Technical-specs-Heat Exchangers

SUPPLY OF EXCHANGER 141A-E-105 (N)
[1]
1. Introduction:
BPCL intends to install a standby Exchanger similar to existing exchanger 141A- E-105
in CCR Unit, Mahul Refinery, Mumbai. Vendor has to follow this purchase specification
for supply of the said Exchanger.
2. Scope of Work:
Scope of work includes Adequacy check and compliance of with latest codes/design of
provided mechanical design with respect to Thermal design and providing the
confirmation and report, Preparation of fabrication drawings for new exchanger based
of Mechanical design and procurement of materials and bought out components,
fabrication, inspection, testing, painting, packing and transportation of the complete
exchanger with test rings, spares as per design data available in the reference drawings,
documents attached, specifications, existing exchangers’ drawings, latest codes and
standards.
Vendor shall design test ring (Carbon steel) and supply along with exchanger.
Applicable codes and standards:
Following codes and standards in their latest editions shall form basis for design,
materials selection, fabrication, inspection, testing and acceptance of documents -
ASME boiler and pressure vessel code section VIII DIV 1

ASME Section II part A, B, C and D
ASME Section V
ASME section IX
TEMA class R
National and local laws or regulations as applicable
All material required for fabrication, testing, inspection shall be in vendor scope.
3. EQUIPMENT QUALIFICATION CRITERIA:
a. Bidder shall be capable of Designing, Manufacturing, Testing, Supply and

commissioning of Shell & Tube Heat exchangers as per ASME SEC VIII DIV I and
TEMA Class R.
b. During the last Seven (7) years, Bidder on his own must have fabricated and supplied
at least a single unit of Carbon Steel shell and carbon steel tube exchanger with shell
thickness ranging from 25 mm & above and minimum shell diameter of 1000 mm &
above.
[2]
c. Bidder shall submit the documents meeting the Equipment Qualification Criteria (i.e.,
Purchase Order Copy, Inspection release note / completion certificate and Drawings
clearing indicating the above parameters.
4. SCOPE OF SUPPLY:
Supply of following items is in vendor scope:
a. Exchanger as per design data sheet, drawings, Specification and Codes.

b. Test rings and testing accessories– Carbon Steel (A105)
c. Fasteners for all Nozzles and their companion flanges (5 sets, each set individually
packed)
Fastener specification:
Material spec-stud-bolts : ASTM A193 GRADE B7

Material spec-nuts : ASTM A194 GRADE 2H
Service : HIGH TEMP SERVICE UPTO 450 C
Design-spec-stud-bolt : ANSI B18.2.1
Design-spec-nut : ANSI B18.2.2
Thread-class-symbol-stud-bolt : 2A
Thread-class-symbol-nut : 2B
Type-of-thread : UNC
Type-nut : HEAVY HEXAGONAL NUT
Number-nuts-per-stud-bolt : 2
d. Gaskets for all Nozzles (8 Sets, each set individually packed)
Gaskets Specification:
Gasket Type : Spiral wound
Design-spec : ASME B16.20
Design-spec-flange-s : ANSI B16.5
Mat-windings : STAINLESS STEEL 316L
Mat-filler : GRAFOIL
Mat-centring-ring : CARBON STEEL
Mat-spec-windings : AISI 316 L
Note: (Spacer Ring on Inlet & Outlet Nozzles shall be considered for fastener length)
[3]
5. PRE BID MEETING AND SITE VIST:
Pre Bid meeting will be held at BPCL Mumbai refinery on dates mentioned elsewhere in the
tender followed by site visit.
Site Visit is mandatory for better understanding of job.
Pre Bid Queries shall be submitted within one week or as mentioned in tender. Queries
raised after this date may not be entertained/ considered.
6. DOCUMENTATION:
The successful vendor shall make fabrication drawings of the Exchanger and submit to
BPCL for review/approval before starting the fabrication. If any discrepancy is found
during design and fabrication stages the fabricator shall inform BPCL immediately, and
obtain necessary approval before proceeding with that portion of the job any further.
BPCL review of fabrication drawings and documents must not be considered as a check
and shall not relieve the Vendor of his responsibilities to supply equipment as per tender
document.
Vendor shall remain responsible for conflicts between his drawings /documents and
BPCL drawings / documents.
All fabrication drawings submitted to BPCL shall be based on tender document and shall
bear reference number and revision of the corresponding drawings. In addition it shall
indicate item number, client’s name, fabricator’s name, purchase order number, drawing
number etc. All revisions shall be clearly marked by encircling with revision marks.
Submission of required drawing / documents shall be the responsibility of the vendor.
Drawing index shall be prepared for each item giving serial number, description of
drawing, drawing number and revision number. Updated index shall be forwarded along
with each submission. Submission of all required drawing / documents in time shall be
responsibility of the fabricator.
7. AS BUILT DRAWING:
Six sets of “As built” drawings and “Data folder” (containing test certificates, inspection
reports etc.), including one set of reproducible and electronic formats (CD), shall be
supplied by the successful bidder along with the equipment. Soft copies of all drawings
in AutoCAD (.DWG format) shall be submitted to BPCL in CD as part of final
documentation. Gasket drawings shall be given separately in A4 size drawings. Vendor
[4]
shall ensure that all data folder documents including the “AS BUILT DRAWING” are
updated & complete in all respects and shall incorporate all suggestions/correction
informed by BPCL or the authorized inspector while obtaining certificate of
completeness from the Inspection Agency. In the event of the fabricator’s failure to meet
the above requirements, the supply of equipment shall be considered as incomplete.
8. VENDORS RESPONSIBILITIES:
It shall be entirely the vendor’s responsibility to ensure compliance to codes and

standards specified for design, fabrication, testing etc. and to all requirements of the
requisition including specifications and drawings after the order is placed. In view of this,
the fabrication drawings prepared by vendor will be reviewed by BPCL to the following
extent only:
a) Nozzle data, orientation and location, support location, dimensions for

interfacing.
b) Design data and materials of construction
c) Pass partition arrangement, tube layout and bundle detail.
d) Critical details like tube to tube-sheet joint detail.
Vendor has to ensure that all aspects covered in the Specifications and design data
mentioned in attached drawings with the enquiry are complied with.
All drawings shall be thoroughly checked and duly signed by the Vendor. Unchecked
drawings and drawings without revisions clearly marked shall be returned without
review. Successive review of the same fabrication drawing shall apply only to BPCL s
latest data sheet/ comments on the previous revision. Drawings and documents
returned to the Vendor for revision shall be resubmitted at the earliest. Vendor must
ensure that all the vendor documents are thoroughly checked and approved at vendor’s
end by vendor’s competent engineer and responsible engineering office in charge,
before the same are submitted to BPCL for review.
Vendor shall furnish list of drawings/ documents with schedule of submission of

drawings for approval by BPCL. The same shall be submitted to BPCL immediately after
[5]
placement of order. Drawing index duly updated to be submitted with each submission
of documents. While preparing fabrication drawing it shall be endeavored to cover all
fabrication details in minimum number of drawings, not exceeding 5 in any case.
Fabrication drawings shall be submitted in the following sequence (whichever is
applicable)
1) General arrangement drawing indicating design data, fabricated equipment’s

weight, general notes, nozzle schedule, detail of shell, head, skirt / supporting
arrangement, main weld seams, nozzle orientation plan etc.
2) Detail of all nozzles, accessories etc.
3) Detail of internals, gaskets etc.
4) Detail of external clips for ladder, platform, pipe support, insulation, fire
proofing, pipe davit, lifting lugs etc.
5) Shell development drawings incorporating all attachments and weld seams.
6) Bill of material for each item showing part size, quantity, material
specification, scope of supply and weight etc.
All the drawings shall be prepared on Auto CAD 2000 or later versions. English
language and metric units shall be used in all documents. Drawings shall be prepared
in prescribed sizes as standardized by Bureau of Indian Standards (BIS).
9. MATERIAL PROCUREMENT:
1. Material/bought out items required for the fabrication of Exchangers shall be

procured from BPCL approved Vendors.
10. PAINTING:
Vendor shall follow the BPCL painting specification AES 5340 Rev 1 (enclosed in
tender) for painting of Exchanger.
11. THIRD PARTY INSPECTION:
Vendor shall submit Quality Assurance Plan for review and approval by BPCL. Quality
assurance plan shall be as per standard inspection and test plan for exchangers. The
exchanger shall be inspected by BPCL approved third party inspection agency.
[6]
Inspection shall be carried out stage wise as per QAP. Vendor shall coordinate with
inspection agency for each stage wise inspection. It is vendor responsibility to give prior
information to TPI agency for timely inspection. Delivery period mentioned in the tender
is inclusive of all stage wise inspection. Delay in inspection cannot be considered for
extension of delivery period. Fabrication shall not commence before the approval of the
QAP and necessary stage wise inspection by the inspection agency. Vendor shall make
all arrangements for carrying out all tests, including hydro test of the tube bundle. All
materials and accessories, like test rings / test flanges etc. required for carrying out the
tests shall be in vendor’s scope.
12. SCHEDULE OF EXECUTION OF JOB/ PROGRESS REPORTS:
After receipt of order, the Vendor shall submit the detailed schedule of execution of job
in the form of progress reports. The schedule shall be prepared right from purchasing
of equipment components to the end of fabrication and delivery of equipment. A time
period of 2 to 3 weeks shall be considered for approval of drawings by BPCL.
13. SPARES
Vendor shall supply the spare gaskets and bolts as per quantity mentioned below, as a
minimum, along with the equipment. Any higher quantity mentioned elsewhere in the
standard specifications shall also be furnished. The spares shall be listed separately
along with description, item no., detailed specifications, name of supplier etc.
Gaskets = 400% (Except Nozzles)
Bolting = 20% each size (min 4 studs with 8 nuts) (Except for Nozzles)
2 YEARS MAINTENANCE SPARES:
Vendor to quote item wise separate prices for 2 years maintenance spares and special
tools and tackles, if any. A list of the same to be included in the vendor’s offer. (Separate
Quote and shall not be considered for evaluation purpose)
14. DELIVERY PERIOD:
6 months from date of issue of LOI/PO.
Vendor shall submit QAP and drawings within 7 to 15 days from the date of issue of
LOI/PO.
BPCL will approve the QAP/drawings within 7 to 15 days from the date of submission of
QAP/drawings. Delivery period is inclusive of submission & approval of QAP/ drawings.
[7]
15. DELIVERY ADDRESS:
Vendor shall deliver the material at below location:
Main Warehouse,
BPCL Mahul Refinery,
Chembur,
Mumbai – 400074
16. TERMS OF PAYMENT:
i) 10% on approval of all drawings by BPCL against submission of bank guarantee for an
equivalent amount valid till complete execution of order plus six months claim period as
per BPCL format.
ii) 10% after placement of order for major material subject to submission of Unpriced copy
of PO against certification by BPCL Engineer-in-Charge and submission of bank
guarantee for equivalent amount valid till complete execution of order plus six months
claim period as per BPCL format.
iii) 10% after receipt of raw materials at vendor’s works and against certification by BPCL
Engineer-in-Charge and submission of bank guarantee for equivalent amount valid till
complete execution of order plus six months claim period as per BPCL format.
iv) 70% within 30 days from the date of supply and acceptance of Material at BPCL
Warehouse and on receipt of final documentation against submission of Performance
Bank Guarantee for 10% of the PO value with six months claim period, as per BPCL
format.
17. REFERENCE DOCUMENTS/DRAWINGS:
 Thermal Design Data Sheet _ TDS-141-A-E105

 Mechanical Design Data Sheet _ MDS-141-A-E105_R0
 Standard Specifications
 Fabrication Standard drawing
[8]
Engineering Services
CCR PROJECT AT MAHUL, MUMBAI
DOCUMENT TITLE:
TEMA DATASHEET FOR
HP ABSORBER FEED COOLER (141-A-E105)
DOCUMENT NUMBER:
TDS-141-A-E105
Client BHARAT PETROLEUM CORP. LTD.
Unit CCR Octanizing Unit / Reaction Section
Location Mahul, Mumbai
0 21-05-2018 Issued for Review PK CNR PB

