Understanding heat exchanger reading 03 part 1 of 2 optimized the aramco std

My Reading on Heat Exchanger Reading 03- The ARAMCO Std. P Part 1 off 2 for my Aramco AOC’s QM31 Exam Preparations

27th May 2018

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Charlie Chong/ Fion Zhang

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Fion Zhang at Shanghai Damuqiao 大木桥路 27th May 2018

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The Magical Book of Heat Exchanger Reading

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Parts: 1. API660/ ISO 16812:2007 Shell-and-tube Heat Exchangers 2. Materials System Specification 32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

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American Petroleum Institute API 600 Std.

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Part 1: Shell-and-tube Heat Exchangers ANSI/API STANDARD 660 EIGHTH EDITION, AUGUST 2007 ISO 16812:2007 (Identical), Petroleum, petrochemical and natural gas industries-Shell-and-tube Heat Exchangers

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Contents 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Scope Normative references Terms and definitions General Proposals Drawings and other required Design Materials Fabrication Inspection and testing Preparation for shipment Supplemental requirements

Annex A (informative) Recommended practices Annex B (informative) Shell-and-tube heat exchanger checklist Annex C (informative) Shell-and-tube heat exchanger data sheets Annex 0 (informative) Responsibility data sheet

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Foreword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee.

International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards.

Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.

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Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 16812 was prepared by Technical Committee ISO/TC 67, Materials, equipment and offshore structures for petroleum, petrochemical and natural gas industries, Subcommittee SC 6, Processing equipment and systems. This second edition cancels and replaces the first edition (ISO 16812:2002), which has been technically revised.

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ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

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ISO Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.

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Introduction Users of this International Standard should be aware that further or differing requirements may be needed for individual applications. This International Standard is not intended to inhibit a vendor from offering, or the purchaser from accepting, alternative equipment or engineering solutions for the individual application. This may be particularly applicable where there is innovative or developing technology. Where an alternative is offered, the vendor should identify any variations from this International Standard and provide details.

Annex A provides some optional recommended practices.

A bullet (•) at the beginning of a clause or sub-clause indicates a requirement for the purchaser to make a decision or provide information (see checklist in Annex B).

In this International Standard, where practical, US Customary (USC) units are included in parentheses for information.

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A bullet (•) at the beginning of a clause or sub-clause indicates a requirement for the purchaser to make a decision or provide information (see checklist in Annex B).

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A bullet (•) at the beginning of a clause or sub-clause indicates a requirement for the purchaser to make a decision or provide information (see checklist in Annex B).

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In this International Standard, where practical, US Customary (USC) units are included in parentheses for information.

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Petroleum, petrochemical and natural gas industries - Shelland-tube heat exchangers 1 Scope This International Standard specifies requirements and gives recommendations for the: 1. mechanical design, 2. material selection, 3. fabrication, inspection, testing and 4. preparation for shipment of shell-and-tube heat exchangers for the petroleum, petrochemical and natural gas industries.

This International Standard is applicable to the following types of shell-andtube heat exchangers: ď Ž heaters, condensers, coolers and reboilers.

This International Standard is not applicable to vacuum-operated steam surface condensers and feed-water heaters.

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Vacuum-operated Steam Surface Condensers

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Vacuum operated Steam Surface Condensers

Power Plant- Vacuumoperated Steam Surface Condensers

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2 Normative references

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.       

ISO 15156 (all parts) (NACE MR0175), Petroleum and natural gas industries- Materials for use in H2S-containing environments in oil and gas production ASME B 16.5, Pipe Flanges and Flanged Fittings ASME B 16.11, Forged Fittings, Socket-Welding and Threaded ASME B 1.20.1, Pipe Threads, General Purpose (Inch) EJMA, Standards of the Expansion Joint Manufacturers Association NACE MR0103 -Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments TEMA Standards Set, 8th Edition, Standards of the Tubular Exchanger Manufacturers Association

Normative : of or relating to a norm, especially an assumed norm regarded as the standard of correctness in behavior, speech, writing, etc. (规范的;标准的) Charlie Chong/ Fion Zhang

The following NACE referenced documents are indispensable for the application of this document. ď Ž ď Ž

ISO 15156 (all parts) (NACE MR0175), Petroleum and natural gas industries- Materials for use in H2S-containing environments in oil and gas production NACE MR0103 -Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments

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3 Terms and definitions For the purposes of this document, the following terms and definitions apply.

3.1 annular distributor additional chamber incorporated into a shell side nozzle to more evenly distribute shell side fluids entering or exiting the tube bundle

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Annular Distributor

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3.2 category A welded joint longitudinal welded joint within the main shell, communicating chambers, nozzles or transitions in diameter; or any welded joint within a sphere or within a formed or flat head; or circumferential welded joint connecting hemispherical heads to main shells, to transitions in diameters or to communicating chambers 3.3 category B welded joint circumferential welded joint within the main shell, communicating chambers, nozzles or transitions in diameter, including joints between the transitions and a cylinder at either the large or small end; or circumferential welded joint connecting formed heads, other than hemispherical, to main shells, to transitions in diameter, to nozzles or to communicating chambers

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Cat “B” includes most circumferential welded joints including formed heads (other than hemispherical) to main shells welds.

FIG. UW-3 ILLUSTRATION OF WELDED JOINT LOCATIONS TYPICAL OF CATEGORIES A, B, C, and D Charlie Chong/ Fion Zhang

ASME VIII-UW-03

Cat “A” includes all longitudinal welds and critical circumferential welds such as hemispherical head to shell welds.

FIG. UW-3 ILLUSTRATION OF WELDED JOINT LOCATIONS TYPICAL OF CATEGORIES A, B, C, and D Charlie Chong/ Fion Zhang

ASME VIII-UW-03

 Cat “A” includes all longitudinal welds and critical circumferential welds such as hemispherical head to shell welds.  Cat “B” includes most circumferential welded joints including formed heads (other than hemispherical) to main shells welds.  Cat “C” includes welded joints connecting: . flanges to nozzles or shell components. one side plate to another in a flat-sided vessel.  Cat “D” includes welded joints connecting nozzles to shells, heads or flat-sided vessels.

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ASME VIII-UW-03

 Cat “A” includes all longitudinal welds and critical circumferential welds such as hemispherical head to shell welds.  Cat “B” includes most circumferential welded joints including formed heads (other than hemispherical) to main shells welds

Cat A Cat B Except Hemispherical Head Charlie Chong/ Fion Zhang

ASME VIII-UW-03

Exercise:

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Exercise: ?

D

D

C

D ?

C B D

A

B A

D Charlie Chong/ Fion Zhang

D

Exercise: ?

D

D

C

D ?

C B D

A

B A

D Charlie Chong/ Fion Zhang

D

Exercise:

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Why Hemispherical Head fall under Cat “A” and What is RT1 and RT2?

ASME Pressure Vessel Joint Efficiencies The ASME Pressure Vessel Joint Efficiencies article provides you with information about pressure vessel joint efficiency requirements and their connection with radiography testing.

You may know Pressure Vessel Joint Efficiencies are linked to the radiography testing grades and there is a concession for full radiography testing as per the UW-11(a) (5) (b) clause which it is a little bit confusing.

This article provides you the ASME pressure vessel joint efficiencies requirements and guidelines for the above clause.

Based on the ASME Code requirement, manufacturers have to mark the type of RT i.e. RT1, RT2, RT3 and RT4 in the pressure vessel name plate and state the same in Pressure Vessel Data Report.

We have seen many professionals, from inspectors to quality control engineers who are confused between RT1 and RT2, specifically when they see ASME Pressure Vessel Joint Efficiencies for both RT1 and RT2 is the same and equal to 1(E=1).

They say both RT1 and RT2 are categorized in the “Full Radiography” part in UW-11 clause ...

So why are some joints in RT2 radiographed in spots?

We are making spot radiography, but it is categorized in full radiography!!!

So in this "ASME Pressure Vessel Joint Efficiencies" article we want to answer this question in very simple way, but before this, we need review joint categories and summarize them as below: Category A: All longitudinal welds in shell and nozzles All welds in heads, Hemispheric-head to shell weld joint Category B: All circumferential welds in shell and nozzles Head to shell joint (other than Hemispheric.)

Category C and D are flange welds and nozzle attachment welds respectively

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http://www.inspection-for-industry.com/asme-pressure-vessel-joint-efficiencies.html

Do you know why? Why ASME considered the stringent rule for Category “A” weld than Category “B” weld?

Longitudinal welds (Category A) are more critical than Circumferential welds (Category B) because they are under double stress.

This the reason why in different part of ASME code we have stringent rules in category A joint compared to category B joint.

See the following Fig. for joint categories:

Now let's get back to the ASME Pressure Vessel Joint Efficiencies subject, to remove the above confusion about RT1 and RT2.

