ES 3201
ENGINEERING STANDARD
HEAT EXCHANGERS
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 2 OF 23
CONTENTS
CLAUSE
NO.
DESCRIPTION
SHEET NO.
1.0
GENERAL
2.0
RESPONSIBILITY OF SUPPLIER
3.0
MECHANICAL DESIGN
4.0
MATERIALS
5.0
SCOPE OF SUPPLY
11
6.0
FABRICATION
12
7.0
16
8.0
18
9.0
GUARANTEE
20
10.0
DOCUMENTATION
21
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 3 OF 23
1.0
GENERAL
1.1
The specification defines the responsibility of the supplier and covers supplementary
requirements relating to design, materials, fabrication, inspection, testing,
painting, packing and dispatch etc. The specification shall be read in conjunction
with code, specification sheet and other enquiry documents. In case of conflict
between code and enquiry documents, the vendor shall contact TPI for
clarifications. As a general rule the most stringent requirement shall govern.
1.2
The offer shall include a sketch indicating thicknesses of major parts, empty
weight, operating weight and test weight. It may be noted that decrease in
offered thickness shall not be allowed.
1.3
-------------------------------------------------------------------------------------------------------------
1.4
TPI shall have the right to split the order and part orders shall be acceptable to the
supplier.
1.5
The offer must be technically and commercially complete. Incomplete offers are
liable to be rejected.
1.6
Any deviation from the clauses stipulated herein, specified codes and other enquiry
documents shall be clearly mentioned in the offer with proper references to clause
numbers. In absence of any such indication it shall be assumed that the offer
complies with all requirements and such assumption shall be strictly binding on the
supplier.
1.7
Some of the sizes and dimension marked under HOLD on enquiry drawings and
data sheets shall be removed later on and the required size/dimensions shall have to
be adopted by supplier without any commercial implication.
2.0
2.1
The responsibility of the supplier shall include but not be limited to the following. Any
other item/activity which is not listed here but is required for completion of the supply
as per the enquiry document shall also be the responsibility of the supplier.
a)
b)
To obtain approval
specified in para 10.0.
c)
To obtain statutory
wherever applicable.
d)
Procurement of all the materials whatsoever required to meet the scope of supply.
e)
f)
Submission of the periodic progress report showing the status of the job.
g)
of
TPI on
approval
drawings
of
and
drawings
other documents as
and
other documents
3.0
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 4 OF 23
MECHANICAL DESIGN
3.1
3.2
For high alloy steel parts/components designed as per ASME Sec.VIII DIV.1
lower allowable stresses shall be adopted, for tubesheet and flanges of
gasketed joints unless otherwise specified. After the approval of various documents
subsequent deviations shall be discouraged.
3.3
___________________________________________________________________
3.4
All equipments shall also be designed for hydrostatic test in operating position in
corroded condition considering 25% of design wind load. Allowable stress during
hydraulic testing shall be 90% of yield stress.
3.5
Unless other wise specified elsewhere in enquiry/order document, Wind loads shall
be calculated in accordance with BIS:875 (Part 3) with following consideration:
Equipment shall be considered as Important Building Class of Structure accordingly
risk coefficient (K1 Factor) shall be taken from Table 1 BIS:875.
Terrain category (K2 Factor) shall be taken conservatively as 2, Terrain Class shall
depend upon the size of equipment.
Topography (K3 Factor) shall be taken to be equal to 1.0.
Force coefficient (Cf) for the equipment (non-smooth) shall be taken from table 23
accordingly wind force calculated.
Wind forces shall be increased by 20% to cater for the effect of piping system,
platforms and ladders etc.
Vertical vessels with height/diameter ratio equal to or greater than 6 shall be
analyzed for vibration due to vortex shedding when critical wind speed does not
exceed 30 m/s.
Unless otherwise site spectra furnished by client, Seismic loads shall be calculated in
accordance with BIS : 1893. For the design values of horizontal seismic co-efficient
3.6
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 5 OF 23
3.7
All items whether internal or external which are welded directly to a shell or head
shall be of the same material category as that of the shell or head. This shall apply to
all nozzles, brackets, pads and upper portion of the skirt for vertical exchangers.