Prepared Checked Approved
Rev Date Document Status
By By By
CCR Octanizing Unit / Reaction Section TEMA Datasheet for HP Absorber FEED Cooler
TDS-141-A-E105
RECORD OF REVISIONS
Rev Date Revision Details
Page 2 of 5
TDS-141-A-E105
Rev.
1. CHARACTERISTICS
2. Service of Unit HP Absorber Feed Cooler Item No. 141-A-E105
3. Size (2) 1240 x 8100 mm Type AES Horizontal Connected In 1 Parallel 1 Series
4. Surf/Unit (Gross/Eff) 575.1 / 534.6 m2 Shell/Unit 1 Surf/Shell (Gross/Eff) 575.1 / 534.6 m2
5. PERFORMANCE OF ONE UNIT
6. Fluid Allocation Shell Side Tube Side
7. Fluid Name HP ABSORBER FEED RAW COOLING WATER
8. Fluid Quantity, Total kg/hr 151015 190910
9. Vapor (In/Out) 20983 17972
10. Liquid 130032 133043 190910 190910
11. Steam
12. Water
13. Noncondensables
14. Temperature (In/Out) C 66 45 34 45
15. Density kg/m3 6.12 V/L 784.57 5.62 V/L 798.7 994.6 990.4
16. Viscosity cP 0.0120 V/L 0.3200 0.0110 V/L 0.3794 0.7339 0.5962
17. Molecular Weight, Vapor
18. Molecular Weight, Noncondensables
19. Specific Heat kcal/kg-C 1.3087 V/L 0.4761 1.4475 V/L 0.4601 0.9986 0.9989
20. Thermal Conductivity kcal/hr-m-C 0.0770 V/L 0.1050 0.0780 V/L 0.1099 0.5340 0.5461
21. Latent Heat kcal/kg
22. Inlet Pressure kgf/cm2[g] 27.4 4
23. Velocity m/s 3.6 1.25
24. Pressure Drop, Allow/Calc kgf/cm2 0.3 0.1 (4) 0.7 0.591 (5)
25. Fouling Resistance (min) m2-hr-C/kcal 0.0004 0.0004
26. Heat Exchanged (3) 2.1 MMkcal/hr MTD (Corrected) 12.2 C
27. Transfer Rate, Service 322.5 kcal/m2-hr-C Clean 553.5 kcal/m2-hr-C Actual 367.7 kcal/m2-hr-C
28. CONSTRUCTION OF ONE SHELL Sketch (Bundle/Nozzle Orientation)
29. Shell Side Tube Side
30. Design/Test Pressure kgf/cm2G 47.5, FV / 36.5 /
31. Design Temperature C (9) 150 70
32. No Passes per Shell 1 6
33. Corrosion Allowance mm 3 3
34. Connections In 1 @ 20" NPS (14) 1 @ 10" NPS (14)
35. Size & Out 1 @ 20" NPS (14) 1 @ 10" NPS (14)
36. Rating Intermediate @ @
37. Tube No. 904 OD 25 mm Thk(min.) 2.5 mm Length (2) 8100 mm Pitch 31.25 mm
38. Tube Type Plain Material SA 210 Gr. A1 Tube pattern90
39. Shell SA-516 Gr. 60 N ID 1240 OD mm Shell Cover SA-516 Gr. 60 N
40. Channel or Bonnet SA-516 Gr. 60 N Channel Cover SA-266 Gr.2
41. Tubesheet-Stationary SA-266 Gr.2 Tubesheet-Floating SA-266 Gr.2
42. Floating Head Cover SA-516 Gr. 60 N Impingement Plate Circular plate
43. Baffles-Cross SA-516 Gr. 60 N Type Double-Seg. (V) %Cut (Diam) 22.9 Spacing(c/c) 455 Inlet 1100 mm
44. Baffles-Long - Seal Type None
45. Supports-Tube (16)(17)(18) U-Bend Type None
46. Bypass Seal Arrangement 4 pairs seal strips (13)(15) Tube-Tubesheet Joint (11)
47. Expansion Joint Type
48. Rho-V2-Inlet Nozzle 1687 kg/m-s2 Bundle Entrance 956 Bundle Exit 1137 kg/m-s2
49. Gaskets-Shell Side Tube Side
50. - Floating Head
51. Code Requirements ASME Sec VIII, Div 1; API 660 TEMA Class R
52. Weight/Shell kg Filled with Water kg Bundle kg
53. Remarks: 1) The process conditions and THX curve has been considered as per Axens datasheet for heat exchanger
54. Doc no 3290-141A-2EX-141A-E105 page 1 to 6
55. 2) The indicated tube length is overall tube length. Effective length for heat transfer is 7530 mm from inside of fixed tubesheet upto
56. floating head support plate.
57. 3) Indicated duty is 100% of process datasheet duty. Exchanger is designed for 120% of duty specified.
58. 4) Shellside design flowrate = 166117 kg/hr, corresponding to 110% of case2 MRT operating flowrate.
59. Shellside pressure drop for design flowrate is 0.12 kg/cm2
60. 5) Tubeside design flowrate = 211200 kg/hr, corresponding to 110% of case2 MRT operating flowrate.
61. Tubeside pressure drop for design flowrate is 0.7 kg/cm2.
62. 6) Max. continuous H2 partial pressure: 365.6 psia (case 2 NOP).
63. 7) Hydrogen service is applicable for shellside.
64. 8) Based on 10/13 of shellside design pressure.
65. 9) MDMT: 9°C for shellside and tubeside
66.
67.
68.
69.
70.
Page 3 of 5
TDS-141-A-E105
Rev.
1. CHARACTERISTICS
5. REMARKS
6.
7. 10) Material for exchanger parts.
8. LHS Channel Cover - SA 266 Gr.2
9. Channel Shell - SA 516 Gr 60 N
10. Floating Head Cover - SA 516 Gr 60 N
11. Floating head Flange - SA 266 Gr 2
12. Backing Ring - SA 266 Gr 2
13. Tie Rods, Seal Rods - CS
14. Sealing Strips / Sliding Rail - SA 516 Gr 60 N
15. Spacer - CS
16. Eye Bolt - SA 105
17. Tie Rod nuts - SA 194 Gr.2H
18.
19. 11) Tubes to be strength welded and light expanded (upto 5%)
20. 12) 13 no. of baffles with inlet spacing of 1100 mm and central spacing of 455 mm. Double segmental baffles with 6 tuberows overlap
21. 13) Provide 20 seal rods of 9 mm OD.
22. 14) Refer nozzle schedule
23. 15) Sealing strip provided on the bottom and top halfs of the exchanger will be of different heights as seen in the tube layout.
24. 16) Inlet vibration support plate to be provided for topmost 7 tuberows. To be placed at a distace of 550 mm from support plate at rear end.
25. 17) Outlet vibration support plate to be provided for bottom 7 tuberows. To be placed at a distace of 485 mm from fixed
26. tubesheet shellside face.
27. 18) Floating head support plate has been considered.
28. 19) Insulation Shellside: Personnel Protection
29.
30.
31.
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33.
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40.
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Page 4 of 5
TDS-141-A-E105
Rev.
1. CHARACTERISTICS
5. TUBE LAYOUT
6.
7.
8. Item number 141A-E-105
TEMA type AES
9. Shell ID 1240.00 mm
448.000 mm
10. Actual OTL 1174.82 mm
11. Height under inlet nozzle 170.325 mm
Height under outlet nozzle 123.000 mm
12. Tube type Plain
13. Tube OD 25.000 mm
Tube pitch 31.250 mm
14. Tube layout angle 90 deg
15. Tubes 904
Tube positions available 904
16. Tie rods 10
17. Seal strip pairs 4
Passlane seal rods 20
18. Tube Passes 6
19. Parallel passlane width 22.000 mm
20. Perpendicular passlane width 22.000 mm
Baffle cut % diameter 22.9
21.
22. TUBEPASS DETAILS
Pass Rows Tubes
23. 1 11 156
24. 2 11 155
3 8 143
25. 4 8 144
26. 5 10 152
6 10 154
27.
28. SYMBOL LEGEND
29. Tube
Dummy Short Tube
30. Dummy Long Tube
31. Plugged Tube
Tie Rod
32. Seal Rod
33. 6 5 Impingement Rod
34.
35. 3 4
36.
37.
448.000 mm 2 1
38.
39.
40.
41. NOZZLE SCHEDULE
42. MARK SIZE SERVICE QTY RATING REMARKS
43. S1 20" SHELLSIDE INLET 1 600#
44. S2 20" SHELL SIDE OUTLET 1 600#
45. S3 2" SHELLSIDE VENT 1 600#
46. S4 2" SHELLSIDE DRAIN 1 600#
47. T1 10" TUBE SIDE INLET 1 300#
48. T2 10" TUBE SIDE OUTLET 1 300#
49. T3 2" TUBESIDE STUB CONNECTION -1 1 300#
51.
52.
53. SKETCH
54.
55.
56. S1
T2 S3
57.
58.
59.
60.
61.
62.
63.
64.
65.
T1 S4
66. S2
67.
68.
69.
70.
Page 5 of 5
MATERIAL OF CONSTRUCTION DESIGN SPECIFICATION STANDARDS NOTES
SHELL SIDE SERVICE : HP ABSORBER FEED COOLER 1. ALL DIMENSIONS ARE IN MM UNLESS & OTHER WISE SPECIFIED.
PART DETAILS 2. WALL THICKNESSES INDICATED ARE MINIMUM PRELIMINARY. VENDOR TO VERIFY THE THICKNESSES AND
SHELL SA-516 Gr. 60 N CODE OF CONSTRUCTION : ASME SEC VIII DIV 1.ED 2017,TEMA 9 th ED-2007,API-660 MES-ST-2001
INCREASE BASED ON STRESS CALCULATIONS.
SHELL COVER BARREL & BONNET SA-516 Gr. 60 N TEMA TYPE : AES (HORIZONTAL) TEMA CLASS : R CODE STAMP : NO TYPES OF NON STANDARD GASKETS MES-ST-2002 3. FLANGE DIMENSIONS SHALL BE AS PER ASME B 16.5 & GASKET SHALL BE AS PER ASME B 16.20.
GIRTH FLANGES SA 266 GR 2 DUTY : 2.1 MMKcal/Hr SIZE : 1240 X 8100 MM SLIDING & DEFLECTOR STRIPS MES-ST-2007 4. TUBE TO TUBESHEET JOINT SHALL BE STRENGTH WELDED AND LIGHT EXPANDED.
SS304 SPWD GRAFOIL FILLED SHELLS / UNIT : 1 NO. OF UNITS : 1 EYE BOLT DETAILS MES-ST-2008 5. HARDNESS OF PARENT METAL, WELD AND HAZ SHALL NOT EXCEED 200 BHN.
GASKET AT SHELL FLANGE WITH SS304 INNER AND OUTER 6. HARDNESS OF GASKET SHALL BE AS LOW AS POSSIBLE AND SHALL BE MINIMUM 20 BHN THAN FOR THE
AREA PER UNIT (EFFECTIVE) m2 534.6 JACK SCREW TAPPING AND ARRANGEMENT MES-ST-2010
NOSE MATERIAL OF THE FLANGE GASKET FACING.
BOLTING AT SHELL FLANGE SA-193 Gr. B7 / SA-194 Gr. 2H FIXING DETAIL OF DOWEL PINS MES-ST-2011 7. EQUIPMENT IS IN HYDROGEN SERVICE.HYDROGEN PARTIAL PRESSURE IS ON SHELL SIDE 365.6 PSIA.
LIFTING LUG DETAIL 8. COMPLETE EXCHANGER SHALL UNDERGO PWHT, PWHT CYCLE SHALL BE AS PER CODE.
NOZZLE NECK / FLANGE SA-105 MES-ST-2013
9. MOCKUP TEST OF TUBE TO TUBESHEET JOINT SHAL BE CARRIED OUT.
NOZZLE BOLTING SA-193 Gr. B7 / SA-194 Gr. 2H DAVIT FOR SHELL AND CHANNEL COVER MES-ST-2014 10.10% STUDS AND NUTS BUT NOT LESS THAN 4 STUDS WITH 8 NUTS FOR EACH PAIR OF MATING
SS304 SPWD GRAFOIL FILLED AS EARTHING LUG MES-ST-2016 FLANGES,INTERCONNECTING NOZZLES, NOZZLES WITH BLIND FLANGES ETC. SHALL BE SUPPLIED AS
NOZZLE GASKET MANDATORY SPARES.
PER ASME B 16.20 NAME PLATE MES-ST-2017
DESRIPTION SHELL SIDE TUBE SIDE 11. ALL FLANGE BOLT HOLES SHALL BE STRADDLE PRINCIPAL CENTER LINE OF THE VESSEL
BAFFLES/SUPPORT PLATE SA-516 Gr. 60 N TOLERANCES MES-ST-2019
12. GASKET SEATING SURFACE OF ALL FLANGES SHALL HAVE FINISH OF 125-250 MICRO INCH AARH EXCEPT
TIE ROD & NUTS CS FLUID : HP ABSORBER FEED RAW COOLING WATER FLOATING HEAD FLANGE.
SPACER CS FLUID DENSITY (IN / OUT) (VAPOR/LIQUID) Kg/m3 6.12/784.57 & 5.62/798.7 994.6/990.4 13. ALL WELDS SHALL BE FULL PENETRATION WELDS. WELDS ACCESSIBLE FROM SECOND SIDE SHALL BE BACK
CHIPPED TO SOUND METAL, DP CHECKED AND REWELD FROM SECOND SIDE.WHEREVER BACKCHIPPING IS NOT
RF PAD/WEAR PLATE SA-516 Gr. 60 N OPERATING PRESSURE : Kg/cm2 (g) 27.4 4
POSSIBLE ROOT RUN TO BE CARRIED OUT
OPERATING TEMP.(IN/OUT) : o
C 66/45 34/45 STANDARD SPECIFICATIONS 14. ALL CS MATERIAL INCLUDING FORGING USED FOR THE PRESSURE PARTS SHALL BE PROCURED IN FULLY
SEALING STRIPS /SLIDING STRIPS AND ALLOWABLE NOZZLE LOADINGS FOR PRESSURE KILLED & NORMALIZED CONDITION.
CS
IT'S STUDS DESIGN PRESSURE(INT/EXT) Kg/cm2 G 47.5/FV 36.5 VESSELS AND MES-ST-1038 15. PLATES HAVING THICKNESS 16 MM TO 50 MM (BOTH INCLUSIVE) SHALL BE EXAMINED ULTRASONICALLY
SHELL & TUBE HEAT EXCHANGER AS PER ASTM-A-435
o 16. FOR THICKNESS ABOVE 50 MM, ULTRASONIC EXAMINATION SHALL BE CARRIED OUT AS PER ASTM-A 578
ATTACHMENTS WELDED TO SHELL SA-516 Gr. 60 N DESIGN TEMPERATURE C 150 70
GENERAL SPECIFICATION FOR HEAT EXCHANGERS MES-SP-0041 AND SHALL HAVE ACCEPTANCE STANDARD OF LEVEL-I. ULTRASONIC EXAMINATION SHALL BE DONE AFTER THE
IMPINGEMENT PLATE SA-516 Gr. 60 N o
MEAN METAL TEMPERATURE C NA NA SPECIFIED HEAT TREATMENT.
SADDLE SUPPORT SA-516 Gr. 60 N o
MIN. DESIGN METAL TEMP. C 9 9 STANDARD SPECIFICATION FOR HARDNESS 17. THE CS PRESSURE FORGINGS SHALL BE SA-105 OR BETTER FOR STANDARD NOZZLE FLANGES / COUPLINGS /
MES-SP-0083
NAME PLATE SS304 TEST PRESSURE Kg/cm2 G UG-99(b) UG-99(b) REQUIREMENT PLUGS ETC. OTHER NON STANDARD CS PRESSURE FORGINGS SHALL BE SA 266 CLASS 2 OR BETTER.
2
NONSTANDARD FORGING SHALL BE IN NORMALISED & TEMPERED CONDITION.
NAME PLATE BRACKET SA-516 Gr. 60 N ALLOWABLE / CALCULATED PRESSURE DROP Kg/cm 0.3/0.1 0.7/0.591 SPECIFICATION FOR WELDED TUBE TO TUBESHEET
MES-SP-0044 18. THE CARBON CONTENT OF CS PLATE SHALL NOT EXCEED 0.20% AND CARBON EQUIVALENT SHALL BE LESS
NUMBER OF PASSES 1 6 JOINT THAN 0.42 WHERE Ceq=C+Mn/6+(Cr+Mo+V)/5+(Ni+Cu)/15
CORROSION ALLOWANCE mm 3 3 STANDARD SPECIFICATION FOR POSITIVE 19. CS NON STANDARD FORGINGS ABOVE 75 MM THICKNESS, ALL TUBE SHEET FORGINGS AND ALL NON
MATERIAL IDENTIFICATION (PMI) AT SUPPLIER`S MES-SP-0092 STANDARD FORGINGS OF OTHER MATERIALS SHALL BE 100% ULTRASONICALLY TESTED AS PER ASTM A-388.
RADIOGRAPHY / JOINT EFFICIENCY 100% 100% WORKS ACCEPTANCE STANDARDS SHALL BE AS PER PARA AM 203.2 OF ASME SECTION VIII DIV. II.
TUBE SIDE PWHT / HEAT TREATMENT YES YES 20. SEAMLESS TUBES HAVE TO BE DELIVERED IN NORMALISED CONDITION (INCLUDING FINAL
NORMALISATION FOR COLD DRAWN TUBES)
TUBE SA-210 GR A1 INSULATION THICKNESS mm 25 MM (BY OTHERS) - JOB SPECIFICATIONS
21. VENDOR SHALL SUPPLY TEST RING AND TEST FLANGES FOR HYDROTESTING PURPOSE
CHANNEL SHELL SA-516 Gr. 60 N FIREPROOFING mm YES (BY OTHERS) DESIGN BASIS FOR STATIC EQUIP. - 22. ALLOWABLE NOZZLE LOADINGS AS PER MES-ST-1038
GIRTH FLANGE AT CHANNEL COVER SA 266 GR 2 PAINTING/CLEANING 23. MINIMUM NDT REQUIREMENT.
A) ALL LONG SEAMS, CIRC SEAMS ON SHELL SIDE SHALL BE 100% RADIOGRAPHED.
GIRTH FLANGE AT TUBESHEET SA 266 GR 2 INSPECTION - STAGEWISE/FINAL B) ALL LONG SEAMS, CIRC SEAMS ON TUBE SIDE SHALL BE 100% RADIOGRAPHED.
FLOATING TUBESHEET SA 266 GR 2 C) DPT: ROOT (BACKCHIPPED) AND FINAL PASS ON ALL PRESSURE WELDS BEFORE PWHT, DP TEST ON FINAL
PASS TO BE CARRIED OUT AFTER PWHT ALSO
FLOATING HEAD FLANGE SA 266 GR 2 OTHER SPECIFICATIONS
D) TUBE TO TUBESHEET JOINT SHALL BE DP TESTED FOR EACH PASS FOR ALL TUBES.
FLOATING HEAD DISH SA-516 Gr. 60 N THERMAL DATASHEET TDS-141-A-E-105 E) TUBESHEET AND FLANGES SHALL BE ULTRASONIC TESTED AS PER APPLICABLE MATERIAL SPECIFICATION.
SS304 SPWD GRAFOIL FILLED LOADING DATA F)NOZZLE FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED.
GASKET AT TUBESHEET WITH SS304 INNER RING & OUTER 24. NOZZLE RF PAD SHALL BE PNEUMATICALLY TESTED AT 0.5 KG/CM2 PRESSURE WITH SOAP SOLUTION.
NOSE EMPTY WEIGHT kg 35500
25. EQUIPMENT SHALL BE TRASNPORTED IN FIELD WITH DRY NITROGEN AT 0.5 KG/CM2 FITTED WITH
BACKING RING SA 266 GR 2 OPERATING WEIGHT kg 45000 PAINT SPECIFICATION PRESSURE GUAGE AND NON RETURN VALVE.
FULL OF WATER WEIGHT kg 47000 BEFORE SURFACE PREPARATION , THE SURFACE SHALL BE DEGREASED BY
GASKET- PASS PARTITION SECTION SS 304 FLAT METAL JACKETED
AROMATIC SOLVENT TO REMOVE ALL GREASE, OIL ETC AS PER SSPC-SP-1.
GASKET- FLOATING HEAD FLANGE (GRAPHITE FILLED) BUNDLE WEIGHT kg 17000 BLAST CLEANING SHALL BE SA 2-1/2 AS PER SWEDISH STANDARD SIS-055900
CONNECTING PIECE SA-516 Gr. 60 N (LATEST EDITION) OR SSPC-SP OR ISO 8501-01.
SHELL SIDE-
PASS PARTITION PLATE SA-516 Gr. 60 N
A. HEAT RESISTANT SILICONE ALUMINIUM PAINT SUITABLE UP TO 540°C DRY
STUD WITH NUTS SA-193 Gr. B7 / SA-194 Gr. 2H WIND FORCE kgf 820 TEMP.; 3 COATS @20μ DFT/coat ; TOTAL 60μ DFT (MIN.)
STUD WITH NUTS FOR INTERNAL PARTS SA-193 Gr. B7 / SA-194 Gr. 2H WIND MOMENT kgf x m 660 TUBE SIDE-
A.SSPC-SP-10; 1COAT OF INORGANIC ZINC SILICATE COATING@ 65-75μ
GASKET- CHANNEL COVER FLANGE SS304 SPWD GRAFOIL FILLED SEISMIC FORCE kgf 5920 DFT/COAT
WITH SS304 INNER RING & OUTER B. 1 COAT OF EPOXY ZINC PHOSPHATE PRIMER @ 40 μ DFT/COAT
GASKET- ST. T/S TO CHANNEL FLANGE NOSE SEISMIC MOMENT kgf x m 4740 C. 1 COAT OF POLYAMIDE CURED EPOXY RESIN MEDIUM SUITABLY PIGMENTED
@ 100 μ DFT/COAT+ 1COAT OF ACRYLIC POLYURETHANE FINISH PAINT @ 40μ
LIFTING LUG FOR FLOATING HEAD CS DFT/COAT
NOZZLE NECK SA-106 GR B
NOZZLE NECK FLANGE SA-105
SS304 SPWD GRAFOIL FILLED AS
NOZZLE GASKET
PER ASME B 16.20
HOLD UPS
CHANNEL COVER SA 266 GR 2 NOZZLE ORIENTATION
OTHERS
TUBESHEET SA 266 GR 2 R0 ISSUED FOR ENQUIRY 21.5.18 PMS VSS BBB
EYE BOLT SA-105 REV. NO. DESCRIPTION DATE DRN CHECKED APP.
NOZZLE SCHEDULE
DOWEL PIN SA-105
JACK SCREW SA-105 NOZZLE
MARK
SIZE SCH / THK TYPE RATING PAD OD X THK SERVICE OWNER BHARAT PETROLEUM CORPORATION LIMITED
SETTING BOLT CS
DAVIT CS S1 20" 30 THK SRN 600# REFER SHT.2 SHELL INLET
PLUG FOR EYEBOLT & INSERSION PIECE CS S2 20" 30 THK SRN 600# REFER SHT.2 SHELL OUTLET
LIFTING LUG CS S3 2'' 16.6 THK LWN 600# - VENT CONSULTANT L&T ENGINEERING SERVICES, MUMBAI
S4 2'' 16.6 THK LWN 600# - DRAIN
T1 10'' 140 SCH WNRF 300# 510 X 25 TUBE INLET
T2 10 140 SCH WNRF 300# 510 X 25 TUBE OUTLET DATE: 21.05.18
TITLE HP ABSORBER FEED COOLER(141-A-E105)
ACCESSORIES T3 2'' 16.6 THK WNRF 300# - TUBESIDE STUB CONNECTION-1 DEPT: MES
LIFTING LUG INSULATION CLEATS T4 2'' 16.6 THK WNRF 300# - TUBESIDE STUB CONNECTION-2
PRP BY: PMS PROJECT CCR PROJECT AT MAHUL,MUMBAI
LIFTING & PULLING EYEBOLT DAVIT FOR SHELL COVER
PLUG FOR PULLING EYEBOLT TEST RING
CHK BY: VSS SH. 1 OF 4
JACK SCREW & DOWEL PIN TEST FLANGE
DRG. NO. MDS-141-A-E-105
NAME PLATE 6 mm THK PLATE @SLIDING END
APP BY: BBB REV. 0
EARTHING LUG
ALLOWABLE NOZZLE LOADINGS
FOR
PRESSURE VESSELS
AND
SHELL & TUBE HEAT EXCHANGERS
01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

00 22/04/2010 ISSUED FOR IMPLEMENTATION AKV AND AKG
REV. DATE DESCRIPTION BY CHKD. APPD.
STANDARD NO.
ALLOWABLE NOZZLE LOADS
REV.
L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

SHELL & TUBE HEAT EXCHANGER)
SHEET 1 OF 9
FLANGE RATING : 150#
CIRCUMFERENTIAL
NOZZLE SIZE TORSIONAL LONGITUDINAL
AXIAL FORCE LONGITUDINAL CIRCUMFERENTIAL MOMENT MC (Kgf-m)
SHEAR SHEAR MOMENT MOMENT
FA (Kgf)
NPS NB
FL (Kgf) FC (Kgf) MT (Kgf-m) CS & LAS SS ML (Kgf-m)
(Inch) (mm)
1.5 40 90 135 135 20 14 12 18
2 50 120 180 180 36 26 21 32
3 80 180 270 270 81 58 47 72
4 100 240 360 360 144 102 83 128
6 150 360 540 540 324 230 187 288
8 200 480 720 720 576 410 333 512
10 250 600 900 900 900 640 520 800
12 300 720 1080 1080 1296 922 749 1152
14 350 840 1260 1260 1764 1254 1019 1568
16 400 960 1440 1440 2304 1638 1331 2048
18 450 1080 1620 1620 2916 2074 1685 2592
20 500 1200 1800 1800 3600 2560 2080 3200
24 600 1440 2160 2160 5184 3686 2995 4608
26 650 1560 2340 2340 6084 4326 3515 5408
28 700 1680 2520 2520 7056 5018 4077 6272
30 750 1800 2700 2700 8100 5760 4680 7200
32 800 1920 2880 2880 9216 6554 5325 8192
34 850 2040 3060 3060 10404 7398 6011 9248
36 900 2160 3240 3240 11664 8294 6739 10368
38 950 2280 3420 3420 12996 9242 7509 11552
40 1000 2400 3600 3600 14400 10240 8320 12800
42 1050 2520 3780 3780 15876 11290 9173 14112
44 1100 2640 3960 3960 17424 12390 10067 15488
46 1150 2760 4140 4140 19044 13542 11003 16928
48 1200 2880 4320 4320 20736 14746 11981 18432
50 1250 3000 4500 4500 22500 16000 13000 20000
52 1300 3120 4680 4680 24336 17306 14061 21632
54 1350 3240 4860 4860 26244 18662 15163 23328
56 1400 3360 5040 5040 28224 20070 16307 25088
58 1450 3480 5220 5220 30276 21530 17493 26912
60 1500 3600 5400 5400 32400 23040 18720 28800

STANDARD NO.
REV.

SHEET 2 OF 9
CIRCUMFERENTIAL
NOZZLE SIZE TORSIONAL
FA (Kgf)
NPS NB
(Inch) (mm)
1.5 40 113 169 169 25 18 15 23
2 50 150 225 225 45 32 26 40
3 80 225 338 338 101 72 59 90
4 100 300 450 450 180 128 104 160
6 150 450 675 675 405 288 234 360
8 200 600 900 900 720 512 416 640
10 250 750 1125 1125 1125 800 650 1000
12 300 900 1350 1350 1620 1152 936 1440
14 350 1050 1575 1575 2205 1568 1274 1960
16 400 1200 1800 1800 2880 2048 1664 2560
18 450 1350 2025 2025 3645 2592 2106 3240
20 500 1500 2250 2250 4500 3200 2600 4000
24 600 1800 2700 2700 6480 4608 3744 5760
26 650 1950 2925 2925 7605 5408 4394 6760
28 700 2100 3150 3150 8820 6272 5096 7840
30 750 2250 3375 3375 10125 7200 5850 9000
32 800 2400 3600 3600 11520 8192 6656 10240
34 850 2550 3825 3825 13005 9248 7514 11560
36 900 2700 4050 4050 14580 10368 8424 12960
38 950 2850 4275 4275 16245 11552 9386 14440
40 1000 3000 4500 4500 18000 12800 10400 16000
42 1050 3150 4725 4725 19845 14112 11466 17640
44 1100 3300 4950 4950 21780 15488 12584 19360
46 1150 3450 5175 5175 23805 16928 13754 21160
48 1200 3600 5400 5400 25920 18432 14976 23040
50 1250 3750 5625 5625 28125 20000 16250 25000
52 1300 3900 5850 5850 30420 21632 17576 27040
54 1350 4050 6075 6075 32805 23328 18954 29160
56 1400 4200 6300 6300 35280 25088 20384 31360
58 1450 4350 6525 6525 37845 26912 21866 33640
60 1500 4500 6750 6750 40500 28800 23400 36000

STANDARD NO.
REV.

SHEET 3 OF 9
CIRCUMFERENTIAL
FA (Kgf)
NPS NB
(Inch) (mm)
1.5 40 135 203 203 30 22 18 27
2 50 180 270 270 54 38 31 48
3 80 270 405 405 122 86 70 108
4 100 360 540 540 216 154 125 192
6 150 540 810 810 486 346 281 432
8 200 720 1080 1080 864 614 499 768
10 250 900 1350 1350 1350 960 780 1200
12 300 1080 1620 1620 1944 1382 1123 1728
14 350 1260 1890 1890 2646 1882 1529 2352
16 400 1440 2160 2160 3456 2458 1997 3072
18 450 1620 2430 2430 4674 3110 2527 3888
20 500 1800 2700 2700 5400 3840 3120 4800
24 600 2160 3240 3240 7776 5530 4493 6912
26 650 2340 3510 3510 9126 6490 5273 8112
28 700 2520 3780 3780 10584 7526 6115 9408
30 750 2700 4050 4050 12150 8640 7020 10800
32 800 2880 4320 4320 13824 9830 7987 12288
34 850 3060 4590 4590 15606 11098 9017 13872
36 900 3240 4860 4860 17496 12442 10109 15552
38 950 3420 5130 5130 19494 13862 11263 17328
40 1000 3600 5400 5400 21600 15360 12480 19200
42 1050 3780 5670 5670 23814 16934 13759 21168
44 1100 3960 5940 5940 26136 18586 15101 23232
46 1150 4140 6210 6210 28566 20314 16505 25392
48 1200 4320 6480 6480 31104 22118 17971 27648
50 1250 4500 6750 6750 33750 24000 19500 30000
52 1300 4680 7020 7020 36504 25958 21091 32448
54 1350 4860 7290 7290 39366 27994 22745 34992
56 1400 5040 7560 7560 42336 30106 24461 37632
58 1450 5220 7830 7830 45414 32294 26239 40368
60 1500 5400 8100 8100 48600 34560 28080 43200

STANDARD NO.
REV.

SHEET 4 OF 9
CIRCUMFERENTIAL
FA (Kgf)
NPS NB
(Inch) (mm)
1.5 40 158 236 236 35 25 20 32
2 50 210 315 315 63 45 36 56
3 80 315 473 473 142 101 82 126
4 100 420 630 630 252 179 146 224
6 150 630 945 945 567 403 328 504
8 200 840 1260 1260 1008 717 582 896
10 250 1050 1575 1575 1575 1120 910 1400
12 300 1260 1890 1890 2268 1613 1310 2016
14 350 1470 2205 2205 3087 2195 1784 2744
16 400 1680 2520 2520 4032 2867 2330 3584
18 450 1890 2835 2835 5103 3629 2948 4536
20 500 2100 3150 3150 6300 4480 3640 5600
24 600 2520 3780 3780 9072 6451 5242 8064
26 650 2730 4095 4095 10647 7571 6152 9464
28 700 2940 4410 4410 12348 8781 7134 10976
30 750 3150 4725 4725 14175 10080 8190 12600
32 800 3360 5040 5040 16128 11469 9318 14336
34 850 3570 5355 5355 18207 12947 10520 16184
36 900 3780 5670 5670 20412 14515 11794 18144
38 950 3990 5985 5985 22743 16173 13140 20216
40 1000 4200 6300 6300 25200 17920 14560 22400
42 1050 4410 6615 6615 27783 19757 16052 24696
44 1100 4620 6930 6930 30492 21683 17618 27104
46 1150 4830 7245 7245 33327 23699 19256 29624
48 1200 5040 7560 7560 36288 25805 20966 32256
50 1250 5250 7875 7875 39375 28000 22750 35000
52 1300 5460 8190 8190 42588 30285 24606 37856
54 1350 5670 8505 8505 45927 32659 26536 40824
56 1400 5880 8820 8820 49392 35123 28538 43904
58 1450 6090 9135 9135 52983 37677 30612 47096
60 1500 6300 9450 9450 56700 40320 32760 50400

STANDARD NO.
REV.

