09-00 - Shell and Tube Heat Exchangers For Routine Service
09-00 - Shell and Tube Heat Exchangers For Routine Service
09-00 - Shell and Tube Heat Exchangers For Routine Service
Specification 9.00
22/02/15 1
SECTION
1.0 SCOPE
2.1 Conflicts
3.0 MATERIALS
3.3 Tubesheets
3.6 Castings
4.0 DESIGN
Page 1 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
SECTION
5.0 WELDING
5.4 Preheat
6.2 Tubes
7.0 INSPECTION
9.0 PAINTING
10.0 SHIPPING
11.0 GUARANTEE
12.0 SUBMITTALS
ATTACHMENT
Page 2 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
This specification applies to shell and tube heat exchangers with thin-wall
carbon steel shells and channels. This specification also covers heat
exchangers with alloy or nonferrous tubes and tubesheets.
Special requirements associated with solid alloy or alloy clad shells and
channels or thick wall construction are covered in Specification 9.01.
Thick wall construction applies if the thickness of any of the following
exchanger parts exceeds 1.5 inches: cylindrical wall of shell or channel,
tapered transition section, head, or tubesheet when the tubesheet is
welded to shell or integrally forged with shell.
Shell and tube heat exchangers shall conform to the latest printing of the
latest edition of the Standards of the Tubular Exchanger Manufacturer's
Association (hereinafter referred to as TEMA), Section VIII, Division 1 of
the ASME Boiler and Pressure Vessel Code (hereinafter referred to as the
Code); and API 660, Shell and Tube Exchangers for General Refinery
Services. The additional requirements of this specification, the data sheet
that accompanies this specification, and the Company Technical
Requirements shall also be met.
2.1 Conflicts
In case of conflict between this specification, the data sheet, the Code,
and documents referenced herein, Contractor shall request an
interpretation by Company. Contractor shall not assume which instruction
governs.
3.0 MATERIALS
Page 3 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
3.3 Tubesheets
Carbon Steel Plate, SA-285 Gr. C, SA-442, SA-515, SA-516, SA-537 Cl. 1
Carbon Steel Forgings, SA-105, SA-181, SA-350 Gr LF2
Carbon Steel Seamless Pipe, SA-53 Gr. A or B, SA-106 Gr. A or B, SA-333
Gr. 1 or 3
3.5.1 Bolts shall conform to SA-193 Grade B7 for design temperatures equal to
750F or less and Grade B16 for design temperatures equal to 950F or
less. Nuts shall conform to SA-194 Grade 2 or 2H. Bolts and nuts shall be
cadmium plated.
3.5.2 For studs in blind holes, either the end of the stud or the bottom of the
hole shall be relieved to prevent galling.
3.6 Castings
All plate, forging, and pipe grades of material must meet the
requirements of Code Paragraph UCS-66 and 67 for the minimum
design metal temperature (minimum pressurizing temperature)
specified with the following additional requirement.
Page 4 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
Plate
3.7.2 When normalized materials are used, the normalizing temperature shall
not exceed 1750F.
3.7.3 Hot forming temperature for normalized material shall not exceed the
normalizing temperature unless the material is renormalized after hot
forming.
4.0 DESIGN
4.1.1 All exchangers designed for internal pressure shall also be adequate for,
and stamped for, at least 7.5 psi external pressure at 450F (excluding
corrosion allowance).
4.1.2 The design pressure and temperature and the hydrostatic test pressure of
a vessel shall not be limited by the mechanical design of minor
components such as nozzles, manholes, or reinforcing pads, unless
approved in writing by the Company.
4.2.2 Sealing devices (dummy tubes, tie rods with spacers, or combinations
thereof) shall be inserted in each pass partition lane that is coincident
with the crossflow direction. One sealing device shall be installed for
each three to four tube rows located along the pass partition lane
between baffle cuts.
4.2.3 For segmental transverse baffled exchangers, other than Kettle type,
longitudinal seal strips (bars) shall be provided in the peripheral space
between the bundle OD and the shell ID, when that gap exceeds half the
tube pitch. Clearance between seal strips and tubes shall not exceed half
the tube pitch. One pair of seal strips shall be provided for each five to
seven tube rows crossed by the shell side crossflow stream between
baffle cuts. When this results in a single pair of seal strips they shall be
equidistant between adjacent baffle cuts. The outermost of multiple seal
strip pairs shall be located between 1 and 3 inches from the edge of
Page 5 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
4.2.5 On U-tube bundles, 1/8 inch of the outer rear edge of the tube support
nearest the U-bends shall be tapered by 30 degrees. See Figure 3 on
Standard Drawing GD-E1274.
4.2.6 Longitudinal baffles for TEMA Type F, G, and H shells shall have a width
equal to the diameter of transverse baffles and shall have points of extra
width at the four corners as shown in Figure 2 on Standard Drawing
GD-E1274. These points of extra width may be made by weld buildup
and may be thinner than the longitudinal baffle. The dimension across
the points of extra width shall be 1/16 inch less than the actual (as built)
shell I.D.