3.8
Base rings for skirt supported equipment shall be in accordance with standard as
applicable. Base ring dimensions shall be calculated to ensure that the compressive
stress on the grout under any part of the base ring does not exceed 44 Kg/cm2g.
3.9
3.10
3.11
3.12
Expansion bellows shall be designed for min. 5000 cycles, as per TEMA.
3.13
Tube and shell side components shall be designed considering mean metal
temperatures as per section UHX of ASME Sec. VIII Div.1.
Unless detailed thermal calculations prove otherwise the tube sheet design
temperature shall be considered to be the design temperature of either the tube-side
fluid or the shell-side fluid, whichever is higher.
FE Analysis shall be carried out for thin tube sheet exchanger and the same shall
be submitted for TPIs reference / record. Stresses shall be evaluated as per
ASME Sec. VIII Div.2.
3.14
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 6 OF 23
3.15
3.16
Baffles and support plates in horizontal exchangers shall be provided drain & vent
with notches at the extreme point. Whenever bypass area exists, dummy
tubes/sealing strips shall be provided.
3.17
Tubesheets in vertical exchangers shall be provided with drain and vent arrangement
with threaded plug seal welded.
3.18
Components in contact with both shell and tube side fluids shall be designed for the
most stringent pressure/temperature combination.
3.19
In no case minimum corrosion allowance for C.S and low alloy steel material shall be
less than that specified in equipment specification sheet or TEMA unless otherwise
specified.
3.20
Adequacy of tube bundle against flow induced vibration shall be checked by supplier
if called for and any modification, if required, shall be carried out in consultation
with TPI without any commercial implication. Vibration analysis shall be
submitted to TPI for review.
3.21
Impingement Baffles
Unless otherwise stated inlet nozzles on shell side shall be provided with
impingement plate in compliance with TEMA requirement.
3.21.1
The flow area around solid impingement plate shall be at least equal to the inlet
nozzle cross-section. In case of two phase flow impingement baffle shall be
perforated.
3.21.2
Impingement baffle plate shall extent at least 25 mm beyond the projection of the
nozzle bore.
3.21.3
The clear distance from the nozzle (at the inner surface) to the impingement plate
shall be at least 0.25 x nozzle diameters.
3.21.4
3.22
In case of girth flange design, minimum width of gasket shall be checked to withstand
required design condition.
3.23
In case of girth flange design correction factor for flange moment shall be based on
maximum bolt spacing as 2db + t where db is bolt diameter and t is the flange
thickness.
3.24
For equipment to be designed as per I.B.R all requirements specified therein shall be
taken care of.
For parts/components, design of which is not covered in I.B.R, recommendations
of ISO R 831 or any other international code accepted by I.B.R shall be followed
and it shall be with the prior approval of TPI.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 7 OF 23
3.25
Baffle and support plates shall be tied together with tie rods and spacer pipes unless
otherwise specified. Tie rods and spacers should be preferably on the peripheral
open area so as to block the bypass area between outer most tubes and shell inside.
3.26
Unless otherwise stated all girth flange joints shall be confined type.
3.27
For equipment to be lined with refractory material by the supplier, calculation for
refractory thickness along with the properties of the refractory selected shall be
submitted for comments & approval in addition to other design calculations.
3.28
Bolts of size M52 and above shall be designed and spaced so as to permit tightening
with a hydraulic stud tensioner. The bolts shall have an extra threaded length at one
end of appx. 1 bolt diameter and shall be provided with threaded protection caps.
Hex nuts shall have suitable holes for manual tightening.
3.29
Kettle- type shells must be provided with rails on which the tube bundles can be
supported and guided. The baffle should be designed accordingly. Also proper tube
bundle holding arrangement shall be provided at last support baffle to avoid any
damage during handling/ transportation.
3.30
3.31
Where the operating load on the sliding saddle > 2500 kg. It shall preferably rest on
low friction pad or rollers. The drawing shall show this pad included in the saddle
height. No slotted holes are required in the saddle base. But the saddle shall be
guided and prevented from lifting. When low friction pads e.g. Teflon are used,
counterpart shall be polished SS plate and be designed so that low friction pads are
entirely covered by the SS plate under all operating conditions.