SHEET 5 OF 9
CIRCUMFERENTIAL
FA (Kgf)
NPS NB
(Inch) (mm)
1.5 40 180 270 270 41 29 23 36
2 50 240 360 360 72 51 42 64
3 80 360 540 540 162 115 94 144
4 100 480 720 720 288 205 166 256
6 150 720 1080 1080 648 461 374 576
8 200 960 1440 1440 1152 819 666 1024
10 250 1200 1800 1800 1800 1280 1040 1600
12 300 1440 2160 2160 2592 1843 1498 2304
14 350 1680 2520 2520 3528 2509 2038 3136
16 400 1920 2880 2880 4608 3277 2662 4096
18 450 2160 3240 3240 5382 4147 3370 5184
20 500 2400 3600 3600 7200 5120 4160 6400
24 600 2880 4320 4320 10368 7373 5990 9216
26 650 3120 4680 4680 12168 8653 7030 10816
28 700 3360 5040 5040 14112 10035 8154 12544
30 750 3600 5400 5400 16200 11520 9360 14400
32 800 3840 5760 5760 18432 13107 10650 16384
34 850 4080 6120 6120 20808 14797 12022 18496
36 900 4320 6480 6480 23328 16589 13478 20736
38 950 4560 6840 6840 25992 18483 15018 23104
40 1000 4800 7200 7200 28880 20480 16640 25600
42 1050 5040 7560 7560 31752 22579 18346 28224
44 1100 5280 7920 7920 34848 24781 20134 30976
46 1150 5520 8280 8280 38088 27085 22006 33856
48 1200 5760 8640 8640 41472 29491 23962 36864
50 1250 6000 9000 9000 45000 32000 26000 40000
52 1300 6240 9360 9360 48672 34611 28122 43264
54 1350 6480 9720 9720 52488 37325 30326 46656
56 1400 6720 10080 10080 56448 40141 32614 50176
58 1450 6960 10440 10440 60552 43059 34986 53824
60 1500 7200 10800 10800 64800 46080 37440 57600

STANDARD NO.
REV.

SHEET 6 OF 9
CIRCUMFERENTIAL
FA (Kgf)
NPS NB
(Inch) (mm)
1.5 40 225 338 338 51 36 29 45
2 50 300 450 450 90 64 52 80
3 80 450 675 675 203 144 117 180
4 100 600 900 900 360 256 208 320
6 150 900 1350 1350 810 576 468 720
8 200 1200 1800 1800 1440 1024 832 1280
10 250 1500 2250 2250 2250 1600 1300 2000
12 300 1800 2700 2700 3240 2304 1872 2880
14 350 2100 3150 3150 4410 3136 2548 3920
16 400 2400 3600 3600 5760 4096 3328 5120
18 450 2700 4050 4050 7290 5184 4212 6480
20 500 3000 4500 4500 9000 6400 5200 8000
24 600 3600 5400 5400 12960 9216 7488 11520
26 650 3900 5850 5850 15210 10816 8788 13520
28 700 4200 6300 6300 17640 12544 10192 15680
30 750 4500 6750 6750 20250 14400 11700 18000
32 800 4800 7200 7200 23040 16384 13312 20480
34 850 5100 7650 7650 26010 18496 15028 23120
36 900 5400 8100 8100 29160 20736 16848 25920
38 950 5700 8550 8550 32490 23104 18772 28880
40 1000 6000 9000 9000 36000 25600 20800 32000
42 1050 6300 9450 9450 39690 28224 22932 35280
44 1100 6600 9900 9900 43560 30976 25168 38720
46 1150 6900 10350 10350 47610 33856 27508 42320
48 1200 7200 10800 10800 51840 36864 29952 46080
50 1250 7500 11250 11250 56250 40000 32500 50000
52 1300 7800 11700 11700 60840 43264 35152 54080
54 1350 8100 12150 12150 65610 46656 37908 58320
56 1400 8400 12600 12600 70560 50176 40768 62720
58 1450 8700 13050 13050 75690 53824 43732 67280
60 1500 9000 13500 13500 81000 57600 46800 72000

STANDARD NO.
REV.

SHEET 7 OF 9
FA
MT
ML
FC
FL
MC
FA
MT
MB
FB
2
FB = ¥(FL2+ FC )
MB = ¥(ML2 + MC2 )

STANDARD NO.
REV.

SHEET 8 OF 9
NOTES :-
1. This standard covers allowable nozzle loads for pressure vessels, columns and shell & tube
heat exchangers.
2. Each process nozzle and relief valve nozzles shall be analyzed for the loads provided in this
standard.
3. Loads specified here do not apply to manway or instrument connections, but are applicable to
other blanked nozzles indicated as "spare".
4. The indicated loads are to be considered to act at the shell / head to nozzle intersection and to
be true normal and tangential to the shell at the point.
5. For radial loads, firstly calculations shall be made with the force acting radially outwards in
conjunction with internal pressure and then with the force acting inwards. In second instance,
radial loads inward shall be considered with no internal pressure.
6. Localized stresses at nozzle locations in shells and formed heads shall be evaluated using
one of the method shown below. For each method, the acceptance criteria shall be in
accordance with Part 5 of ASME sec VIII Div.2.
(a) Nozzles in cylindrical shells - stress calculations shall be in accordance with WRC 297.
(b) Nozzles in formed heads - stress calculations shall be in accordance with WRC 107.
(c) For nozzle configuration going beyond WRC, Vendor shall perform the calculation using
alternate design practices like PD 5500 or Finite element analysis (FEA).
7. For nozzles as end connections on heads following formulae shall be used to calculate the
combined shear and bending moments.
FB = ¥(FL2 + FC2 ) MB = ¥(ML2 + MC2 )
8. The above loads are developed based on general design conditions. For cases where design
pressure and/or design temperature are excessively high (this may be decided at discretion of
designer/user). The load values stated here shall be reviewed & carefully analyzed before
usage.
9. Abbreviations used:
CS : Carbon steel material.
LAS : Low alloy steel material.
SS : Stainless steel material.

STANDARD NO.
REV.

SHEET 9 OF 9

Mechanical Static DOC.NO.:MESŞSPŞ0041

General Specification for
(QJLQHHULQJ6HUYLFHV
Heat Exchangers Sheet1of23 REV01
GENERAL SPECIFICATION
FOR
HEAT EXCHANGERS
01 Revised and Reissued as Standard Specification SAC SBG RGO 17-May-2016

00 Issued for Use AG HS RG 12/05/2012
Prepared Reviewed Approved Approved
REV DESCRIPTION
by by by Date
© 2016 LTHE Engineering Services. All rights reserved. Electronic documents once printed are uncontrolled. Control documents are
electronic documents on designated server or originally signed print copy.
Contains confidential and / or proprietary information of LTHE Engineering Services and its affiliated companies, which shall not be
used, disclosed or reproduced in any format without prior written permission of LTHE- Engineering Services.


(QJLQHHULQJ6HUYLFHV
CONTENTS
1. SCOPE ......................................................................................................................................... 4

2. CODE & REGULATIONS ............................................................................................................. 4
3. DEFINITIONS ............................................................................................................................... 6
4. MATERIAL SPECIFICATION ....................................................................................................... 6
5. FABRICATION ............................................................................................................................ 10
6. NON DESTRUCTIVE TESTS ..................................................................................................... 16
7. HEAT TREATMENT ................................................................................................................... 17
8. INSPECTION AND TESTING ..................................................................................................... 18
9. SUPPLY ...................................................................................................................................... 19
10.GUARANTEE.............................................................................................................................. 21
11.TRANSPORTATION,SITE FABRICATION AND ERECTION..................................................... 21
12.FINAL DOCUMENTATION ......................................................................................................... 22


(QJLQHHULQJ6HUYLFHV
Abbreviations:
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
AWS American Welding Specification
BHN Brinell Hardness Number
BTD Bolt Tensioning Device
BV Bureau Veritas
CIB Chief Inspector of Boilers
CS Carbon Steel
DIA Designated Inspection Agency
DNV Det Norske Veritas
DP Dye Penetrant
FPW Full Penetration Weld
GPC General Purchase Condition
HAZ Heat Affected Zone
HIC Hydrogen Induced Cracking
IBR Indian Boiler Regulation
ID Inside Diameter
IGC Inter Granular Cracking
IS Indian Standards
LAS Low Alloy Steel
LTCS Low Temperature Carbon Steel
MDMT Minimum Design Metal Temperature
MP Magnetic Particle
NB Nominal Bore
NDT Non Destructive Testing
PO Purchase Order
PPM Parts Per Million
PTC Production Test Coupons
PWHT Post Weld Heat Treatment
QAP Quality Assurance Plan
SS Stainless Steel
TEMA Tubular Exchangers Manufacturers' Association
UT Ultrasonically Tested
UTS Ultimate Tensile Strength


(QJLQHHULQJ6HUYLFHV
1. SCOPE
1.1. This specification specifies the general requirements for residual design, engineering, materials,
fabrication, workmanship, inspection, testing and supply of heat exchangers and is intended to
supplement the requirements of the applicable Codes, L&T specifications & standards wherever
indicated in the requisition shall be followed unless stated otherwise.
1.2. Supplementary specification indicating special or additional requirements shall form addenda to this
specification and shall be referred to in the Material / Purchase Requisition and/or Purchase Order.
1.3. This specification shall not be applied to the design of non-TEMA exchangers, such as sometimes
used for lube and seal oil cooling duties for packaged equipment like compressors, pumps and
turbines.
1.4. In case of conflict, the order of precedence shall be as follows:
x Local Laws and Statutory Requirements
x Data Sheets
x Specifications
x International Codes and Standards
As a general rule, the most stringent requirements shall govern. Where a requirement of a licensor’s
or a relevant industry standard/specification is more stringent than that of this specification, the
most stringent requirement will govern.
2. CODE & REGULATIONS

2.1. Design Codes
The following codes / Standards in their latest edition including their addenda referenced in
drawings, datasheets or design basis along with other specifications enclosed with the requisition at
the time of enquiry shall form the basis of design, fabrication, inspection, testing and acceptance of
equipment:
2.1.1 Boiler & Pressure Vessel Codes
x ASME Section VIII
x ASME Section IX
x ASME Section V
x ASME B 16.5 / 16.47 for flanges
x ASME B 16.20 / 16.21 for gaskets
x IBR (Indian Boiler Regulations) as applicable
x The Static and Mobile Pressure Vessel (Unfired) Rules 1981 (whenever applicable)
x TEMA (Class as specified on the drawings or data sheets or design basis)
2.1.2 National Association of Corrosion Engineers Standards
x NACE MR 0103: Material resistant to sulfide stress cracking in corrosive petroleum
refining environment
x NACE MR 0175: Petroleum and natural gas industries material for use in H2S
containing environment in oil and gas production


(QJLQHHULQJ6HUYLFHV
x NACE TM 0284: Evaluation of pipeline and pressure vessels steels for resistance to
hydrogen induced cracking
x NACE TM 0177: Laboratory testing of metal for resistance to sulfide stress cracking
in H2S environment.
2.1.3 Welding Research Council Bulletins
x WRC 107 / WRC 537: Local Stresses in Spherical and Cylindrical Shells Due to
External Loadings
x WRC 297: Local Stresses in Cylindrical Shells Due to External Loadings on Nozzles
2.2. Material Codes
Material to be used shall conform to:
x ASME Section II.
x Other international Standard Specification materials of equivalent grade can be used only after
written approval from Purchaser.
2.3. L&T Specifications
x MES-SP-0002 Supplementary Specification for Carbon Steel Vessels
x MES-SP-0003 Supplementary Specification for Low Alloy Steel Vessels
x MES-SP-0004 Supplementary Specification for Austenitic Steel Vessels
x MES-SP-0005 Supplementary Specification for Stainless Steel Clad Vessels
x MES-SP-0042 Specification for Vendor Designed Shell & Tube Exchanger
2.4. Regulation
National laws and regulations together with any local by-laws for the country or state wherever the
vessels are to be used must be complied with by the Vessel manufacturer.
2.5. For Heat Exchangers Under the Purview of IBR
2.5.1 Vendor shall carry out design calculations as per IBR and only in case of any doubt refer
the same to Purchaser for clarifications. All materials, fabrication, welding, testing etc. shall
meet the requirements of IBR.
2.5.2 In case the equipment is manufactured in India, the design calculations and fabrication
drawings after preliminary review of Purchaser shall be got approved by Vendor from CIB of
the State where Vendor's shop is located, prior to start of fabrication. Vendor shall also
provide the necessary assistance to Purchaser for obtaining approval from CIB of State of
installation, such as providing additional copies of calculations and drawings etc. as
required by CIB of that State.
2.5.3 In case the equipment is manufactured outside India, the design calculations and
fabrication drawings after preliminary review by Purchaser shall be got approved by Vendor
from the agency authorized by IBR in the country of fabrication and the CIB of the State
where the equipment is to be installed, before the start of fabrication.
2.5.4 It shall be the responsibility of Vendor to incorporate modifications or additions required by
CIB or its authorized agency and obtain the final approval. Purchaser shall be kept informed
about these. All costs towards approval from CIB shall be borne by Vendor. All IBR
approved design calculations and drawings shall be furnished to Purchaser for final review
of fabrication drawings and in equipment dossier.


(QJLQHHULQJ6HUYLFHV
3. DEFINITIONS
Company: Public or Private Entity referred as owner of the Project
Contractor: Public or Private Entity responsible for detailed engineering, design, engineering,
procurement, construction Pre-Commissioning and Start-up of the Project.
Vendor: Single point responsible firm or other Corporate Entity contracted by purchaser to
supply goods to purchaser i.e. Company or Contractor.
4. MATERIAL SPECIFICATION
4.1 General
4.1.1 All material used for fabrication shall be new and of first quality. All materials and
accessories required for the fabrication, inspection, testing etc. of the heat exchanger shall
be supplied by the Vendor unless otherwise stated. Whenever some material is to be
supplied by the Purchaser, this shall be so indicated as Free Issue Material and the
supplementary specifications in this regard shall be complied with.
4.1.2 In addition to the requirement of materials as per material specifications, materials shall
also meet the requirements mentioned in this specification and other specifications
enclosed with the requisition. All materials shall be certified for compliance with applicable
specifications for the item(s) so specified. While procuring materials, Vendor shall stipulate
additional requirements such as limits on hardness, UTS, yield strength, chemical
composition, heat treatment and any other specific requirements to ensure that final
requirement as per specification and Code are met with.
4.1.3 All materials for pressure parts and parts welded to pressure parts including materials in the
scope of sub-Vendors shall be accompanied with mill test certificates duly certified by a
reputed third party inspection agency. In the absence of mill test certificate the material
shall be got tested from a reputed third party inspection and test results shall be submitted
in lieu of mill test certificate. All cost towards such testing and inspection shall be borne by
the Vendor. All materials shall be inspected at Vendor and sub-Vendor's shop for
verification prior to use on the job. The decision of DIA to accept or reject materials on the
basis of such testing shall be final.
4.1.4 Wherever simulated heat treatment of test specimens is required as per Code or
specification, the simulation cycle shall include one extra cycle of stress relieving for any
eventuality of repair at site by Purchaser during the life of the equipment.
4.1.5 MDMT shall be taken as 0°C or the design temperature specified in drawing or datasheet
whichever is lower, unless specified otherwise in design basis or datasheets or drawings.
For low temperature service, all CS and LTCS materials for pressure parts and attachments
to pressure parts shall be charpy V-notch impact tested. All LAS materials for pressure
parts and attachments to pressure parts shall be charpy V-notch impact tested irrespective
of the design temperature. Impact test temperature shall be lowest of minimum ambient
temperature, design temperature and MDMT. Low temperature service shall be specified in
datasheets or drawings.
4.1.6 Plates
a) Pressure parts having thickness 16 to 50 mm (both inclusive) shall be UT as per SA-
435.
b) Pressure parts having thickness >50mm shall be UT as per ASME SA-578 Level B.
4.1.7 Tubes


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a) All the tubes shall be seamless and cold drawn.

b) Product analysis of tubes shall be carried out and reported in the material test
certification.
c) Tubes shall be in fully heat-treated condition as received from the mill. CS tubes shall
be in annealed condition and copper alloy tubes shall be in annealed temper condition.
LAS tubes shall be supplied in normalized and tempered condition.
d) All un-stabilized SS tubes shall be supplied in the solution annealed condition and all
stabilized grades of SS such as SS 321 and SS 347 shall be supplied in stabilization
heat treated condition, in addition to solution annealing.
e) It is preferable while ordering tubes the maximum yield strength and hardness of tubes
are specified such as to be lower than those of tube sheet, in order to achieve a sound
expanded tube to tube sheet joint, complying with Code requirements.
f) “Air under water” testing shall be carried out for all tubes except non-ferrous tubes. As
an alternative, tubes can be hydro tested. In case the tubes are hydro tested, hydro test
pressure of tubes shall be higher of tube side test pressure or as required by Code.
Water quality shall be as per Para 8.2.1 of this specification.
g) For requirement of U tubes refer L&T specification MES-SP-0043.
4.1.8 Forgings
Forgings manufactured to SA-105 and SA-266 above 75 mm thickness, all tube sheet
forgings and all forgings of other materials, except for the standard nozzle flanges up to 8"
NB and small forgings (of couplings, plugs and eye bolts) shall be 100% UT as per SA-388.
Acceptance criteria shall be as per ASME Section VIII Division 2.
4.1.9 Pipes
Pipe shall be seamless and size above 1.5’’ NB shall be hot finished. Dimension and
tolerances shall be in accordance with ASME 36.10 or ASME 36.19, as applicable, as per
material specification.
4.2 Specific Material Requirement (Pressure Part And Part Welded To Pressure Parts)
4.2.1 CS and LTCS Materials
a) Carbon content shall not exceed 0.23%.
b) All plates shall be in normalized condition and forgings in normalized & tempered
condition.
c) Use of SA 515 of any grade is not permitted.
d) Plates > 50mm thickness shall meet following additional requirements of SA-20 :
i. Vacuum treatment as per the supplementary requirement S1. If vacuum
degassing is not reported in the certificates, then through thickness test as per
SA 770 shall be conducted in area of 35% shall be ensured.
ii. Charpy V-notch test as per supplementary requirement S5 of the Specification
SA-20. Material to be used for design temperature warmer than 0°C, Impact test
shall be carried out at 0°C or MDMT whichever is lower and acceptance criteria
for energy absorption shall be as per applicable design code. Orientation of test
bar shall be transverse to rolling direction.
e) Unless specified otherwise in requisition or bid document, all CS materials specified as
HIC test shall meet the following requirement


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i. Carbon equivalent shall be <0.40% nickel content shall be<0.2%.

ii. Sulpher content shall be < 0.002% for plates and < 0.01 % for tubes, pipes and
forgings.
iii. Hardness of plates and pipes shall not exceed 200 BHN, and that of forgings
shall not exceed 187 BHN.
iv. Plate shall conform to SA 516 Gr 60 only (higher grades like SA 516 Gr.65 and
70 are not acceptable). The plates shall be treated with calcium or other rare
earth elements to create spherical inclusions instead of stringers. The plates shall
be tested in accordance with NACE TM-0284 using the test solution 'A' of NACE
TM-01-77. The acceptance criteria shall be crack length ratio 10 % maximum.
f) All LTCS and CS charpy plate material shall be made to fine grain practice and the
Primary austenitic grain size, shall be measured and reported in mill test certificates.
g) CS pipes shall be SA-106 Gr. B LTCS pipes shall be SA 333 Gr.1 or 6.
4.2.2 LAS Materials
a) All LAS plates, pipes, forgings and fittings shall be in normalized and tempered
condition. Use of C-1/2 Mo material is prohibited. All LAS materials shall be charpy V-
notch impact tested. Test temperatures shall be lowest of minimum ambient
temperature, design temperature, MDMT and minus 18°C (0 °C instead of -18 °C for
5Cr- l/2Mo materials). Impact energy values as per UG-84 or applicable specification,
whichever is higher.
b) In the case of 1.25 Cr – 0.5 Mo materials and weldments, the maximum room
temperature tensile strength for all pressure containing components, materials and
welds shall be 100000 psi.
c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside of
the tubes as per SA-450.
d) For LAS plates > 50 mm thickness, following supplementary requirements of SA-20
shall also apply:
i. Vacuum treatment as per supplementary requirement S1. If vacuum degassing is
not reported in the test certificates, then through thickness test as per SA 770
shall be conducted and minimum reduction in area of 35% shall be ensured.
ii. Bend test as per supplementary requirement S14.
4.2.3 SS and Other High Alloy Material
a) All SS material (300 series) shall be in the solution heat-treated (fully annealed) and
pickled condition. All stabilized grades of SS (SS 321, SS 347 etc.) shall be given
stabilization heat treatment, in addition to solution annealing.
b) SS (300 series) plates shall be hot rolled and shall have No.1 finish on both sides.
c) SS (300 series) materials for all components including non-pressure parts like baffles,
tie rods, etc. shall be procured with the IGC test as per ASTM A-262 (test shall be
carried out, after the specified heat treatment and sensitization per specification) with
acceptable corrosion rate and practices as under:
i. For all services except nitric acid services, practice E shall be followed. Specimen
after exposure shall be bent as per requirement mentioned in A 262 practice E
and shall be inspected under magnification of 200X. The bent specimen shall be


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free of any cracks or grain dropping. The microstructure shall be submitted to DIA
for approval.
ii. Nitric acid service: Practice C with corrosion rate not > 25 mils per year.
d) For straight chrome (13% Cr.) material, Maximum carbon content shall be < 0.06%.
Hardness of UNS no. S41000 & S40500 shall be < 85 RB.
4.2.4 Non-Ferrous Material
a) All copper based non-ferrous plates shall be procured in annealed condition.
b) Plates for pressure parts shall be 100% UT. Vendor shall submit the procedure for UT
to DIA for approval.
c) In addition to hydro test, all tubes shall be eddy current tested in their final annealed
condition.
d) All pipe bends shall be stress relief annealed after bending.
e) The paragraph NF7 and NF14 in part UNF of Code are mandatory. This applies to non-
ferrous cladding and weld overlay also.
4.2.5 Clad Materials
a) Cladding shall be integrally and continuously bonded to the base metal. All clad plates
shall be rolled-on or explosion bonded type.
b) Clad plates shall be UT from the cladding surface as per SA-578. Scanning shall be
100% of the plate surface. Acceptance standard shall be level B. Clad plates shall meet
the supplementary requirements of S7 of SA-578. All UT shall be undertaken after
specified heat treatment of clad plates.
c) Both base material and clad material shall meet the specification of the respective
materials as stipulated in this specification.
d) Alloy Clad steel plates shall be as per SA 263 or SA 264 or SA 265. Bond between
cladding and the base metal shall be checked for a minimum strength of 14 kg/mm2 in
shear for alloy clad steel plates, by conducting shear test as per applicable material
specification.
e) For copper alloy clad plates, the bond between cladding and base metal shall be
checked for a minimum strength of 10 kg/mm2 in shear by conducting shear test.
f) During tension test of clad plates the cladding shall be removed and the tensile
properties of the base material shall meet the Code material requirements.
g) For austenitic SS clad plates the SS surface shall be acid pickled as per ASTM A- 380.
For chromium steel clad surfaces the pickling shall be as per Vendor's established
procedure. The same shall be submitted to Purchaser for approval.
h) For clad components, Vendor to ensure that plate thickness after bonding and
machining shall not be less than the thickness specified in drawings. Vendor to
consider sufficient margin on clad and base materials so that thickness after machining
and complete fabrication shall be as per the drawings. For nozzle necks with weld
deposit, sufficient margin on ID shall be taken to allow for shrinkage.
4.3 Non Pressure part
4.3.1 The basic allowable stressed for non-pressure parts shall be 33-1/3% of the ultimate tensile
strength or 66-2/3% of the yield strength, whichever is less, and for welds attaching non
pressure parts to pressure parts shall be the same as for pressure parts.


