This technical specification outlines requirements for stainless steel heat exchangers for a project in Iran. It specifies that materials will be stainless steel type 304 with minimum yield strength of 210 MPa. It provides details on fabrication, testing, inspection and shipping requirements to ensure the heat exchangers meet design specifications and standards. Quality control processes are also defined to confirm materials and workmanship meet the project's needs.
This technical specification outlines requirements for stainless steel heat exchangers for a project in Iran. It specifies that materials will be stainless steel type 304 with minimum yield strength of 210 MPa. It provides details on fabrication, testing, inspection and shipping requirements to ensure the heat exchangers meet design specifications and standards. Quality control processes are also defined to confirm materials and workmanship meet the project's needs.
This technical specification outlines requirements for stainless steel heat exchangers for a project in Iran. It specifies that materials will be stainless steel type 304 with minimum yield strength of 210 MPa. It provides details on fabrication, testing, inspection and shipping requirements to ensure the heat exchangers meet design specifications and standards. Quality control processes are also defined to confirm materials and workmanship meet the project's needs.
338033/4604-45ES-0004 Rvision Date Page 3 of 13 05 15/10/2013
REVISION INDEX
Revision
Pages Revised
Remarks # By App. Date 02 Y. Sadeghinejad M. Kianifard 09/04/2013 2,3,5,6,7,9,10,11 IFR 03 Y. Sadeghinejad M. Kianifard 08/05/2013 3,5,6,7,9,10,11 IFT 04 Y. Sadeghinejad M. Kianifard 08/05/2013 1,6,10 IFC 05 E.Mirbaha M. Kianifard 15/10/2013 7,8,10,11,12,13 IFC 05 E.Mirbaha M. Kianifard 17/10/2013 AFC
INSTRUCTION TO PRINT CONTROL (Indicate X where applicable)
Issued for Tender. Issued for Approval. Issued for Comment. Issued for Information. Approved for Tender. Approved for Design. X Approved for Construction.
2.0 GENERAL .......................................................................................................................................... 5
338033/4604-45ES-0004 Rvision Date Page 5 of 13 05 15/10/2013
1.1 This specification covers the requirements for furnishing all materials, equipment, tools, accessories, labor and supervision for the fabrication and testing of the Stainless Steel Gas to-Gas Heat Exchangers.
1.2 The extent of the work is defined in the Scope of Work Specification 338033/4604-45EW-0002.
2.0 GENERAL
2.1 Fabricator shall furnish all material as shown on the drawings, except as noted.
2.2 Fabrication shall be to C.E approved drawings, stamped "Issued for Construction".
2.3 If the exchangers physical dimensions are within the allowable limits for shipping, it shall be completely shop fabricated and tested before shipment.
2.4 The exchangers shall have lifting lugs designed by the Fabricator. Lifting lugs shall be permanent attachments and the vessel clearly marked with net weight. If vessel is fabricated in sections, each section must have a set of lifting lugs.
2.5 Special Note
C.E shall not assume the responsibility for searching out deviations in the Fabricator's drawings. All deviations must be clearly noted on approval drawings.
2.6 Fabricator shall not sublet work to others without the written approval of MC/Client.
3.0 MATERIALS
3.1 All plates used in the execution of this work shall be new, clean stock free from surface laminations or other physical imperfections.
3.2 All materials shall be identified throughout fabrication. Material certification shall be provided to C.E or Inspector upon request.
3.3 Materials of construction shall be as follows. In the event of conflict between this specification and design drawings, design drawings govern the requirements.
338033/4604-45ES-0004 Rvision Date Page 6 of 13 05 15/10/2013
3.4.1 Platework & Structural Members
The entire vessel including all internal and external attachments and also including the gas inlet and outlet stub nozzles is to be fabricated from stainless steel to ASTM-A-240 Type 304 with a minimum yield strength of 210 MPa.
Notes:
*a) Stainless steel types 304L and N are not acceptable.
* Special Note:
Type 304H may be considered if pricing advantage exists. No premium will be paid for 304H material.
Prior approval is required from C.E
Do not mix materials.
b) Carbon content to be in the range of 0.04 to 0.08%.
3.4.2 Tubesheet Support Posts
To be welded or seamless stainless steel pipe to ASTM A-312, Grade TP304.
* Grades TP304L or N are unacceptable. Minimum carbon content to be in the range of 0.04 to 0.08%.
3.4.3 Expansion Joint
Same material as Item 3.4.1
3.4.4 Nuts & Bolts
All sizes: Stud bolts, stainless steel to ASTM A-193, Gr. B8M, complete with heavy, semi -finished hex nuts to ASTM A-194 Gr.8M.