We need to know:

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http://www.inspection-for-industry.com/asme-pressure-vessel-joint-efficiencies.html

When and where is there a code requirement for full radiography?

Item 1: All butt welds in vessels used to contain a lethal substance (UW-11(a)).Lethal substances have specific definitions in ASME Code in UW-2 and it is the responsibility of the end user to determine if they ordered a vessel that contains lethal substances.

Item 2: All butt welds in vessels in which the nominal thickness exceeds specified values (UW-11(a). You can find these values in subsection C, in UCS-57, UNF-57, etc. For example, this value for P-No.1 in UCS-57 is 1 ¼ inch.

Item 3: All butt welds in an unfired steam boiler with design pressure > 50 psi (UW-11(a)).

Item 4: All category A and D butt welds in vessel when “Full Radiography” optionally selected from table UW-12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet the spot radiography requirement (UW-11(a) (5) (b)).

The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is mandated by code; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) in UW-12 table.

But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in table UW-12 for full radiography.

So here there is a concession or bonus to manufacturers for categories B and C.

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http://www.inspection-for-industry.com/asme-pressure-vessel-joint-efficiencies.html

What is concept behind this concession or bonus in pressure vessel RT2?

If you review item 1, 2 and 3 one more time, you will see that the pressure vessel RT tests are related to the type of welds and services.

You can see the pressure vessels in these items are critical from a safety point of view, one contains a lethal substance, the other one has a high thickness, which implicates high pressure, and the last one is an unfired steam boiler. But item 4 has no criticality like the other items have.

But you should note all 4 items have been categorized in full radiography clause( U-11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT symbols are used in Code (UG-116).

RT 1: Items 1, 2 and 3, (E=1), All butt welds-full length radiography RT 2: Item 4 (E=1), Category A and D butt welds full length radiography and category B and C butt welds spot Radiography RT 3: (E=0.85), Spot radiography butt welds RT 4: (E=0.7), Partial / No radiography You need to consider the hemispherical head joint to shell as category A, but ellipsoidal and torispherical head joint to shell as category B;

Do you know why? Why ASME considered the stringent rule for pressure vessel RT test in hemispherical head joint?

It is because this joint is more critical, because the thickness obtained from the formula for hemispherical head approximately would be half of the shell thickness; It means if the shell thickness is 1 inch, the hemispherical head thickness would be 0.5 inch.

For more detail, you may review the Pressure Vessel Heads http://www.inspection-for-industry.com/pressure-vessel-heads.html article.

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http://www.inspection-for-industry.com/asme-pressure-vessel-joint-efficiencies.html

Do you know why? Why ASME considered the stringent rule for Category “A” weld than Category “B” weld?

Longitudinal welds (Category A) are more critical than Circumferential welds (Category B) because they are under double stress.

This the reason why in different part of ASME code we have stringent rules in category A joint compared to category B joint.

Weld Types: Here is some clarification about the different type of welds that have specific definitions in ASME Code SEC VIII DIV 1 and related to the pressure vessel RT test.

The concept is to define the different types and then introduce some restriction for using them.

For example, a Type 1 weld is defined as a full penetration weld, typically double welded and Type 2 is welds with backing strips.

So when you go to service restriction for a vessel containing a lethal substance, you see there is a restriction there that says all category A joints shall be weld Type 1 and Category B and C shall be type 1 or type 2.

You should take this point in to account, which is this: the same joint category with different weld types have different joint efficiencies.

Summary of weld types: Type 1: Full penetration welds (Typically Double welded) Type 2: Welds with backing strip Type 3: Single welded partial penetration welds Type 4, 5 and 6: Various Lap welds (rarely used)

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http://www.inspection-for-industry.com/asme-pressure-vessel-joint-efficiencies.html

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UW-11 RADIOGRAPHIC AND ULTRASONIC EXAMINATION (a) Full Radiography. The following welded joints shall be examined radiographically for their full length in the manner prescribed in UW-51: 1. (1) all butt welds in the shell and heads of vessels used to contain lethal substances [see UW-2(a)]; 2. (2) all butt welds in the shell and heads of vessels in which the nominal thickness [see (g) below] at the welded joint exceeds 11/2 in. (38 mm), or exceeds the lesser thicknesses prescribed in UCS-57, UNF-57, UHA-33, UCL-35, or UCL-36 for the materials covered therein, or as otherwise prescribed in UHT-57, ULW51, ULW-52(d), ULW-54, or ULT-57; 3. (3) all butt welds in the shell and heads of unfired steam boilers having design pressures (-a) exceeding 50 psi (350 kPa) [see UW-2(c)]; (-b) not exceeding 50 psi (350 kPa) [see UW-2(c)] but with nominal thickness at the welded joint exceeding the thickness specified in (2) above; 4. (4) all butt welds in nozzles, communicating chambers, etc., with the nominal thickness at the welded joint that exceeds the thickness in (2) above or attached to the shell or heads of vessels under (1), (2), or (3) above that are required to be fully radiographed; however, except as required by UHT-57(a), Categories B and C butt welds in nozzles and communicating chambers that neither exceed NPS 10 (DN 250) nor 11/8 in. (29 mm) wall thickness do not require any radiographic examination;

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UW-11(a) Full Radiography. The following welded joints shall be examined radiographically for their full length in the manner prescribed in UW-51: (5) all Category A and D butt welds in the shell and heads of vessels where the design of the joint or part is based on a joint efficiency permitted by UW-12(a), in which case: (-a) Category A and B welds connecting the shell or heads of vessels shall be of Type No. (1) or Type No. (2) of Table UW-12; (-b) Category B or C butt welds [but not including those in nozzles and communicating chambers except as

which intersect the Category A butt welds in the shell or heads of vessels or connect seamless vessel shell or heads shall, as a minimum, meet the requirements for spot radiography in accordance with UW-52. Spot radiographs required by this paragraph shall not be used to satisfy the spot radiography rules as applied to any other weld increment. required in (4) above]

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Table UW-12 Maximum ALLowabLe Joint Efficiencies for Arc and Gas Welded Joints Degree of Radiographic Examination Type No.

Joint Description

Limitations

Joint Category

(a) Full [Note (1)]

(b) Spot [Note (2)]

(c) None

[1)

Butt joints as attained by double welding or by other means which will obtain the same quality of deposited weld metal on the inside and outside weld surfaces to agree with the requirements of UW 35 . Welds using metal backing strips which remain in place are excluded.

None

A, B, C & D

1.00

0.85

0.70

(2)

Single welded butt joint with backing strip other than those included under (1)

(a) None except as in (b) below (b)Circumferential butt joints with one plate offset; see UW 13(b)[4) and Figure UW 13.1, sketch [i)

A, B, C & D A, B & C

0.90 0.90

0.80 0.80

0.65 0.65

[3)

Single welded buttjointwithoutuse ofbacking strip

Circumferential butt joints only, not over% in. [16 mm) thick and not over 24 in. [600 mm) outside diameter

A, B & C

NA

NA

0.60

(4)

Double full fillet lap joint

(a) Longitudinal joints not over %in. (10 mm) thick (b) Circumferential joints not over %in. (16 mm) thick

NA NA

NA NA

0.55 0.55

(5)

Single full fillet lap joints with plug welds conforming t o UW 17

(a) Circumferential joints [Note (4)] for attachment of heads not over 24 in. (600 mm) outside diameter to shells not over "/2 in. [13 mm) thick (b) Circumferential joints for the attachment to shells of jackets not over % in. [16 mm) in nominal thickness where the distance from the center of the plug weld to the edge of the plate is not less than 11h times the diameter of the hole for the plug.

B

NA

NA

0.50

c

NA

NA

0.50

A&B

NA

NA

0.45

A&B

NA

NA

0.45

C & D [Note (5)]

NA

NA

NA

B, C & D

NA

NA

NA

Single full fillet lap joints without plug welds

(6)

(a) For the attachment of heads convex to pressure to shells not over %in. (16 mm) required thickness, only with use of fillet weld on inside of shell; or (b) for attachment of heads having pressure on either side, to shells not over 24 in. [600 mm) inside diameter and not over %in. [6 mm) required thickness with fillet weld on outside of head flange only

(7)

Corner joints, full penetration, partial penetration, and/ or fillet welded

As limited by Figure UW 13.2 and Figure UW 16.1

(8)

Angle joints

Design Eer U 2 (g) for Category B and C joints

A B & C [Note (3)]

GENERAL NOTES: (a} (b)

The single factor shown for each combination of joint category and degree of radiographic examination replaces both the stress reduction factor and the joint efficiency factor considerations previously used in this Division.

E" 1.0 for butt joints in compression.

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Table UW-12 Maximum Allowable Joint Efficiencies for Arc and Gas Welded Joints Degree of Radiographic Examination Type No.

