Air Cooled Heat Exchangers

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TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 13

TABLE OF CONTENTS

Section Title Page No.


1. SCOPE................................................................................................................................ 1
2. REFERENCED PUBLICATIONS .......................................................................................... 2
4. PROPOSALS ...................................................................................................................... 2
5. DOCUMENTATION.............................................................................................................. 3
6. DESIGN............................................................................................................................... 3
7. MATERIALS ........................................................................................................................ 7
8. FABRICATION .................................................................................................................... 8
9. INSPECTION, EXAMINATION, AND TESTING ....................................................................10
10. PREPARATION FOR SHIPMENT........................................................................................10
11. SUPPLEMENTAL REQUIREMENTS ...................................................................................12

INTRODUCTION

KBR requirements for air cooled heat exchangers correspond to those of API Standard 661 with the specific
options, deletions, additions or modifications contained in this specification.

The paragraph numbers in this specification correspond to those used in API 661. Paragraph numbers may not
be consecutive and all API paragraphs not addressed herein shall be considered to be verbatim requirements of
this specification.

Instructions contained in this specification such as "add" or "substitute" shall be interpreted as follows: If
information is "added" to an existing paragraph in the API Standard, the requirements of this specification shall
be read as a continuation of the API paragraph. If information is "substituted", the API requirement shall be
replaced in its entirety by the requirements of this specification. API paragraphs which are "revised" have
specific revisions noted in this specification. If (New) is next to a paragraph number not appearing in API 661, it
shall be read as a KBR added requirement.

1. SCOPE

(Add): This specification and API 661-97 defines mandatory technical requirements for the design, material,
fabrication, testing and inspection for air cooled heat exchangers.

1.1 GENERAL

(Add): The Vendor shall comply with the applicable local rules and regulations.

(New): When the exchanger is in hydrogen, H2S, amine, caustic or cyclic service as identified on the
specification sheet, special requirements as noted in this specification shall apply.

1.2 CONFLICTING REQUIREMENTS

1.2.3 (New): Conflicts are to be reported to the Purchaser. If the Vendor fails to reach an agreement or
proceeds with the work without getting written approval, the most stringent requirements will apply, as
determined by the Purchaser.

1.4 (New) GUARANTEE:

1.4.1 (New): The Vendor shall guarantee the mechanical, thermal and hydraulic performance of an air cooled
heat exchanger for 12 months after its placement in the specified service, but not exceeding 24 months from the
date of shipment unless otherwise specified. The Vendor shall repair or replace without charge any defect
found within the guarantee period.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 13

2. REFERENCED PUBLICATIONS

(Add): The following documents are referenced herein and form part of the Order. Additional KBR documents,
when applicable, will be listed on the Requisition. The issue dates of KBR documents shall be as specified in
the Requisition. Current editions of the industry standards including all mandatory addenda in effect at the time
of the order shall apply unless otherwise indicated.

KBR DOCUMENTS
4-7TS, “General Welding Requirements"
9-4D, "Design Requirements for Wind Loads"
9-5D, “Design Requirements for Earthquake Loads”
MC1-4TS, "Protection and Packaging, Class MC: Exchangers"
MC2-1PS, "General Purchasing Requirements for Heat Exchangers"
MC13-1M, "Heat Exchanger Materials"
MJ41-1E, "NEMA Frame Electric Motors"
SDR-1MC, "Supplier Drawing and Data Requirements for Heat Exchangers"

AM ERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)


ASME Boiler and Pressure Vessel Code and referenced standards listed in ASME Section VIII, Table U-3.

Section II, "Materials"


Part A - "Ferrous Material Specifications"
Part B - "Nonferrous Material Specifications"
Part C - "Specifications for Welding Rods, Electrodes and Filler Metals"
Part D - "Properties"

ASME B16.21, “Nonmetallic Flat Gaskets for Pipe Flanges”

4. PROPOSALS

4.2 VENDOR'S RESPONSIBILITIES

4.2.3 (Substitute): Motors shall be mounted in the shaft down position.

