kPa at design temperature.

7.2.7 Tube bundles including tubesheet are designed for a minimum differential pressure of 2.5 MPa when the design pressure of either heat exchanger sides (shell or tubes) is above 4.5 MPa and service conditions make it impossible to pressurize one side of the exchanger without simultaneously pressurizing the other side. The system process design shall determine the correct minimum differential design pressure, which may be higher than 2.5 MPa. In other cases, all parts of tube bundle including

Page 17: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 17 of 39

tubesheet and floating head shall be designed for full design pressure on tube side with atmospheric pressure or specified vacuum the other side.

7.2.8 The values of normal operating pressure, maximum operating pressure, design pressure, and differential pressure (if any) shall be specified on the data sheet.

7.2.9 In exchangers with tube side as the high-pressure side, design pressure of the shell side should be at least 10/13 of the tube side design pressure and vice versa.

Commentary Note:

This is to prevent any unexpected catastrophic failure in case of tube leak in exchangers.

7.2.10 For exchangers designed at full vacuum, a minimum internal pressure of 0.35 MPa (g) shall be also considered.

7.3 Design Temperature

7.3.1 Design temperature shall not be less than the maximum operating temperature plus 28°C.

7.3.2 The design temperature shall not be lower than 80°C.

7.3.3 If the fluid temperature is more than 100°C and the exchanger is “cold walled”, refractory lined on the inside, the design temperature shall be determined by a heat calculation taking into account the maximum temperature of the fluid and an ambient temperature of 45°C without wind.

7.3.4 If a exchanger or a part of exchanger normally operated below 0°C can be submitted to temperature above ambient during particular operating phases (dry out, start-up, regeneration,…) or accidental causes (except fire), a hot design temperature will be indicated with associated design pressure.

7.3.5 The components separating the channel and the shell sides (tube sheets, tubes, floating head, internal expansion bellow…) shall be designed considering that the design temperature to be used for those components is the highest of design temperatures of each side.

7.3.6 For exchanger trains with by-pass of individual exchanger, the design temperature (hot side) of the downstream exchanger will be the higher of the maximum continuous operating temperature +28°C and the normal operating temperature of the by-passed exchanger assuming that shells are by-passed piece by piece (simultaneous by-pass of several exchangers in series is not considered).

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7.4 Minimum Design Metal Temperature

The minimum design metal temperature (MDMT) shall be specified on the data sheet and shall be equal to the lowest of the following conditions:

1) The LODMAT at the site location, unless a higher start-up temperature is specified, and a suitable warm-up start-up procedure has been developed.

2) The temperature of a process stream causing shock-chilling condition as defined in Section 4 of this standard.

3) Auto-refrigeration condition as defined in Section 4 of this standard.

4) The minimum operating temperature at an operating pressure greater than 25% of the design pressure.

7.5 TEMA Class

The TEMA mechanical class corresponding to the type of service shall be specified on the data sheet in accordance with the following:

1) For utility (non-hydrocarbon) plants and for exchangers that are part of packaged units such as pumps and compressors, TEMA class C may be specified.

2) For all other services, TEMA class R shall be specified.

7.6 Service Type

Services falling under the categories of: wet sour, lethal, hydrogen, caustic and cyclic shall be specified as such on the data sheets.

7.7 Joint Efficiency

A joint efficiency of 85% or higher shall be specified for the design of all pressure containing components of ASME Code Div.1 heat exchangers.

7.8 Corrosion Allowance

7.8.1 The minimum corrosion allowances of pressure components shall be in accordance with TEMA and the following.

7.8.2 Corrosion allowance shall be based on achieving a minimum service life of twenty years.

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7.8.3 The maximum corrosion allowance shall be 6.0 mm. Should a higher corrosion allowance be required in order to obtain a twenty year service life, the exchanger shall be integrally clad or weld overlaid with a corrosion resistant metallic lining or as an alternative solid corrosion resistant material shall be specified for the exchanger. Selection of any of the alternatives shall be based on cost effectiveness and a proven history of satisfactory service in similar service environments.

The cladding and weld deposit overlay shall not be included in the strength calculations.