4.2.7 For TEMA Type F shells, the longitudinal baffle shall be welded to the
tubesheet.
4.2.8 For TEMA Type G and H shells, the longitudinal baffle may be made with
windows and welded to the stationary tubesheet. Alternatively, the
longitudinal baffle may be welded to a transverse baffle by continuous
fillet welds. Do not weld longitudinal baffles to more than one transverse
baffle.
4.2.9 The seals at the edge of a longitudinal baffle shall consist of a stack of
eight strips of soft or annealed Type 304 SS, each 0.004 inch thick (unless
another material is specified). They shall extend five-eighths of an inch
beyond the edge of the baffle, and shall be attached by a bolting bar set
back five-eighths of an inch from the edge of the baffle.
4.3.1 Dowel pins shall be provided for proper alignment of pull-through floating
heads with floating tubesheets or alignment of split ring floating heads
with split backing rings.
4.3.2 For TEMA Type S units, the split ring shall have two counterbores as
shown in Figure 4 on Standard Drawing GD-E1274. The outermost
counterbore shall be 0.125 inch deep and the inner counterbore shall be
such that clearance between the split ring and the floating head is 0.032
inch when the gasket is in the compressed state.
Page 6 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
When impingement rods are specified, they shall consist of two rows of
staggered rods on the same pitch as the tube bundle centered in the path
of the shell inlet flow. The length of the rods shall be at least 20% greater
than the inlet nozzle I.D. The width of the rod array (distance between
centerlines of the outermost rods in the first row) shall not be less than
the inlet nozzle I.D.
Tubes shall be roll expanded into the tube sheets without seal welding.
Tubes should not be rolled to more than 95% of the tubesheet thickness.
4.7.1 Flanged nozzles: Nozzles for sizes 2 inches and larger shall be in
accordance with Standard Drawing GF-C14311. Nozzles 1 1/2 inches and
smaller shall be seamless, long weld-neck flanges, or fabricated from
schedule 160 or XXS seamless pipe and weld-neck flanges. "Set-on"
nozzle designs are not permitted.
4.7.3 Threaded connections over 1 1/2 inch NPS shall not be used. Threaded
connections 1 1/2 inch and less, when shown on the vessel drawing, may
be either:
1. Full coupling ANSI class 6000, "set through" the vessel shell with a full
penetration weld, or
Page 7 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
4.7.4 Seamless long weld neck and integrally reinforced nozzle forgings are
acceptable for nozzles and manholes.
4.7.5 When reinforcing pads will cover a welded joint, the covered area of the
joint shall be ground flush and 100% radiographed.
4.7.6 On nozzles and manways having tongue and groove facing, the groove
shall be on the vessel unless the flange face is directed downward, in
which case the tongue shall be on the vessel.
4.7.7 Inner edges of nozzles, manway necks, bosses, and other vessel
penetrations shall be ground smooth to 1/8-inch minimum radius.
4.7.9 Steam heated vertical reboilers shall be provided with a shell side vent as
close to the top tubesheet as possible to relieve noncondensible (carbon
dioxide) accumulation.
4.8.1 All supports shall be designed to withstand the following forces: (1)
Seismic and wind loads in accordance with the Uniform Building Code and
(2) a bundle pulling force in an axial direction equal to twice the empty
weight of the bundle.
4.8.2 External carbon steel supports shall have a corrosion allowance of 1/16
inch.
4.8.3 One support of horizontal heat exchangers shall have slotted bolt holes to
allow for thermal expansion of the unit.
4.8.4 Vertically mounted exchangers shall be supplied with lifting lugs designed
and located such that the unit can be lifted in a horizontal position and
then swung into a vertical position without exceeding allowable stresses.
4.8.5 All external attachments, including saddles, pads, name plate, and
brackets, shall be continuously welded to the vessel unless otherwise
agreed to by the Company. Vents shall be provided in all pads and similar
attachments. Pads and saddles shall be circular, or have a corner radius
of at least five times the pad thickness.
Page 8 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
4.9.1 The Code method for flange design shall be used with the following
definition for design bolt load.
4.9.2 Cover plate thickness shall be designed according to Code using the bolt
load, W, defined above, with the thickness being the maximum thickness
obtained using the following pressure and allowable stress combinations
in the Code formula: (1) hydrotest pressure and allowable stress at
ambient temperature and (2) design pressure and allowable stress at
design temperature.
Page 9 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
4.10.1 Where horizontal heat exchangers are stacked and connected, the
Contractor shall supply straight pipe spools, if any, between flanged
nozzles, shims between interconnecting supports, jack screws at
interconnecting supports to facilitate gasket replacement, and spectacle
blinds in the interconnecting pipe.
4.10.2 Contractor shall shop-assemble, hydrotest, and ship assembled the units
in such a stack.
5.0 WELDING
5.1.1 The interrupted-arc (short circuit transfer) GMAW process shall not be
used without Company approval.
5.1.2 All joints welded from two sides shall be back chipped or back gouged to
sound metal before continuing welding on the backside of the joint.