Joint Description

Limitations

Joint Category

(a) Full [Note (1)]

(b) Spot [Note (2)]

(c) None

Butt joints as attained by double welding or by other means which will obtain the same quality of deposited weld metal on the inside and outside weld surfaces to agree with the requirements of UW 35. Welds using metal backing strips which remain in place are excluded.

None

A, B, C & D

1.00

0.85

0.70

(2)

Single welded butt joint with backing strip other than those included under (1)

(a) None except as in (b) below (b)Circumferential butt joints with one plate offset; see UW 13(b)(4) and Figure UW 13.1, sketch (i)

A, B, C & D A, B & C

0.90 0.90

0.80 0.80

0.65 0.65

(3)

Single welded butt joint without use of backing strip

Circumferential butt joints only, not over 5/8 in. (16 mm) thick and not over 24 in. (600 mm) outside diameter

A, B & C

NA

NA

0.60

(4)

Double full fillet lap joint

(a) Longitudinal joints not over 3/8 in. (10 mm) thick (b) Circumferential joints not over 5/8 in. (16 mm) thick

A B & C [Note (3)]

NA NA

NA NA

0.55 0.55

(5)

Single full fillet lap joints with plug welds conforming to UW 17

(a) Circumferential joints [Note (4)] for attachment of heads not over 24 in. (600 mm) outside diameter to shells not over 1/2 in. (13 mm) thick (b) Circumferential joints for the attachment to shells of jackets not over 5/8 in. (16 mm) in nominal thickness where the distance from the center of the plug weld to the edge of the plate is not less than 11/2 times the diameter of the hole for the plug.

B

NA

NA

0.50

C

NA

NA

0.50

(a) For the attachment of heads convex to pressure to shells not over 5/8 in. (16 mm) required thickness, only with use of fillet weld on inside of shell; or (b) for attachment of heads having pressure on either side, to shells not over 24 in. (600 mm) inside diameter and not over 1/4 in. (6 mm) required thickness with fillet weld on outside of head flange only

A&B

NA

NA

0.45

A&B

NA

NA

0.45

C & D [Note (5)]

NA

NA

NA

B, C & D

NA

NA

NA

(6)

Single full fillet lap joints without plug welds

(7)

Corner joints, full penetration, partial penetration, and/or fillet welded

As limited by Figure UW 13.2 and Figure UW 16.1

(8)

Angle joints

Design per U 2(g) for Category B and C joints

UW-13

GENERAL NOTES: (a) The single factor shown for each combination of joint category and degree of radiographic examination replaces both the stress reduction factor and the joint efficiency factor considerations previously used in this Division. (b) E = 1.0 for butt joints in compression.

2013 SECTION VIII - DIVISION 1

115

(1)

UW-11 RADIOGRAPHIC AND ULTRASONIC EXAMINATION (a) Full Radiography. The following welded joints shall be examined radiographically for their full length in the manner prescribed in UW-51: 1. (1) all butt welds in the shell and heads of vessels used to contain lethal substances [see UW-2(a)]; 2. (2) all butt welds in the shell and heads of vessels in which the nominal thickness [see (g) below] at the welded joint exceeds 11/2 in. (38 mm), or exceeds the lesser thicknesses prescribed in UCS-57, UNF-57, UHA-33, UCL-35, or UCL-36 for the materials covered therein, or as otherwise prescribed in UHT-57, ULW-51, ULW-52(d), ULW-54, or ULT-57; 3. (3) all butt welds in the shell and heads of unfired steam boilers having design pressures (-a) exceeding 50 psi (350 kPa) [see UW-2(c)]; (-b) not exceeding 50 psi (350 kPa) [see UW-2(c)] but with nominal thickness at the welded joint exceeding the thickness specified in (2) above; 4. (4) all butt welds in nozzles, communicating chambers, etc., with the nominal thickness at the welded joint that exceeds the thickness in (2) above or attached to the shell or heads of vessels under (1), (2), or (3) above that are required to be fully radiographed; however, except as required by UHT-57(a), Categories B and C butt welds in nozzles and communicating chambers that neither exceed NPS 10 (DN 250) nor 11/8 in. (29 mm) wall thickness do not require any radiographic examination; 5. (5) all Category A and D butt welds in the shell and heads of vessels where the design of the joint or part is based on a joint efficiency permitted by UW-12(a), in which case: (-a) Category A and B welds connecting the shell or heads of vessels shall be of Type No. (1) or Type No. (2) of Table UW-12; (-b) Category B or C butt welds [but not including those in nozzles and communicating chambers except as required in (4) above] which intersect the Category A butt welds in the shell or heads of vessels or connect seamless vessel shell or heads shall, as a minimum, meet the requirements for spot radiography in accordance with UW-52. Spot radiographs required by this paragraph shall not be used to satisfy the spot radiography rules as applied to any other weld increment.

6. (6) all butt welds joined by electrogas welding with any single pass greater than 11/2 in. (38 mm) and all butt welds joined by electroslag welding; 7. (7) ultrasonic examination in accordance with UW-53 may be substituted for radiography for the final closure seam of a pressure vessel if the construction of the vessel does not permit interpretable radiographs in accordance with Code requirements. The absence of suitable radiographic equipment shall not be justification for such substitution.

8. (8) exemptions from radiographic examination for certain welds in nozzles and communicating chambers as described in (2), (4), and (5) above take precedence over the radiographic requirements of Subsection C of this Division.

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(b) Spot Radiography. Except when spot radiography is required for Category B or C butt welds by (a)(5)(-b) above, butt welded joints made in accordance with Type No. (1) or (2) of Table UW-12 which are not required to be fully radiographed by (a) above, may be examined by spot radiography. Spot radiography shall be in accordance with UW-52. If spot radiography is specified for the entire vessel, radiographic examination is not required of Category B and C butt welds in nozzles and communicating chambers that exceed neither NPS 10 (DN 250) nor 11/8 in. (29 mm) wall thickness.

NOTE: This requirement specifies spot radiography for butt welds of Type No. (1) or No. (2) that are used in a vessel, but does not preclude the use of fillet and/or corner welds permitted by other paragraphs, such as for nozzle and manhole attachments, welded stays, flat heads, etc., which need not be spot radiographed.

(c) No Radiography. Except as required in (a) above, no radiographic examination of welded joints is required when the vessel or vessel part is designed for external pressure only, or when the joint design complies with UW-12(c).

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UG-116 REQUIRED MARKING (e) When radiographic or ultrasonic examination has been performed on a vessel in accordance with UW-11, marking shall be applied under the Certification Mark as follows: 1. “RT 1” when all pressure‐retaining butt welds, other than Category B and C butt welds associated with nozzles and communicating chambers that neither exceed NPS 10 (DN 250) nor 11/8 in. (29 mm) wall thickness [except as required by UHT-57(a)], satisfy the full radiography requirements of UW-11(a) for their full length; full radiography of the above exempted Category B and C butt welds, if performed, may be recorded on the Manufacturer’s Data Report; or 2. “RT 2” when the complete vessel satisfies the requirements of UW-11(a)(5) and when the spot radiography requirements of UW-11(a)(5)(-b) have been applied; or

3. “RT 3” when the complete vessel satisfies the spot radiography requirements of UW-11(b); or 4. “RT 4” when only part of the complete vessel has satisfied the radiographic requirements of UW-11(a) or where none of the markings “RT 1,” “RT 2,” or “RT 3” are applicable.

The extent of radiography and the applicable joint efficiencies shall be noted on the Manufacturer’s Data Report.

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Vessel for a specified service that mayRadiography include alternative operating conditions UW-11 UW-51

RT1: Full Radiography mandatory by code based on Service, thickness, toxicity UW-11(a)1,2,3,4

Extent of radiography to be selected as permitted by code for conveniences or for desired joint efficiency factor

UW-51

RT2: Full radiography complying to UW-11(a) 5 Charlie Chong/ Fion Zhang

UW-52

RT3: Spot radiography complying to UW-11(b)

RT4: No radiography complying to UW-11(c)

3.4 communicating chamber heat-exchanger appurtenance that intersects the shell or heads of the heat exchanger and forms an integral part of the pressure-containing envelope EXAMPLES Sump, annular distributor.

Communicating Chamber

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3.5 effective surface outside surface area of the tubes that contributes to heat transfer 3.6 full-penetration weld welded joint that results in weld metal through the entire thickness of the components being joined 3.7 heat-exchanger unit one or more heat exchangers for a specified service that may include alternative operating conditions

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3.8 hydrogen service service that contains hydrogen at a partial pressure exceeding 700 kPa (100 psi) absolute 700 kPa?

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Hydrogen Service service that contains hydrogen at a partial pressure exceeding 700 kPa (100 psi) absolute 0.7MPa?