4.2.5 (Substitute): Maximum shop assembly is required. If any field assembly is required, the proposal shall
include a general description and weight of the components to be assembled in the field and the approximate
workhours for field assembly and erection.

4.2.8 (Substitute): The proposal shall include a noise data sheet (see Appendix C).

4.2.9 (Substitute): The proposal shall include fan performance curves.

4.2.13 (New): Proposals shall also include:

a. Vendor and type of mechanical components (fans, motors, hubs, actuators, etc).

b. Weight of the assembled air cooler empty and full of water.

c. For winterized units, a diagram showing the control scheme and other essential features.

d. Unit pricing for pre-assembly and run-in test in accordance with paragraph 9.4.1 - 9.4.2.

e. Unit pricing for noise tests at manufacturer's shop in accordance with Appendix F.

f. When units require field assembly, the vendor shall provide a separate price for the addition of 1/2 inch
(6 mm) plywood to protect the surface of the bundles.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 13

4.2.14 (New): Consideration shall be given to standardizing tube diameter, length, fan diameter and other
similar components to the maximum economical extent.

5. DOCUM ENTATION

5.1 (Revise): Change "APPROVAL INFORMATION" to "REQUIRED INFORMATION".

5.1.1.o (Add): A plan view, a side elevation view, and an end elevation view of all bays as a continuous
structure. Include vendor supplied walkways, platforms and ladders.

5.1.1.p (Add): Minimum access areas for maintenance.

5.1.1.q. (Add): Location and design load for pipe supports.

5.1.1.r. (Add): The displacement of the movable header due to thermal expansion for bundles with piping
connections on the movable header.

5.1.1.s (Add): Slope requirements for the tube bundle or the heating coil.

5.1.1.t (Add): Erection drawings with piece marks on all walkways, platforms, ladders, etc. which will require
field installation.

5.2 FINAL RECORDS

5.2.1.h (Substitute): Certified noise data sheet for the air-cooled heat exchanger when the fans operate at
rated speed and design conditions.

5.2.1.j (Substitute): Louver characteristic performance curve.

5.2.1.k (New): Heat exchanger performance due to natural convection.

6. DESIGN

6.1 TUBE BUNDLE DESIGN

6.1.1 General Requirements

6.1.1.2 (Substitute): The Vendor shall make provision for lateral movement of the tube bundles to
accommodate the thermal expansion of the manifolds. If a manifold sketch is not provided, Vendor shall
assume a movement of 1/2 in. (12 mm) in each of 2 directions or 1.0 in. (25 mm) in one direction. Teflon
coated slide plates shall be used.

6.1.3 Tube Bundle Design Temperature

6.1.3.5 (New): The following table shows the fin type and the maximum process inlet temperature. If the
maximum process inlet temperature is not stated, the Vendor shall use the normal process inlet temperature
plus 20°F (11°C):
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 13

Maximum
Fin Type Temperature °F (°C)
Embedded Aluminum 750 (400)
Bimetallic Tubes Extruded Aluminum 500 (260)
Footed Wrap-on Aluminum 300 (150)
Welded Steel 1000 (540)
Edge Wound Not Permitted

6.1.3.6 (New): When full vacuum (FV) is specified as a design pressure, the coincident design temperature
shall be 300°F (149°C).

6.1.6 HEADERS

6.1.6.1 General

6.1.6.1.6 (Revise): The minimum thickness of tubesheets shall be 1 inch (25 mm) for carbon and low alloy
steels, including the specified corrosion allowance and 3/4 in. (19 mm) plus the specified corrosion allowance for
high alloy steel.

6.1.6.1.10 (New): Split headers shall have slide plates between the support frame and boxes of the split
header.

6.1.6.1.11 (New): Header passes shall be self-draining type unless otherwise specified. Partition plates in
multi-pass headers shall have weep holes for draining.