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4.3.2 CS plate shall be minimum IS-2062 or SA 283 Gr. C or equivalent. Pipe shall be to IS 1239
or SA 53 or equivalent.
4.3.3 Saddle material shall be of same as of shell for shell design temperature > 350 ºC.
4.4 Equivalent materials
The materials for various components in a heat exchanger shall be as per Purchaser’s requirement.
This does not preclude use of equivalent or better materials. However, these deviations should be
clearly indicated in the prescribed format. If an equivalent material sought by the Vendor is to a
specification, other than IS or ASTM or ASME, it is necessary for the Vendor to submit the
specifications of the equivalent material with complete details in English for approval.
5. FABRICATION
5.1 Edge Preparation
5.1.1 For CS, the edges for welding shall be made by machining, chipping, cold shearing, oxy-
acetylene flame cutting or a combination of these. Chipping or cold shearing shall be
followed by grinding to a smooth and regular surface. Oxy-acetylene flame cutting shall be
followed by machining or grinding to eliminate any discoloration of material affected.
5.1.2 For LAS, the edges for welding shall be made by oxy-acetylene flame cutting or by
machining. Cold shearing may be used for cutting thickness up to 10 mm. Oxy-acetylene
flame cutting shall be used with preheat and shall be followed by machining or grinding to
eliminate any discoloration of material affected.
5.1.3 For austenitic SS, the edges for welding shall be made by plasma arc; however, cold
shearing may be adopted for thickness up to 15 mm. In all cases the cut edges shall be
ground back or machined back by 2 to 3 mm.
5.1.4 All welding edges after cutting shall be DP or MP examined for laminations, cracks or
segregation. Additionally UT shall be carried out within five times the material thickness of
edge for LAS materials or when the service is low temperature or hydrogen or HIC.
5.1.5 The paragraphs NF7 and NF14 in part UNF of Code are mandatory. This applies to non-
ferrous cladding and weld overlay also.
5.2 Rolling and Dishing of Plates
5.2.1 Rolling
Rolling for bending and forming of plates shall be in the longitudinal direction of the plates.
This direction shall be clearly marked on the plates.
Rerolling after welding is not normally recommended. However, if for large diameter shells,
rerolling of welded shell course is inevitable, procedure for rerolling along with extent of
NDT shall be submitted for approval of the DIA. All welds on the section to be rerolled must
be ground flush. After rerolling all the welds on the re-rolled section must be DP checked.
Such Welds shall then be subjected to radiography as required by drawings and Code.
5.2.2 Dishing
All dished heads shall preferably be of single piece construction. However dished ends with
one chordal seam are acceptable for shells with diameter greater than 1 m. In such cases,
the chordal seam shall preferably be in the one-third of the blank. Dished ends shall be tori-
spherical (knuckle radius 15% of outside diameter and crown radius 80% of outside
diameter) or 2:1 ellipsoidal. Dished heads shall be subjected to DP test on knuckle portions
(both inside and outside) and weld edges after heat treatment. Vendor to ensure adequacy
of indicated thinning allowance for dished head. If nominal thickness indicated is not


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adequate then the nominal thickness should be increased accordingly, keeping minimum
thickness as per item drawing. A straight face of 38 mm or 3 times the nominal thickness of
dished head, whichever is more, shall be provided, but maximum straight face shall be
limited to 50 mm.
5.3 Welding
5.3.1 All welding and weld overlays shall be done with electrodes, fillers and fluxes of reputed
make with proven reproducibility of results. DIA shall specifically approve brand names. For
CS pressure parts, the electrodes shall be of low hydrogen type. IGC test as per ASTM
A262 Practice E shall be done for austenitic SS consumables, which are to be used in
application involving solution annealing. Austenitic SS consumables of low carbon and
stabilized grade shall also be IGC tested as per ASTM A262 Practice E. Straight chrome
materials shall be welded with electrode that produces an austenitic chromium nickel weld
deposit or a non-air hardening nickel-chromium-iron weld deposit.
5.3.2 All welding procedures shall be submitted for approval by DIA giving all relevant details.
Welding qualification records shall indicate hardness values of weld metal, HAZ and parent
metal and also results of impact tests when design temperature are below 0°C or when
specifically indicated for materials being welded. No welding shall be undertaken until DIA
has approved the welding procedure and welder's qualification. All welding procedures and
welders shall be qualified for the particular type of welding and material in accordance with
the ASME Section IX. Vendor shall be responsible for the quality of the welds performed.
5.3.3 Pressure holding joints shall be FPW. Root pass of single side welded joints shall be done
with GTAW process. Backing strip for single side welded joints is not permitted. For LTCS
materials, both inside and outside of welds shall be ground flush and dressed smooth. All
internal welds in the shell shall be ground flush in order to insert and remove tube bundle.
Also all internal welds shall be ground flush to the extent of facilitating draining of complete
equipment. All other weld may be left in the descaled condition only.
5.3.4 Longitudinal seams shall be staggered with the circumferential distance between the
centers of welds being at least 5 times the thickness of the thicker-plate. Weld seams shall
be located so as to avoid interference with weld seam of nozzles and external attachments.
5.3.5 Attachment to pressure part shall be of same quality as the pressure part. All LAS weld
attachments to pressure retaining component shall be FPW and ground to a smooth
concave contour. External attachments like lugs, supports etc. of CS shall not be welded
directly to high alloy or austenitic SS heat exchanger components. These attachments
should be of the same material as the heat exchanger component. If this is not so,
intermediate pad plate of the same material type as the heat exchanger component may be
used. These pads shall be at least 100mm wider and longer than the attachment and shall
be at least 5 mm thick. Welding of CS or LAS to austenitic SS shall be done with austenitic
SS electrodes or filler wire (AWS-ASTM-E 309L or E-309 Mo L only).
Wrapper plates, reinforcing pads, saddle plates or stiffeners of higher thickness than
specified can be used provided there is no change in basic dimensions and with the
approval from DIA. No separate deviation permit is required for the same.
5.3.6 Partition plates of CS and 300 series SS except for low temperature service, shall be
welded to channels etc. by continuous fillet welds with minimum size of 6 mm on both sides.
For all other materials and for hydrogen and low temperature services, all welds involving
partition plates shall be FPW. However all pass partition plates shall be FPW up to a
distance of 2"(50mm) from the gasket contact surface. Partition plates thicker than 10 mm
shall be tapered to 10 mm at partition groove end except when mentioned otherwise on
drawings. One weep hole of 6 mm diameter shall be provided at the center of each


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horizontal pass partition plate and a 5 mm radius notch on top and bottom point of each
vertical pass partition plate for all multi-pass exchangers for effective venting and draining.
5.3.7 Welding of shell to unhubbed tube sheet shall meet the requirements of Code considering
that the tube sheet is unsupported.
5.3.8 When impact tests are required on material as per Code or specification the welds shall
also be qualified for impact test. In such case following special requirement shall apply to
the welding procedure qualification:
a) Qualification test shall be made on plates of the ASME specification as specified for the
exchanger using welding electrodes of AWS or SFA specification and wire & flux of the
specification and brand as are to be used on the job.
b) Welding current and travel speed shall be considered essential variables in order to
ensure that production welding is substantially equivalent to the procedure qualification.
c) Welding test plates shall be subjected to a total thermal cycle sequence similar to the
finished equipment. Specifically, test plates shall be held at intermediate and final
stress relief temperatures for approximately the same length of time as the finished
exchanger. Final cooling rate shall be approximate to that expected for the finished
exchanger.
d) Charpy V-notch impact tests shall be made on the weld and HAZ of the test plate for
each welding procedure to be qualified. Test procedure shall be as per UG 84 of Code.
Test temperature shall not be higher than MDMT. Impact energy requirements shall be
as per Table 2.15 of SA 20 of ASME Section II Part A or UG 84 of Code whichever is
higher.
5.3.9 Weld Overlay
a) Wherever cladding is specified in datasheets or drawings, weld overlays are not
acceptable.
b) Weld deposit overlay shall be done by a qualified welding procedure and surface shall
be properly machined or ground flush after overlay. Minimum thickness of finished weld
deposit shall be as indicated in the datasheet or specifications. In case a higher
deposition thickness and multiple weld layers are required to achieve the minimum
specified undiluted deposit metal, the same shall be done only after taking prior
approval from Purchaser. Minimum thickness of undiluted finished weld overlay from
top shall be 3 mm or as specified in the datasheet. For non-ferrous weld deposit, the
iron dilution should be restricted to 2.5% (maximum) in the finished undiluted layer
(thickness defined above).
c) The weld overlay procedure shall be qualified on base metal of the same composition
as the exchanger component and meeting the requirements of ASME Section IX.
d) The weld overlay relatively smooth with no notches and undercuts that would act as
stress raisers. All cracks, fissures and circular defects greater than 1/16 inch diameter
shall be removed. Repaired areas shall be DP checked. Weld overlay shall be applied
to base metal, which has been grit blasted and is smooth and clean so as to ensure full
bonding. Welding overlay cladding shall be applied after any normalizing but before
PWHT. The weld overlay shall consist of at least 2 layers.
e) The alloy cladding shall be cut back at all seams to permit back welding of the base
metal. Weld metal shall be ground flush and fully covered with the applicable weld
deposit. The weld joint in base plate shall be 100% DP tested for detection of cracks
and flaws before welding from clad side. The weld deposit shall be at least as thick as
the cladding.


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f) Shells, cones, dished heads and nozzles formed from clad plates shall be subject to UT
after forming, for a minimum of 10% of the clad surface, but no less than one square
feet in each 10 square feet or fraction thereof. Un-bonded areas that cannot be
encompassed by a 3 inch diameter circle shall be repaired by weld overlay. When
repairs in excess of 5 % of the total examined area are required, the complete
component shall be subject to 100% UT. Repaired areas and weld deposit overlay at
weld seams shall be DP examined. UT shall be repeated for dished heads after heat
treatment. UT procedures shall be in accordance with SA 578 S6 for spot examination
and SA 578 S7 for 100% examination.
g) All weld overlays shall be 100% DP examined in accordance with the method described
in ASTM-E-165. The barrier layer shall be 100% examined. When the overlay involves
multiple passes (layers) and the procedure uses an intermediate heat treatment with
cooling to room temperature prior to applying the subsequent layer, each layer shall be
examined by DP. Where overlay is to be machined such as for flange facing, machined
surface shall be 100 % examined after final PWHT. If 100% of overlay is examined prior
to the final PWHT, overlay shall be spot examined (not less than 10% of the surface)
after heat treatment.
h) Sample of the weld overlay shall be taken to perform chemical analysis to the specified
depth. The number and location of samples and method of taking samples shall be
approved by DIA. However, they shall be representative of each exchanger component
for each type of welding process. Report of chemical analysis shall be submitted to DIA
for approval.
i) For all weld overlays used in hydrogen or H2S service with design temperature greater
than 350°C, Hydrogen dis-bonding test shall be carried out. The test condition shall be
representative of the actual design conditions and the procedure shall be submitted to
DIA for approval. Rate of cooling shall be 100°C/hr (min.) unless specified otherwise in
datasheets. Holding time shall be 48 hours unless specified otherwise in datasheets.
j) PTCs are required for CS welds above 50 mm thickness and for LAS welds above 25
mm or when required by the Code or when specified in the requisition. The following
shall apply: -
i. Two PTCs representative of one longitudinal and another circumferential seam
shall be provided for each procedure, position and thickness.
ii. PTC shall be from material of the same heat and thickness as that of parent metal.
During and after production welding PTC shall be subjected to same heat treatment
as and together with the course they represent. Extra PTC shall be preserved to
take care of eventuality of retests.
iii. The test mentioned below shall be carried out as per method of testing in code :
a. One transverse tension test.
b. Two sides bend test with weld located in the center of bend.
c. One hardness test on PTC weld and HAZ. The acceptable limits are 200 BHN
for CS, 225 BHN for P3 & P4 materials and 235 BHN for P5.
d. Micro and macro structural examination of welds.
e. For CS charpy V notch test on weld and HAZ shall be carried out. For MDMT <
0°C, impact test temperature shall be MDMT and for MDMT > or equal to 0°C,
the test temperature shall be 0°C. The acceptance criteria for impact energy
shall be as per table a 2.15 of SA 20 of ASME Section II part A or UG-84 of
Code whichever is higher.


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f. LAS, charpy V notch test on weld and HAZ shall be carried out. Test
temperature and acceptance criteria shall be as per clause 4.2.2 (d) (ii).
5.4 Tube to tube sheet joints
Requirement of L&T specification no. MES-SP-0044 shall be complied with for welded tube-to-tube
sheet joints and that of L&T specification no. MES-SP-0045 shall be complied with for expanded
tube-to-tube sheet joints.
5.5 Hardness limitation
Hardness limitation for CS and LAS materials, welds and HAZ wherever specified on drawings or
datasheets shall be ensured as per Specification MES-SP-0083. Hardness limitation compliance for
tube-to-tube sheet welded joints shall be established / verified on a mock-up with simulation heat
treatment
5.6 Nozzle flanges, nozzle and reinforcing pad
5.6.1 Flanges
Unless otherwise indicated, dimensions, drilling, facing and tolerances for nozzle flanges
(and blind covers if required) shall be as per ASME B 16.5 (for size up to 24" NB) and
ASME B 16.47 series B (for sizes above 24" NB) for the respective class. Weld overlays,
wherever specified or required, shall be in addition to the thickness as per these standards.
Bolt holes on these nozzle flanges shall straddle principal vertical and horizontal centerlines
of equipment. If the component to which nozzles are attached is subsequently stress
relieved, it shall be Vendor's responsibility to maintain true gasket faces by machining or
otherwise. If distortion is expected, final machining operation should be done after stress
relieving; sufficient machining allowance for this purpose should be available. Gaskets, for
flanges to ASME B 16.5 and B16.47, shall be as per ASME B16.20.
5.6.2 Nozzles
a) Nozzle pipes shall be attached to the heat exchanger components by FPW. Attachment
welds using only inner and outer fillet welds are not permitted. Unless otherwise
indicated on the datasheets or drawings, necks of all nozzles shall be flush with the
inside of the heat exchanger component. Inside corners of nozzle pipes at shell and
channel inside diameter shall be radiused. All nozzles 2" NB and below, except long
weld neck, shall have two stiffeners (30 mm x 6 mm) at right angles.
b) Whenever nozzle inside surface is required to be overlaid, these shall be done by weld
overlay or cladding. Minimum nozzle ID before weld depositing to be 50 mm. Liners are
not acceptable.
5.6.3 Reinforcing Pads and Testing
Reinforcing pads whenever required as per drawings or Code shall be of the same material
or equivalent as the heat exchanger component to which it is welded. All reinforcing pads
shall be provided with two 1/8" (3 mm) NPT tapped holes located 180 apart for air soap
solution test with a pressure of 1.25 kg/cm2 (g). This test shall also be required to be carried
out for slip on flanges. Higher test pressures are not recommended because of
accompanying risks and also because the soap bubbles have a chance to blow off. Tell-tale
holes in the reinforcing pads shall be plugged with hard grease unless otherwise indicated
after the hydro test of the exchanger.
5.7 Bolts, Studs and Tapped Holes


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5.7.1 All inch bolting and threading shall conform to ASME B 1.1 except for size 1" and above
where it shall be 8 threads per inch. Metric bolting and threading shall conform to ISO-R261
except for size M24 and above, where it shall have 3 mm pitch.
5.7.2 Studs shall extend beyond the nut by about 10 mm and shall be threaded full length except
when square ends are required for use with BTD, in which case the extension shall be as
per BTD manufacturer's recommendation. The studs for extended tube sheets and the
studs for use with connecting piece shall also have square ends.
5.7.3 All nuts shall be of heavy series only and nut seating faces shall be machined or spot faced.
5.7.4 Threads on external bolting, plugs etc. shall be lubricated with graphite grease for working
temperature up to 200°C and with Molybdenum Disulphide for higher temperatures.
5.7.5 Tapped holes on the channel side face of clad tube sheet for removable bundles shall be
fitted with plugs of a material similar to channel side material in contact with tube side fluid.
5.7.6 All floating head bolting to have 2 mm wide and 0.5 mm deep groove at both ends to
prevent mix up with other bolts.
5.7.7 In addition to stamping, the specifications and manufacturers symbol as specified in ASME
material specifications, on one of the ends the size of the studs shall be clearly punch
marked. Similarly the nuts shall have the size punch marked on one of the faces. In case of
tapped hole the size shall be punch marked near the hole without disturbing the gasket
seating area. Further for all alloy/SS metallurgy bolts & nuts shall also be identified by
distinct color marking at the stud end/bolt side face.
5.8 Assembly and Handling
5.8.1 Vendor shall be responsible for taking adequate preventive measures to ensure the quality
and finish of materials and to avoid any rusting.
5.8.2 Suitable method of alignment like dowels etc. shall be provided for proper assembly of
channel, channel covers, stationary tube sheet etc.
5.8.3 Stacked exchangers shall be assembled in the shop for a trial fit. Special care shall be
exercised in truing up connecting nozzle flanges.
5.8.4 “T” wherever indicated on drawings, denotes match mark for assembly and shall be
punched on all mating parts.
5.8.5 Lifting lugs shall be provided as per standard for lifting of channels, channel covers, floating
heads, shell covers, test rings, test flanges etc.
5.8.6 In case of removable bundles the following are required: -
a) Stationary tube sheets shall be drilled and tapped at vertical (0º) position for attaching
eyebolts or a lifting lug of adequate thickness shall be welded with 25 mm (minimum)
diameter hole.
b) Drilling and tapping as above shall be carried out on floating tube sheet.
c) Last support plate shall be drilled (25 mm diameter hole) for lifting the assembled
bundle. Local stiffening may be necessary to withstand the bundle and load, which shall
be designed by the Vendor.
5.8.7 Pulling eyebolts made from forged CS shall be provided for all removable bundles. These
shall be sent loose along with the spares. Insert piece shall be provided for all clad tube
sheets. Material of insert piece shall be same as that of cladding material.
5.8.8 Stationary tube sheet shall be drilled and tapped for tie rods. Care should be taken to
ensure that holes are not drilled through.


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5.8.9 Interchangeable and 180° rotatable bundles shall have common pass-partition groove
arrangement in the respective tube sheet. For exchangers where bundles are specified to
be interchangeable, the same shall be ensured at the Vendor's shop by actually inserting
the bundles or using a template consisting of 4 full diameter baffles, each spaced at a
distance equal to the baffle pitch.
5.8.10 Jackscrews shall be provided on all girth flanges.
5.9 Fabrication tolerances and finish
5.9.1 The dimensional tolerances shall be within the limits indicated on L&T standard no. MS-ST-
2019. Where tolerances are not specified, these shall be in accordance with the
requirements of TEMA and Code.
5.9.2 All edges and corners including baffle holes shall be de-burred (or rounded, if shown).
5.9.3 Finish of all machined components shall be minimum 12 microns (500 RMS) unless
otherwise indicated. Parts subjected to UT shall have minimum finish of 6 microns.
5.9.4 Tube sheet face shall be flat within +/- 1.5 mm (camber).
5.10 Descaling
Pickling and passivation shall be done for all SS parts in accordance with ASTM A-380. The Vendor
shall furnish details of the procedure for approval to DIA.
5.11 No distortion whatsoever shall be permitted on the gasket seating surfaces due to tube to tube
sheet welding, shell to tube sheet welding, PWHT etc. If distorted, the same shall be machined
subsequently.
5.12 Stamping, Name Plates And Warning Plates
5.12.1 Each exchanger shall be fitted with an SS nameplate.
5.12.2 Warning plates, if required, shall be provided.
5.12.3 The following exchanger parts shall have the item number stamped except for heat
exchangers in low temperature service in which case the item number shall be marked with
non-removable ink:
Shell girth flanges, shell cover flange, channel girth flanges, flat channel cover, stationary
and floating tube sheets, floating head cover flange, floating head backing ring, connecting
pieces, test rings, test flanges and other main removable parts.
6. NON DESTRUCTIVE TESTS

6.1 All the NDT procedures shall be submitted to DIA for approval. For all NDT activities, only qualified
NDT technicians shall be deployed with the approval of DIA.
6.2 The extent of radiography shall be as specified in datasheets or drawings or job specification.
Radiography shall be performed after PWHT. In case radiography is carried out before PWHT, then
UT shall be carried out on the welds after PWHT.
6.3 Minimum extent of radiography shall be spot, unless full radiography is specified in the drawings or
required as per specification or Code. Spot radiography shall mean that at least 10% of the total
welded length must be radio graphed. Further, all "T joints must be radio graphed and at least one
shot must be taken on each longitudinal and circumferential seam. This requirement shall
supplement the ones specified in Code. DIA shall be consulted in marking the areas to be radio
graphed.


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6.4 Full radiography when specified shall imply 100% radiography of all butt welds including nozzle
flange to nozzle neck, pipe to pipe and pipe to fitting (Irrespective of size of the nozzle or fitting).
6.5 All welds of nozzle necks fabricated, from plate, irrespective of diameter, thickness of plate and
radiography specified, shall be 100% radio graphed.
6.6 Weld seams of formed heads shall be 100% radio graphed after forming and heat treatment.
6.7 All nozzle to shell welds and unhubbed tube sheet to shell welds shall be DP or MP checked at the
root run and final weld.
6.8 All welds, which cannot be fully radio graphed such as nozzle to shell, shell to unhubbed tube
sheet, unhubbed floating head to cover etc., shall be 100% UT after final PWHT. Fillet welds and
welds which cannot be radio graphed or UT (i.e. pass partition plate to channel and floating head
etc.), the root run shall be DP checked and the welds shall be finally MP checked after PWHT.
6.9 All attachment welds shall be either DP or MP tested.
6.10 If radiography is being substituted by UT for the final closing seam as permitted by Code, MP shall
be carried out in addition to UT.
7. HEAT TREATMENT
7.1 PWHT shall be done if required by datasheets, drawings, specifications, Code etc. PWHT when
mentioned on the datasheet shall be over and above the requirements of specifications or Code. No
welding or heating is permitted after PWHT. All machining operations shall preferably be carried out
after PWHT (also refer clause 5.4.6.1). It shall be the responsibility of the Vendor to leave sufficient
allowance for this purpose. Vendor shall submit all the procedures for PWHT to DIA for review.
7.2 During PWHT of assemblies of fixed tube sheet exchangers, care shall be taken to ensure that
differential stresses are not caused between tubes, shell and tube sheet. The temperature
differential between shell and tubes during PWHT to be minimized (not to exceed 25°C) and the
rate of heating and cooling shall not exceed 25-30°C per hour. For this purpose, thermocouples
shall be installed on various components and compliance assured.
7.3 Heat treatment of SS clad assemblies shall be at reduced temperature to avoid sensitization of SS
materials. The soaking time shall be increased accordingly as per Code.
7.4 Heat treatment of non-ferrous clad assemblies, if required, shall be performed with extra care, at
reduced temperatures to avoid differential thermal expansion. The soaking time in such a case shall
be increased accordingly as per Code.
7.5 Heat treatment of CS and LAS dished heads shall be as follows:
7.5.1 Stress Relieving for:
a) Cold formed dish heads up to 16 mm thick.
b) Cold formed floating head cover up to 16 mm thick if fiber stretch exceeds 5 %.
7.5.2 Normalizing for CS and normalizing and tempering for LAS:
a) Hot formed dish head and floating head dish if not formed in normalizing range.
b) Cold formed dish heads for thickness greater than 16 mm.
c) Cold formed floating head dish above 16 mm thick.
This heat treatment need not be given if same heat treatment is given subsequently on sub-
assembly. Thicknesses specified above are nominal.