When the rollers are used, the rollers shall be prevented from running out. The roller
can, for example, be 40 mm nominal diameter CS bars linked together in parallel at
60 mm spacing. They shall extend to the outer vertical webs of the saddle, but shall
not be attached either to the saddle or to the supporting steel. The vessel drawings
also shall show that the saddle resting on the rollers is 40 mm shorter than the fix
saddle.
3.32
When deciding which saddle should be chosen as fixed, the permissible deflection of
any large bore pipe attached to the equipment shall be taken into consideration.
3.33
When design pressure is more than 400# class and/or shell thickness is 50 mm and
above, selfreinforced forged nozzle shall be provided. Nozzle size 3 NPS Shell to
SR nozzle welding shall be set-in type welding. For small sizes shell to SR nozzle
welding may be set-on type welding.
3.34
ENGINEERING STANDARD
HEAT EXCHANGERS
ES 3201
SHEET 8 OF 23
4.0
MATERIALS
4.1
All materials, whatsoever, required to complete the supplies shall be procured by the
supplier and all such materials shall be covered with due identifiable material test
certificates.
4.2
4.3
Material procured to other approved specification than stipulated in design code shall
be acceptable provided it meets all the requirements of applicable design code.
4.4
Unless otherwise specified all C.S and low alloy steel materials including forging
used for pressure parts shall be fully killed and in normalized condition.
4.5
Unless otherwise specified copper or copper alloys shall not be used. Copper content
up to 0.40% are acceptable in carbon steel and 0.6% in stainless steel.
4.6
4.7
For coarse grained and high tensile materials in carbon steel (UTS 52 Kg/mm2) and
low alloy steel, guaranteed impact strength shall be ensured at a temperature 15OC
below envisaged hydraulic test temperature as a precaution against brittle fracture
during hydraulic test. Similar precaution shall be taken for thicker plates > 50 mm for
equipment designed for pressure 15 Kg/cm2g.
4.8
C.S. and low alloy steel exceeding thickness of 50 mm shall be vacuum degassed
except for plate ring flanges.
4.9
4.10
4.11
Temper embrittlement
The risk of temper embrittlement (TE) must be taken into consideration for Cr-Mo low
alloy steel plates and forgings (P. Nos. 4, 5A and 5C as per ASME PV Code ) used in
pressure vessels and piping operating in the temperature range of 375C to 575C.
In order to reduce the risk of TE the following requirements shall be applied:
1 Cr- Mo (P4) Base Metal
(Elements weight %)
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 9 OF 23
(Elements in weight %)
(Elements weight %)
All forgings shall be ultrasonically tested as per Sec. ASTM A 388 for thickness
greater than 100 mm with the criteria shown in ASME Sec.VIII Div.2 para AM-203-2.
In case any defect is found, no repair by welding shall be allowed. ASME flange for
equipment designed as per ASME Sec.VIII Div.1 need not be UT tested.
4.13
All forgings including nozzles flanges shall be examined for surface defects MP/DP
after machining.
4.14
For SS 316 and 316L material, ferrite content for plates, pipes, tubes & forgings shall
be maximum 2%. However, for SS316L Urea grade ferrite content shall be
maximum 0.6%.
4.15
Intergranular corrosion test shall be carried out on all SS 316L Mod (Urea grade)
materials, weld and HAZ as per ASTM A 262 practice C if specified. The corrosion
rate shall not exceed 0.025 mm / month.
4.16
Inter granular corrosion test shall be carried out on all SS 316L materials, weld &
HAZ as per ASTM A 262 practice E (Strauss test) unless otherwise specified in
specification.
4.17
For equipment designed as per IBR, materials shall strictly comply with the
requirement of the IBR code. All materials must be procured from well known steel
maker recognized by IBR (refer Appendix G of IBR).
4.18
For equipment designed as per IBR, certificate for materials in respect of yield point
at design temperature, the average stress to produce elongation of 1% in 100,000 hrs
and the minimum stress to rupture in 100,000 hrs shall be obtained from the steel
makers wherever design conditions call for use of these data.