6.1.6.2 Headers - Removable-Cover-Plate and Removable-Bonnet Types

6.1.6.2.3 (Substitute): Bolted joints shall be designed with confined gaskets. Typical construction is shown in
Figures 4(A) and 4(B).

6.1.6.2.7 (Substitute): Stud bolts shall be used for removable cover plate type headers. Through-bolt design
may be quoted as an alternative.

6.1.6.2.8 (Substitute): The minimum nominal bolt size shall be 3/4 in. (M20).

6.1.6.3 Plug Headers

6.1.6.3.4 (New): Plug type headers shall not be used for design pressures larger than 3000 psi (20 700 kPa).

6.1.7 Tube Access Plugs

6.1.7.1 (Add): Plugs shall be bar stock and of the same alloy content as the header or cladding.

6.1.8 Gaskets

6.1.8.1 (Substitute): Tube access plug gaskets shall be soft solid metal with the same general material
classification as the plug.

6.1.8.4 (Substitute): Cover-plate and bonnet gaskets shall be double metal jacketed flexible graphite filled, with
the same general material classification as the header.

6.1.8.5 (Delete)
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 13

6.1.9 Nozzles and Other Connections

6.1.9.3 (Substitute): When Hydrogen Service is specified on the Heat Exchanger Specification Sheet, all
connections shall be flanged.

6.1.9.8 (Substitute): Flanged carbon steel connections shall be of the following types:

a. Integral forged flange.

b. Seamless pipe or seamless transition welded to a forged welding neck flange.

c. Seamless pipe or seamless transition welded to a forged slip-on flange.

d. Cast flanges or transitions shall not be used.

6.1.9.10 (Substitute): Slip-on flanges may be used when the design conditions do not exceed ASME B16.5,
Class 150 nozzle rating in non-cyclic, non-hydrogen services and with design temperatures less than 650°F
(343°C).

6.1.9.13 thru 6.1.9.14 (Delete): Thermowell and pressure gauge connections shall not be provided.

6.1.9.23 (New): Flange bolt holes shall straddle the natural centerlines.

6.2 AIR-SIDE DESIGN

6.2.3 Fans and Fan Hubs

6.2.3.1 (Add): Two speed motors shall be provided for single fan units.

6.2.3.11.b (Substitute): The pneumatic actuator shall be equipped with either a positioner or a bias relay.

6.2.3.11.e (Substitute): Auto-variable fans shall stay in last position with loss of control air pressure.

6.2.3.17 (New): Fan hubs shall be designed so that the individual blades can be replaced. The base of the fan
blade shall have a shoulder. Hubs shall interlock the shoulder of the blade to prevent the loss of a blade due to
centrifugal force.

6.2.3.18 (New): The minimum excess capacity of fans shall be the equivalent of two degrees additional pitch or
a total pressure of 0.1 inch (2.5 mm) water above the design operating point before reaching a stall position.

6.2.3.19 (New): All fans shall be capable of reversing air flow to the extent necessary to overcome natural
convection cooling. They shall have pitch stops to limit travel in both directions.

6.2.7 Drivers

6.2.7.1 General Requirements

6.2.7.1.3 (New): Drivers shall be rated to operate at the minimum air temperature with the blade angle set for
operation at the design air temperature. An exception may be allowed for Auto-variable pitch fans, but approval
shall be obtained from the Purchaser.

6.2.7.2 Electric Motor Drivers

6.2.7.2.6 (Substitute): All motors shall be mounted in the shaft down position. A rain shield shall be provided.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 13

6.2.8 COUPLINGS AND POWER TRANSMISSIONS

6.2.8.2 Belt Drives

6.2.8.2.8 (Substitute): V-belts shall have a minimum service factor of 2 based on driver rated brake horsepower.