(QJLQHHULQJ6HUYLFHV
7.6 SS components shall be solution annealed in the following cases.

x Cold formed dished heads with nominal thickness of 16 mm or above.
x Hardness value of dished heads after cold forming exceeds 235 BHN.
x Hot formed shells, cones, dished heads.
After any heat treatment on austenitic SS, IGC test shall be carried out as per clause 4.2.3 (c)
7.7 All LAS welds shall be PWHT.
7.8 If stress relieving is indicated on shell side or tube side and the service on either side is lethal or low
temperature or if specifically indicated in the datasheet or drawings, the welded tube-to-tube sheet
joints of CS or LTCS material shall be stress relieved.
7.9 For LAS materials, preheating procedure shall be established in the welding procedure and got
approved by DIA. Preheating by resistance or induction-heating method is preferred. Preheating
shall extend uniformly to at least three times the thickness of joint but not less than 50 mm on both
sides of the weld. Temperature indicating crayons shall be used for assessment of correct pre-heat
temperature.
8. INSPECTION AND TESTING

8.1 Inspection
8.1.1 The inspection shall be carried out by DIA. The materials, fabrication and testing of
exchangers shall be open to inspection by DIA in addition to any inspection required by the
specified Code or local authorities having jurisdiction over the installation.
8.1.2 Inspection shall be carried out both during fabrication and before delivery and also for sub
ordered materials. In addition to final inspection and certification by DIA during the course
of manufacture, DIA's written approval shall be obtained by the Vendor at various stages of
fabrication. For this purpose, Vendor shall prepare his QAP, defining the stages of
fabrication, hold points for his own inspection and that by the DIA or Code or Statutory
Authorities etc. The QAP shall be discussed with DIA before start of job and mutually
agreed. The various stages of fabrication to be inspected (either by Vendor or DIA or both)
shall include but not limited to the following.
x Raw material identification and verification of mill test certificate.
x Edge preparation for welding, including visual cheek for lamination.
x Alignment of longitudinal and circumferential seams.
x Rolling tolerances on individual section.
x Alignment and fit up of sections and components.
x Root pass clearance before further welding and cleaning.
x Profile and thinning of dished ends and tori conical pieces after forming.
x Checking of tube sheet after drilling including checking of tube layout patterns, tube
holes, pass partitions, visual check for lamination.
x Tube sheet to shell set up for fixed sheet exchangers, prior to welding.
x Tube to tube sheet joint expansion or welding.
x Visual check of shell inside and tube bundle insertion.
x Welding of expansion bellows or joints, if required.
x Review of NDT reports and heat treatment charts.
x Final visual and dimensional inspection.


(QJLQHHULQJ6HUYLFHV
x Witnessing of hydro test.

8.1.3 The presence of DIA shall not modify or reduce the obligation of the Vendor to carry out his
own tests and control. If any material and/or equipment are not found in compliance with
the specified requirements, DIA or his delegate shall be entitled to irrevocably reject them,
even if such non-compliance has not been evidenced in the course of inspection and/or
tests.
8.1.4 DIA will, at the time of his initial visit, set up with the Vendor actual details of inspection
stages to be witnessed or carried out, the schedule of future visits and subsequent
inspection notices can be arranged between DIA and the Vendor
8.1.5 The Vendor shall notify DIA sufficiently in advance of any fabrication operations to permit
arrival at the Vendor's shop in time to witness these.
8.1.6 The Vendor shall provide to DIA, free access to his shops at all times. He shall also supply
all tools and tackles to DIA for carrying out the inspection. The Vendor shall also arrange for
similar facilities at his sub-contractor's shops.
8.1.7 The Vendor must satisfy DIA that the welding procedures, welders, electrodes, fluxes,
welding wires etc. are in accordance with the requirements of the Code and specifications.
Further the welder's qualification test must be carried out in the presence of DIA.
8.1.8 Prior to final inspection, all slag, weld spatter, loose scale, dirt, grit, paint, grease, oil and
other foreign matter shall be removed in order to facilitate inspection. All reinforcing pads
and slip-on type flange welds shall be pressure tested with air and soap solution before and
after heat treatment (if any) and before final hydrostatic test.
8.1.9 A dimensional check of equipment shall be carried out taking into account the tolerances
shown on drawings, standards, specifications or Code, the more stringent values shall
govern. Dimensional checks are to be taken of the internal measurements of equipment
together with external ones and these are to be recorded on the drawings as being the "As-
Built" dimensions.
8.2 Hydrostatic test
8.2.1 Hydrostatic tests shall be witnessed by DIA. When hydrostatic tests are performed the
indicating gauge shall be connected to the upper most part of the equipment. Testing water
shall be clean potable water. Seawater shall not be used. For SS equipment, water used for
these tests shall not contain more than 25 ppm chlorides. Minimum metal temperature
during hydrostatic tests shall be 200C. Test pressures shall be maintained for at least one
hour. Shell and tube sides shall be tested separately, unless otherwise mentioned on the
drawing. For tube sheets designed for differential pressure, special care shall be taken
during testing. Equipment drawings shall clearly indicate if tube sheets have been designed
for differential pressure. Drying out as per this specification shall be carried out immediately
after hydro test.
8.2.2 All vertical exchangers shall be tested in vertical position. Alternatively, exchanger may be
tested in horizontal position with test pressure modified with prior approval of Designer.
8.2.3 Stacked exchangers with nozzles interconnected shall be hydro tested in stacked condition
except when the hydro test pressure of the individual exchanger is different.
9. SUPPLY
Supply shall be in accordance with requisition or bid document to which this specification is attached. It
shall, however, include the following also.
9.1 Test ring assembly, dummy shell and flange


(QJLQHHULQJ6HUYLFHV
9.1.1 Test ring assemblies, dummy shells and test flanges wherever required shall be designed
and supplied by the Vendor. The stresses shall not exceed 90% of the minimum yield
stress of the material as stipulated in material specification. Material used for fabricating
these shall be of tested quality. For removable bundle with tube side test pressure higher
than shell side, the bundle shall be tested outside the shell, with tube side pressurized for
tube side test pressure to check tube to tube sheet joint leakage from the back of tube
sheet. Test flange shall be designed accordingly.
9.1.2 Test ring assembly construction shall be stuffing box type as per fig. E-4.13.2 of TEMA. It is
preferred that the test ring flange thickness not exceed the shell cover flange thickness,
Otherwise, Vendor to provide separate bolting for assembling test ring flange to shell.
Similarly, Vendor to check that the studs for stationary tube sheet bolting can be used with
test flange. Else separate bolting shall be provided for assembling test flange.
9.1.3 For "T" type of floating head exchanger necessary washers, bolts and nuts for sealing of
bolt holes in tube sheet to be provided during hydro test.
9.2 Accessories for testing
All necessary accessories such as supports, blind flanges, test gaskets, bolts, nuts etc. shall be
provided and supplied by the Vendor for testing of heat exchangers in Vendor's shop and for
subsequent testing by Purchaser at site, whenever required.
9.3 Other accessories
9.3.1 Vendor shall also supply tie bolts, leveling shims or intermediate supports for stacked units.
Gaskets, nuts and bolts for interconnecting nozzles (both tube and shell side) along with
spares shall be supplied by Vendor. All these components shall be dispatched separately
with due care having been taken regarding identification of these for ease of installation.
9.3.2 Earthing lugs shall be provided on each heat exchanger and shall be located in such a way
as to avoid any fouling with the exchanger foundation bolts at site.
9.3.3 Hydraulic Bolt Tensioner
Hydraulic bolt tensioner shall be used for tightening of bolts are as per details given below.
Length of the stud/bolts shall be longer by one diameter to suit the bolt tensioner. Hydraulic
bolt tensioning shall be used for following:
Nominal Bolt Diameter Condition
50 mm and above All joints
Class 600 and over

38 mm and above Hydrogen Service
Lethal / Toxic Service
Joints subject to high temperature and cyclic duties

Joints with leakage history
25 mm and above
Joints where high accuracy is required
Other duties specified by the Purchaser
9.3.4 Davits, if required as per design basis or drawings, shall be provided.


(QJLQHHULQJ6HUYLFHV
9.3.5 Addition like cleats for piping, ladder, platform, insulation etc. that may be required at a later
stage shall be provided.
9.4 Cathodic protection
Whenever cathodic protection is specified both sacrificial anodes and internal painting shall be
provided. Separate specifications shall be provided in the requisition.
For exchangers having dissimilar metallurgy and having cathodic protection on tube side, weld
deposit of minimum 5 mm compatible with tube sheet metallurgy on channel flange adjacent to tube
sheet, floating head flange & pass partition plate and weld deposit of 3 mm on inside of channel
flange ( up to a distance of 25 mm) and floating head flange, shall be provided.
9.5 Spares Quantities
9.5.1 Mandatory Spares:
S. No. Description Spares Quantity

20% (Minimum 4 studs & 8 nuts per joint) for each girth
1 Fasteners flange, nozzle with blind flange, interconnected nozzle and
companion flange.
400% For each Girth flange, nozzle with blind flange,
2 Gaskets
interconnected nozzles & Companion flanges.
9.5.2 Two years Operation and Maintenance Spares:
Vendor shall furnish a list of recommended spares for two years of normal operation along
with the firm unit prices.
9.5.3 Erection and Commissioning Spares
S. No. Description Spares Quantity
1 Fasteners 10% (Minimum two in each size) of installed fasteners.
2 Gaskets 100% For each girth flanges.
Over and above, vendor shall recommend and supply all the spares considered necessary
for successful erection and commissioning of the Equipment’s. The list of such
recommended spares shall be submitted along with the offer. Any commissioning spare
consumed over and above the recommended commissioning spare during commissioning
of the equipment shall be supplied by the Vendor, at no cost to the Purchaser.
10. GUARANTEE
The Vendor shall be completely responsible for the compliance to Code requirements, residual design,
detailing, fabrication, materials and workmanship of the exchangers as per the stipulations of the
requisition and its attachments. In this regard, it may be noted that review by Purchaser shall not relieve
the Vendor of his responsibility of meeting all requirements and ensuring satisfactory performance of the
equipment. Guarantee period shall be as per GPC of Purchaser.
11. TRANSPORTATION,SITE FABRICATION AND ERECTION

11.1 After completion of all testing and inspection, the inside of complete equipment shall be thoroughly
drained and dried out. Equipment shall be completely dried by passing hot air for sufficient time until
no further increase in relative humidity of outgoing air is observed. Dry out shall be done


(QJLQHHULQJ6HUYLFHV
simultaneously on both shell and tube sides. After drying, the equipment shall be purged and filled
with dry N2 at 0.25 kg/cm2. The equipment shall be provided with pressure gauge to monitor N2
pressure, and ½” non-return valve. All threaded holes, other than telltale holes for testing, shall be
suitably protected with steel bar plugs. All nozzles not provided with blind flange shall be provided
with steel covers, temporary gaskets and bolts.
11.2 Shop Painting
For shop painting of equipment, vendor shall comply the requirements given in L&T specification
no. MES-SP-0082,”Specification for Painting”.
11.3 The equipment item number, PO number and Purchaser name and address shall be painted in bold
white paint letters written with stencil, on the heat exchanger.
Sliding end of exchangers shall be painted as "CAUTION-SLIDING END" in black on the primer
coating in the shop.
11.4 Dispatch of Equipment
11.4.1 Transportation saddles shall be checked for the following forces as minimum acting
simultaneously during transit, plus ambient wind condition.
x Longitudinal = 0.6*g
x Transverse = 0.7*g
x Vertical Upwards = 0.2*g
x Vertical downwards = 1.5*g
11.4.2 No heat exchanger shall be released for shipment until it has been approved by DIA. Heat
exchangers shall be dispatched after the operations as required by clauses 11.1, 11.2 and
11.3 have been carried out and shall be dispatched in as-tested condition. In case stacked
exchanger shells are dispatched separately the Vendor shall provide additional set of
gaskets for interconnected nozzles other than the gaskets included in spares. Heat
exchangers shall be securely anchored for dispatch in order to prevent any shifting and
damage during transportation. Expansion joints and bellows shall be suitably protected
against any possible damage by providing tie bars before boxing up. Packaging shall be
suitable for rail or road transport and also sea worthy if transported by sea. Spares shall be
dispatched separately in a box and marked with PO number, item number and Purchaser’s
name and address.
Vendor shall provide sling mark identification on all heat exchangers with respect to center
of gravity of the equipment.
12. FINAL DOCUMENTATION

Vendor shall complete requisite no. of copies of final document folder as required in purchase order. This
folder shall contain the following information duly certified by Inspector:
x Vendor’s Code Certificate.
x Sketches of Exchanger showing `As Built’ dimensions and the plates used with their cast and test
numbers.
x Material test and analysis certificates.
x Welding procedure qualification reports.
x Welder qualification reports.
x Radiographic results.


(QJLQHHULQJ6HUYLFHV
x Ultrasonic, Magnetic particle, Dye-penetrant test results (if applicable).

x Hardness, corrosion and leak test records (if applicable).
x Record charts showing complete heat treatment cycle (if applicable).
x Production test coupon results (if applicable).
x Charpy V-notch test results (if applicable).
x Record chart of pressure test (Hydrostatic and/or pneumatic).
x Rubbing of name plate.
x Any other documentation as required in the purchase requisition/purchase order.
x Any special handling instruction, in case equipment is to be delivered in pieces.

Mechanical Static
'2&120(663

Specification for Welded
(QJLQHHULQJ6HUYLFHV 6KHHWRI 5(9
Tube to Tubesheet Joint
SPECIFICATION
FOR
WELDED TUBE TO TUBESHEET JOINT
01 Revised and Reissued as Standard Specification SMP SGB RGO 17-May-2016

00 Issued for Use AG HS RG 21/05/2012
REV DESCRIPTION
by by by Date

Mechanical Static
'2&120(663

CONTENTS
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Abbreviations:
API American Petroleum Institute
ASME American Society of Mechanical Engineers
AWS American Welding Society
OD Outside Diameter
TEMA Tubular Exchangers Manufacturer’s Association
TIG Tungsten Inert Gas shielded Arc

Mechanical Static
'2&120(663

1. SCOPE
This specification covers minimum requirements for the welding and testing of tube to tubesheet joints of
shell and tube heat exchangers and air coolers. It is the Fabricator's responsibility to furnish sound, leak free
joints. For the purpose of this specification, the terms "joints" shall be construed to mean "tube-to-tube sheet
joints".
2. APPLICABLE CODES AND STANDARD

The latest edition of the following codes and standards shall be complied with:
a) ASME Section VIII Division 1/2
b) ASME Section V
c) ASME Section IX
d) TEMA for tubular exchangers
e) API 661 for air-coolers.
f) AWS
3. WELDING PROCESS AND JOINT DETAIL

3.1 Manual or automatic Tungsten Inert Gas shielded Arc (TIG) welding shall be used. All joints shall be
made by using minimum two weld passes. The first pass should be preferably made without filler wire
to ensure root fusion. The second or final pass shall be with filler wire. Any other welding process can
be used only after obtaining written approval from the Authorized Inspector.
3.2 Joint detail shall be as indicated on the data sheet by giving reference to figure numbers in
Appendix-1 of this specification. In absence of any data sheet or indication regarding type of joint,
Figure 2 or Figure 3 shall be used depending upon whether tube thickness is 2 mm or < 2 mm
respectively.
4. WELDING PROCEDURE QUALIFICATION

4.1 Welding Procedure Specification shall be compiled by the Fabricator and submitted to the Authorized
Inspector for approval before the qualification tests are performed. Mock up test shall commence only
after approval is obtained from the Authorized Inspector.
4.2 Welding procedure qualification test is required to be carried out if :-
4.2.1 Authorized Inspector requires the test to be carried out.
4.2.2 There exists no previous qualification tests within last three years for the proposed
combination of tube and tubesheet ‘P’ number and ‘G’ number (as per ASME Section IX),
tube outside diameter (OD), tube thickness, tubesheet thickness, tube pitch, tube pitch
pattern, welding procedure and joint detail. All other factors remaining same, the procedure
test need not be repeated if the job tubesheet thickness exceeds 40 mm and qualification
exists for 40 mm or higher tubesheet thickness.
For plug type air coolers additional procedure qualification test is required to be performed
for any of the following conditions:
a) The job has lower clearances between tube and any of the header plates like top /
bottom / end / stiffener / pass partition plate compared to earlier tests.
b) The job has lower plug size for the same tube size compared to earlier tests.
c) The job has higher plug sheet thickness compared to earlier tests.
4.2.3 Code or standard or data sheet or specification(s) requires the test to be carried out.

Mechanical Static
'2&120(663

4.3 If required as per 4.2 above, the Fabricator shall perform a procedure qualification test, at least two
weeks before the scheduled beginning of production. Procedure shall be qualified for the same hand
position as is being proposed for production. Procedure test shall consist of the welding of nine tubes
for square pitch and eight tubes, (three, two and three tubes per row arrangement) for triangular pitch.
This shall be done for each set of combination of tube and tubesheet ‘P’ number and ‘G’ number,
welding procedure, joint detail, tube OD, tube thickness, tube pitch, tube pitch pattern, tubesheet
thickness. Additionally for air cooler, tests shall be done for each tube size with lowest plug size,
lowest clearance between tube and any of the header plates, and the lowest plugsheet thickness to be
used on the job. Thickness of the tubesheet used for procedure testing shall be same as used for job,
except that for carbon steel and austenitic stainless steel materials, it need not exceed 40 mm, unless
otherwise indicated. Refer Appendix-2 of this specification for test specimen details.
4.4 The following data report shall be furnished for review to Authorized Inspector with the weld samples
as outlined below.
4.4.1 Complete details of welding procedure employed indicating various machine settings,
welding rods, inert gas composition & purities, flow rate, weld sequence etc.
4.4.2 Mechanical properties and chemical composition of tubesheet, tubes and filler metal.
4.4.3 The hardness of the weld, the tube, the tubesheet heat affected zone and the tubesheet
base metal after each pass.
4.4.4 The complete test sample shall be cut (by sawing) as per Appendix- 2 of this specification.
These shall then be subjected to various tests as outlined below:
a) Section 1 shall be polished, etched and micro-photographed for examination of depth of
weld, penetration and definition of boundaries. The minimum leak path of each weld shall
be not less than the nominal thickness of the tube. The weld leg shall also be measured
and shall be minimum 1.4 times the nominal thickness of the tube.
b) Section 2 (two specimens) shall be subjected to tear test. These specimens shall be
tongue bent to show the extent of weld penetration. The underside of the weld shall show
evidence of adequate & uniform weld penetration.
c) A section 10 mm thick containing the tube end welds shall be sawed from section 3 and
radiographed for weld quality. The radiograph shall be submitted to Authorized Inspector.
No cracks or crack like or visual defects are acceptable. Acceptance shall be as per
Appendix 4 of ASME Section VIII Division 1. In case the radiograph is not acceptable,
welding procedures shall be suitably modified so that proper weld and acceptable
radiographs are obtained. These shall be proved by retests.
d) Section 4 shall be etched and polished and given to Authorized Inspector.
4.4.5 A tension strength test shall be carried out as per ASME Section VIII Division I Appendix A.
This strength test shall be performed at room temperature for each combination set of tube
and tubesheet ‘P’ number and ‘G’ number, tube OD, tube thickness and joint detail. The
breaking loads shall be at least equal to the load required for breaking the tube using the
minimum specified ultimate tensile strength of tube as indicated in certificates issued by the
tube supplier. When tube material is to a specification which does not call for mechanical
tests to be performed, ultimate tensile strength of the tube material shall be considered as
four times the allowable stress at room temperature as indicated by the ASME Section II Part
D, or other relevant code. Failure of the test piece at the weld shall not be a cause for
rejection in case the minimum strength is attained, but the fracture should be examined for
any evidence of faulty workmanship.
4.5 Fabricator is advised to satisfy himself that the procedures employed are the best for the job and
would enable him to give workmanship guarantee for the equipment. Authorized Inspector's approval
shall in no way relieve the Fabricator of his responsibility and guarantee to supply the equipment as

Mechanical Static
'2&120(663

per the conditions of the purchase order.
5. WELDERS QUALIFICATION
The purpose of this operator qualification test is to demonstrate that both the welding operator and the
welding machines are capable of producing satisfactory joints. Once welding procedures have been
qualified as above, welding operators employed on welding shall be required to prove their ability by making
test samples similar to that prescribed above for welding procedure qualification. Welding operators may be
qualified based on para d (i), d (ii), and d (iii) above only, provided same welding machines and
welding procedures are used. This welding operator qualification test should also be carried out if the
welding operator has not executed similar welding six months prior to production. Repeat tests may be
called for in the course of manufacture to determine the consistency of operator or machine to produce
sound welds.
6. PREPARATION OF TUBES AND TUBESHEET

6.1 Tube holes to ‘special close fit’ tolerance as per TEMA for shell and tube exchangers and as per API
661 for air coolers. Tube holes shall be free from any burns and the bundle side edge of tube holes
shall be chamfered or radiused. Tube holes shall have smooth finish to 63 AARH.
6.2 Prior to assembly, the tubesheet and tube ends (inside and outside for a distance equal to the
tubesheet thickness + 30 mm) shall be cleaned and degreased to free from dirt, grease etc. It is
essential that the solvent used for degreasing shall be chloride free and sulfide free and non-residue
forming. The solvent should not lead to any possible fire hazard.
7. WELDING
Tubes shall be individually welded, using the procedure approved by the Authorized Inspector. Systematic
welding procedure shall be adopted so as to result in minimum tubesheet distortion. All tubes are to have
initial pass completely cleaned as necessary, visually examined and tested as per para 8.1 below, if
required, before subsequent layers are applied. Welds shall be suitably finished and any spillage or spatter
on tubesheet shall be removed. Spillage of weld metal into the bores of tube is not permitted.
8. EXAMINATION OF JOINTS
8.1 Joints shall be subjected to air-soap solution test after first weld pass with air at 1.25 kg/cm2 (g).
Procedures outlined in ASME Section V, Article 10 shall be followed.
8.2 After completion of welding, the tubesheet face, the welds and internal tube surfaces to a distance of
25 mm beyond the fusion line must be cleaned thoroughly by wire brushing and examined carefully
for surface defects. Defects such as cracks, surface breaking porosity, slag inclusions and lack of
fusion are not acceptable.
8.3 After the visual inspection, a liquid penetrant examination in accordance with ASME Section VIII
Division I, Appendix-8 & Section V, and Article 6 shall be done. Before conducting this test, the faces
of the carbon steel tubesheets shall be cleaned thoroughly by wire brush and solvents to remove all
weld slag, rust and scale.
8.4 When specified on the datasheet or specification(s), a halide test shall be performed after the tests as
per para 8.1, 8.2, and 8.3 above have been successfully completed. Procedures for halide test shall
be as per ASME Section V, Article 10, and Appendix - III Halogen diode detector probe test.
8.5 After the final tube expanding (refer para 9.0) has been completed, the liquid penetrant examination
as outlined in para 8.3 above shall be repeated.
8.6 Whenever a halide test has been specified, an envelope test shall also be done as a further test for
leaks after final tube expanding. For this test, tubesheets shall be securely wrapped in plastic sheets
and the shell allowed to remain under test pressure with halogen tracer, for a period of 10 to 12 hours.
Then with the detection set at a maximum sensitivity, the probe shall be inserted through the plastic

Mechanical Static
'2&120(663

cover at the bottom of the tubesheets and readings taken to observe if any leakage has occurred.
8.7 Final acceptance hydraulic pressure test shall be conducted after tube expansion at hydrotest
pressure for at least one hour.
9. TUBE EXPANDING
After the tests outlined in 8.1, 8.2, 8.3, and 8.4 have been successfully completed and all leaking welds
repaired, the tubes shall be "contact expanded" with a PARALLEL type expander. Contact expanding is
intended to bring the tube OD into contact with the tubesheet hole. Contact expanding shall begin 12 mm
from the tubesheet face and extend to 3 mm from the back face. The contact expansion shall have thinning
of 3-5% which shall be ensured by measuring the inside diameter of tubes.
10. REPAIRS
If leaks are found during any of the above testing procedures these shall be reported to the Authorized
Inspector and after obtaining his approval, repairs shall be made by removing the defects down to sound
parent metal and repeating the qualified weld procedures. All weld repairs shall be retested in accordance
with procedures outlined in para 8.0 above.
11. TEST AND REPAIR REPORTS

Test and repair reports shall be included in the Data Folder. These reports shall also indicate the number of
leaks discovered on each test and the extent of the repair done.