7.8.4 The minimum corrosion allowance shall be specified on the data sheet as follows:

1) For all carbon and low alloy steels in all services, except wet sour services, the minimum corrosion allowance shall be specified as 3.0 mm for TEMA class R exchangers. Corrosion allowance of 1.5 mm may be used for TEMA class C exchangers after Company Representative approval.

2) For carbon and low-chrome alloy steel exchangers in wet sour services, the minimum corrosion allowance shall be specified as 3.0 mm irrespective of TEMA class.

3) For all integrally clad exchangers, in all services, the minimum corrosion allowance shall be the cladding thickness of not less than 3.0 mm. Additional requirements are defined in JERMS-D-3231.

4) For all weld overlaid exchangers, in all services, the minimum corrosion allowance shall be the weld overlay thickness of the undiluted specified chemical composition of not less than 3.0 mm. Additional requirements are defined in JERMS-D-3231.

5) For all clad or weld overlaid exchangers, in all services, with an operating temperature less than 150°C, the minimum external corrosion allowance shall be specified as 1.5mm or 3.0mm when exchangers are under insulation.

7.8.5 Minimum corrosion thickness allowance for non pressure retaining parts:

1) A minimum total corrosion allowance of 1.5 mm shall be provided for exchanger supports (saddles, brackets…) and on external gusset plates of non-alloy and low-alloy steel.

2) A 3.0 mm corrosion allowance on root diameter for anchor bolts shall be considered.

7.9 Heads

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7.9.1 The types of heads shall be specified on the data sheet. The type of heads to be used shall be ASME 2:1 ellipsoidal or ASME hemispherical.

7.9.2 ASME flanged and dished heads (torispherical) can be used for air and water utilities up to a design pressure of 700 kPa (g). For other services Company approval is requested.

7.9.3 For thick wall exchangers, heads shall be specified as hemispherical unless 2:1 ellipsoidal heads are deemed economical.

7.10 Loads

7.10.1 Wind and earthquake loads

1) Wind and earthquake loads shall be determined by the Exchanger Manufacturer in accordance with the procedures detailed in ASCE 7.

2) The Design Engineer shall determine the basic wind speed corresponding to the Company site in accordance with JERES-A-112. The basic wind speed shall be specified on the data sheet.

3) The Design Engineer shall determine the earthquake zone, soil coefficient and effective peak acceleration ratio (Av) corresponding to the Company site in accordance with JERES-A-112. The earthquake zone and site soil coefficient shall be specified on the data sheet.

7.10.2 Weight of liquid contents

The Design Engineer shall specify on the exchanger data sheet the maximum operating liquid level and density of liquid as well as full hydrostatic test load for the exchanger in the erected position.

7.10.3 Piping and equipment loads

1) Nozzles shall be designed for external piping loads, such as may be produced from thermal expansion/contraction and weight.

2) Piping loads on nozzles, as detailed in Appendix I, shall be used when no other data are available.

3) For exchanger supporting equipment (e.g., stab-in type heat exchanger, reboilers, etc.), the equipment loads imposed on the exchanger are to be determined and specified on the data sheet by the Design Engineer.

7.10.4 Refractory linings

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1) For exchangers which are refractory lined, the extent and design density of the refractory lining shall be specified on the data sheet.

2) The value of the design density of the refractory shall be determined in accordance with JERES-N-100.

7.10.5 Loading Combinations

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Including the additional data defined in the construction code, at least the following load cases must be studied:

CONDITION: a) Transportation (1) / Lifting (2): exchanger under atmospheric pressure and

ambient temperature, non-corroded thickness, complete with attached piping, all welded internals and insulation (if any), without any removable internal.

Note (1): For vertical exchangers transported in the horizontal position, the body of the exchanger shall be checked in the transport and lifting position, considering the exchanger in both horizontal and vertical positions.

Note (2): The lifting devices (lifting lugs, trunnions, lifting beams, and so on) shall be calculated, as shell the local stresses induced by them on the body of the exchanger; for these calculations, a safety factor of 1.5 shall be applied to the weight of the equipment.

b) Erection: exchanger under atmospheric pressure and ambient temperature, non-corroded thickness, complete with attached piping, all welded internals and insulation (if any), without any removable internal, all combined with wind and earthquake loads that shall no act simultaneously.

c) Normal operation (1): exchanger under design pressure and temperature, corroded thickness, complete with attached piping, all welded internals and insulation (if any), all internal and the maximum operating liquid level, other loadings (see section 7.10.3), all combined with wind and earthquake loads that shall not act simultaneously.