4.19
For IS 2062 materials without mill test certificates, check test, if called for by the
inspector, shall be performed without any commercial implication. Material shall be
fully killed.
4.20
4.21
Spiral- wound gasket shall be provided with S.S guide rings. Outside diameter of
gaskets shall extend up to bolting.
4.22
All pipe fittings including elbows for sizes 10 NPS shall be forged / wrought.
4.23.1
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 10 OF 23
4.23.2
Where seam welded tubes are permitted as an alternative, the weld shall be
inspected through out the whole length by eddy current or ultrasonic method.
4.23.3
As a general rule the preferred tube size is O.D. The minimum tube wall thickness
for O.D. carbon steel tubes is 2.11 mm (B.W.G.14) and for stainless steel 1.65
mm (B.W.G.16). (Heat exchanger for steam systems, under the preview of IBR
requires, according to paragraph 338, a minimum tube wall thickness of 2.03 mm for
both carbon and stainless steel. The nearest TEMA wall thickness is B.W.G. 14 =
2.11 mm).
4.23.4
4.24
The mean bending radius of U - tubes shall be not less than 1.5 times the tube
outside diameter.
Thickness of two-inner most rows of U-tube bundle shall be higher by 2 gauge.
4.25
4.26
Unless otherwise specified tube sheets and girth flanges shall be of forged quality
and ultrasonically tested.
4.27
Tubesheet and girth flanges must be in one piece. Segmental butt-weld construction
shall not be accepted.
4.28
All tubes including U-tubes must be in one piece. Circumferential welds are not
allowed.
4.29
Where heat treatment of U-bends is required, the heat treated portion shall extend at
least 150 mm beyond the point of tangency.
4.30
Shear test according to ASTM A 264 is required for clad plates. At least 14 Kg/cm2
shear strength shall result from such test. All clad plates shall undergo ultrasonic
examination at the steel work in accordance with ASTM A 578 level S8.
4.31
Gasket for all medium except cooling water service with flange rating 600 # shall be
spiral wound graphite filled gasket with external & internal guide rings 3.2 mm thk.
For prevention of crushing of gasket. For CW service gaskets for flange rating 150 #
compressed fiber gasket type in accordance with ANSI B 16.21 shall be used.
Gaskets with flange rating 900 # shall be octagonal ring-joint gasket. Hardness of
the gasket shall be 50 BHN lesser than that of the mating flange gasket groove.
4.32
Special flat closures shall normally be furnished with gaskets of one of the following
types:
i.
Double conical - Where double conical gaskets are used, a seating membrane
of graphite tape, 0.25 mm thick, shall be inserted between the joint ring and the
conical surfaces on the vessel and the flange. The quality of the graphite tape
will be specified by the purchaser.
ii.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 11 OF 23
5.0
SCOPE OF SUPPLY
5.1
Unless otherwise specified the complete main equipment and its various components
as specified in specification sheets and enquiry documents shall be included in
suppliers scope of supply.
Scope of supply shall included but not be limited to the following:
5.1.1
Cover flanges for manholes, handholes, inspection openings etc. with bolting and
gaskets.
5.1.2
5.1.3
5.1.4
5.1.5
All external welded attachments like platforms and ladder cleats, insulation supports
and pipe support cleats etc.
5.1.6
5.1.7
Impingement baffle.
5.1.8
Gland packing.
5.1.9
5.1.10
5.1.11
5.1.12
5.1.13
Support stool.
5.1.14
5.1.15
5.1.16
5.1.17
5.1.18
5.1.19
Hydraulic stud tension device. Complete with all accessories and operating manual
for bolt size M52 and above.
5.1.20
Internal sliding arrangement, guide rails, rollers and pulling Yoke for removable tube
bundle exchangers.
5.1.21
Ferrules.
5.1.22
5.1.23
5.1.24
5.1.25
5.1.26
Seasoned wooden blocks under support base for LT exchangers with bolting.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 12 OF 23
5.1.27
5.1.28
5.1.29
5.1.30
5.1.31
5.2
The following 2-Years Operation Spares shall be supplied along with the
equipment.
i)
ii)
iii)
iv)
v)
vi)
10% bolts/nuts for each nozzles with blind/companion flanges (min 5 pieces).
vii)
viii) 10% internal bolts, nuts & clamps (min 5 pieces of each size).
ix)
x)
5% tube plugs for both ends.(Tube plug length equal to tubesheet thickness).
xi)
10% ferrules.