6.2.9 Vibration Cutoff Switches

6.2.9.1 (Substitute): A double-throw, two-contact, vibration cut-out switch shall be provided for each fan drive
unit. This switch shall be readily accessible from walkways or platforms.

6.2.10 Louvers

6.2.10.19 (Substitute): Louvers shall stay in last position with loss of control air pressure.

6.2.10.25 (New): Automatic louvers shall have a manual mechanical override.

6.2.10.27 (New): If automatic louvers are used, they shall be opposed action blade type.

6.2.10.28 (New): For automatic louvers, one louver operator per bay shall be furnished. On fully winterized
units, the single operator shall be adequate for control of both top exhaust louvers and recirculating louvers.

6.3 STRUCTURAL DESIGN

6.3.1 General Requirements

6.3.1.5 (Revise): Delete the phrase "if specified by the purchaser".

6.3.1.6 (New): The exchanger vendor will not supply the pipe rack runner beam that supports the exchangers.

All cross beams and other support beams above the pipe rack runner beam shall be designed and furnished by
the exchanger vendor as shown in Figure 11.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 13

6.3.3 Structural Design Loads and Forces

6.3.3.1.b.2 (Revise): Change "50 pounds per square foot (245 kilograms per square meter)" to 75 pounds per
square foot (370 kilograms per square meter)".

6.3.3.1.b.4 (Substitute): Ladders shall be capable of supporting a moving vertical concentrated load of 20 lb/ft
2
(30 kb/m) but not less than 200 pounds (90 kg) total. Stairs shall be capable of supporting a load of 75 lb/ft
2
(365 kg/m ) or a moving concentrated load of 1000 pounds (455 kg), whichever is greater.

6.3.3.1.f (Substitute): Wind load design shall be in accordance with KBR Specification 9-4D.

6.3.3.1.g (Substitute): Earthquake design shall be in accordance with KBR Specification 9-5D.

6.3.6 Lifting Devices

6.3.6.7 (New): Lifting lugs shall be provided for lifting the entire air cooler assembly. All units shall be designed
to maintain structural integrity when lifted by lugs during transportation, field erection and maintenance.

7. MATERIALS

7.1 GENERAL

7.1.7 (Substitute): All structural steel, ladders, platforms, handrails, plenums, etc. shall be hot dip galvanized.
The only parts that are not galvanized are the tubes, header boxes, fan and driver assembly.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 8 OF 13

8. FABRICATION

8.1 WELDING

8.1.1 General

8.1.1.1 (Add): Welding and selection of electrodes, except structural welding, shall be in accordance with KBR
Specification 4-7TS.

8.1.1.5 (New): Permanent backing strips shall not be used.

8.1.1.6 (New): Weld metal shall not be used to build up the edges of plates that are too short or those that
contain cavities.

8.1.1.7 (New): Fabrication involving welding shall not be sublet to others without prior acceptance.

8.1.1.8 (New): All temporary attachment welds and arc strikes on pressure retaining parts shall be removed.
The surfaces shall be properly conditioned to eliminate stress risers. Such surfaces shall be MT or PT
examined. Any defects found shall be repaired and re-examined.

8.1.1.9 (New): All P-3 and P-4 materials shall be preheated to 300°F (149°C) minimum. All P-5 materials shall
be preheated to 400°F (204°C) minimum.

8.1.1.10 (New): Corner welds between the top plate, the bottom plate and the end plates of the header box to
the tubesheet and the plug sheet shall be in accordance with the ASME Section VIII, Division 1, Figure UW-13.2
(b) or (c).

8.2 POSTWELD HEAT TREATMENT

8.2.3 (New): Local postweld heat treatment shall not be performed without prior acceptance.

8.2.4 (New): P-3 materials shall be postweld heat treated at a temperature of 1150°F (621°C) minimum. P-4
materials shall be postweld heat treated at a temperature of 1250°F (677°C) minimum.