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3.9 item number purchaser's identification number for a heat-exchanger unit 3.10 nubbin projection on the flange gasket surface, positioned at the centre of the gasket, used to concentrate the bolt load on the gasket 3.11 pressure design code recognized pressure vessel standard specified or agreed by the purchaser

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Nubbin projection on the flange gasket surface, positioned at the centre of the gasket, used to concentrate the bolt load

Charlie Chong/ Fion Zhang

Nubbin projection on the flange gasket surface, positioned at the centre of the gasket, used to concentrate the bolt load

Nubbin projection on the flange gasket surface, positioned at the centre of the gasket, used to concentrate the bolt load

Charlie Chong/ Fion Zhang

Nubbin Double-jacketed gaskets are probably the most commonly used style of gaskets in heat exchanger applications. They are available in virtually any material that is commercially available in 26-gauge sheet. They are also extensively used in standard flanges where the service is not critical. Since most doublejacketed gaskets are custom made, there is virtually no limit to size, shape or configuration in which these gaskets can be made.

In some cases nubbins are provided on heat exchanger designs to provide an intermediate seal. This nubbin is normally 1/64" high by 1/8" wide. Experience has indicated, however, that there is little advantage to this particular design. The primary seal is still dependent on the inner lap of the gasket doing the brute work and the secondary seal, when applicable, would be provided by the outer lap.

Nubbin projection on the flange gasket surface, positioned at the centre of the gasket, used to concentrate the bolt load

Charlie Chong/ Fion Zhang

3.12 seal-welded tube-to-tubesheet joint weld of unspecified strength applied between the tubes and tubesheets for the sole purpose of reducing the potential for leakage 3.13 strength-welded tube-to-tubesheet joint welded so that the design strength is equal to, or greater than, the axial tube strength specified by the pressure design code

Charlie Chong/ Fion Zhang

4 General • 4.1 The pressure design code shall be specified or agreed by the purchaser.

Pressure components shall comply with the pressure design code and the supplemental requirements given in this International Standard.

4.2 Heat-exchanger construction shall conform to TEMA (8th edition), Class R, unless another TEMA class is specified. • 4.3 The vendor shall comply with the applicable local regulations specified by the purchaser.

4.4 Annex A includes some recommended mechanical and design details for information.

4.5 Annex B provides a checklist that can be used by the purchaser to ensure that bulletted items in this International Standard are addressed.

4.6 Annex C provides examples of data sheets.

4. 7 Annex D includes a recommended division of responsibility for completing the data sheet.

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TEMA (Mechanical Design) Heat-exchanger construction shall conform to TEMA (8th edition), Class R, unless another TEMA class is specified.

Charlie Chong/ Fion Zhang

http://www.tema.org/

5 Proposals 5.1 The vendor's proposal shall include, for each heat exchanger unit, completed data sheets such as those given in Annex C or, if a data sheet is included in the inquiry, a statement indicating complete compliance with that data sheet.

5.2 Designs that are not fully defined by the nomenclature in TEMA (8th edition), Section 1, shall be accompanied by sketches that are sufficient to describe the details of construction.

5.3 If an annular distributor is provided, the vendor shall define the type of construction proposed.

5.4 The vendor shall determine the need for, and if required, include expansion joints based on all conditions supplied by the purchaser. The vendor shall state the type of construction proposed.

5.5 The proposal shall include a detailed description of all exceptions to the requirements of the purchaser's inquiry.

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5.6 For stacked heat exchangers, the vendor shall supply the following components unless otherwise specified by the purchaser: a. bolts, nuts and gaskets for interconnecting nozzles; b. shims and bolting for interconnecting supports.

5. 7 The vendor shall provide a separate quotation for the following items unless otherwise specified by the purchaser: a. a test component consisting of a test ring and gland, in accordance with TEMA (8th edition), Figure E-4.13-2 or equivalent, for each heat exchanger or group of similar heat exchangers with floating heads; b. one spare set of gaskets per heat-exchanger unit.

Charlie Chong/ Fion Zhang

Stacked Heat Exchangers, the vendor shall supply the following components unless otherwise specified by the purchaser: a. bolts, nuts and gaskets for interconnecting nozzles; b. shims and bolting for interconnecting supports.

Charlie Chong/ Fion Zhang

TEMA- FIGURE E-4.13-2 Test Ring

Floating Tubesheet

Shell Flange- Rear Head End

Packing

Packing Gland

Charlie Chong/ Fion Zhang

Gaskket

Stacked Heat Exchangers

Charlie Chong/ Fion Zhang

Stacked Heat Exchangers

Charlie Chong/ Fion Zhang

Stacked Heat Exchangers

Charlie Chong/ Fion Zhang

Stacked Heat Exchangers

Charlie Chong/ Fion Zhang

Stacked Heat Exchangers

Charlie Chong/ Fion Zhang

Break 20180528-1043hrs

Charlie Chong/ Fion Zhang

Break 20180528-1043hrs

Charlie Chong/ Fion Zhang

6 Drawings and other required data 6.1 Outline drawings and other supporting data 6.1.1 The vendor shall submit, for review by the purchaser, outline drawings for each heat exchanger unit. The drawings shall include the following information: a) service, item number, project name and location, purchaser's order number, vendor's shop order number and other special identification numbers; b) design pressure, test pressure, design temperature, minimum design metal temperature and any restriction on testing or operation of the heat exchanger; c) maximum allowable working pressure (MAWP) in the corroded condition and at the design temperature for the shell side and tube side; d) connection sizes, location, orientation, projection, direction of flow and, if flanged, the rating and facing; e) coupling sizes, rating and orientation; f) dimensions, orientation and location of supports, including bolt holes and slots, and the stacking arrangement; g) overall dimensions of the heat exchanger; Charlie Chong/ Fion Zhang

h) tube-bundle removal clearance; i) mass of the heat exchanger, empty and full of water, and of removable components with a mass greater than 25 kg (60 lb)(e.g. removable tube bundle, channel, channel cover and shell cover); j) specified corrosion allowance for each side of the heat exchanger; k) references to the applicable code and the purchaser's specification; l) requirements for post-weld heat treatment; m) requirements for radiographic examination; n) requirements for material impact testing; o) requirements for surface preparation and painting; p) gasket materials; q) insulation thickness; r) location of expansion joints, annular distributors and any other special components or closures; s) location and orientation of nameplates, lifting lugs, grounding clips or other attachments;

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t) location of the centre of gravity of the heat exchanger; u) forces and moments on connections as specified by the purchaser.

6.1.2 The vendor shall submit flow-induced vibration analysis, if specified by the purchaser.

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Flow-induced Vibration Analysis

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6.2 Information required after outline drawings are reviewed 6.2.1 Gasket details, including type and material, shall be shown on a separate drawing. This drawing shall not be marked with any restrictions for use. • 6.2.2 Qualified welding procedure specifications and procedure qualification records as required by the pressure design code shall be submitted for review, if specified by the purchaser.

6.2.3 Upon receipt of the purchaser's review comments on the outline drawings, the vendor shall submit copies of all detailed drawings. These shall fully describe the heat exchanger and shall include at least the following information:

Charlie Chong/ Fion Zhang

a) full views and cross-sectional views with all dimensions and materials sufficient for stress calculations for each part; b) bundle details, including the following: 1. tube layout, tube description and number in each pass, 2. number of baffles, cross-baffle cut, layout and orientation in a view that shows the cuts, 3. details and locations of all sealing and sliding strips, 4. details and locations of tie-rods and spacers, 5. details and locations of support plates, 6. details of tubesheet and tube holes, including cladding or weld overlay if required, 7. gasket drawings, 8. details of pass-partition plates;

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

http://www.plati.ru/itm/Chertezhi+teploobmennika+800+TKG%252D1%252C0%252DM8%252F20G%252D2%252D1/1886479?lang=en-US

Heat exchangers BOWMAN Solar 70 Titan

Charlie Chong/ Fion Zhang

http://olsson-group.com/en/heat-exchangers-bowman/heat-exchanger-bowman-70-solar/

Heat exchangers BOWMAN Solar 70 Titan Charlie Chong/ Fion Zhang

c) details of each pressure-retaining weld, including weld material, weld nominal thickness, weld location and applicable non-destructive examination method; d) details of each weld and weld nominal thickness for non-pressure attachments; e) complete bills of materials, including the material specification; f) expansion joint details; g) details of cladding and weld overlay; h) weld map for each heat exchanger showing the weld joints, including welding procedure number(s); i) details of tube-to-tubesheet joints, including procedures for installation, welding, expansion, inspection and testing; j) flange-face finish; k) special installation and maintenance instructions including lifting and handling.