FABRICATION
6.1
The manufacturer of the equipment shall comply in all respects with the provisions of
the applicable code/standards and specifications with respect to welding, fabrication,
forming of heads, radiography, heat treatment, inspection, testing and quality control
etc.
6.2
All welding shall be carried out by qualified welders using approved procedure in
compliance with the requirements of code & specifications and duly certified by the
inspecting authority. All welding procedure must be got approved from authorized
inspecting authority before starting any fabrication job. Welding of all parts must be
completed before heat treatment.
6.3
Plates of different thicknesses shall be made flush with the inner surfaces of
equipment unless otherwise stated.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 13 OF 23
6.4
Top portion of skirt (Minimum 1000 mm skirt) welded with bottom head shall be of
same material as that of shell/head. Skirt to head joint shall be full penetration type.
6.5
6.6
6.7
CS / Alloy steel dished end/toriconical head including cone if cold formed or hot
formed below normalizing temperature shall be subsequently normalized. In case
of austenitic SS materials solution annealing shall be carried out if hot worked.
Formed ends of vessels with diameters less than 1600 mm shall preferably be
made in one piece. Larger heads which can not be formed in one piece shall
be fabricated as follows with prior approval from TPI :a.
In two pieces, with the welding seam included in the middle third and
preferably on the centre line.
b.
Formed heads when fabricated in pieces shall be normalized and weld seams
radiographed after forming.
6.8
Impact test when required as per code & specifications shall be carried out on parent
metal, weld and HAZ.
6.9
In case of CS and low alloy steel expansion bellows, all joints shall be fully
radiographed and bellow shall be stress relieved.
6.10
Production control coupons, when required as per code & specifications shall be
subjected to impact test, corrosion test etc. in addition to mechanical tests as
required. In case of heat treated equipment test coupons shall be given similar heat
treatment as for the equipment.
6.11
Each shell section having diameter equal for less than 2 meters to the extent
possible, shall be rolled out of a single plate with one longitudinal seam.
6.12
6.13
The centers of the welded longitudinal joints of adjacent courses shall be staggered
or separated by a distance of five times the thickness of the thicker plate or 100 mm
whichever is greater.
6.14
All parts involving welding construction including internals and stiffener ring shall
have continuous welds unless otherwise stated.
6.15
In case of SS welds, procedure must be qualified to ensure that the weld meets the
minimum requirements of C, Cr, Ni and Mo as that of the parent metal. In addition to
various tests required as per code, weld procedure shall be qualified for intergranular
corrosion test, as per ASTM A 262 practice C/E, if specified. Carbide contamination
shall be avoided during welding.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 14 OF 23
6.16
In case of equipment fabricated of materials SS 316L/ SS 316 for urea service, low
ferrite filler material shall be so selected that ferrite content in two subsequent weld
pass in contact with process fluid shall be maximum 2% & for equipment fabricated of
materials SS 316L urea grade the limitation of ferrite content shall be 1%. The
welding not in contact with process fluid may have ferrite content limited to 6%.
6.17
All welds shall be full penetration welds with back chipping and rewelding from the
second side. For those joints which are inaccessible for back chipping the root run
shall be carried out with TIG process. Single side welding with backing strip is not
permitted.
6.18
Due provisions must be kept for venting out entrapped gases during welding of pads,
flanges and liner plates etc.
6.19
All nozzle reinforcing pads shall be tested pneumatically at 0.5 Kg/cm2g pressure
with soap solution on attachment welds. Vent holes shall be plugged with non
hardening mastic to prevent ingress of water.
6.20
Pads for supports and external cleats etc. shall be of same material as that of shell.
6.21
All sharp corners shall be rounded off with smooth radius. Inside edge of manhole
and hand hole at the internal surface shall be rounded to min. radius 5 mm.