8.3 TUBE-TO-TUBESHEET JOINTS

8.3.1 Tube Hole Diameters and Tolerances

8.3.1.2 (Substitute): The special close-fit tolerances for tube holes as listed in Table 2 shall be mandatory for:

a. Austenitic tubes with expanded and grooved tube-to-tubesheet joints.

b. Tubes with seal welded or strength welded tube-to-tubesheet joints.

8.3.4 Welded Tube-to-Tube-Sheet Joints

8.3.4.4 (New): Strength welds shall be in accordance with ASME Section VIII, Division 1, UW-20.

8.3.4.5 (New): Welded tube-to-tubesheet joints shall be preheated to 200°F (93°C) minimum when the
tubesheet is P-1 material greater than 1 1/4 inches (32 mm) thick.

8.3.4.6 (New): Final tube expanding operation shall be performed after welding.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 9 OF 13

9. INSPECTION, EXAMINATION, AND TESTING

9.1 GENERAL

9.1.6 (New): Stamping on austenitic steel and impact tested steel shall be with "low-stress" steel stamps having
round or "U" shaped cross sections or with "interrupted-dot" die stamps. Marking paint or water insoluble ink for
use on austenitic and high nickel alloy parts shall contain no substance (e.g. metallic pigments, sulfur, or
chlorides) which would be harmful to these materials at operating temperature.

9.1.7 (New): Brinell hardness testing to verify compliance with Paragraph 9.2.14.d shall be performed using
portable macro hardness testing equipment. The location and frequency of testing shall be as specified in API
661 except that testing is required on each header.
:
a. Testing shall be done on all accessible inside surfaces that are not clad or overlayed.

b. Testing shall be done on the outside surfaces when the inside surfaces are clad or overlayed.

c. Testing shall be done after postweld heat treatment when postweld heat treatment is required.

9.2 QUALITY CONTROL

9.2.14.d (Substitute): Brinell Hardness of the weld metal and heat affected zone (HAZ) shall not exceed the
limits set in Table 3. Frequency and location of tests is defined in Article 9.1.8.

TABLE 3
BRINELL HARDNESS
MATERIAL P NUMBER MAXIMUM BRINELL HARDNESS
P1 Groups 1, 2, 3 200 (Note 1)
P1 Groups 1, 2, 3 225
P1 Group 4 250
P3, P4 225
P5 235
P6, P7 240

NOTES TO TABLE 3:

1. Equipment in wet H2S, AMINE, or CAUSTIC service (all welds). Hardness is to be taken after PWHT, if
PWHT is specified on the Purchasers specification sheet.

9.2.20 (New): All tube-t o-tubesheet strength welds shall be PT examined on the finished surface before and
after tube expansion. All tube-to-tubesheet seal welds shall be PT examined on the finished surface after
expanding.

9.2.21 (New): Welds with defective areas shall have:

a. the defect removed

b. confirmation of defect removal by MT or PT examination

c. repair welding using qualified welding procedures

d. re-postweld heat treatment if originally required.

e. The finished weld-repair shall be radiographed if originally required and the surface shall be re-examined by
MT or PT examination.
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 10 OF 13

9.3 Pressure Test

9.3.4 (Substitute): Exchangers shall be hydrostatically tested with potable water only; salt, brackish, or raw river
water shall not be used. Testing of exchangers or components made with austenitic stainless steel materials
shall be conducted with water containing no more than 50 ppm chloride and the pH controlled between 6 and 9.
Water containing more than 50 ppm chloride but no more than 250 ppm may be used if the duration of the test
is 72 hours or less and includes rinsing with water containing less than 50 ppm chloride.

9.4 SHOP RUN-IN

9.4.1 (Substitute): Pre-assembly and shop run-in tests shall consist of:

a. Complete assembly of one unit with the necessary substructure for shipping. Assembly shall include
installation of motors, bearings, shafts, sheaves, belts, machinery mount, fans with hub seals, and grease
lines. Fan blade pitches shall be set.

b. After assembly, the motors shall be wired and fans run for at least 30 minutes. During this time, the unit
shall be checked for excess vibration, loose bolts and fan balance. Fan blade pitch angles shall be
checked after run-in if necessary.

c. The vendor in the presence of the Purchaser's inspector shall perform noise testing in accordance with
Appendix F, when specified.