Note (1): The total moment due to wind shall be increased the eccentric loads from overhead vapour line and heavy equipment attached to the exchanger. If final additional loads (if any) are unknown, as minimum the 10% of increase shall be considered.

d) Hydrostatic test (1), (2): exchanger under test pressure and ambient temperature, considering the static head, full of water, corroded thickness, complete with

LOADING

CONDITION Pressure Temperature Dead/Live

Loads

Wind Earthquake

Transportation / Lifting Atmospheric Ambient (a) - -

Erection Atmospheric Ambient (b) (b) (b)

Normal operation Design Design (c) (c) (c)

Hydrostatic Test Test Ambient (d) (d) -

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attached piping, all welded internals and insulation (if any), all combined with the 50% of wind load.

Note (1): Unless otherwise specified for particular equipment, the exchanger shall be considered in its service position (horizontal or vertical). The manufacturer shall also check the strength of the equipment during the workshop test, in non-corroded thickness (may in some cases be a dimensioning factor for certain elements).

Note (2): Unless more stringent indications given in the chosen construction code or the national regulation, the nominal design stress of the material at test temperature shall be equal to 90% of the yield strength except for the bolting, equal to 50% of the yield strength expressed as 0.2% for non-alloy steels and 1/3 of tensile strength for an austenitic steels.

7.11 Stress Analysis

7.11.1 Where applicable, the requirements for Division 2-Alternate rules and fatigue stress analysis are to be specified by the Design Engineer in accordance with this standard. When a thermal or fatigue analysis is required per this standard for a Division 1 exchanger, the analysis methods and stress combination limits presented in Division 2, Appendix 4, may be used. However, the basic design stress intensity value, Sm, shall be taken from the Division 1 tables of ASME SEC II for the corresponding material and temperature.

7.11.2 The Design Engineer is responsible for specifying the heat transfer coefficients to be used for all thermal stress analysis.

7.11.3 Thermal stress analysis

1) A thermal stress analysis is required for ASME SEC VIII D1 exchanger if a thermal gradient along the circumferential or longitudinal axes, under steady state operating conditions, exceeds 65°C in a distance measured as the square root of R times T, where:

− R is the radius of the exchanger component under consideration and,

− T is the thickness of the component under consideration

− R and T are measured in the same units.

2) Thermal gradients may be reduced to within allowable limits with the addition of thermal sleeves.

7.11.4 Exchangers designed in accordance with Division 2

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1) The scope of the required stress analysis shall be specified by the Design Engineer in accordance with the rules of Division 2.

2) As a minimum, the scope of the stress analysis (in the steady state condition) shall include the following:

− Special nozzle configuration to shell welds including external piping loads

− Discontinuities in shell material, thickness, shape

7.11.5 Fatigue analysis

1) A fatigue analysis, if required, shall be based on the calculated number of cycles for a minimum 20-year life, as determined in accordance with the rules of Division 2, paragraph AD-160.

2) The number of cycles shall include the number of start-ups, shutdowns, emergency shut-downs and upset conditions.

7.11.6 Local stress analysis

Stress analysis due to piping, equipment, lifting, supports and other external loads shall be completed in accordance with the procedures as detailed in WRC 107, WRC 297 or a finite element analysis.

7.12 Tube to Tubesheet Connection

7.12.1 Tubes are normally expanded into the tubesheet. However, for the following services, the tubes shall be strength welded to the tubesheet, with two weld passes minimum.

1) When the difference in the shell and tube side design pressures is greater than 6.0 MPa.

2) When steam at 540°C or above is one of the fluids.

Commentary Note:

Strength welded shall include a slight expansion for fit-up. It shall consist of 2 passes with offset starting point (min 90 °) and shall be made with a bevel except otherwise approved by Company

7.12.2 Tubes shall be seal welded (at least) to the tubesheet for exchangers:

1) in sea water service, and when inter-mixing of the streams must be avoided (in the event of a tube leak)

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2) With at least one of the process fluids containing H2 or H2S

3) With clad tube sheets on the tube side.