6.22
Unless otherwise stated all nozzle flanges shall be weld neck type. For nozzle flange
size 24 dimensions shall conform to ASME ANSI B16.5 and nozzle flange
size >24 NPS dimensions shall conform to ASME ANSI B16.47 (Series - B).
All welding neck flanges shall be bored to suit nozzle I.D. Flange facings shall have
suitable serrations for gasket seating in case of plain, male/female and raised.
6.23
Unless otherwise stated all girth flange joins shall be confined type. Minimum depth
of gasket facing for girth flanges shall be 5 mm for compressed fiber gaskets and 6
mm for spiral wound / metal jacketed gaskets.
6.24
All internals fabricated in pieces shall be shop assembled and properly match
marked for easy assembly at site.
6.25
Each partition plate shall be welded to channel for their full length with full penetration
welds.
6.26
Each partition plate shall be provided with 3 mm dia drainage hole located as far
from the tubesheet as possible
6.27
Procedure shall be qualified for tube to tubesheet joint. Mock-up test shall be carried
out to establish all the requirements to the satisfaction of inspector.
6.28
6.29
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 15 OF 23
6.30
In case of equipment involving site assembly/fabrication, the entire site job including
fabrication, radiography, heat treatment, inspection, testing and transportation to site
shall be in suppliers scope of works at his cost.
6.31
All flange bolts & skirt-bolts shall straddle centre line unless otherwise stated.
6.32
Flange gasket contact surface shall not exceed 125 in roughness. In case of
metallic gasket the side wall surface of the gasket groove shall not exceed
63microns.
6.33
All nozzles less than or equal to NPS 65 shall be stiffened with three equispaced
plate ribs of the same material as that of shell.
6.34
External bolting for gasketed flanges shall always be stud bolts and nuts. Bolt
threads shall be in accordance with ANSI B1.1 (UNC for dia. 1, 8 UN for dia.> 1).
Threads of bolts and nuts shall be coated before installation with lubricant to prevent
galling of the threads.
6.35
Tubes holes in tube sheets of high alloy steel exchanger shall be finished to the
diameter and tolerances as special close fit specified in TEMA.
6.36
Tubes shall be flush with or extend by 3 mm beyond the face of each tube sheet,
except that tubes shall be flush with the top tube sheet in vertical exchangers unless
otherwise specified.
6.37
Bent portion of C-Mo, Cr-Mo U-tubes shall be heat treated after bending. Non ferrous
tubes shall be annealed.
6.38
Tubes in exchangers having design pressure less than 60 Kg/cm2g shall be rolled in
grooved holes in tube sheets and seal welded. Weld shall be DP checked. Tubes in
exchangers having design pressure equal to or more than 60
Kg/cm2g shall be expanded in plain holes in tube sheets and strength welded in
minimum 2 runs. Each pass DP checked.
All welding of tube to tubesheet joint shall be done using TIG method.
6.39
In case of overlayed tubesheet three grooves shall be made out of which one groove
shall be in overlayed thickness.
6.40
In case of lip seal gasket, lip shall be welded after successful hydraulic test. Lip seals
shall preferably be of hollow type and shall be furnished with O ring groove to
facilitate hydrotesting at work. O ring shall be removed after hydrotesting.
6.41
6.42
6.43
All nozzle necks, nozzle flanges and blind flanges shall be of weld deposit
construction for clad equipment. Loose liners are not permitted.
7.0
7.1
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 16 OF 23
7.2
All equipment shall be inspected during various stages of manufacture starting from
identification of raw materials to completion. The equipment shall be considered
acceptable for dispatch only after final certification for acceptance is issued by the
inspector.
7.3
7.4
Inspection by third party, if specified, shall be arranged by the supplier. It shall be the
responsibility of the supplier to make available to the inspector all the new/revised
drawings, calculations and other enquiry documents.
7.5
Inspection order on third party shall also include specific instructions for
marking copies of all correspondence from inspecting authorities to TPI
and reporting monthly progress of the order to TPI. Complete responsibility of
getting approval of drawings/calculations and documents from inspecting authority
shall be that of the supplier.
7.6
For equipment coming under IBR preview, the items shall be inspected during
various stages of fabrication and testing by an inspecting authority acceptable to IBR.