Charlie Chong/ Fion Zhang

6.2.4 The vendor shall submit for the purchaser's review the following documentation. a) Mechanical design calculations for all the heat exchanger pressureretaining components. If calculations are made on a computer, all input and output data shall be detailed so as to facilitate an understanding of the calculation procedures. The formulas in the applicable sections of the pressure design code and TEMA shall be referenced. b) Design calculations based on seismic, wind, transportation and/or piping loads, if these loads are provided by the purchaser. c) Proposed procedures for assembly of flanged joints, if controlled bolttightening procedures (such as hydraulic torque wrenches or hydraulic tensioning devices) are used. Any required lubricants shall be stated. d) Design calculations for thermal loads imposed on nozzles of stacked heat exchangers.

Charlie Chong/ Fion Zhang

• 6.2.5 The vendor shall submit design calculations for supports or lifting and pulling devices, if specified by the purchaser.

6.2.6 After final review, the vendor shall revise all the required drawings and welding procedures and submit each with the following text marked on every sheet separately and dated: "CERTIFIED FOR CONSTRUCTION".

Charlie Chong/ Fion Zhang

6.3 Reports and records • After the heat exchanger is completed the vendor shall furnish the purchaser with the following documents in the format and quantities specified by the purchaser: a) "as-built" data sheet; b) all outline and detail drawings, marked "CERTIFIED AS-BUILT"; c) certified record of all impact tests performed; d) certified mill test reports for all pressure parts, including tubes (each material test report shall be identified by a part number); e) complete certified bill of materials suitable for obtaining all replacement parts, including quantity, description, material specification and identification of each part;

Charlie Chong/ Fion Zhang

f) temperature charts of all post-weld heat treatments; g) completed manufacturer's data report in accordance with the pressure design code; h) nameplate rubbing or a facsimile; i) all mechanical design calculations, marked "CERTIFIED AS-BUILT"; j) non-destructive examination (NDE) map; k) all associated NDE reports, including radiographic, magnetic-particle, liquid-penetrant, ultrasonic, hardness, impact, positive material identification (PM I) and any other reports as applicable; l) tube-to-tubesheet leak-test results; m) hydrostatic test records in the form of a chart or certification.

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7 Design 7.1 Design temperature • 7.1.1 All heat exchangers shall have two design temperatures for each side, a maximum design temperature and a minimum design metal temperature (MDMT), as specified by the purchaser (e.g. in the form shown in Annex C).

7 .1.2 The design temperature of a component (including external bolting) influenced by both the shell side and tube side fluids shall be the shell side or tube side design temperature, whichever is the more severe. • 7.1.3 The input data needed to design an expansion joint shall be provided by the purchaser (e.g. in the form shown in Annex C).

Charlie Chong/ Fion Zhang

7.2 Cladding for corrosion allowance 7.2.1 If cladding (including weld overlay) is used, the full thickness of the cladding shall be used as corrosion allowance unless specified otherwise or approved by the purchaser.

7 .2.2 The minimum cladding thickness at the tube side face of a tubesheet shall not be less than 10 mm (3/8 in) when tubes are expanded only, and 5 mm (3/16 in) when tubes are welded to the tubesheet. The minimum cladding thickness on the shell side face shall not be less than 10 mm (3/8 in).

Weld overlays shall have sufficient thickness to provide the specified chemical composition to a depth of at least 1,5 mm (1/16 in).

Charlie Chong/ Fion Zhang

Cladding For Corrosion Allowance

Charlie Chong/ Fion Zhang

Cladding For Corrosion Allowance

Charlie Chong/ Fion Zhang

http://www.flyvalve.com/tantalum-zirconium-titanium-steel-clad-plate-reaction-vessel.php/#.Wwu7u9Suxdg

Charlie Chong/ Fion Zhang

Tantalum Shell And Tube Heat Exchanger

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Hastalloy Shell And Tube Heat Exchanger

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Titanium Shell And Tube Heat Exchanger

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Titanium Shell And Tube Heat Exchanger

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

7.3 Shell supports 7.3.1 The fixed shell support of removable-bundle heat exchangers shall be designed to withstand a longitudinal force equal to 150 % of the bundle mass applied at the heat exchanger bundle centre line. The shear stress for supports shall not exceed 40 % of the yield strength of the material.

7 .3.2 Horizontal heat exchangers shall be provided with two or more saddles designed to support the heat exchanger under all specified conditions. Design of the saddles shall be as follows. a) Saddles shall be attached to saddle-bearing plates. b) The bearing surface of the saddles shall be at least one-third of the circumference of the shell. c) The saddle-bearing plates shall have the same nominal chemical composition as the shell and shall be continuously welded directly to the heat exchanger shells. d) The saddle-bearing plates shall be provided with vent holes 6 mm (1/4 in) in diameter, located at the vertical centre-line. e) The saddle-bearing plates shall be at least 6 mm (1/4 in) thick and shall have all corners rounded to a radius of at least 25 mm (1 in).

Charlie Chong/ Fion Zhang

Saddles/ Shell supports The fixed shell support of removable-bundle heat exchangers shall be designed to withstand a longitudinal force equal to 150 % of the bundle mass applied at the heat exchanger bundle centre line.

Saddles/ Shell Supports

Charlie Chong/ Fion Zhang

Shell supports The fixed shell support of removable-bundle heat exchangers shall be designed to withstand a longitudinal force equal to 150 % of the bundle mass applied at the heat exchanger bundle centre line.

Shell Supports

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7 .3.3 The lower shells of stacked removable-bundle heat exchangers shall be designed to carry the superimposed loads without suffering distortion that can cause binding of the tube bundles.

7.3.4 The vendor's design shall provide for a shim allowance of approximately 6 mm (1/4 in) between the faces of stacked heat exchanger intermediate supports.

7.3.5 For horizontal heat exchangers, slotted holes shall be provided in the base plate of all but one of the saddles, to allow for longitudinal movement due to thermal expansion or contraction. The width of the slot shall be equal to the anchor bolt diameter plus 8 mm (5/16 in). The length of the slot shall be equal to the anchor bolt diameter, plus the allowance for longitudinal movement, plus 8 mm (5/16 in).

Charlie Chong/ Fion Zhang

W: The width of the slot shall be equal to the anchor bolt diameter plus 8 mm (5/16 in).

L

W

L: The length of the slot shall be equal to the anchor bolt diameter, plus the allowance for longitudinal movement, plus 8 mm (5/16 in).

Charlie Chong/ Fion Zhang

7.4 Stationary head 7 .4.1 Structural bracing shall not be used to retain pressure.

7.4.2 The pressure differential used to calculate the pass-partition plate thickness in accordance with TEMA (81h edition), RCB-9.132, shall be the allowable tube-side pressure drop of the entire exchanger unit.

7.5 Floating head 7 .5.1 Floating-head cover bolting shall comply with TEMA (8th edition), Section 5, Paragraph RCB-11. Bolt spacings and clearances shall be not less than the minimum recommended by TEMA. 7 .5.2 Floating-head cover bolting shall be readily accessible and shall have adequate spanner (wrench) clearance between the floating-head bolts and the shell flange at the cover end when the shell cover is removed.

Charlie Chong/ Fion Zhang

7.5.3 Packed floating-head tailpipe and packed floating tubesheet designs (e.g. TEMA types P and W) shall not be used.

P

W

P: Outside packed floating head

W: External sealed floating tubesheet (Outside packed floating tubesheet?)

7 .5.4 Floating heads shall be designed for design pressure on either side, with atmospheric pressure or vacuum (if specified) on the other side, unless otherwise specified by the purchaser. Examples of acceptable floating-head designs are shown in Figure 1.

Charlie Chong/ Fion Zhang

http://www.piping-designer.com/index.php/disciplines/mechanical/stationary-equipment/heat-exchangers/2083-shell-and-tube-heat-exchanger-tema-designation

Rear Floating Head Allowed

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Rear Floating Head Allowed- AFS

S

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http://nptel.ac.in/courses/103103027/module1/lec1/4.html

Rear Floating Head Allowed- AES

1. Stationary Head-Channel 2. Stationary Head-Bonnet 3. Stationary Head Flange Channel or Bonnet 4. Channel Cover 5. Stationary Head Nozzle 6. Stationary Tubesheet 7. Tubes 8. Shell 9. Shell Flange Stationary Head End 10. Shell Flange Rear Head End 11. Shell Nozzle 12. Shell Cover Flange

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13. Floating Tubesheet 14. Floating Head Cover 15. Floating Head Cover Flange 16. Floating Head Backing Device 17. Tierods and Spacers 18. Transverse Baffles or Support Plates 19. Impingement Plate 20. Vent Connection 21. Drain Connection 22. Instrument Connection 23. Support Saddle 24. Lifting Lug 25. Pass Partition

http://www.wermac.org/equipment/heatexchanger_part5.html

Rear Floating Head Allowed- AET Type

Channel

Bonnet

Charlie Chong/ Fion Zhang

http://www.wermac.org/equipment/heatexchanger_part5.html

7 .5.4 Floating heads shall be designed for design pressure on either side, with atmospheric pressure or vacuum (if specified) on the other side, unless otherwise specified by the purchaser. Examples of acceptable floating-head designs are shown in Figure 1.