7.13 Impingement Protection

7.13.1 For inlet nozzles, on shell side, an impingement protection plate shall be provided by a plate baffle or rods on the tube bundle.

7.13.2 In no case shall the shell or bundle entrance or exit area produce a value of RHO x V² in excess of 5953, where 'RHO' is the density of the shell-side fluid in kg/m³ and 'V' is the flow velocity in m/s (4000, where 'RHO' is in lb/ft³ and 'V' is in ft/s) per TEMA RCB-4.62.

7.13.3 For tube bundles that can be rotated 180 degrees, additional impingement plate, bundle runners etc. shall be provided.

8 Nozzles and Gaskets

8.1 General

8.1.1 The quantity, types, sizes and pressure classes of all nozzles shall be specified on the data sheet.

8.1.2 The Design Engineer is responsible for ensuring that the facings, bolt centers, number and size of bolts of exchanger nozzles match the mating piping flanges.

8.1.3 NPS 2½, 3½, and 5 nozzles shall not be used.

8.1.4 Nozzles less than NPS 2 are not allowed except for instrument & vent nozzles using 1 ½” LWN type, if any.

8.1.5 Threaded and socket-welded connections are prohibited

8.1.6 In total condensing services, a minimum of NPS 1½ LWN type connection shall be provided as a vent. The vent shall be located near the condensate outlet.

8.1.7 The use of distributor belts on the shell-side shall be considered in lieu of normal nozzle arrangement when the shell nozzles are large.

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Commentary Note:

Large shell side nozzles result in long unsupported tube span in the shell inlet and outlet areas. The use of distributor belts will help in better utilization of the heat transfer surface and reduce the tendency for tube vibration in these critical areas.

8.1.8 The instrument nozzles rating shall be specified as 300# minimum.

8.2 Ratings (ASME Pressure Classes) and Facings

8.2.1 The ASME pressure classes shall be specified on the data sheet.

8.2.2 ASME pressure class 400 shall not be used.

8.2.3 Pressure ratings shall be in accordance with the following:

1) Pressure ratings of flanges 24 inch NPS and smaller shall be specified in accordance with ASME B16.5.

2) Pressure ratings of flanges larger than 24 inch NPS shall be specified in accordance with ASME B16.47, Series A.

8.2.4 The facings of flanges shall be raised face or ring-type joint in accordance with JERES-L-109.

8.2.5 Bolted joints specified with non-ASME flanges shall be designed to meet all anticipated loading conditions of the exchanger.

8.3 Chemical Cleaning and Instrument Connections

8.3.1 Chemical cleaning connections, if required, shall be preferably located on exchanger nozzles.

8.3.2 Connections for the measurement of temperature, pressure and flow shall be preferably located in the adjoining piping, except when required in intermediate nozzles of stacked exchangers.

8.4 Gaskets

8.4.1 The type of gasket shall be specified on the data sheet in accordance with JERES-L-109.

8.4.2 All gaskets shall be in accordance with API STD 660, ASME B16.20 and ASME B16.21.

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8.5 For exchangers with fixed tube sheet, a minimum of two 8”-NPS minimum inspection holes shall be located on the shell in such a way as to allow for the evaluation of fouling and corrosion of external side of tubes. If they are carefully located, such inspection holes can be used for chemical injection.

8.6 Weld Attachment Details

8.6.1 All nozzles and man way necks shall be attached by welding completely through the total thickness of the exchanger shell, head or nozzle wall, including any reinforcement. All nozzles and man way necks shall be of set-in type and shall not project inside the exchanger. The inside edge of all nozzles shall be rounded to a radius of at least 3 mm. Backing rings are not allowed.

8.6.2 Permissible types of nozzles and manway necks weld-attachments are:

a) Division 1 exchangers: Figure UW-16.1 (c), (d), (e), (f-1), (f-2), (f-3), (f-4) or (g).

b) Division 2 exchangers: Figure AD-610.1: (c), (d), (e), (e-1), (g) or weld attachments in paragraph 8.6.3(b).