For list of inspection authorities recognized under IBR, reference shall be made to
appendix C of IBR. It is the responsibility of the supplier to get the fabrication
drawings and design calculations approved by IBR authority in India before the start
of fabrication.
7.7
For equipment coming under the purview of IBR, the inspection by local IBR
authorities shall have to be arranged by the supplier and all cost borne by the
supplier.
7.8
7.9
In case of castable refractory, 3 Nos. slab of each size shall be cast at site before
application and tested to meet the refractory specification in the presence of the
inspector.
7.10
Unless otherwise stated gaskets used during testing shall be same as specified for
operating conditions. After testing, gaskets used during testing shall be replaced by
new gaskets.
7.11
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 17 OF 23
Ultrasonic Examinations
i.
ii.
ii.
iii. All welds having thk. > 50 mm, all welds of low alloy steels and all
materials with UTS 52 Kg/mm2.
iv. Fillet welds of 3% nickel and SS.
v.
All welds of SS and non ferrous materials and welds for vessels with
design temp. (-) 45OC and below after hydrotesting.
Radiography when called for shell is applicable to all pressure welds i.e.
longitudinal & circumferential.
ii.
In case heads are formed of welded plates / petal construction, all the weld
seams prior to forming and after forming.
iii.
iv.
v.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 18 OF 23
d) Hardness
i.
Weld and Heat Affected zone (HAZ) of all pressure bearing welds in
Cr-Mo steel vessels shall be tested after final heat treatment using a
portable hardness tester.
Hardness value shall not exceed 215 HB for steel having Cr < 2% and
240 HB for steel having Cr 2%.
ii.
7.12
7.13
7.14
Tube to tube sheet joints shall be leak tested with air and soap solution at a pressure
of 2.0 Kg/cm2g. When specified leak testing with Halogen shall be carried out.
7.15
7.16
8.0
8.1
After hydraulic testing, the equipment shall be dried, thoroughly cleaned from inside
and outside and shall be free from all shop dirt, loose scale, grease etc.
8.2
8.3
i)
ii)
The equipment shall be shot/grit blasted (min SA 2.5 ISO 8501-1) before the
primer coat is applied on external surfaces. Primer shall be compatible to
succeeding painting.
iii) In general, uninsulated equipment working below 94C, alkyd high build primer
of thickness 50 microns DFT shall be applied.
iv) For Uninsulated equipment above 94C to 204C working temperature,
aluminum paint of 30 microns DFT shall be applied.
v)
For uninsulated equipment upto 420C working temp. inorganic zinc silicate of
50 microns zinc silicate shall be applied.
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 19 OF 23
vi) For insulated equipment up to 94C, primer painting shall be of alkyd high build
epoxy primer of 50 microns DFT shall be applied.
vii) For insulated equipment temperature exceeding 94C, primer shall be aluminum
paint of 30 microns DFT.
viii) Thermo-indicative paint (three colour phases) shall be applied on refractory lined
equipment to give warning of insulation/refractory failure. Paint manufacturers
recommendation shall be followed.
ix) All flange faces, bolting and other machined surfaces shall be painted with an
easily removable rust-preventive coating.
All machined surfaces, boltings and flange faces shall be properly protected from rust
and mechanical injury during transit and storage.
8.4
Nozzles shall be sealed suitably. Threaded connections and beveled openings shall
be suitably protected.
8.5
8.6
After hydraulic testing, all SS parts of equipment shall be pickled and passivated as
per the following procedure :
a)
Cleaning
Clean surface and remove all extraneous matter with a hard fiber brush or SS
wire brush. M.S. wire brush shall not be used. All organic materials shall be
removed with any paint remover like light solvent naphtha or benzene or
equivalent. Motor petrol shall not be used.
b)
Pickling
Aqueous pickling solution shall be as follows:
Nitric acid (Tech. grade) 10 to 25% plus Hydrofluoric acid 1 to 8% (to be used
only for stabilized SS grades). Temperature 50 to 60C for 10% Nitric acid and
20C for 25% Nitric acid. When size and shape of product permit, total
immersion in the pickling solution is preferred. Where immersion is impractical,
pickling may be accomplished by wetting the surface by:1) Swabbing or spraying.