Figure 1 - Typical designs for floating-head covers

a) Ring and dish construction

Key 1 ring 3 dish 5 flange Charlie Chong/ Fion Zhang

b) Flange and dish construction

c) Integral construction

2 gasket 4 full-penetration weld 6 integral machined cover http://www.piping-designer.com/index.php/disciplines/mechanical/stationary-equipment/heat-exchangers/2083-shell-and-tube-heat-exchanger-tema-designation

Typical designs for floating-head covers ď Ž Ring and dish construction ď Ž Internally Clamp Split Ring construction

S

Charlie Chong/ Fion Zhang

Typical designs for floating-head covers Pull Thru Floating Head

Charlie Chong/ Fion Zhang

Typical designs for floating-head covers Floating Head with Packing Device

Charlie Chong/ Fion Zhang

Packing Device

Floating Head with Packing Device Charlie Chong/ Fion Zhang

http://slideplayer.com/slide/6637804/

Floating Head with Packing Device Charlie Chong/ Fion Zhang

Packing Device

http://slideplayer.com/slide/4151102/

7.5.5 Internal floating-head covers shall have the specified corrosion allowance on all wetted surfaces except gasket-seating surfaces. The specified corrosion allowance shall be included on the back side of the floating-head backing device.

Floating Head with Packing Device

Charlie Chong/ Fion Zhang

The specified corrosion allowance shall be included on the back side of the floating-head backing device.

7.6 Tube bundle 7.6.1 Tubes 7.6.1.1 The minimum outside diameter of the tubes shall be 19,05 mm (3/4 in) unless otherwise specified or approved by the purchaser.

7.6.1.2 The tube-wall thickness shall be as listed in Table 1, or thicker if required by the design conditions, unless otherwise specified or approved by the purchaser.

7.6.1.3 The mean radius of U-bends shall be not less than 1,5 times the nominal outside diameter of the tube.

Charlie Chong/ Fion Zhang

Table 1 - Minimum wall thickness of tubes Dimensions in millimeters (inches) Material Type

Minimum Wall Thickness a

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu and Cu alloys

1.65 mm

High alloy (austenitic, ferritic Stainless and Duplex )and other non-ferrous materials

1.473 mm

Titanium

1.067 mm

a For

low-fin tubing, this shall be minimum thickness at the root diameter

Charlie Chong/ Fion Zhang

Minimum wall thickness of tubes Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.peinemannequipment.com/products/bundle_extraction/aerial_tube_bundle_extractor/

Minimum wall thickness of tubes - Low Alloy CS Low Alloy

2.11mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.peinemannequipment.com/products/bundle_extraction/aerial_tube_bundle_extractor/

Minimum wall thickness of tubes - Duplex Duplex

1.067mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Minimum wall thickness of tubes of other non-ferrous - Alloy 625 Alloy 625 1.067mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Inconel 625 is a nickel-base alloy used both for its high strength and outstanding aqueous corrosion resistance.

The strength of alloy 625 is primarily a solid solution effect from molybdenum and columbium. Alloy 625 has excellent weldability and is frequently used to weld AL-6XNÂŽ alloy.

Matching filler metals are also used to join dissimilar metals. https://www.rolledalloys.com/alloys/nickel-alloys/625/en/

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Minimum wall thickness of tubes - Hastelloy Hastelloy 1.473mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Minimum wall thickness of tubes - Titanium Titanium

1.067mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Minimum wall thickness of tubes - Titanium Tantalum 1.473mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

http://www.titanmf.com/photo-gallery/heat-exchangers/

Minimum wall thickness of tubes - Copper Copper

1.650mm

Material Type

Minimum Wall Thickness

CS, low alloy steel (9% Cr max) Al and Al alloy

2.11 mm

Cu

1.65 mm

Stainless and Duplex and other non-ferrous

1.473 mm

Titanium

1.067 mm

Charlie Chong/ Fion Zhang

Galvanic Series In Sea Water The galvanic series chart below shows metals and their electrochemical voltage range (relative activity in flowing sea water). A typical rule of thumb is that voltage differences of 0.2 Volts or more suggest a galvanic corrosion risk.

Generally speaking the further apart the metals in the galvanic series the greater the risk of corrosion, with the metal being of least noble (Anodic) class typically corroding.

It should be noted that although stainless steels are generally in the more noble or cathodic region in the series, studies have shown that stainless steels exhibit a different voltage range in crevices or stagnant and poorly aerated water (these values are shown in brackets).

Charlie Chong/ Fion Zhang

http://structx.com/Material_Properties_001.html

Figure 5-9 – Corrosion rate curves for various alloys in H2/H2S service.

(Ref. 1) - API571- SECTION 5.0 REFINING INDUSTRY DAMAGE MECHANISMS

Charlie Chong/ Fion Zhang

https://quizlet.com/159646683/refinery-uniform-or-localized-loss-in-thickness-phenomena-flash-cards/

7 .6.2 Tubesheets 7.6.2.1 For a vertical heat exchanger where the stationary tubesheet is at the bottom, a suitable means of holding the bundle in place shall be provided. If collar bolts or drilled-and-tapped holes are used, at least four shall be provided and their location shall be identified on the drawings and by stamped markings on the OD of the tubesheet.

7.6.2.2 The distance between the edge of the tube holes and the edge of all gasket grooves shall be not less than 1,5 mm (1/16 in) for tubesheets with expanded tube-to-tubesheet joints and not less than 3 mm (1/8 in) for tubesheets with seal-welded or strength-welded tube-to-tubesheet joints.

7.6.2.3 Tubesheets shall be designed for design pressure on either side, with atmospheric pressure or vacuum, if specified, on the other side unless otherwise specified or approved by the purchaser.

Charlie Chong/ Fion Zhang

7.6.2.4 A full-diameter stationary tubesheet shall be provided for removable bundle exchangers with bonnets (see TEMA (8th edition), Figure N-1.2, Type B stationary head]. The tubesheet shall be designed to maintain the gasket seal through the use of collar studs or tapped tubesheet holes and allow hydrotesting of the shell side without the bonnet installed.

B

A

Charlie Chong/ Fion Zhang

Bonnet Stationary Head A full-diameter stationary tubesheet shall be provided for removable bundle exchangers with bonnets (see TEMA (8th edition), Figure N-1.2, Type B stationary head]. The tubesheet shall be designed to maintain the gasket seal through the use of collar studs or tapped tubesheet holes and allow hydrotesting of the shell side without the bonnet installed.

B Charlie Chong/ Fion Zhang

Vertical Heat Exchanger- Support

Charlie Chong/ Fion Zhang

B

C

7 .6.3 Baffles and support plates 7.6.3.1 The thickness of carbon steel or low-alloy steel (max. 9% chromium) transverse baffles and support plates shall be not less than twice the specified shell side corrosion allowance.

7.6.3.2 Transverse baffles and support plates shall have notches that are 10 mm (3/8 in) high to facilitate drainage.

7.6.3.3 If shell-side longitudinal baffles are used, the minimum clearance between the longitudinal baffle and the adjacent tubes shall be 3 mm (1/8 in).

Charlie Chong/ Fion Zhang

Transverse baffles and support plates shall have notches that are 10 mm (3/8 in) high to facilitate drainage.

10 mm notches?

Charlie Chong/ Fion Zhang

Longitudinal Baffles the minimum clearance between the longitudinal baffle and the adjacent tubes shall be 3 mm (1/8 in).

Minimum clearance between the longitudinal baffle and the adjacent tubes shall be 3 mm Charlie Chong/ Fion Zhang

3 mm

F

7 .6.4 Impingement protection 7 .6.4.1 If required by TEMA (8th edition), RCB-4.61, impingement protection shall be provided by a plate baffle or rods on the tube bundle, an annular distributor or another means agreed upon by the purchaser and the vendor.

7.6.4.2 If an impingement plate baffle is used, it shall extend at least 25 mm (1 in) beyond the projection of the nozzle bore.

7.6.4.3 If an impingement plate baffle is used, the shell entrance and bundle entrance areas (as defined by TEMA) shall be not less than the flow area of the inlet nozzle.

7.6.4.4 The nominal thickness of the impingement plate baffle shall be not less than 6 mm (1/4 in).

7.6.4.5 The impingement plate baffle shall be adequately supported (e.g. by welding to at least two spacers) to avoid mechanical damage due to vibration.

7.6.4.6 ¡Perforated impingement plate baffles shall not be used.