8.6.3 The nozzle and manway necks weld attachments shall be of the self reinforcing type (with no reinforcing pad) in the following services and/or conditions :

a) Cyclic service

b) Equipments subject to thermal choc

c) Thick wall vessels in carbon steel (i.e. thickness greater or equal to 50 mm)

d) Low alloy steels with thickness greater or equal to 25 mm

e) Openings which are 900 mm and larger with design temperature greater than 400°C

f) Vessels with design Temperature above 370°C

h) Vessels with design Temperature below -45°C

8.6.4 The following types of nozzle and manway (self-reinforced with lip) necks weld-attachments :

a) Division 1 vessels: Figure UW-16.1: (f-1), (f-2), (f-3) or (f-4).

b) Division 2 vessels: Figure AD-613.1: (a), (b), (c), (c-1), (d) or (e)

shall be considered when:

1) The design pressure is more or equal to 7.0 MPa(g).

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2) The flange rating is more or equal to 600# except for carbon steel material in non-cyclic condition.

3) For carbon steel material in non-cyclic condition and the flange rating is more or equal to 900#.

4) when required by project specifications such as JERMS-D-3232 or JERMS-D-3233

5) Lethal service

9 Exchanger Supports

9.1 General

The type of support required shall be specified by the Design Engineer in the data sheet in accordance with JERSD (2271-AAA-STC-0490-000 & 2271-AAA-STC-0690-000).

9.2 Supports for Vertical Exchangers

Where brackets are used as a support for vertical exchangers, minimum number of four brackets shall be specified for exchangers above 700 mm in outside diameter. The locations of brackets shall be specified on the data sheet.

9.3 Supports for Horizontal Exchangers

9.3.1 Horizontal exchangers shall be supported by at least two saddles. The exchanger shall be fixed at one saddle and free to move in the longitudinal direction, due to thermal and pressure differentials, at the other saddle.

9.3.2 The data sheet shall specify locations of the fixed and sliding saddles and dimension from exchanger's centerline to underside of saddle base plate.

10 Material Selection

10.1 General

The materials of construction for pressure and non-pressure components shall be based on the design temperature; minimum design metal temperature; and service in accordance with JERMS-E-3207, Table 1, Acceptable Materials for Carbon and Low-Chrome Alloy Steels. Use of materials other than those listed in the materials section of JERMS-E-3207 requires approval of Company Representative.

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10.2 Impact Testing

The impact testing of exchanger components shall be determined by the Exchanger Manufacturer based on the material minimum design metal temperature (MDMT), in accordance with the requirements specified in JERMS-E-3207.

10.3 Postweld Heat Treatment (PWHT)

10.3.1 For carbon and low alloy steels, the following process services require PWHT. Other process conditions may also require PWHT, as determined during the project design or as specified by the Company Representative.

1) All caustic soda (NaOH) solutions at all temperatures.

2) All monoethanolamine (MEA), methyldiethanolamine (MDEA) and diethanolamine (DEA) solutions, at all temperatures..

3) All di-glycol amine (DGA) solutions above 140°C design temperature.

4) All rich amino di-isopropanol (ADIP) solutions above 90°C design temperature.

5) All lean ADIP solutions above 60°C design temperature.

6) Exchangers in hydrogen service at all temperatures manufactured from P-No.3, 4 and 5A/B/C base materials.

7) Exchangers in Wet Sour Service.

10.3.2 Code exemptions for PWHT are not permitted if PWHT is specified for process conditions in accordance with this standard.

11 Insulation and Surface Coating

11.1 The extent and thickness of external insulation shall be specified on the data sheet in accordance with JERES-N-001.

11.2 The selection of the type of coating shall be in accordance with JERES-H-001.

12 Fireproofing

The extent of fireproofing required on exchanger supports shall be determined in accordance with the requirements of JERES-B-006 and specified on the data sheet.

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13 Cathodic Protection

Exchangers shall be cathodically protected when specifically required by JERES-X-500.

14 Drawings and Calculations

14.1 The data sheet and any relevant forms shall be completed by the Design Engineer to the extent as detailed in this standard. The data sheets shall include all information necessary for the Exchanger Manufacturer to carry out the mechanical design and verify the thermal design.