3.4.5 Gaskets
Spiral wound 316 S.S. metal rings with ceramic filler, 3 mm thick, complete with bolt holes to suit ANSI 150 Ibs. flat face flange.
The bolt hole diameter will be specified on the drawings if different from the ANSI standard.
338033/4604-45ES-0004 Rvision Date Page 7 of 13 05 15/10/2013
All sizes: Garlock FLEXSEAL style RW or approved equal.
3.4.6 Bearing Plate Assemblies
The base plate welded to the support column shall be stainless steel per paragraph 3.4.1.
The bearing (sole) plate is to be fabricated from carbon steel to ASTM A36 or ST37-2.
Slide bearings are to be Fluorotemp Type "A" high load bearings, as manufactured by Fluorocarbon, Pine Brook, New Jersey, U.S.A., or approved equal.
The bearing pads shall be supplied for the following condition:
Bearings shall be designed for a sulphuric acid plant type environment.
The coefficient of friction between bearing plate and carbon steel plate shall be no greater than 0.10.
Vendor to supply installation instructions with plate shipment to job site.
3.5 Tubing
a) Exchangers tubes, both working and dummy, shall be stainless steel to ASTM A-249 Grade TP304 (Grades TP304 L and N are unacceptable) ERW carbon content 0.04 to 0.08% and shall be 13 Gauge (BWG).
b) Tolerances for tube OD. shall be to specification ASTM A-450. Tubes will be ring gauged at random to ensure that the OD. tolerances are met.
c) The maximum deviation from straightness over the full tube length shall not exceed 3 mm. Tolerances of the overall tube length will be +5 mm - 0 mm.
4.0 WELDING
4.1 All welding procedures and welders shall be qualified in accordance with Section IX of the ASME Boiler and Pressure Vessel Code, 2010 edition.
All welding shall conform to the requirements specified herein and also to the requirements of the American Welding Society Standards of (D1.1 2010 edition for welds not covered herein. All welding shall be identified by AWS symbols on the shop drawings. Symbols shall include all pertinent information, such as location, type, size and extent of grinding, if required.
4.2 All welding (including tack and intermittent) shall be free of visible imperfections, such as: cracks, excessive undercuts (0.8 mm) and surface slag inclusions. 4.3 Complete penetration and complete fusion of all platework joints is required, unless noted
338033/4604-45ES-0004 Rvision Date Page 8 of 13 05 15/10/2013
otherwise on drawings.
4.4 The deposited weld metal shall have properties equal to or better than the parent metal and shall be "full strength" for the thinner plate connected.
4.5 All fillet welds shall be with equal legs. The leg of each weld shall be equal to or greater than the thickness of the thinnest plate being joined, except as noted on a drawing approved by C.E.
4.6 Weld heat must be properly controlled to eliminate dimpling of the plates.
4.7 In assembling and joining parts to the members, the procedure and sequence shall such as will minimize distortion and shrinkage.
4.8 All attachments to the heat exchanger shall have continuous welds unless otherwise noted.
4.9 No lap or skip welds will be allowed.
4.10 Slag between passes shall be removed.
4.11 Platework shall be welded by any or all of the processes covered under Section IX of the ASME Boiler and Pressure Vessel Code:
4.12 Welding electrodes within the carbon content range of 0.04 to 0.08% shall be used and the following electrodes are acceptable: E308H, E308-16, E308-15, ER308, E308T-3. 'L' grades are not acceptable.
5.0 FABRICATION
5.1 General
5.1.1 Shop and field fabrication shall be carried out in accordance with the procedures outlined in Section 4 (Fabrication) of A.P.I. Standard 620 11th edition, except as modified herein or on the drawings.
5.1.2 All sharp edges and burrs shall be removed.
5.1.3 All nozzles are oriented horizontally on the true composite orientation plans and vertically on the vertical sections. Flange face shall be flat and true with tolerance to suit gasket. All welds shall be ground flush with face of flange.
5.1.4 Vendor shall provide whatever additional treatment such as preheat, post weld heating, which is a requirement of the material used. The shop drawings must identify such treatments. If stress relief heat treatment is required, finish machining shall preferably be done after stress relieving.
5.1.5 Set of proper match marks must be provided if items are erected by others.
338033/4604-45ES-0004 Rvision Date Page 9 of 13 05 15/10/2013
5.1.6 In assembling and joining parts to the members, the procedure and sequence shall be such as will minimize distortion and shrinkage.