Mechanical Static
'2&120(663

12. APPENDIX 1 – JOINT DETAILS

Mechanical Static
'2&120(663

13. APPENDIX 2 – DETAILS OF TEST SPECIMEN (MOCK ASSEMBLY)

Mechanical Static
'2&120(663
Standard Specification for
(QJLQHHULQJ6HUYLFHV Hardness Requirement 6KHHWRI 5(9
of Static Equipment
STANDARD SPECIFICATION
FOR
HARDNESS REQUIREMENT
OF
STATIC EQUIPMENTS
00 Issued as Standard Specification SMP SGB RGO 17-May-2016

REV DESCRIPTION
by by by Date

Mechanical Static
'2&120(663
of Static Equipment
CONTENTS
6&23(
+$5'1(665(48,5(0(17
:(/',1*48$/,),&$7,217(67
352'8&7,217(67
$33529$/
ABBREVIATIONS:
ASTM American Society of Testing Materials
HAZ Heat Affected Zone
PWHT Post Weld Heat Treatment

Mechanical Static
'2&120(663
of Static Equipment
1. SCOPE
1.1 This specification covers general requirement of hardness of base metal, weld and heat affected zone
(HAZ) and is applicable to all C-1/2 Mo, Cr-Mo and other materials whenever specified in data sheet /
specifications / standards.
1.2 On heat-treated vessels, hardness testing shall be carried out after PWHT.
2. HARDNESS REQUIREMENT
Hardness in base metals, weld and heat affected zone as per ASTM E10 shall not exceed the following:
Material P No. Brinell Hardness Number (BHN)

P1 200
P3 & P4 225
P5 & P6 235
3. WELDING QUALIFICATION TEST

3.1 For each welding procedure qualification six tests shall be made, three in weld metal and three in
HAZ. Hardness requirements shall be as per clause 2.0 above.
3.2 In addition to the requirement of clause 3.1 above, Vickers Micro hardness test shall be made on a full
cross-section at 25 mm intervals beginning at 3 mm from the top surface with 5 kg load or with a load
approved by the authorized inspector. Tests shall be made at each level for each of the following
locations as per ASTM E 92:
Three tests shall be made in the weld metals, two tests in HAZ and one test in the base metal in
accordance with Fig.1 and the hardness shall not exceed the following in base metal, weld metal and
HAZ.
Material P No. Vickers Hardness Number (VHN)
P1 210
P3 & P4 237
P5 & P6 247
4. PRODUCTION TEST
4.1 All pressure containing weld metals are to be checked for hardness of weld and HAZ after PWHT but
before hydro-test. The hardness shall not exceed the value stipulated above.
4.2 Each longitudinal seam shall be checked both internally and externally near the center and at one
end.
4.3 Each circumferential weld shall be checked at four locations approximately 90°apart, both internally
and externally.
4.4 Each nozzle weldments shall be checked at two locations, 180° apart, both internally and externally.
5. APPROVAL
In case the hardness as obtained on production test is more than the limit specified in clause 2.0 above, the
vendor shall submit the corrective procedure to lower the hardness in writing to purchaser and/or authorized
inspection agency for review/approval.

Mechanical Static
'2&120(663
of Static Equipment


(QJLQHHULQJ6HUYLFHV Positive Material Identification
(PMI) At Supplier`s Works Sheet1of6 REV01
STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL IDENTIFICATION
(PMI)
AT SUPPLIER`S WORKS
01 Issued for implementation RIG BBB MVA 25-Oct-2016

00 Draft SMP SGB RGO 04-Jul-2016
REV DESCRIPTION
by by by Date


CONTENTS
6&23(
5()(5(1&('2&80(176
'(),1,7,216
30,(;$0,1$7,21
$&&(37$%/(0(7+2'6)2530,
(;7(172)30,(;$0,1$7,21
5(&25',1*$1''2&80(17$7,21
0$5.,1*
Abbreviation:
API American Petroleum Institute
PMI Positive Material Identification
Sch Schedule
TPIA Third Party Inspection Agency


1. SCOPE
1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at the Supplier's works on Metallic Materials procured either directly by the Company /
Purchaser / Contractor or indirectly through the sub-Suppliers.
1.2 Any deviation from this specification must be approved by Company / Purchaser in the Deviation /
Waiver Permit format enclosed with Requisition.
1.3 This specification covers the procedures and methodology to be adopted to assure that the chemical
composition of the material is consistent with the material specifications as specified in purchase
documents using 'Alloy Analyzer' at the time of final inspection before dispatch.
1.4 The Scope of this specification shall include but shall not be limited to Positive Material Identification
(PMI) to be performed on Materials listed below:
1.4.1 For alloy Steel materials as below:
x Alloy Steel Pipes including Clad Pipes
x Alloy Steel Flanges & Forgings
x Alloy Steel Fittings including Clad Fittings
x Alloy Steel Fasteners
x Alloy Cast & Forged steel valves
x Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)
x Longitudinal Pipe & Fittings Welds.
x Gaskets (for Ring Type Joints)
1.4.2 For Carbon Steel materials as below:

x All Carbon Steel Piping items under NACE or HIC or H2
x Carbon Steel flanges and valves (Rating 900# and above)
x Carbon Steel Pipes & fittings for following thicknesses:
x Size 1"- 2" NB : Sch 160 & above
x Size 3" NB : Sch XS & above
x Size 4" - 12" NB : Sch 120 & above
1.4.3 Following items shall be excluded from scope of PMI examination.

x Gaskets other than for Ring Type
x Internal Components of valves
1.5 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In case of
any defective materials being found at site, the Supplier shall be responsible to effect replacement of
such defective materials at project site without any delays to the satisfaction of Company / Purchaser.
2. REFERENCE DOCUMENTS
API Recommended Practice 578 (Second edition, March 2010) - Material Verification Program for New and
Existing Alloy Piping Systems.
3. DEFINITIONS
3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referred items.
This definition shall also include any sub-Supplier or manufacturer on whom a sub-order is placed by
the Supplier.
3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat and Heat
treatment lot.
3.3 Alloy Material: Any metallic material (including welding filler materials) that contains alloying
elements such as chromium, nickel, molybdenum or vanadium, which are intentionally added to


enhance mechanical or physical properties and/or corrosion resistance.
4. PMI EXAMINATION
4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of this specification
approval of PMI Procedure shall be obtained from Company / Purchaser /TPIA prior to commencing
manufacture / inspection of product.
4.2 PMI examination of materials is independent of any certification, markings or colour coding that may
exist and is aimed at verifying that the alloy used are as per specified grades.
4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting to
ensure maintenance of identification on off-cuts.
4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separately identified
locations to prevent the mix up of materials of different alloy specifications or alloy material with
carbon steel. Non ferro-magnetic materials shall be segregated at all times from ferro-magnetic
materials.
4.5 PMI examination is subject to surveillance inspection by Company / Purchaser / TPIA.
5. ACCEPTABLE METHODS FOR PMI

5.1 The method used for PMI examination shall provide a quantitative determination of the alloying
elements like chromium, nickel, molybdenum or vanadium in Alloy Steel items.
5.2 Instruments or methods used for PMI examination shall be able to provide quantitative, recordable,
elemental composition results for positive identification of alloying elements present.
5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or
"Optical Emission" type each capable of verifying the percentage of alloy elements within specified
range.
5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current or triboelectric
testing methods are not acceptable for PMI examination.
5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the specified
range.
5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use to verify the
suitability of batteries, sources etc., and the data of the last service shall be stated on the PMI Report
Form (Sample enclosed).
5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginning and
end of each shift. Instrument must be checked against known standard for each alloy type to be
inspected during the shift.
5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use as a
random spot check on the instrument calibration.
5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or
abrasive paper. No permanent marks, which are injurious to the usage of product in service, are
acceptable.
5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence
instrument.
5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer being
used. Modification of these procedures if any must be approved by Company / Purchaser.


5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of Company /
Purchaser / TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may perform
the examination. Otherwise PMI examination shall be sub-contracted to an independent testing
agency approved by Purchaser.
5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejection note
shall be issued.
6. EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various items.
A Flanges, Fittings,
100%
Valves & RTJ Gaskets
100% (For Pipes procured from traders)

B Pipes
2 random samples drawn from each Size / Heat / Lot (for pipes
procured directly from mills)
Lot Size Sample Size
Upto 100 2% (Min 2)

C Fasteners
101 to 500 1% (Min 3)
501 and above 0.5% (Min 5)
NOTE:
a. For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as weldments.
b. Whenever any sample drawn to PMI test on the basis of percentage selection in B & C above, fails to
meet specification requirements, 100% of items of lot shall be tested for PMI.
7. RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in a Report Format as enclosed with this specification.
8. MARKING
All alloy materials tested by PMI shall be identified using either of the following methods by indicating
"PMI OK"
a. Bar Code / Hologram Sticker
b. A low stress stamp marking


POSITIVE MATRUAL IDENTIFCATION REPORT

Page of
BULK MATERIALS
Project : Client Job No.
PMI report No. Supplier / Sub-Supplier
Purchase Order No. Testing Agency
Purchase
PMI Location
Requisition No:
Bulk Item Type (as per Requisition)
Material Specification / Grade
Number of items in Lot
Requisition Item No. / Description Remarks

Major Content, Weight Percent
Accept / Reject
Element Cr Mo Ni V
Specified range
Actual Observations
1.
2.
3.
4.
5.
6.
7.
8.
Instrument Type / ID
Last Service Date Inspection Agency Witnessed By
DETAIL-1 DETAIL-2
6x45° T H
BD+1
T +2 T1+1.5
BD+2
-0 6 -0.0
BD+3
7+0.0
R
*** -0.8
Go
A
BCD
D+3
7°
7°
*
TO SUIT
G1
B
6+0.0
-0.8
* T3
MAX 3 SAW CUT

DETAIL-3
E+0.25
D+0.25
-0.25
-0.25
-0.0
D+3
BCD
B-3
B-3
-0.0
T H
-0.0
A+1.5
D+0.0
B-1
E+0.0
B
6x45° **
BD+3
R
Go
A
BCD
D
T2
DETAIL-13
G1
B
DETAIL-4 DETAIL-5 DETAIL-6 DETAIL-7 T1
G1 T
T ***
BD+3
BD+3
BD+3
6x45° T 6x45° ** 6x45° 6x45° **
BD+3
G1
G1
A
A
BCD
BCD
Go
Go
A
BCD
Go
A
BCD
D+3
B-3
D
B
B
H
B
* H
DETAIL-8 DETAIL-9 DETAIL-10 DETAIL-11
** ** ** ** 45° 45°
BD+3
F F ***
*** *** ***
BARREL THK.
SHELL TUBE
SIDE SIDE
F1 F1
BD+3
R1
BCD
A
BCD
A
BCD
A
D
D
B-3
B-3
R2
B-3
T3
T3 T3
T3

BAFFLE/
*** *** SUPPORT PL.
T2=T1+3
25 REF. T/SHT OR CH. COVER

A/2
-1
20
T1
10
A1
A2
D
15
)/2 SLIDING /
+1
B-3
B-3
DEFLECTOR PARTITION PLATE GROOVE DETAIL

(B
STRIPS
T3 SLIDING / DEFLECTOR
STRIP END DETAIL

00 01/02/2010 ISSUED FOR IMPLEMENTATION GKL NIG AKG
STANDARD NO. REV.
L&T Hydrocarbon Engineering PART DETAILS MES-ST-2001 01

SHELL & TUBE HEAT EXCHANGER
SHEET 1 OF 2
DETAIL-16 DETAIL-17 DETAIL-18 DETAIL-19 T
T
T
*
**
BD+3
** *
BD+3
BD+3
# 6x45°
NOTE-4 6x45° 6x45°
G1
BD+3
G1
G1
Go
Go
Go
WELD DEPOSIT
# WELD DEPOSIT
GASKET ID-3
GASKET WIDTH
GASKET WIDTH
A
A
BCD
BCD
A
D+3
D+3
D
BCD
BCD
D
H F
B
B
H
T3
# # : Note-4

** * ** * T H
*** * H T
** 6x45° *
6x45°
R
R
BD+3
BD+3
GASKET WIDTH
Go
Go
GASKET I.D.-3
A
A
BCD
GASKET I.D.-3
GASKET WIDTH
BCD
BCD
A
A
BCD
D+3
D
D
D
D+3
D
B-3
B-3
B-3
G1
G1
B
B
T3 T3
DETAIL-24 * DETAIL-25 ** DETAIL-26 DETAIL-27 T1

*** ** T3
6x45° **
** ***
F ***
BD+3
BD+3
BD+3
GASKET I.D.-3
A
A
BCD
BCD
BCD
A
BCD
A
D+3
D
D
D
B-3
B-3
B-3
T3 # #
T3 NOTE-4
NOTE-4

T H T3
H T 6x45° *** *
6x45° ** *** ***
CHANNEL
SIDE
BD+3
BD+3
R
R
Go
Go
BCD
A
D
D+3
GASKET I.D.-3
A
BCD
A
B-3
D
B-3
B-3
D+3
G1
#
G1
B
#
B
*
# WELD DEPOSIT # #
# WELD DEPOSIT CHANNEL
# : Note-4 NOTE-4 NOTE-4 T3
# : Note-4 SIDE
DETAIL-32 T3 TABLE NO. - 1 NOTES :

7+0.0
-0.8 7°
1. All dimensions are in mm. unless stated otherwise.
*** DIMENSIONS * ** *** 2. For Channel Cover & Tube Sheet : 'A', 'BCD' & 'D' Dimensions shall be same
For Metal Jacketed Gasket as for mating flanges.
& CAF Gasket
5 6 5 3. If spiral wound gasket is used for a joint :
For 4.5 mm, Spiral-wound a) Diameter of tube sheet & channel cover 'D' shall be Gasket OD +
Gasket
6 7 6
(2 x Nose width).
-0.25
D +0.0
-0.00
E+0.25
For 6.35 mm, Spiral-wound b) Diameter of flange recess for gasket shall be Gasket OD + (2 x Nose width +
B-3
8 9 7
B-3
Gasket 3 mm).
For Camprofile (Grooved 4. Weld deposit or cladding shall be as specified in specification or data sheet.
metal with soft gasket seal 6 7 6 5. For asterisk marks refer table no. - 1.
facing) Gasket
6. Wherever "R" is specified, it indicates to be radius.
#
NOTE-4

STANDARD NO. REV.
L&T Hydrocarbon Engineering PART DETAILS MES-ST-2001 01

SHELL & TUBE HEAT EXCHANGER
SHEET 2 OF 2
W
C
W
I.D. I.D. I.D.
O.D. O.D. O.D.
TYPE-1 TYPE-2 TYPE-3
W
A
A
W
B
B
B
I.D. I.D. I.D.

O.D. O.D. O.D.
C
A
A
W
C
B
B
W
I.D. I.D. I.D.

O.D. O.D. O.D.
C
W
W
A
A
A
C
B
B
W
I.D. I.D. I.D.

O.D. O.D. O.D.

STANDARD NO. REV.

TYPES OF NON STANDARD
L&T Hydrocarbon Engineering MES-ST-2002 01
GASKETS
(SHELL & TUBE HEAT EXCHANGERS) SHEET 1 OF 3
B
B
A
W
A
A
A
B
B
W
W
I.D. I.D. I.D.
O.D. O.D. O.D.
C
C
A
A
A
A
B
W
W
I.D. I.D. I.D.
O.D. O.D. O.D.

W
B
C
B
W
A
A
A
B
B
I.D. I.D. I.D.
O.D. O.D. O.D.

W
B
A
A
B
I.D.
O.D.
TYPE-22

STANDARD NO. REV.

GASKETS
'X'
PASS PARTITION PLATE
0.5
THIS SIDE
+0.0
±0.8
-0.8
3
±0.8
±0.8
FILLER
TYPICAL SECTION OF METAL

±0.8 JACKETTED GASKETS
±0.8
PERMISSIBLE TOLERANCES
NOSE WIDTH GASKET O.D.(D) D+8

(OPTIONAL) GASKET O.D. (D)
4 WIDE NOSE GASKET WIDTH CENTERING RING

(OPTIONAL)
NOSE THK.
SOFT SEALING THK
GASKET WIDTH
METAL THK
NOSE THK.
CENTRING RING
GASKET THK.
METAL WINDINGS
METAL WINDINGS
WITH FILLER
THK.
(TYP)
TYPICAL DETAIL OF TYPICAL DETAIL OF

CAMPROFILE GASKET SPIRAL WOUND GASKET
NOTES :-
1. All dimensions are in mm unless stated otherwise.
2. The hardness of the metal for solid or clad gaskets shall be minimum 15 BHN lower than that of the material of the flange gasket
seating surface and in any case not to exceed the following.
a) Low carbon steel / LAS - 110 BHN
b) 5 Cr - 1/2 Mo - 130 BHN
c) Stainless Steel - 160 BHN
d) 11 - 13 Cr - 170 BHN
e) Monel - 130 BHN
f ) Soft Iron - 90 BHN
g) Copper, Brass - 50 BHN
h) Aluminium - 30 BHN
3. Filler in metal jacketed gaskets shall not be of compressed type.
4. All gaskets shall be made in one continuous piece all around including the pass partition ribs and therefore must be cut from one
sheet.
5. The corner radii of all gaskets to be 10 mm.
6. Solid flat metal gasket shall be 2 mm. thk.
7. For spiral wound gaskets : -
a) The pass partition rib shall be of solid metal or metal jacketed welded to centering ring.
b) Centering ring thk. shall be same as nose thk.
c) Gasket thk. shall be as specified in data sheet. It shall be min. 4.5 for shell dia. upto 1000 & min. 6.35 for shell dia.
more than 1000, If not specified.
8. "m" and "y" values shall be as per Appendix-2 of ASME Section VIII Division 1 (except Camprofile gasket).
9. For "m" and "y" values of Camprofile gasket, equipment manufacturer shall confirm from gasket`s manufacturer / supplier.
10. Gasket plan is viewed from direction "X".

STANDARD NO. REV.

GASKETS
38
STATIONARY
15 18
TUBE SHEET
A T
SLIDING STRIP
W
TO SUIT
A
M12 STUD
22 LG. THREADED
SECTION-AA
TYPE - 1
38
STATIONARY
15 18
TUBE SHEET
W
SLIDING STRIP
B
M12 STUD
22 LG. THREADED
SECTION-BB
TYPE - 2
STATIONARY
TUBE SHEET
WxT
SLIDING STRIP
TYPE - 3
Notes :-
1) All dimensions are in mm unless otherwise specified.
2) Use type-1 when sliding strip & tube sheet material are different & W ≥ 25.
3) Use type-2 when sliding strip & tube sheet material are different & W < 25.
4) Use type-3 when sliding strip & tube sheet material are same.
5) For dimensions 'T' & 'W' refer data sheet / TEMA guidelines / Specifications.
6) For deflector strips unless specified otherwise use details as above.

STANDARD NO. REV.

SLIDING & DEFLECTOR STRIPS
L&T Hydrocarbon Engineering TO TUBE SHEET WELDING DETAILS MES-ST-2007 01
(SHELL & TUBE HEAT EXCHANGERS)
SHEET 1 OF 1
E (MIN.) = A
B
L
ØD
ØC
A
R1
0 (T
YP
.)
.)
YP
(T
R3
NOM. BOLT DIA. 'A' THREAD LENGTH - 'L' STOCK - 'B' I.D. - 'C' O.D. - 'D' SAFE LOAD (Kg.)
M10 20 32 26 42 600
M12 24 38 30 52 1000
M16 32 45 35 64 1800
M20 40 50 38 72 2700
M22 44 58 44 84 3000
M24 48 64 46 92 3300
M27 54 70 50 102 4200

M33 66 76 56 114 6800
M39 78 90 64 132 8100
M45 90 96 74 154 9900
M48 96 102 84 162 11400
M56 112 127 102 168 14200
Notes :-
1. All dimensions are in mm unless otherwise specified.
2. For carbon steel material, minimum ultimate tensile strength (UTS) shall be 42 kg/sq.mm.
3. Upto M22 coarse thread series, M24 & above shall have 3 mm pitch.