14.2 When completing the data sheets using the SI system of measurement, the following units shall be used: Flow rate : kg/h Length : mm

Temperature : °C Density : kg/m³

Heat Capacity : kJ/kg K Thermal Conductivity : W/m K

Pressure : kPa Heat Transfer Rate : W/m² K

Latent Heat : kJ/kg Heat Duty : W

14.3 The Design Engineer is responsible for the completion of the Safety Instruction Sheet (JEREF-2713) for the exchanger in accordance with Appendix B and the data on the Exchanger Manufacturer's drawings.

14.4 As built thickness of all pressure components shall be specified by the Design Engineer on the Safety Instruction Sheet (SIS) after the completion of fabrication.

14.5 All approved data sheets, drawings and forms are to be submitted to Company.

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APPENDIX A

NOZZLE LOADS FOR METALLIC SHELL AND TUBE HEAT EXCHANGERS

1 General Each nozzle shall be capable of withstanding forces and moments given below under design conditions. Forces and moments shall be considered to be acting at the intersection of the nozzle axis and the mid-thickness of the shell or head. The more stringent case caused by the axial force Fa acting inward or outward shall be considered. The allowable stress intensity limits shall be based on defined rules in a recognised construction code as ASME VIII Divison 2.

2 Loads to be considered

Data

The abbreviation used in the table hereafter corresponds to:

− Fl: longitudinal force in kN;

− Fa: axial force in kN to be considered as positive

and negative value;

− Fc: circumferential force in kN;

− Mc: circumferential moment in kN.m;

− Mt: torsional moment in kN.m;

− Ml: longitudinal moment in kN.m;

− DN: nominal diameter given in inch.

For heads, the following resultant loads shall be considered: − resultant shear force F in kN: 22 FcFlF += ;

− resultant bending moment M in kN.m: 22 McMlM += .

Tables

The load values in the below tables are given by flange rating and nominal nozzle diameter.

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APPENDIX B

SAFETY INSTRUCTION SHEET

1 Completion of Form JEREF-2713

1 Give short but comprehensive description covering use or function of exchanger; e.g., butane cooler, deethanizer condenser.

2a Plant No. followed by sequence No.; e.g., 190-E-1, 2-E-204 (same as key number 80).

2b Accounting plant No. (to be completed by the user).

3 Manufacturer's name and country where fabricated.

4 From Manufacturer's identification. (If Company Standard Heat Exchanger: Diameter of shell in mm (in) - length of tubes in mm (in) - (surface in m²).

5 As applicable (e.g., shell and tube, or double pipe, for Company Standard Heat exchangers fill in "Company Standard").

6 Serial number as stamped on nameplate.

7 Company purchase order number, including suffix letters such as DA, HA, TA, NA.

8 Year built as indicated on nameplate.

9 ASME or TEMA Code or other whichever is applicable. Show Code section and year of issue.

10, 11 From Manufacturer's data.

12 List major Company drawings and foreign print numbers.

13 Shell side product stream indicated on heat exchanger specification data sheet.

14 Diameter inside or outside (ID or OD).

15 Nominal shell plate thickness (new).

16 Length of shell between flange faces.

17 Specification of material used.

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18 Double or single butt-weld (DBW or SBW). For shells made of seamless pipe - SEAMLESS.

19, 20 Yes or no.

21 Joint efficiency, in accordance with ASME SEC VIII.

22 Basis for Calculated Test Pressure to be indicated is the lowest value of all bases for calculated test pressures determined for the various exchanger components subjected to shell side pressure and design temperature. See ASME Code, paragraph UG-99(c), Appendix 3.

23 Design temperature on the shell side.

24 Hydrostatic test pressure applied by manufacturer as stated in Design Data Sheet or Inspection Report.

25 The exchanger component that limits the Basis for Calculated Test Pressure on the shell side.

26 For dished heads indicate crown radius and knuckle radius; for ellipsoidal heads the ratio of inside major axis to inside minor axis.

27, 28 ASTM Material Specification or equivalent and wall thickness.