5.1.7 During fabrication or field erection, all attachments, brackets, welding lugs, nuts, etc., shall be kept to a minimum and shall be welded to the vessel with small diameter electrodes. Attachments shall be removed by chipping rather than being knocked off. Any damage to plate shall be repaired.
5.2 Shell
5.2.1 At any vertical joint, the misalignment between plates shall not exceed 10% of the plate thickness or 2 mm, whichever is smaller.
Any horizontal joint in the upper plate shall not project beyond the face of the lower plate at any point by more than 20% of the upper plate thickness with a maximum of 3 mm.
5.2.2 Vertical joints in plates of adjoining courses shall be a minimum of 600 mm apart.
5.2.3 The layout of the seams shall be such that longitudinal seams are not behind any obstruction which prevents inspection of these welds. Circumferential seams shall be located so they do not fall on an internal ring (40 mm is the nearest a ring can be to a seam). If possible, nozzles and manholes shall not be located in any seams. If the layouts of the seams result in a major weld seam being covered, it will prior to covering be 100% radiographed in accordance with ASME Section VIII Para. UW-51.
5.2.4 The faces of fabricated plate flanges shall be rough machined after welding. Companion faces of blind fabricated plate flanges shall be rough machined. All fabricated flanges are to be of the same material specification as the body of the vessel.
Machined surfaces, which are warped or distorted due to welding, etc., shall be remachined after these operations are finished.
5.2.5 Flanges will be fixed square to the axis of the vessel with the bolt holes straddling the vessel centerlines.
5.2.6 Slip-on flanges shall be positioned so that the distance from the face of the flange to the pipe end shall be equal to the nominal pipe wall thickness, plus approximately 3 mm. The welds shall be applied in a manner that will not require refacing of the flange.
5.3 Baseplate
5.3.1 The weld on the underside of the baseplate shall be ground flush to allow the stiffeners to sit flat on the baseplate.
5.3.2 Butt joints shall be used for bottom plates. Back-up strips permitted on the underside only
338033/4604-45ES-0004 Rvision Date Page 10 of 13 05 15/10/2013
with the approval of C.E. Back-up strips permitted shall be shown on shop drawings.
5.4 Tubesheets and Baffles
5.4.1 Tubesheets shall be levelled to a tolerance of plus or minus 3 mm prior to drilling.
5.4.2 Tubesheet holes for tubes shall be drilled and reamed to a diameter of tube OD. plus 0.6 mm with the tolerance as defined by the TEMA B 9th edition.
5.4.3 Edges and internal surfaces of the tube holes on both tubesheets shall be free of burrs to prevent cutting of tubes in accordance with the requirements of an AA 250 finish.
5.4.4 Baffle plate holes shall be drilled and reamed to a diameter of tube OD. plus 3 mm.
6.0 TUBE INSTALLATION
6.1 Ends of tubes in contact with the tubesheet must be clean and smooth and free from any residue or particles. The method of cleaning is optional. Wire brushing is a minimum requirement. Other methods may be required if corrosion is deep due to poor protection during transit or storage. Tubes that are pitted shall not be used.
6.2 Tubes shall be rolled into the tubesheets using automatically controlled torque rolling equipment.
6.3 Tubes shall be lightly rolled to seal and expanded (not beaded) into the tubesheet with tube projection max 6 mm min 3 mm beyond the tubesheet face, except for the dummy tubes.
6.4 In the actual "rolling in" operation, care shall be taken not to expand the portion of the tube which projects beyond the tubesheet face. Expansion in this projected portion tends to cause belling or flaring with accompanying cracking.
6.5 Arrange the expander thrust collar so that the front ends of the rolls do not extend beyond the inside face of the tubesheet and preferably retracted a small fraction, say 3 mm towards the front or outside face of the tubesheet.
6.6 Tubes will be rejected if improper rolling technique causes a crack within the tubesheet thickness area. If the crack develops in the projected part only, the affected area shall be removed, with the tube end dye penetrant examined to ensure complete removal of defect.
6.7 Reworked or reprocessed tubes are unacceptable.
338033/4604-45ES-0004 Rvision Date Page 11 of 13 05 15/10/2013
7.1 Where quoted, flanged and dished heads shall be torispherical heads to ASME Code. The radius of the dish shall be equal to the diameter of the head. The straight flange distance shall be 40 mm for all heads. The inside corner radius shall be 100 mm for heads 1676 mm and smaller, 150 mm for heads between 1676 mm and 2590 mm, and 200 mm for heads 2590 mm and larger.