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7.6.5 Bypass-sealing devices 7.6.5.1 Bypass-sealing devices (such as seal bars, dummy tubes or tie-rods as shown in Figure 2) shall be used for non-isothermal service if bypass clearances exceed 16 mm (5/8 in) and shall be located as follows. a) If the distance between baffle-cut edges is six tube pitches or less, a single seal, located approximately halfway between the baffle cuts, shall be provided. b) If the distance between baffle-cut edges exceeds six tube pitches, multiple seals shall be provided. A seal shall be located every five to seven tube pitches between the baffle cuts, with the outermost seals not more than 75 mm (3 in) from each baffle-cut edge.

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Key 1 peripheral edge of baffle 2 tie rods, dummy tubes or flat bar 3 edge of baffle cut 4 plane of U-tube bend 5 detail of seals and tube clearance 6 tubes 7 seal 8 clearance: not to exceed nominal clearance between tubes Charlie Chong/ Fion Zhang

9 single seal on centre-line 10 multiple seals, evenly spaced 11 edge of baffle cut 12 plane of U-tube bend 13 U-tube bend 14 impingement plate 15 peripheral bundle bypass lane 16 internal bundle bypass lane

Figure 2 - Typical cross-sections of tube bundle showing locations of bypass sealing devices

Key 1 peripheral edge of baffle 2 tie rods, dummy tubes or flat bar 3 edge of baffle cut 4 plane of U-tube bend 5 detail of seals and tube clearance 6 tubes 7 seal 8 clearance: not to exceed nominal clearance between tubes Charlie Chong/ Fion Zhang

9 single seal on centre-line 10 multiple seals, evenly spaced 11 edge of baffle cut 12 plane of U-tube bend 13 U-tube bend 14 impingement plate 15 peripheral bundle bypass lane 16 internal bundle bypass lane

Figure 2 - Typical cross-sections of tube bundle showing locations of bypass sealing devices Key 1 peripheral edge of baffle 2 tie rods, dummy tubes or flat bar 3 edge of baffle cut 4 plane of U-tube bend 5 detail of seals and tube clearance 6 tubes 7 seal 8 clearance: not to exceed nominal clearance between tubes

Charlie Chong/ Fion Zhang

9 single seal on centre-line 10 multiple seals, evenly spaced 11 edge of baffle cut 12 plane of U-tube bend 13 U-tube bend 14 impingement plate 15 peripheral bundle bypass lane 16 internal bundle bypass lane

Baffle Cut

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http://slideplayer.com/slide/1418524/

Baffle Cut

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http://slideplayer.com/slide/1418524/

7.6.5.2 Peripheral bypass seals shall extend from the peripheral edge of the transverse baffle into the tube bundle so that the clearance to the nearest tube does not exceed the nominal clearance between tubes.

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7.6.5.2 Peripheral bypass seals shall extend from the peripheral edge of the transverse baffle into the tube bundle so that the clearance to the nearest tube does not exceed the nominal clearance between tubes.

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7 .6.5.3 Internal bypass seals shall be installed so that the clearance to the nearest tube does not exceed the nominal clearance between tubes.

7.6.5.4 Bypass sealing devices shall either be located to minimize obstruction of mechanical cleaning lanes or shall be readily removable. Continuous cleaning lanes shall be maintained for square (90°) and rotated-square (45°) pitch.

7.6.5.5 The nominal thickness of seal strips shall be the nominal thickness of the transverse baffles or 6 mm (1/4 in), whichever is less.

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7.6.5.6 Bypass seal strips shall be attached to the transverse baffles by continuous welds on one side of each baffle.

7.6.5.7 The leading and trailing edges of seal strips shall be provided with a radius or a bevel to prevent damage to the shell when inserting or removing the bundle.

7.6.5.8 Peripheral bypass-seal strips shall not restrict the bundle inlet or outlet flows.

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Sealing Strip The function of the sealing strips is to reduce the effect of the bundle bypass stream that flows around the outside of the tube bundle.

They are usually thin strips of metal that fit into slots in the baffles and extend outward toward the shell wall to block the bypass flow and force it back into the tube bundle.

Charlie Chong/ Fion Zhang

https://www.slideshare.net/Khawwam/lecture-6-shellandtube-heat-exchanger-basic-design-procedure

They are placed in pairs on opposite sides of the baffles running lengthwise along the bundle. Sealing strips are mainly used in floating-head exchangers, where the clearance between the shell and tube bundle is relatively large.

Typically, one pair is used for every four to ten rows of tubes between the baffle tips. Increasing the number of sealing strips tends to increase the shell side heat-transfer coefficient at the expense of a somewhat larger pressure drop.

Penetration Area

Sealing Strip

Charlie Chong/ Fion Zhang

https://www.slideshare.net/Khawwam/lecture-6-shellandtube-heat-exchanger-basic-design-procedure

7.6.6 Bundle skid bars 7.6.6.1 For all removable bundles with a mass of more than 5 450 kg (12 000 lb), continuous sliding surfaces shall be provided to facilitate bundle removal.

7.6.6.2 If skid bars are used, the following shall apply. a) A minimum of two skid bars shall be provided. b) They shall not be situated in the projected area of the nozzles. c) They shall be welded to the transverse baffles and support plates. d) They shall protrude 0,8 mm (1/32 in) beyond the outside diameter of baffle and support plates. e) Their leading and trailing edges shall be provided with a radius or a bevel to prevent damage to the shell when inserting or removing the bundle.

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7 .6. 7 Tube-to-tubesheet joint The tube-to-tubesheet joint shall be expanded only, unless otherwise specified or approved by the purchaser. If welded joints are specified, the joint shall be made by one of the following methods: a) strength-welded only; b) strength-welded and expanded; c) seal-welded and expanded.

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7. 7 Nozzles and other connections • 7. 7.1 Connections DN 40 (NPS 1 %) and larger shall be flanged. The purchaser shall specify the required flange design code (e.g. ASME 816.5).

7.7.2 If welded connections are specified, they shall be bevelled.

7.7.3 Non-flanged connections smaller than ON 40 (NPS 1½” ) shall be forged couplings with an equivalent rating to ASME B 16.11 class 6000 or shall be integrally reinforced welding fittings with tapered threads equivalent to ASME B 1.20.1, and shall comply with the pressure design code. Threaded connections shall not be used in hydrogen or sour service.

7. 7.4 Flanged connections shall be of one of the following types: a) forged integrally flanged; b) pipe or forged cylinder welded to forged welding-neck flange; c) pipe welded to a forged slip-on flange, except as noted in 7.7.5.

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7. 7.5 Slip-on flanges shall not be used in any of the following conditions: a) design pressure greater than 2100 kPa (300 psi) gauge; b) design temperature greater than 400ºC (750 °F); c) corrosion allowance greater than 3 mm (1/8 in); d) hydrogen service; e) cyclic service, if the pressure design code requires fatigue analysis.

1. Slip On flange 2. Filled weld outside 3. Filled weld inside 4. Pipe

Slip-on flanges

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Type of Flange Connection

Socket

Blind

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Threaded

Lap

Slip-on

Weld Neck

1. Threaded flange 2. Thread 3. Pipe or Fitting

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http://www.wermac.org/flanges/flanges_welding-neck_socket-weld_lap-joint_screwed_blind.html

1. Lap Joint flange 2. Stub End 3. Butt weld 4. Pipe or Fitting

1. Slip On flange 2. Filled weld outside 3. Filled weld inside 4. Pipe

Charlie Chong/ Fion Zhang

http://www.wermac.org/flanges/flanges_welding-neck_socket-weld_lap-joint_screwed_blind.html

1. Blind flange 2. Stud Bolt 3. Gasket 4. Other flange

1. Socket Weld flange 2. Filled weld 3. Pipe X = Expansion gap

Charlie Chong/ Fion Zhang

http://www.wermac.org/flanges/flanges_welding-neck_socket-weld_lap-joint_screwed_blind.html

Type of Flange Connection- Swivel Joint

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http://www.calqlata.com/productpages/00061-help.html

Type of Flange Connection - Swivel Joint (Lapped & Thread)

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• 7.7.6 The projection of flanged connections shall allow through-bolting to be removed from either side of the flange without removing the insulation. The insulation thickness shall be specified by the purchaser.

7.7.7 Integrally reinforced nozzles shall be designed so that standard spanners (wrenches) fit the nuts without interference from nozzle neck reinforcement. • 7.7.8 If chemical-cleaning connections are specified by the purchaser, their nominal size shall be not less than DN 50 (NPS 2). • 7.7.9 The design of connections shall be suitable to withstand the loads and moments specified by the purchaser.

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7.8 Flanged external girth joints 7.8.1 Channel and shell external girth joints shall be of through-bolted construction.

7.8.2 Flanges for external girth joints shall be of the forged welding-neck type unless otherwise specified or approved by the purchaser.

7.8.3 Nubbins shall not be used unless approved by the purchaser, in which case nubbins shall be located on the female (grooved) flange.