29 Tube side product as indicated on heat exchanger specification data sheet.

30,31,32 Outside diameter, wall thickness, and length of tubes.

33 Layout may be triangular or rectangular, spacing is center-to-center distance between tubes.

34 Basis for Calculated Test Pressure to be indicated is the lowest value of all bases for calculated test pressures determined for the various exchanger components subjected to the tube side pressure and temperature. See ASME SEC VIII, paragraph UG-99(c), Appendix 3.

35 Design temperature on the tube side.

36 Hydrostatic test pressure applied by Manufacturer as stated in Inspection Report.

37 The exchanger component that limits the Basis for Calculated Test Pressure on the tube side.

Page 36: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 36 of 39

38,39,40 ASTM Material Specifications or equivalent and applicable wall thickness from Manufacter's drawings.

41 To be completed by the user. For single bundle per exchanger, only left side of this section key numbers 41 thru 54 is to be completed.

42 Tube material specification.

43, 46 Number of tubes, see Heat Exchanger Specification Data Sheet and or Manufacturer's drawings.

44, 47 External area of all tubes, see Heat Exchanger Specification Data Sheet.

45, 48 Number of tube passes, see Heat Exchanger Specific Data Sheet.

49,51 Tube sheet material specification.

50,52 Nominal thickness of tube sheet from Manufacturer's drawings.

53 State components which are lined and the material of the lining.

54, 55, For new equipment this information is shown on the Heat Exchanger

64, & 65 Specification Data Sheet for the subject exchanger. When the service conditions of existing equipment are changed the design pressure shall be the maximum inlet pressure plus 100 kPa or 10% whichever is larger and the design temperature shall be 30°C or 10% higher than the maximum operating metal temperature whichever is larger.

56, 66 Usually "operating conditions".

57, 67 Location of relief valve.

58, 68 Relief valve setting. (Refer to JERES-J-600).

59, 69 1.5 times the design pressure.

60, 70 Design pressure or relief valve setting, if less than design pressure.

61, 71 Design temperature.

62, 72 The minimum thickness (tm's) calculated in accordance with ASME Unfired Pressure Vessel Code and TEMA specifications. (tm's) for tube sheets may be

Page 37: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 37 of 39

calculated in accordance with the ASME Unfired Pressure Vessel Code and TEMA specifications but it is usually satisfactory to deduct shell side and tube side corrosion allowances shown on data sheet, from the tube sheet thickness t, where t is the tube sheet thickness in the partition plate groove. For tube sheets clad with non-corrosive material such as monel, deduct shell side corrosion allowance on data sheet, from the tube sheet thickness t, where t is the overall tube sheet thickness minus the cladding thickness.

63, 73 Corrosion allowance = actual thickness minus minimum thickness (tm). If the second method under key numbers 64 and 74 is followed to determine (tm) the tube sheet corrosion allowance = t minus (tm), where "t" is the tube sheet thickness in the partition plate groove. This excludes the partition plate groove depth from the corrosion allowance and this should be stated under key number 78.

74 Drawing number of Design Data Sheet.

75 Drawing number of Bolt and Gasket List.

76 Any particulars that are of interest to Inspection and Maintenance, e.g.,

a) Whether or not the gasket groove depth in the channel cover and partition plate groove depth of tube sheets have been included in the corrosion allowance.

b) Number of spare bundles available.

c) Interchange ability of tube bundle with that of any other exchanger.

d) Any special hazards connected with the equipment.

77 Engineering plant number followed by "-E-" and followed by sequence number; e.g., 16-E-112, 332-E-401.

78 Show area and location.

79 Show plant number

80 Show Index "A".

81 Follow usual procedure to obtain drawing number.

82 Engineering concurrence as indicated in Section 4 plus Project Manager or Plant Manager's, approval as required.

Page 38: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 38 of 39

83 Complete this section showing date prepared and name of originator.

84 Signature of Facility Engineering Division head.

85 Include BI and JO under which the equipment was installed.

Page 39: JERES-E-004 Design Criteria of Shell & Tube Heat Exchangers

Jubail Export Refinery Engineering Standard

JERES-E-004 Rev. 1 Design Criteria of Shell and Tube Heat Exchangers 14 May 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

Page 39 of 39