00 01-FEB-2010 ISSUED FOR IMPLEMENTATION AKV NIG VIP
STANDARD NO. REV.
L&T Hydrocarbon Engineering EYE BOLT DETAIL MES-ST-2008 01

SHEET 1 OF 1
FLANGE OR CHANNEL COVER
GASKET SIDE EXPOSED SIDE
BOLT CIRCLE DIA.
COUNTER BORE
(d+2)
THREAD (2d)
d - DIAMETER OF JACK SCREW
"T" "T" "T"
2 - HOLES 3 - HOLES 4 - HOLES
NO. REQUIRED "d" SHELL I.D.

2 14 UPTO & INCLUDING 300
3 16 301 TO & INCL. 580
4 20 581 & LARGER
LOCATION OF JACK SCREW TAPPING HOLES :-
1. Holes are to be located on the bolt circle diameter of flange and half way between adjacent holes.
2. First hole shall be located between first and second bolt hole counting clockwise from mark "T"
3. Holes shall be spaced as follows :
2-holes layout 180° apart
3-holes layout approx. 120° apart
4-holes layout 90° apart
Note :-

STANDARD NO. REV.

JACK SCREW TAPPING
L&T Hydrocarbon Engineering & ARRANGEMENT MES-ST-2010 01
SHEET 1 OF 1
5 (MIN.) SEE 5 (MIN.)
NOTE-7
22 (TYP.)
Ø21
Ø21
BCD
BCD
FIXING DETAIL OF DOWEL PINS FIXING DETAIL OF DOWEL PINS
(AT STATIONARY TUBE SHEET) (AT CHANNEL COVER)
20 20 *
20Ø
16Ø
SEE NOTE-3
* All sharp edges of dowel pins shall be rounded off.

NOTES:-
2. Dowel pins to be provided only when channel consists of pass-partition plate/s.
3. Dowel pins shall be of carbon steel unless specified otherwise.
4. Min. 2 dowel pins shall be provided for each flange & SHALL NOT BE LOCATED AT 180° APART.
5. Small end of dowel pins shall be held in position BY TIGHT FIT.
6. Lug to be welded to tubesheet. However lug for dowel pin may be threaded and screwed in tube sheet to avoid
PWHT in specific cases. Material of lug shall be compatible with tube sheet material.
7. When gap between shell & channel flanges is 25 mm. or less, dowel pins shall be provided in channel flanges only.
8. At the larger end of dowel pin the length can be reduced in case of a smaller gap between shell and channel
flanges.

STANDARD NO. REV.

FIXING DETAIL OF
L&T Hydrocarbon Engineering DOWEL PINS MES-ST-2011 01
SHEET 1 OF 1
65
= =
10 FULL FILLET
15 45° WELD ALL AROUND
A
R
Ø
D
THK.
D
A1*
Ø
INSULATION R
10
THK.
30°
A1* = A or [Insulation thickness + 25mm + (D/2)] , Whichever is greater.
LIFTING LUG FOR SHELL COVER ASSY & LIFITNG LUG FOR
CHANNEL ASSY (WITHOUT CHANNEL COVER) FLOATING HEAD COVER
65
= =
15 45°
R
Ø SHELL I.D. A D R THK.

D
UPTO 450 37 25 28 12
451 - 1000 40 30 35 16
THK.
1001 - 1200 65 30 35 20
A
10 1201 & ABOVE CUSTOM DESIGN
LIFTING LUG FOR CHANNEL COVER &

SHELL COVER FLANGE
NOTES:-
2. Material of Lug shall be compatible with part to which it is welded.
3. Use two lifting lugs each for channel and shell cover and one for channel cover and floating head cover.
4. All corners shall be rounded-off smooth radius.

STANDARD NO. REV.

LIFTING LUG DETAIL
SHEET 1 OF 1
25
SHELL COVER SHELL
FLANGE SLIDING LINK
FLANGE E
SEE DETAIL
SHELL
CHANNEL
COVER
B
F
N
LIFTING LUG SHELL
ØA
TOP AND BOTTOM LIFTING
25
PLATE LUG
CHANNEL
FLANGE
SHELL/ CHANNEL
CHANNEL FLANGE
COVER
PLAN OF DAVIT SUPPORT ASSEMBLY OF DAVIT ON EXCHANGER
12 C
D
45°
35
50
DETAIL-'A'
STOPPER
25
RIB PLATE
PLATE
16 THK.
B+0.75A+0.5L
SHELL/ CHANNEL TOP PLATE
CL RING FLANGE 'A'

R
d
Ø
= =
AØ
T
35 WIDE
0.5A+L
WELDING AFTER
25
=
0.5 A
INSERTING LIFTING LUG

S
#
5R
= =
30
35
10
DETAIL OF SLIDING LINK

16 (TYP.)
WELD 'W'
NOTE #: BOTTOM PLATE
CALCULATE WITH RESPECT TO
6 Ø FLAT
LIFTING LUG HOLE - REFER STANDARD
Ø10 WEEP
25
DRAWING NO: MS-ST-2013

HOLE
DATAIL OF DAVIT DETAIL OF DAVIT SUPPORT

STANDARD NO. REV.

DAVIT FOR SHELL &
L&T Hydrocarbon Engineering CHANNEL COVER MES-ST-2014 01
00
01
REV.
DAVIT FOR SHELL COVER TABLE-1
DIMENSION-A
DATE
UPTO 501 601 701 801 901 1001 1101 1201 1301 1401 1501 1601 1701 1801 1901 2001 2101 2201 2301 2401
09/03/2010
09-JUN-2016
DAVIT
TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO
DIM.
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
B 230 230 250 250 250 250 275 275 275 300 300 300 325 325 325 325 325 325 325 325 325
C 580 650 750 800 850 900 1000 1050 1100 1190 1240 1290 1360 1410 1460 1510 1560 1610 1660 1710 1760
260 260 300 300 300 300 340 350 380 390 400 430 430 430 430 450 450 460 460 480 480
L&T Hydrocarbon Engineering

D
L 125 150 180 200 230 250 280 300 330 350 390 400 430 450 480 500 530 550 580 600 630
N 20 20 25 25 30 30 30 30 30 30 30 30 30 30 30 30 40 40 40 40 40
d 16 16 20 20 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 30 30
DESCRIPTION
DAVIT FOR CHANNEL COVER TABLE-2
ISSUED FOR IMPLEMENTATION
CHANNEL COVER
DAVIT FOR SHELL &
DIMENSION-A
REVISED & REISSUED AS STANDARD DRAWING

UPTO 501 601 701 801 901 1001 1101 1201 1301 1401 1501 1601 1701 1801 1901 2001 2101 2201 2301 2401

DAVIT
TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO
DIM.
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
B 180 180 200 200 200 200 200 230 230 260 260 260 260 260 290 290 290 290 290 290 290
SHEET
C 350 400 450 525 575 625 675 750 800 875 925 975 1025 1075 1150 1200 1225 1275 1325 1375 1425
BY
GKL
SMP
STANDARD NO.
D 210 210 250 250 260 260 270 300 300 350 350 350 375 375 410 410 410 425 425 450 450
L 125 150 180 200 230 250 280 300 330 350 380 400 430 450 480 500 530 550 580 600 630
NIG
HAS
CHKD.
N 20 20 25 25 30 30 30 30 30 30 30 30 30 30 30 30 40 40 40 40 40
MES-ST-2014
2 OF 3
d 16 16 20 20 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 30 30
AKG
RGO
APPD.
01
REV.
TABLE - 3
DIMENSIONS / SIZE OF DAVITS

WT. x C.
(TON) (MTR)
E F S
T R
NB SCH NB SCH NB SCH.
UPTO 0.1 2"-160 1-1/2"-160 3 32 3"-160
0.11-0.3 3"-160 2"-160 3 47 4"-80
0.31-0.6 4"-160 2"-160 13 59 6"-80
0.61-1.25 6"-80 3"-160 10 86 8"-80
1.26-2.5 8"-80 3"-160 11 112 10"-60
2.6-4.0 10"-60 4"-120 8 139 12"-60
4.1-6.3 10"-120 4"-120 8 139 12"-60
6.4-7.8 10"-160 4"-120 8 139 12"-60
NOTES:-
2. When davits are required, use the following procedure to find out the dimensions.
2.1 Identify the dimension A, i.e; the maximum diameter of the component to be handled.
2.2 Refer table-1 or table-2 (as the case may be) for the dimensions and sizes B,C,D,L,N & d indicated in the
column corresponding to dimension A.
2.3 Determine weight of the part to be handled (i.e; WT. of shell cover assembly or channel cover).
2.4 Calculate the product of weight (in tonnes) X dimensions C (in meters).
2.5 Refer table-3 & obtain dimension and sizes E,F,T,S & R indicated in the row against the product calculated at
2.4 above.
3. Materials of construction (a) top/bottom/rib plate - compatible with part it is welded.
(b) pipe - IS 1239 / IS 2062 / SA 53 / SA 106 GR B / Equivalent.
(c) others - IS 2062 or Equivalent.
4. Lifting Lug of channel cover and shell cover flange shall follow as per standard drawing no: MES-ST-2013.
01 09-JUNE-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

STANDARD NO. REV.

DAVIT FOR SHELL &
L&T Hydrocarbon Engineering CHANNEL COVER MES-ST-2014 01
SHEET 3 OF 3
FIRE-PROOFING
Ø14 HOLE
(FOR M12 BOLT)
7 SMOOTH RADIUS
7 (TYP)
EXCHANGER PART
=
75
=
10 THK.
75 (Min.) 25 PLATE
(NOTE-3)
Notes :-
2. Do not weld earthing lugs to pressure parts.
3. Earthing lug to protrude out of fire-proofing wherever applicable.
4. All exchangers (including stacked condition) to be fitted with 2 earthing lugs.
5. Location of earthing lugs:
(i) For vertical exchanger with 2 Lug Supports : On both lug supports at vertical web.
(ii) For vertical exchanger with 3 Lug Supports : On any two at vertical web.
(iii) For vertical exchanger with 4 Lug Supports : On any two diameterically opposite at vertical web.
(iv) For horizontal exchanger on two saddle supports : One per central web.
(v) For stacked horizontal exchangers on bottom two saddle supports : One per central web.
6. In case of conflict, datasheet shall govern.
7. Material of construction shall be stainless steel.
8. Earthing lugs are not be painted.
9. All corners shall be rounded-off smooth radius.
00 09-JUN-2016 ISSUED AS STANDARD DRAWING SMP HAS RGO

STANDARD NO. REV.

EARTHING LUG MES-ST-2016 00
SHEET 1 OF 1
CLIENT CLIENT NAME
LOGO
PROJECT NAME
ENGINEERED BY
MANUFACTURER
CONTRACT NUMBER
MANUFR`S SERIAL NUMBER
P.O. NUMBER
ITEM NUMBER YEAR BUILT
DESIGN CODE
SHELL ID X TUBE LG. mm
NUMBER OF TUBES/SHELL TEMA TYPE
UNITS SHELL SIDE TUBE SIDE
OPERATING FLUID
OPER. PRESS. kg/cm²(g)
OPER. TEMP. (IN / OUT) °C
DESIGN PRESS. (INT / EXT) kg/cm²(g)
DESIGN TEMP. (MAX / MIN) °C
HEAT DUTY MMkcal/hr
TOTAL SURFACE AREA m²
CORROSION ALLOW. mm
RADIOGRAPHY
PWHT
TEST PRESS. kg/cm²(g)
TEST DATE
EMPTY WEIGHT kg
OPERATING WEIGHT kg
TEST WEIGHT kg
BUNDLE WEIGHT kg
INSPECTED BY
NAME PLATE DETAIL FOR SHELL OUTER DIAMETER 600mm & ABOVE
NOTES:-
1) All dimensions are in mm unless noted otherwise.
2) All letters, letter blocks & border shall be engraved in black.
3) The 'Test date' shall be in ''Day-Month-Year'' format, eg: 01-JAN-2016.
4) Vendor to fill.
5) Letter height shall be 4mm.
6) Name plate shall be 3mm (min.) thick plate of SS 304.
7) Name plate bracket detail shall refer standard drawing MES-ST-1029.
8) For stacked equipment, name plate shall be required on each shell.
9) For stacked exchanger, weight shall be as follow:
a) Empty weight : per shell. b) Test weight : per stack.
c) Operating weight : per stack. d) Bundle weight : per shell.
00 09-JUN-2016 ISSUED AS STANDARD DRAWING GKL HAS RGO

STANDARD NO. REV.
L&T Hydrocarbon Engineering NAME PLATE MES-ST-2017 00

SHEET 1 OF 2
CLIENT CLIENT NAME
LOGO
PROJECT NAME
ENGINEERED BY
MANUFACTURER
CONTRACT NUMBER
MANUFR`S SERIAL NUMBER
P.O. NUMBER
ITEM NUMBER YEAR BUILT
DESIGN CODE
SHELL ID X TUBE LG. mm
NUMBER OF TUBES/SHELL TEMA TYPE
UNITS SHELL SIDE TUBE SIDE
OPERATING FLUID
OPER. PRESS. kg/cm²(g)
OPER. TEMP. (IN / OUT) °C
DESIGN PRESS. (INT / EXT) kg/cm²(g)
DESIGN TEMP. (MAX / MIN) °C
HEAT DUTY MMkcal/hr
TOTAL SURFACE AREA m²
CORROSION ALLOW. mm
RADIOGRAPHY
PWHT
TEST PRESS. kg/cm²(g)
TEST DATE
EMPTY WEIGHT kg
OPERATING WEIGHT kg
TEST WEIGHT kg
BUNDLE WEIGHT kg
INSPECTED BY
NAME PLATE DETAIL FOR SHELL OUTSIDE DIAMETER BELOW 600mm
NOTES:-
2. All letters, letter blocks & border shall be engraved in black.
3. The 'Test date' shall be in ''Day-Month-Year'' format, e.g: 01-JAN-2016.
4. Vendor to fill.
5. Letter height shall be 2.5mm.
6. Name plate shall be 3mm (min.) thick plate of SS 304.
7. Name plate bracket detail shall refer standard drawing MES-ST-1029.
8. For stacked equipment, name plate shall be required on each shell.
9. For stacked exchanger, weight shall be as follow:
a) empty weight : per shell. b) test weight : per stack.
c) Operating weight : per stack. d) Bundle weight : per shell.
00 09-JUN-2016 ISSUED AS STANDARD DRAWING GKL HAS RGO

STANDARD NO. REV.

NAME PLATE MES-ST-2017
L&T Hydrocarbon Engineering (SHELL & TUBE HEAT EXCHANGERS)
00
SHEET 2 OF 2
±16 ±6 ±3
±3
±3
±3
±3
+3
-0
+3
-0
+3
-0
±3
±3
±3
±3
±3
±3 ±3
±6
REFER PARA RCB-3.121 & 3.122 OF TEMA, IN
ADDITION NO LONGITUDIANNAL ELEMENT OF
THE INSIDE SURFACE SHALL HAVE A BOW OF
MORE THAN 1 mm PER METRE OF LENGTH
UP TO MAX. OF 3mm.
+0.0
O.T.L. -0.8
LIGAMENT BETWEEN HOLES
WILL BE SAME AS LIGAMENT
BETWEEN HOLES IN TUBE
±0.4
SHEET(AS PER TEMA) +2.0 +0.0

-0.0 -0.8
+0.8
±1.5 -0.0
±0.4
FOR EXPANDED
HORI CL
±0.4 +1.0
-0.0
FOR WELDED +1.5
-0.0
BAFFLE +0.8
±0.8
+0.00
-0.25
-0.0
±0.8
±0.8
+1.0
-0.0
PARTITION
GROOVE
TAKE (-) TOLERANCE WHEN TAKE (+) TOLERANCE WHEN SEE DETAIL-'B'
CUT IS ON THE CL OF TUBES CUT IS IN BETWEEN THE TUBES
TUBE SHEET/
CHANNEL COVER
PARTITION PLATE DETAIL-'B'

(TYPICAL)
+0.8 +0.8
-0.0 U-TUBE BUNDLE OVERALL LENGTH ±12 -0.0
A
±0.8
±1.5
±3
±1.5
A
+0.8
-0.0
±3 IMPINGEMENT
+1.5
-1.0
±6(MAX.) ±0.8 ±3 PLATE

(NOTE-4)
SECTION-'A-A'
STANDARD NO. REV.

TOLERANCES MES-ST-2019 01
SHEET 1 OF 3
±16 ±16
±3
±6
±3 ±3
±3
±3
±6 ABOVE 1200Ø
±3 UP TO 1200Ø
±3
+3
-0
±3
±3
±3
+3.0
-0.0
±3 ±3
±3
+0.0 +0.0
-0.8 -0.8
+0.2 +0.2 +0.2
+0.8 +0.3
+0.0 -0.0 -0.0 +0.8 -0.0 +0.0 -0.0 -0.0
-0.8 -0.0 -0.8
+0.0
-0.8
±0.8
±0.8
±0.8
±0.8
±0.8
±0.8
±0.8
±0.8
±0.4
±0.4
-0.0
+1.0
TRUE C.L.
+2.0
+0.2
-0.0
-0.0 +0.8
+0.8 +0.8
-0.0 +0.0 +0.0 -0.0
-0.8 -0.8 TRUE VERTICAL C.L.
3 MAX. 3 MAX.
3 MAX. 3 MAX.
+1.5
-0.0
±0.8
+0.8
-0.0
±0.8
3 MAX.
3 MAX.
TURE HORZ. C.L.
ACTUAL CRADLE C.L.

STANDARD NO. REV.

TOLERANCES MES-ST-2019
L&T Hydrocarbon Engineering 01
SHEET 2 OF 3
TRUE VERT. C.L.
1.0 FOR NOZZLE 4" & UNDER
MAXIMUM
2.0 FOR NOZZLE 6" & 10" INCLUDING
3 MAX. 2.5 FOR NOZZLE 12" & 16" INCLUDING
3 MAX. 3.0 FOR NOZZLE 18" & ABOVE
TRUE HORZ. C.L.
+1.0
-0.0
ACTUAL NOZZLE C.L.
+1.0
-0.0
±3
±3
±3 ±3
±3
±3
NOTES:-
1. Cumulative tolerances on consecutive dimensions shall be limited by overall dimension tolerance.
2. Specific tolerances desired for any part shall be shown on the drawing and shall be given
preference to those given in this standard.
3. Tube hole tolerances shall be as per TEMA.
4. Only when number of baffle pitches exceed eight.

STANDARD NO. REV.
L&T Hydrocarbon Engineering TOLERANCES MES-ST-2019 01

SHEET 3 OF 3
CCR PROJECT AT MAHUL, MUMBAI
DOCUMENT TITLE:
TEMA DATASHEET FOR
HP ABSORBER FEED COOLER (141-A-E105)
DOCUMENT NUMBER:
TDS-141-A-E105
Client BHARAT PETROLEUM CORP. LTD.
Unit CCR Octanizing Unit / Reaction Section
Location Mahul, Mumbai
0 21-05-2018 Issued for Review PK CNR PB