2) By partial filling the item with pickling solution and rotating or rocking so that
all the surface receive the required chemical treatment.
The maximum period for which the pickling solution shall be allowed to remain
on the surface is 30 minute. During pickling removal of oxides may be hastened
by brushing with a hard fiber or SS wire brush. Over pickling shall be avoided.
The pickling agent shall be washed off with plenty of water so as to leave no
trace behind.
c)
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 20 OF 23
Passivation
After pickling and water rinsing, an aqueous caustic permanganate solution
containing NaOH 10 weight % and KMnO4 4 weight % shall be used for
neutralizing pickling solution. This shall be followed by thorough water rinsing.
Water used for pickling and washing shall not have chloride contents exceeding
30 ppm.
8.7
Equipment intended for transportation by ship shall be kept in hatch of the ship.
Suitable seaworthy packing/painting shall be applied to avoid any damage during
transshipment.
8.8
8.9
All spares shall be properly packed, marked and sent separately along with
equipment.
8.10
9.0
GUARANTEE
9.1
The supplier shall guarantee equipment and their components against faulty design
with regard to mechanical adequacy, improper material of construction and poor
workmanship for the specified period.
9.2
Approval of detailed shop drawings by TPI, will not in any way absolve
supplier
from his responsibilities to supply the
equipment in accordance with order specification.
9.3
9.4
In case process design is also in suppliers scope, guarantee shall include process
guarantee also in addition to above. All special instruments required to verify the
guarantee, fixtures as outlined in the equipment specification shall have to be brought
by the supplier on draw-back basis.
the
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 21 OF 23
10.0
DOCUMENTATION
10.1
10.2
10.3
10.4
For equipment requiring statutory approval from Inspector of Explosives, it will be the
responsibility of the supplier to get the fabrication drawings of equipment approved at
his cost, wherever required.
10.5
10.6
It will be preferable, if the soft copy along with 4 prints is brought to TPIs
design office for getting approval. Supplier shall depute the concerned
engineers & draftsmen with prior intimation and agreed date for deciding and
incorporating the various agreed comments during their stay. Same procedure shall
be followed for the approval of subsequent revisions, if any. Revisions shall also be
entered in CAD file. Manual revision in drawing shall not be accepted.
10.7
After approval one set of drawings / documents shall be given to the inspector by the
supplier.
10.8
10.9
10.10
10.11
10.12
All documents required as per IBR code for approval must be supplied on IBR
Performa.
10.13
10.14
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 22 OF 23
The number of copies of documents and required delivery time in weeks from date of
letter of intent / order for each document is given below.
Sl.
Description
No.
1
2
Out line sketch showing thickness of main parts, weight &
1.
anchorage details (Refer Clause 10)
Reqd.
with bid
Copies
3
Required after
purchas
Copies Days
4
5
--
--
--
--
--
--
--
--
5 Billing Schedule
--
--
--
--
--
--
List of drawings
--
--
30
--
6
8
6
30
30
30
--
30
--
60
---
6
6
60
--
30
10
11
12
17
---
60
ENGINEERING STANDARD
ES 3201
HEAT EXCHANGERS
SHEET 23 OF 23
Sl.
Description
No.
1
Reqd.
Required after purchase order
with bid
Copies
Copies
18
--
12+ 2 RTF
After dispatch
of equipment
19
--
12
180
20
--
12
After dispatch
of equipment
21
--
-do-
After dispatch
of equipment
22 PWHT Charts ( ** )
--
-do-
After dispatch
of equipment
--
-do-
After dispatch
of equipment
--
-do-
After dispatch
of equipment
--
-do-
After dispatch
of equipment
--
-do-
After dispatch
of equipment
--
-do-
After dispatch
of equipment
--
12 + 2 RTF
After dispatch
of equipment
Transportation
drawing
showing
overall
29 dimension, C.G. weight and handling instructions
duly approved by appropriate authority.
--
120
--
12 +RTF + 2CD
ROM containing
editable soft files
After dispatch
of equipment
--
12
After approval
of CIB
30