Nubbins shall not be used Charlie Chong/ Fion Zhang

7.8.4 The nominal clearance between flanges after assembly shall be not less than 3 mm (1/8 in). The clearance between flanges shall extend within the bolt circle to allow flanges to be checked for radial distortion caused by an excessive bolt load.

7.8.5 Flanges shall be spot-faced or back-faced to the extent required by ASME B 16.5 or the pressure design code. spot-faced or back-faced

3mm Charlie Chong/ Fion Zhang

7.8.6¡Hardened washers shall be provided under nuts for all bolts having diameters of 38 mm (11/2 in) or larger. The washers shall be at least 6 mm ( 1/4 in) thick. • 7.8.7 If the use of bolt-tightening devices is specified by the purchaser, nozzles or girth flanges shall be designed to allow adequate clearance.

7.8.8 Stationary tubesheet flange assembly shall be designed with the same type of gasket on the tube side and shell side, i.e. with similar compressive characteristics.

7 .8.9 Allowable stresses that have been established on the basis of shorttime tensile strength shall not be used for the design of girth flanges, gasketed tubesheets and gasketed flat covers.

NOTE 1 These allowable stresses can cause permanent deformation.

NOTE 2 In ASME Section II, the allowable stresses of some high-nickel alloys have been established in this way.

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7.9 Expansion joints 7 .9.1 Expansion joints shall be thin-wall bellows or thick walled (e.g. flanged or flanged and fluid).

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7 .9.2 Expansion joints made of thin-walled bellows shall comply with the following. a) They shall be protected from internal damage with a metallic liner mounted flush with the inside of the shell. The liner material shall be compatible with the base material to which it is attached. Carbon-steel liners shall be at least 6 mm (1/4 in} thick. liners of stainless steel or other alloys shall be at least 3 mm (1/8 in) thick. For vertically mounted bellows, the liner shall be attached at the top and open at the bottom to allow for free drainage. b) They shall be protected from external damage with a metallic cover that is designed to remain intact during shipping, handling and operation. c) They shall be designed to meet the requirements of the pressure design code. In no case shall the cycle life, as calculated by EJMA, be less than 1000 normal operating cycles. d) They shall have the bellows formed from a cylinder that has only longitudinal weld seams. e) Bellow welds, including attachment welds, shall be 100% examined by the liquid-penetrant method. The acceptance criteria shall comply with the pressure design code.

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f)

They shall be designed with stays to prevent damage during shipping and handling. Stays that require removal or adjustment prior to operation shall be clearly identified. g) Floating-head tailpipe expansion joints shall be fitted with permanent stays that prevent damage during maintenance and hydrostatic testing with the shell cover removed. The stays shall permit the expansion joint's full design movements.

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Thin Walled Expansion Bellow

They shall be protected from internal damage with a metallic liner mounted flush with the inside of the shell.

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Thin Walled Expansion Bellow

They shall be protected from external damage with a metallic cover that is designed to remain intact during shipping, handling and operation.

They shall have the bellows formed from a cylinder that has only longitudinal weld seams.

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Thin Walled Expansion Bellow

They shall be protected from external damage with a metallic cover that is designed to remain intact during shipping, handling and operation.

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Expansion Bellow

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Non-Thin Walled Expansion Bellow

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7.10 Gaskets 7.10.1 Gaskets in hydrocarbon or steam service shall be double-jacketed metal with a soft gasket filler, solid metal, serrated metal with a soft gasketseal facing, corrugated metal with a soft gasket-seal facing or spiral wound.

7.10.2 Pass partition rib(s) for double-jacketed, solid-metal, serrated-metal and corrugated-metal gaskets shall be of the same materials as the perimeter portion of the gasket. Pass partition ribs shall be designed and constructed such that they do not inhibit the compression or seating of the perimeter gasket.

7.10.3 If the gasket OD is less than or equal to 610 mm (24 in), the perimeter portion shall be of one piece (nonwelded) construction. If the gasket OD exceeds 610 mm (24 in), the maximum quantity of welds in the perimeter portion shall not exceed the following. a) Double-jacketed gaskets shall have no more than one weld in the perimeter portion. b) Other gasket types shall have no more than two welds in the perimeter portion, or no more than the ratio of gasket OD /610 mm (24 in), whichever is greater.

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Pass Partition Ribs shall be designed and constructed such that they do not inhibit the compression or seating of the perimeter gasket.

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7.10.4 The gasket welds shall comply with the following. a) Welds in the perimeter portion of the gasket shall be continuous and fullpenetration. The cross-section, finish and flatness of these welded areas shall match the remainder of the perimeter gasket. b) Welds shall not inhibit the sealing or compression of the perimeter gasket or pass ribs.

7.10.5 If adhesives are used to attach facings, they shall be compatible with the core (e.g. chloride content).

7.10.6 Double-jacketed gaskets shall comply with the following. a) They shall be manufactured with the filler material completely enclosed in metal. b) Filler materials shall be selected so as to ensure that no degradation occurs during manufacturing (e.g. welding).

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7.10.7 Serrated gaskets shall comply with the following. a) The top of the serrations at the weld shall be flat in comparison with the rest of the gasket. The grooves shall be dressed to match the standard profile. b) Thickness variations in their metallic core shall not exceed 0,13 mm (0,005 in) along a 25,4 mm (1 in) band. If welds are present, the centre of the bands shall be located at the centre of the welds. c) They shall have no facing joints coincident with a facing joint on the opposite sealing face or coincident with any welds in the core. d) They shall have one-piece continuous facing materials (no joints) if the outside diameter is less than 1 m (40 in). e) There shall be an overlap of the facing material of 1,5 mm (1/16 in) to 3 mm (1/8 in) if the outside diameter is 1 m (40 in) or larger, except that butt joints (gap-free) may be used for flexible-graphite facings.

Charlie Chong/ Fion Zhang

7.10.8 Corrugated metal gaskets shall comply with the following. a) They shall have a minimum core thickness of 0,46 mm (0,018 in). b) They shall have corrugations in the weld area that match the gasket profile. c) They shall have no facing joints coincident with a facing joint on the opposite sealing face or coincident with any welds in the core. d) They shall have one-piece continuous facing materials (no joints) if the outside diameter is less than 1 m (40 in). e) There shall be an overlap of the facing material of 1,5 mm (1/16 in) to 3 mm (1/8 in) if the outside diameter is 1 m (40 in) or larger, except that butt joints (gap-free) may be used for flexible-graphite facings.

7.10.9 Spiral-wound gaskets shall be provided with a means to prevent overcompression or buckling.

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7.11 Handling devices 7 .11.1 The lifting device shall be a weld-on lug or ring provided with a hole not less than 38 mm ( 11/2 in) in diameter. Wherever possible, the lug or ring shall be located at the top of the component, above its centre of gravity; otherwise, two suitably located lugs or rings shall be provided. The lifting device shall be designed to support at least twice the mass of the component.

7.11.2 For stacked heat exchangers, two lifting lugs or rings shall be provided on all covers, located at the top, approximately 45° from the vertical centreline.

7.11.3 Stationary tubesheets shall be provided with pulling lugs or tapped holes on their outer face for the insertion of eyebolts to aid removal of the bundle from the shell. Pulling lugs and tapped holes shall be designed for a pulling force equal to at least 150 % of the bundle mass. Each tapped hole shall be fitted with a threaded plug of the same material as the tubesheet face.

The exposed section of the plug shall be at least 50 mm (2 in) long.

7 .11.4 All vertical heat exchangers shall be provided with lifting devices for the entire heat exchanger. The lifting devices shall be positioned above the centre of gravity of the heat exchanger.

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Handling Devices The lifting device shall be designed to support at least twice the mass of the component.

Charlie Chong/ Fion Zhang

Handling Devices The lifting device shall be designed to support at least twice the mass of the component.

Charlie Chong/ Fion Zhang

Handling Devices The lifting device shall be designed to support at least twice the mass of the component.

Charlie Chong/ Fion Zhang

Handling Devices The lifting device shall be designed to support at least twice the mass of the component.

Charlie Chong/ Fion Zhang

7.12 Hydrogen service • If the purchaser specifies that the tube side and/or shell side will be exposed to hydrogen service, totally enclosed spaces between welds shall be eliminated or vented with a hole of 6 mm (1/4 in) in diameter.

7. 7.5 Slip-on flanges shall not be used in any of the following conditions: a) design pressure greater than 2100 kPa (300 psi) gauge; b) design temperature greater than 400ºC (750 °F); c) corrosion allowance greater than 3 mm (1/8 in); d) hydrogen service; e) cyclic service, if the pressure design code requires fatigue analysis.

Charlie Chong/ Fion Zhang

Skid In

Charlie Chong/ Fion Zhang

Heat Exchanger Skid-In Installation

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

20180531 May

有书真幸福， 无事小神仙

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang Charlie Chong/ Fion Zhang