Prepared Checked Approved
Rev Date Document Status
By By By
TDS-141-A-E105
RECORD OF REVISIONS
Rev Date Revision Details
Page 2 of 5
TDS-141-A-E105
Rev.
1. CHARACTERISTICS
5. PERFORMANCE OF ONE UNIT
6. Fluid Allocation Shell Side Tube Side
7. Fluid Name HP ABSORBER FEED RAW COOLING WATER
8. Fluid Quantity, Total kg/hr 151015 190910
9. Vapor (In/Out) 20983 17972
10. Liquid 130032 133043 190910 190910
11. Steam
12. Water
13. Noncondensables
14. Temperature (In/Out) C 66 45 34 45
15. Density kg/m3 6.12 V/L 784.57 5.62 V/L 798.7 994.6 990.4
16. Viscosity cP 0.0120 V/L 0.3200 0.0110 V/L 0.3794 0.7339 0.5962
17. Molecular Weight, Vapor
18. Molecular Weight, Noncondensables
19. Specific Heat kcal/kg-C 1.3087 V/L 0.4761 1.4475 V/L 0.4601 0.9986 0.9989
20. Thermal Conductivity kcal/hr-m-C 0.0770 V/L 0.1050 0.0780 V/L 0.1099 0.5340 0.5461
21. Latent Heat kcal/kg
22. Inlet Pressure kgf/cm2[g] 27.4 4
23. Velocity m/s 3.6 1.25
24. Pressure Drop, Allow/Calc kgf/cm2 0.3 0.1 (4) 0.7 0.591 (5)
25. Fouling Resistance (min) m2-hr-C/kcal 0.0004 0.0004
26. Heat Exchanged (3) 2.1 MMkcal/hr MTD (Corrected) 12.2 C
27. Transfer Rate, Service 322.5 kcal/m2-hr-C Clean 553.5 kcal/m2-hr-C Actual 367.7 kcal/m2-hr-C
28. CONSTRUCTION OF ONE SHELL Sketch (Bundle/Nozzle Orientation)
29. Shell Side Tube Side
30. Design/Test Pressure kgf/cm2G 47.5, FV / 36.5 /
31. Design Temperature C (9) 150 70
32. No Passes per Shell 1 6
33. Corrosion Allowance mm 3 3
34. Connections In 1 @ 20" NPS (14) 1 @ 10" NPS (14)
35. Size & Out 1 @ 20" NPS (14) 1 @ 10" NPS (14)
36. Rating Intermediate @ @
37. Tube No. 904 OD 25 mm Thk(min.) 2.5 mm Length (2) 8100 mm Pitch 31.25 mm
38. Tube Type Plain Material SA 210 Gr. A1 Tube pattern90
39. Shell SA-516 Gr. 60 N ID 1240 OD mm Shell Cover SA-516 Gr. 60 N
40. Channel or Bonnet SA-516 Gr. 60 N Channel Cover SA-266 Gr.2
41. Tubesheet-Stationary SA-266 Gr.2 Tubesheet-Floating SA-266 Gr.2
42. Floating Head Cover SA-516 Gr. 60 N Impingement Plate Circular plate
43. Baffles-Cross SA-516 Gr. 60 N Type Double-Seg. (V) %Cut (Diam) 22.9 Spacing(c/c) 455 Inlet 1100 mm
44. Baffles-Long - Seal Type None
45. Supports-Tube (16)(17)(18) U-Bend Type None
46. Bypass Seal Arrangement 4 pairs seal strips (13)(15) Tube-Tubesheet Joint (11)
47. Expansion Joint Type
48. Rho-V2-Inlet Nozzle 1687 kg/m-s2 Bundle Entrance 956 Bundle Exit 1137 kg/m-s2
49. Gaskets-Shell Side Tube Side
50. - Floating Head
51. Code Requirements ASME Sec VIII, Div 1; API 660 TEMA Class R
52. Weight/Shell kg Filled with Water kg Bundle kg
53. Remarks: 1) The process conditions and THX curve has been considered as per Axens datasheet for heat exchanger
54. Doc no 3290-141A-2EX-141A-E105 page 1 to 6
55. 2) The indicated tube length is overall tube length. Effective length for heat transfer is 7530 mm from inside of fixed tubesheet upto
56. floating head support plate.
57. 3) Indicated duty is 100% of process datasheet duty. Exchanger is designed for 120% of duty specified.
58. 4) Shellside design flowrate = 166117 kg/hr, corresponding to 110% of case2 MRT operating flowrate.
59. Shellside pressure drop for design flowrate is 0.12 kg/cm2
60. 5) Tubeside design flowrate = 211200 kg/hr, corresponding to 110% of case2 MRT operating flowrate.
61. Tubeside pressure drop for design flowrate is 0.7 kg/cm2.
62. 6) Max. continuous H2 partial pressure: 365.6 psia (case 2 NOP).
63. 7) Hydrogen service is applicable for shellside.
64. 8) Based on 10/13 of shellside design pressure.
65. 9) MDMT: 9°C for shellside and tubeside
66.
67.
68.
69.
70.
Page 3 of 5
TDS-141-A-E105
Rev.
1. CHARACTERISTICS
5. REMARKS
6.
7. 10) Material for exchanger parts.
8. LHS Channel Cover - SA 266 Gr.2
9. Channel Shell - SA 516 Gr 60 N
10. Floating Head Cover - SA 516 Gr 60 N
11. Floating head Flange - SA 266 Gr 2
12. Backing Ring - SA 266 Gr 2
13. Tie Rods, Seal Rods - CS
14. Sealing Strips / Sliding Rail - SA 516 Gr 60 N
15. Spacer - CS
16. Eye Bolt - SA 105
17. Tie Rod nuts - SA 194 Gr.2H
18.
19. 11) Tubes to be strength welded and light expanded (upto 5%)
20. 12) 13 no. of baffles with inlet spacing of 1100 mm and central spacing of 455 mm. Double segmental baffles with 6 tuberows overlap
21. 13) Provide 20 seal rods of 9 mm OD.
22. 14) Refer nozzle schedule
23. 15) Sealing strip provided on the bottom and top halfs of the exchanger will be of different heights as seen in the tube layout.
24. 16) Inlet vibration support plate to be provided for topmost 7 tuberows. To be placed at a distace of 550 mm from support plate at rear end.
25. 17) Outlet vibration support plate to be provided for bottom 7 tuberows. To be placed at a distace of 485 mm from fixed
26. tubesheet shellside face.
27. 18) Floating head support plate has been considered.
28. 19) Insulation Shellside: Personnel Protection
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
Page 4 of 5
TDS-141-A-E105
Rev.
1. CHARACTERISTICS
5. TUBE LAYOUT
6.
7.
8. Item number 141A-E-105
TEMA type AES
9. Shell ID 1240.00 mm
448.000 mm
10. Actual OTL 1174.82 mm
11. Height under inlet nozzle 170.325 mm
Height under outlet nozzle 123.000 mm
12. Tube type Plain
13. Tube OD 25.000 mm
Tube pitch 31.250 mm
14. Tube layout angle 90 deg
15. Tubes 904
Tube positions available 904
16. Tie rods 10
17. Seal strip pairs 4
Passlane seal rods 20
18. Tube Passes 6
19. Parallel passlane width 22.000 mm
20. Perpendicular passlane width 22.000 mm
Baffle cut % diameter 22.9
21.
22. TUBEPASS DETAILS
Pass Rows Tubes
23. 1 11 156
24. 2 11 155
3 8 143
25. 4 8 144
26. 5 10 152
6 10 154
27.
28. SYMBOL LEGEND
29. Tube
Dummy Short Tube
30. Dummy Long Tube
31. Plugged Tube
Tie Rod
32. Seal Rod
33. 6 5 Impingement Rod
34.
35. 3 4
36.
37.
448.000 mm 2 1
38.
39.
40.
41. NOZZLE SCHEDULE
42. MARK SIZE SERVICE QTY RATING REMARKS
43. S1 20" SHELLSIDE INLET 1 600#
44. S2 20" SHELL SIDE OUTLET 1 600#
45. S3 2" SHELLSIDE VENT 1 600#
46. S4 2" SHELLSIDE DRAIN 1 600#
47. T1 10" TUBE SIDE INLET 1 300#
48. T2 10" TUBE SIDE OUTLET 1 300#
51.
52.
53. SKETCH
54.
55.
56. S1
T2 S3
57.
58.
59.
60.
61.
62.
63.
64.
65.
T1 S4
66. S2
67.
68.
69.
70.
Page 5 of 5
MATERIAL OF CONSTRUCTION DESIGN SPECIFICATION STANDARDS NOTES
SHELL SIDE SERVICE : HP ABSORBER FEED COOLER 1. ALL DIMENSIONS ARE IN MM UNLESS & OTHER WISE SPECIFIED.
PART DETAILS 2. WALL THICKNESSES INDICATED ARE MINIMUM PRELIMINARY. VENDOR TO VERIFY THE THICKNESSES AND
SHELL SA-516 Gr. 60 N CODE OF CONSTRUCTION : ASME SEC VIII DIV 1.ED 2017,TEMA 9 th ED-2007,API-660 MES-ST-2001
INCREASE BASED ON STRESS CALCULATIONS.
SHELL COVER BARREL & BONNET SA-516 Gr. 60 N TEMA TYPE : AES (HORIZONTAL) TEMA CLASS : R CODE STAMP : NO TYPES OF NON STANDARD GASKETS MES-ST-2002 3. FLANGE DIMENSIONS SHALL BE AS PER ASME B 16.5 & GASKET SHALL BE AS PER ASME B 16.20.
GIRTH FLANGES SA 266 GR 2 DUTY : 2.1 MMKcal/Hr SIZE : 1240 X 8100 MM SLIDING & DEFLECTOR STRIPS MES-ST-2007 4. TUBE TO TUBESHEET JOINT SHALL BE STRENGTH WELDED AND LIGHT EXPANDED.
SS304 SPWD GRAFOIL FILLED SHELLS / UNIT : 1 NO. OF UNITS : 1 EYE BOLT DETAILS MES-ST-2008 5. HARDNESS OF PARENT METAL, WELD AND HAZ SHALL NOT EXCEED 200 BHN.
GASKET AT SHELL FLANGE WITH SS304 INNER AND OUTER 6. HARDNESS OF GASKET SHALL BE AS LOW AS POSSIBLE AND SHALL BE MINIMUM 20 BHN THAN FOR THE
AREA PER UNIT (EFFECTIVE) m2 534.6 JACK SCREW TAPPING AND ARRANGEMENT MES-ST-2010
NOSE MATERIAL OF THE FLANGE GASKET FACING.
BOLTING AT SHELL FLANGE SA-193 Gr. B7 / SA-194 Gr. 2H FIXING DETAIL OF DOWEL PINS MES-ST-2011 7. EQUIPMENT IS IN HYDROGEN SERVICE.HYDROGEN PARTIAL PRESSURE IS ON SHELL SIDE 365.6 PSIA.
LIFTING LUG DETAIL 8. COMPLETE EXCHANGER SHALL UNDERGO PWHT, PWHT CYCLE SHALL BE AS PER CODE.
NOZZLE NECK / FLANGE SA-105 MES-ST-2013
9. MOCKUP TEST OF TUBE TO TUBESHEET JOINT SHAL BE CARRIED OUT.
NOZZLE BOLTING SA-193 Gr. B7 / SA-194 Gr. 2H DAVIT FOR SHELL AND CHANNEL COVER MES-ST-2014 10.10% STUDS AND NUTS BUT NOT LESS THAN 4 STUDS WITH 8 NUTS FOR EACH PAIR OF MATING
SS304 SPWD GRAFOIL FILLED AS EARTHING LUG MES-ST-2016 FLANGES,INTERCONNECTING NOZZLES, NOZZLES WITH BLIND FLANGES ETC. SHALL BE SUPPLIED AS
NOZZLE GASKET MANDATORY SPARES.
PER ASME B 16.20 NAME PLATE MES-ST-2017
DESRIPTION SHELL SIDE TUBE SIDE 11. ALL FLANGE BOLT HOLES SHALL BE STRADDLE PRINCIPAL CENTER LINE OF THE VESSEL
BAFFLES/SUPPORT PLATE SA-516 Gr. 60 N TOLERANCES MES-ST-2019
12. GASKET SEATING SURFACE OF ALL FLANGES SHALL HAVE FINISH OF 125-250 MICRO INCH AARH EXCEPT
TIE ROD & NUTS CS FLUID : HP ABSORBER FEED RAW COOLING WATER FLOATING HEAD FLANGE.
SPACER CS FLUID DENSITY (IN / OUT) (VAPOR/LIQUID) Kg/m3 6.12/784.57 & 5.62/798.7 994.6/990.4 13. ALL WELDS SHALL BE FULL PENETRATION WELDS. WELDS ACCESSIBLE FROM SECOND SIDE SHALL BE BACK
CHIPPED TO SOUND METAL, DP CHECKED AND REWELD FROM SECOND SIDE.WHEREVER BACKCHIPPING IS NOT
RF PAD/WEAR PLATE SA-516 Gr. 60 N OPERATING PRESSURE : Kg/cm2 (g) 27.4 4
POSSIBLE ROOT RUN TO BE CARRIED OUT
OPERATING TEMP.(IN/OUT) : o
C 66/45 34/45 STANDARD SPECIFICATIONS 14. ALL CS MATERIAL INCLUDING FORGING USED FOR THE PRESSURE PARTS SHALL BE PROCURED IN FULLY
SEALING STRIPS /SLIDING STRIPS AND ALLOWABLE NOZZLE LOADINGS FOR PRESSURE KILLED & NORMALIZED CONDITION.
CS
IT'S STUDS DESIGN PRESSURE(INT/EXT) Kg/cm2 G 47.5/FV 36.5 VESSELS AND MES-ST-1038 15. PLATES HAVING THICKNESS 16 MM TO 50 MM (BOTH INCLUSIVE) SHALL BE EXAMINED ULTRASONICALLY
SHELL & TUBE HEAT EXCHANGER AS PER ASTM-A-435
o 16. FOR THICKNESS ABOVE 50 MM, ULTRASONIC EXAMINATION SHALL BE CARRIED OUT AS PER ASTM-A 578
ATTACHMENTS WELDED TO SHELL SA-516 Gr. 60 N DESIGN TEMPERATURE C 150 70
GENERAL SPECIFICATION FOR HEAT EXCHANGERS MES-SP-0041 AND SHALL HAVE ACCEPTANCE STANDARD OF LEVEL-I. ULTRASONIC EXAMINATION SHALL BE DONE AFTER THE
IMPINGEMENT PLATE SA-516 Gr. 60 N o
MEAN METAL TEMPERATURE C NA NA SPECIFIED HEAT TREATMENT.
SADDLE SUPPORT SA-516 Gr. 60 N o
MIN. DESIGN METAL TEMP. C 9 9 STANDARD SPECIFICATION FOR HARDNESS 17. THE CS PRESSURE FORGINGS SHALL BE SA-105 OR BETTER FOR STANDARD NOZZLE FLANGES / COUPLINGS /
MES-SP-0083
NAME PLATE SS304 TEST PRESSURE Kg/cm2 G UG-99(b) UG-99(b) REQUIREMENT PLUGS ETC. OTHER NON STANDARD CS PRESSURE FORGINGS SHALL BE SA 266 CLASS 2 OR BETTER.
2
NONSTANDARD FORGING SHALL BE IN NORMALISED & TEMPERED CONDITION.
NAME PLATE BRACKET SA-516 Gr. 60 N ALLOWABLE / CALCULATED PRESSURE DROP Kg/cm 0.3/0.1 0.7/0.591 SPECIFICATION FOR WELDED TUBE TO TUBESHEET
MES-SP-0044 18. THE CARBON CONTENT OF CS PLATE SHALL NOT EXCEED 0.20% AND CARBON EQUIVALENT SHALL BE LESS
NUMBER OF PASSES 1 6 JOINT THAN 0.42 WHERE Ceq=C+Mn/6+(Cr+Mo+V)/5+(Ni+Cu)/15
CORROSION ALLOWANCE mm 3 3 STANDARD SPECIFICATION FOR POSITIVE 19. CS NON STANDARD FORGINGS ABOVE 75 MM THICKNESS, ALL TUBE SHEET FORGINGS AND ALL NON
MATERIAL IDENTIFICATION (PMI) AT SUPPLIER`S MES-SP-0092 STANDARD FORGINGS OF OTHER MATERIALS SHALL BE 100% ULTRASONICALLY TESTED AS PER ASTM A-388.
RADIOGRAPHY / JOINT EFFICIENCY 100% 100% WORKS ACCEPTANCE STANDARDS SHALL BE AS PER PARA AM 203.2 OF ASME SECTION VIII DIV. II.
TUBE SIDE PWHT / HEAT TREATMENT YES YES 20. SEAMLESS TUBES HAVE TO BE DELIVERED IN NORMALISED CONDITION (INCLUDING FINAL
NORMALISATION FOR COLD DRAWN TUBES)
TUBE SA-210 GR A1 INSULATION THICKNESS mm 25 MM (BY OTHERS) - JOB SPECIFICATIONS
21. VENDOR SHALL SUPPLY TEST RING AND TEST FLANGES FOR HYDROTESTING PURPOSE
CHANNEL SHELL SA-516 Gr. 60 N FIREPROOFING mm YES (BY OTHERS) DESIGN BASIS FOR STATIC EQUIP. - 22. ALLOWABLE NOZZLE LOADINGS AS PER MES-ST-1038
GIRTH FLANGE AT CHANNEL COVER SA 266 GR 2 PAINTING/CLEANING 23. MINIMUM NDT REQUIREMENT.
A) ALL LONG SEAMS, CIRC SEAMS ON SHELL SIDE SHALL BE 100% RADIOGRAPHED.
GIRTH FLANGE AT TUBESHEET SA 266 GR 2 INSPECTION - STAGEWISE/FINAL B) ALL LONG SEAMS, CIRC SEAMS ON TUBE SIDE SHALL BE 100% RADIOGRAPHED.
FLOATING TUBESHEET SA 266 GR 2 C) DPT: ROOT (BACKCHIPPED) AND FINAL PASS ON ALL PRESSURE WELDS BEFORE PWHT, DP TEST ON FINAL
PASS TO BE CARRIED OUT AFTER PWHT ALSO
FLOATING HEAD FLANGE SA 266 GR 2 OTHER SPECIFICATIONS
D) TUBE TO TUBESHEET JOINT SHALL BE DP TESTED FOR EACH PASS FOR ALL TUBES.
FLOATING HEAD DISH SA-516 Gr. 60 N THERMAL DATASHEET TDS-141-A-E-105 E) TUBESHEET AND FLANGES SHALL BE ULTRASONIC TESTED AS PER APPLICABLE MATERIAL SPECIFICATION.
SS304 SPWD GRAFOIL FILLED LOADING DATA F)NOZZLE FABRICATED FROM PLATE SHALL BE 100% RADIOGRAPHED.
GASKET AT TUBESHEET WITH SS304 INNER RING & OUTER 24. NOZZLE RF PAD SHALL BE PNEUMATICALLY TESTED AT 0.5 KG/CM2 PRESSURE WITH SOAP SOLUTION.
NOSE EMPTY WEIGHT kg 35500
25. EQUIPMENT SHALL BE TRASNPORTED IN FIELD WITH DRY NITROGEN AT 0.5 KG/CM2 FITTED WITH
BACKING RING SA 266 GR 2 OPERATING WEIGHT kg 45000 PAINT SPECIFICATION PRESSURE GUAGE AND NON RETURN VALVE.
FULL OF WATER WEIGHT kg 47000 BEFORE SURFACE PREPARATION , THE SURFACE SHALL BE DEGREASED BY
GASKET- PASS PARTITION SECTION SS 304 FLAT METAL JACKETED
AROMATIC SOLVENT TO REMOVE ALL GREASE, OIL ETC AS PER SSPC-SP-1.
GASKET- FLOATING HEAD FLANGE (GRAPHITE FILLED) BUNDLE WEIGHT kg 17000 BLAST CLEANING SHALL BE SA 2-1/2 AS PER SWEDISH STANDARD SIS-055900
CONNECTING PIECE SA-516 Gr. 60 N (LATEST EDITION) OR SSPC-SP OR ISO 8501-01.
SHELL SIDE-
PASS PARTITION PLATE SA-516 Gr. 60 N
A. HEAT RESISTANT SILICONE ALUMINIUM PAINT SUITABLE UP TO 540°C DRY
STUD WITH NUTS SA-193 Gr. B7 / SA-194 Gr. 2H WIND FORCE kgf 820 TEMP.; 3 COATS @20μ DFT/coat ; TOTAL 60μ DFT (MIN.)
STUD WITH NUTS FOR INTERNAL PARTS SA-193 Gr. B7 / SA-194 Gr. 2H WIND MOMENT kgf x m 660 TUBE SIDE-
A.SSPC-SP-10; 1COAT OF INORGANIC ZINC SILICATE COATING@ 65-75μ
GASKET- CHANNEL COVER FLANGE SS304 SPWD GRAFOIL FILLED SEISMIC FORCE kgf 5920 DFT/COAT
WITH SS304 INNER RING & OUTER B. 1 COAT OF EPOXY ZINC PHOSPHATE PRIMER @ 40 μ DFT/COAT
GASKET- ST. T/S TO CHANNEL FLANGE NOSE SEISMIC MOMENT kgf x m 4740 C. 1 COAT OF POLYAMIDE CURED EPOXY RESIN MEDIUM SUITABLY PIGMENTED
@ 100 μ DFT/COAT+ 1COAT OF ACRYLIC POLYURETHANE FINISH PAINT @ 40μ
LIFTING LUG FOR FLOATING HEAD CS DFT/COAT
NOZZLE NECK SA-106 GR B
NOZZLE NECK FLANGE SA-105
SS304 SPWD GRAFOIL FILLED AS
NOZZLE GASKET
PER ASME B 16.20
HOLD UPS
CHANNEL COVER SA 266 GR 2 NOZZLE ORIENTATION
OTHERS
TUBESHEET SA 266 GR 2 R0 ISSUED FOR ENQUIRY 21.5.18 PMS VSS BBB
EYE BOLT SA-105 REV. NO. DESCRIPTION DATE DRN CHECKED APP.
NOZZLE SCHEDULE
DOWEL PIN SA-105
JACK SCREW SA-105 NOZZLE
MARK
SIZE SCH / THK TYPE RATING PAD OD X THK SERVICE OWNER BHARAT PETROLEUM CORPORATION LIMITED
SETTING BOLT CS
DAVIT CS S1 20" 30 THK SRN 600# REFER SHT.2 SHELL INLET
PLUG FOR EYEBOLT & INSERSION PIECE CS S2 20" 30 THK SRN 600# REFER SHT.2 SHELL OUTLET
LIFTING LUG CS S3 2'' 16.6 THK LWN 600# - VENT CONSULTANT L&T ENGINEERING SERVICES, MUMBAI
S4 2'' 16.6 THK LWN 600# - DRAIN
T1 10'' 140 SCH WNRF 300# 510 X 25 TUBE INLET
T2 10 140 SCH WNRF 300# 510 X 25 TUBE OUTLET DATE: 21.05.18
TITLE HP ABSORBER FEED COOLER(141-A-E105)
ACCESSORIES T3 2'' 16.6 THK WNRF 300# - TUBESIDE STUB CONNECTION-1 DEPT: MES
LIFTING LUG INSULATION CLEATS T4 2'' 16.6 THK WNRF 300# - TUBESIDE STUB CONNECTION-2
PRP BY: PMS PROJECT CCR PROJECT AT MAHUL,MUMBAI
LIFTING & PULLING EYEBOLT DAVIT FOR SHELL COVER
PLUG FOR PULLING EYEBOLT TEST RING
CHK BY: VSS SH. 1 OF 4
JACK SCREW & DOWEL PIN TEST FLANGE
DRG. NO. MDS-141-A-E-105
NAME PLATE 6 mm THK PLATE @SLIDING END
APP BY: BBB REV. 0
EARTHING LUG

Technical-specs-Heat Exchangers

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SUPPLY OF EXCHANGER 141A-E-105 (N)

Applicable codes and standards:

ASME boiler and pressure vessel code section VIII DIV 1

National and local laws or regulations as applicable

3. EQUIPMENT QUALIFICATION CRITERIA:

a. Bidder shall be capable of Designing, Manufacturing, Testing, Supply and

Supply of following items is in vendor scope:

a. Exchanger as per design data sheet, drawings, Specification and Codes.

Material spec-stud-bolts : ASTM A193 GRADE B7

d. Gaskets for all Nozzles (8 Sets, each set individually packed)

Site Visit is mandatory for better understanding of job.

It shall be entirely the vendor’s responsibility to ensure compliance to codes and

a) Nozzle data, orientation and location, support location, dimensions for

b) Design data and materials of construction

c) Pass partition arrangement, tube layout and bundle detail.

d) Critical details like tube to tube-sheet joint detail.

Vendor shall furnish list of drawings/ documents with schedule of submission of

1) General arrangement drawing indicating design data, fabricated equipment’s

2) Detail of all nozzles, accessories etc.

3) Detail of internals, gaskets etc.

5) Shell development drawings incorporating all attachments and weld seams.

1. Material/bought out items required for the fabrication of Exchangers shall be

11. THIRD PARTY INSPECTION:

12. SCHEDULE OF EXECUTION OF JOB/ PROGRESS REPORTS:

Gaskets = 400% (Except Nozzles)

2 YEARS MAINTENANCE SPARES:

14. DELIVERY PERIOD:

6 months from date of issue of LOI/PO.

16. TERMS OF PAYMENT:

17. REFERENCE DOCUMENTS/DRAWINGS:

 Thermal Design Data Sheet _ TDS-141-A-E105

CCR PROJECT AT MAHUL, MUMBAI

Client BHARAT PETROLEUM CORP. LTD.

Unit CCR Octanizing Unit / Reaction Section

Location Mahul, Mumbai

0 21-05-2018 Issued for Review PK CNR PB

Rev Date Revision Details

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

FB = ¥(FL2 + FC2 ) MB = ¥(ML2 + MC2 )

01 10-JUN-2016 REVISED & REISSUED AS STANDARD DRAWING SMP HAS RGO

L&T Hydrocarbon Engineering (PRESSURE VESSELS AND MES-ST-1038 01

01 Revised and Reissued as Standard Specification SAC SBG RGO 17-May-2016

1. SCOPE ......................................................................................................................................... 4

2. CODE & REGULATIONS

a) All the tubes shall be seamless and cold drawn.

i. Carbon equivalent shall be <0.40% nickel content shall be<0.2%.

6. NON DESTRUCTIVE TESTS

7.6 SS components shall be solution annealed in the following cases.

8. INSPECTION AND TESTING