Tensile strength of the weld metal shall be limited to 100 ksi maximum.
This shall be verified by a hardness test of the weld metal in the weld
procedure qualification or a hardness test of each vessel seam.
Page 10 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
5.4 Preheat
When Cv-impact testing is required by Paragraph 3.7, one test plate shall
be made for each exchanger, for each welding procedure used for
Category A and B joints.
5.6.1 All Category A and B joints shall be double butt welded (Type 1) or an
acceptable equivalent agreed to by Company.
5.6.3 All Category C and D joints shall be double welded and have full
penetration, or an acceptable equivalent agreed to by the Company.
5.7 No welding shall be done on the vessel shell and channel after postweld
heat treatment (PWHT) or hydrostatic test.
6.1.1 Postweld heat treatment (PWHT) shall be in accordance with the Code, or
as specified by Company for the service conditions.
6.1.3 During postweld heat treatment, vessels shall be blocked and supported
as necessary to avoid any deformation or damage.
Page 11 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
6.1.4 Bolted internal parts shall not be installed in the exchangers before
postweld heat treatment.
6.1.5 All lead or sulfur containing substances, such as oil, grease, thread
lubricants, and paint, shall be removed from all vessel surfaces prior to
postweld heat treatment.
6.2 Tubes
6.2.1 Methods
6.2.1.1 Heat treatment by furnace and/or electric resistance methods are allowed
only as shown in the list below. If no temperature is shown, that method
shall not be used for that material. Temperatures are +/- 50F.
Electric
Furnace (F)
6.2.1.2 Ferritic and martensitic stainless steels (400 Series) shall be stress
relieved only when specified by Company. If stress relief is specified, it
shall be conducted full-length by furnace heat treatment only.
6.2.2.1 Holding time for furnace stress relief of tubes shall be 1 hour.
6.2.2.3 If stress relieving by furnace is done after assembly of the tubes into the
tubesheet, the tubesheet shall not be heated, and sealing strips on
longitudinal baffles shall be installed after the tubes are stress relieved.
Page 12 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
6.2.3.1 Pulse heating or other method shall be used to control tube temperature.
The controlling temperature shall be measured with a thermocouple or
calibrated optical pyrometer on the straight tangent near a U-bend or
adjacent to the circumferential weld. The temperature on the inside of
U-bends shall not exceed the value specified in Paragraph 6.2.1 (+/- 50F)
above.
6.2.3.2 For austenitic stainless steel tubes, total time above 800F shall be less
than five minutes. To cool, blow air, nitrogen, or inert gas through the
inside of the tubes. Water quenching is not acceptable.
6.2.4.1 Stress relieve the entire U-bend plus 1 foot (minimum) beyond the
tangent for electric resistance stress relief.
6.2.4.2 Stress relieve the entire U-bend plus 3 feet (minimum) beyond the
tangent for furnace stress relief.
7.0 INSPECTION
7.2 Before spot radiographs are made, the Company shall be notified 5
working days in advance so that the Company's Inspector can designate
the locations at which the spot radiographs will be taken.
7.3.a Spot radiography per Paragraph 7.1 is also mandatory for all Category B
welds, including nozzles.
Page 13 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
3. Fabricator shall schedule (1) and (2) above to minimize the number of
inspection visits by Company Inspector.
7.4 Radiographs shall be retained by the fabricator for at least one year after
the date of shipment, and shall be made available for review upon
request by the Company. Radiographs shall be offered to the Company at
the end of the year.
8.1 Contractor shall furnish all test materials and facilities including blinds,
bolts, and gaskets.
8.2 The vessel shall be cleaned internally and externally of dirt, debris,
welding slag, and weld spatter before the hydrostatic test.
8.4 For austenitic and ferritic stainless steel, limit chloride content of
hydrotest water to 50 ppm. Potable water is acceptable for other
materials.
8.5 Company shall be notified five days in advance so that the hydrostatic
test can be witnessed.
8.6 Gaskets used in tests shall be of the type required in service. Gaskets not
damaged in the test may be shipped with the vessel.
8.7 Following the hydrostatic test, the channel cover shall be removed. The
unit shall then be up-ended to drain out residual water. The channel
cover shall then be re-installed. For heat exchangers with other than
TEMA Type A channels, the Contractor shall propose a suitable procedure
to drain out residual water.
9.0 PAINTING
10.0 SHIPPING
10.1 All flange faces shall be protected against corrosion and damage by
Page 14 of 15
MAMTECH SERVICES LIMITED
Specification 9.00
10.2 Nozzles fitted with blind flanges shall be bolted with specified bolts, nuts,
and gaskets in place ready for service.
10.4 All vent holes in reinforcing pads, saddles, etc., shall be plugged with stiff
grease.
10.6 The Contractor shall load and block the vessel in a manner to avoid
damage during shipment.
11.0 GUARANTEE
12.0 SUBMITTALS
- Design drawings
- Weld procedure
- Heat treatment procedure
- Hydrotest procedure
Page 15 of 15