8.0 TOLERANCES
8.1 The maximum elevation difference between any two points on the baseplate shall be 6 mm. The shell tolerance is based on vessel diameter.
8.2 Dimensional tolerances shall be as follows, unless otherwise noted:
1828 and under .................................. 2 mm 1828 to 7315 ...................................... 3 mm 7315 to 18288 .................................... 5 mm Over 18288 ........................................ 6 mm
All tolerances are equal plus and minus unless otherwise specified.
9.0 TESTING
9.1 General
9.1.1 The inspector shall have free access to all reasonable times to the areas where the work on equipment is being performed.
9.1.2 Vendor shall notify CE & MC in advance (minimum two weeks) of scheduled vessel testing to allow reasonable time for the inspector to arrange to be at the test site before testing begins.
9.2 Radiography
9.2.1 Five (5%) percent of all the buttwelds on all heat exchanger shall be examined by spot radiography in accordance with the details as outlined in Section 5 of API Standard 620, 11th edition. Spot radiography shall be progressive with schedule to be approved by inspector. inspector reserves the right to review all radiographs.
9.2.2 In addition to the radiography requirements above, all tubesheets which are shop welded shall have 100% of their welds radiographed. Radiographs to be reviewed by Inspector prior to welding to shell.
9.2.3 All radiographs shall be interpreted to Para. UW-51 of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, 2010 edition.
338033/4604-45ES-0004 Rvision Date Page 12 of 13 05 15/10/2013
9.3 Dye Penetrant Inspection
9.3.1 All welds shall be 100% dye penetrant inspected. The welds will be sound and free from cracks.
9.3.2 Dye penetrant shall be in accordance with Appendix 8 of ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, 2010 edition.
9.4 Pneumatic Testing
9.4.1 The heat exchanger will be leak tested in the area between the tube sheets by the fabricator prior to shipping. As well, the exchanger are to be leak tested in the field after installation (by fabricator). All testing is to be in accordance with these specifications.
9.4.2 The testing shall be done with air at a pressure of 173 kPag(from the shell side with soapwater bubble test prior to expanding the tubes). The pressure shall be maintained on the vessel for the entire duration of the leak testing.
9.4.3 All welds between the tubesheets on the exchangers shall be checked for leaks during the air test using a soapwater bubble solution. No leaks are allowable.
9.4.4 All tubes in the exchangers shall be checked for leaks at the tube sheets as well as all tubesheet welds during the air test using a soapwater bubble solution. No leaks are allowable.
9.4.5 After the last leak is found and repaired, the test air pressure shall be maintained on the vessel for a minimum period of 60 minutes without loss of pressure.
10.0 LEAKS
10.1 Where leaks are discovered, the welds shall be completely removed, rewelded and retested.
10.2 The fabricator shall notify C.E/Inspector regarding any necessary repair work and have written approval before proceeding.
11.0 INSPECTION
11.1 C.E/Inspector to review mill test certificates for all materials to confirm compliance with materials ordered to this specification.
11.2 All fillet weld sizes must be checked against design drawings. Convex or concave fillet welding is not permitted.
11.3 Examine all radiographs which have been taken. Radiographic reports to be reviewed by C.E/Inspector.
338033/4604-45ES-0004 Rvision Date Page 13 of 13 05 15/10/2013
12.0 PROTECTION & SHIPPING
12.1 Before shipment, shop fabricated vessel shall be cleaned internally and externally of shop dirt, grease, scale, weld spatter, and any other foreign substance.
12.2 Adequate crating, skidding, strapping, etc., shall be provided to prevent damage to any part of the fabricated item being shipped.(Packing Procedure shall be provide by vendor)
12.3 Tubing shall be protected against damage during transit and installation by suitably clamping the shell expansion joint in a fixed position during fabrication.
N.B. Remove clamps only when the vessel is in an installed position.
During field erection, all attachments, brackets, welding lugs, nuts, etc., shall be kept to a minimum and shall be welded to the vessel with small diameter electrodes. Attachments shall be removed by chipping rather than being knocked off. Any damage to plate shall be repaired with careful welding. All areas where temporary attachments have been removed will be liquid penetrant examined.
12.4 All open nozzles and flanged connections shall be covered and protected against damage during transit and installation.
13.0 IDENTIFICATION
Parts sent loose to site will be clearly tagged showing equipment.
14.0 QUALITY CONTROL
Vendor shall provide an inspection and test plan for C.E and inspector review detailing all inspection points performed during the manufacturing cycle. This plan shall have an area designated for input of client / customer Hold / Witness / Review points.