9.5 NAMEPLATES

9.5.3 (Add): In addition to the required ASME code and API information, the nameplate shall include:

a. The exchanger service.

b. The purchase order number.

c. Any test or operating limitations.

9.5.5 (New): All information on the nameplate shall be in the English language and the units used shall be those
on the Exchanger Specification Sheet.

10. PREPARATION FOR SHIPMENT

10.1 GENERAL

10.1.1 (Substitute): After hydrostatic testing, the exchanger shall be drained and dried. Any remaining water in
austenitic stainless steel or austenitic stainless clad exchangers shall be dried by blowing with air. Heat or hot
air shall not be used to dry exchangers containing austenitic stainless steel. The service gaskets provided by
the vendor shall be used for the hydrotest and remain installed for shipment.

10.1.4 (New): The following spare parts shall be provided:

a. 2 sets of gaskets

b. 10% of structural bolts, nuts, washers that are required for field assembly

10.2 SURFACES AND FINISHES

10.2.2 (Delete)
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 11 OF 13

10.2.2.1 (Add): All machined and threaded surfaces of carbon steel and ferritic alloy steel materials, except
weld bevels, shall be coated with one of the following rust preventives:

a. E. F. Houghton Co. Rust-Veto No. 342

b. Exxon Chemical Co. Rust Ban No. 326

10.2.2.2 (Add): Weld bevels shall be coated on the inside and outside for a distance of approximately 3 inches
(75 mm) from the end of the weld bevel with one of the following weldable rust preventives or an equal approved
by the Purchaser.

a. "Deoxaluminite" manufactured by: AACCO, Phone: (414) 781-7160, FAX: (414) 781-3558

b. "Aluminized Bloxide" manufactured by: Tempil Div. of Big 3 Industries Inc., Phone: (201) 757-8300

10.2.3 (Add): Outside surfaces of tubesheets shall be painted before the installation of tubes. Precaution shall
be taken to avoid getting paint in the tube holes.

10.2.4 (Substitute): Exchangers shall be shop painted in accordance with the Purchaser's painting specification.

10.2.5 (New): Austenitic stainless steel and nickel-iron-chromium alloy material parts shall be kept free of paints
containing zinc to avoid the possibility of embrittlement at elevated operating temperatures. All traces of zinc
containing paints, which spatter on such parts, shall be promptly removed.

10.3 IDENTIFICATION, CONDITIONING, AND NOTIFICATION

10.3.1 (Add): Attachments that are removable and are to be assembled by others shall be piece marked and
match-marked for assembly.

10.3.3 (Add): Transit and erection clips or fasteners that require removal after erection shall be painted bright
yellow.

10.3.4 (Substitute): Refer to KBR Specification MC1-4TS for shipping requirements.

10.3.5 (New): Nozzles and connections shall be protected as follows:

a. Stub end nozzles shall be closed with carbon steel weld caps. The weld caps shall be welded to a 3/8 inch
(10 mm) minimum thickness carbon steel ring welded to the outside of the nozzle neck so that the cap can
be removed at the job site without damage to the nozzle neck. The weld attaching the cap to the nozzle
shall be 1/4 inch (6 mm) continuous fillet weld.

b. Vent holes in carbon and low alloy steel nozzle reinforcing pads shall be filled with heavy grease.

c. All socket-weld ends shall be closed with metal protectors that fit either inside or outside to prevent damage
and entrance of foreign materials.

e. Threaded openings shall be plugged with threaded plugs of the same material P-number as the opening
and sealed with tetrafluoroethylene or graphite tape thread sealant.

10.3.6 (New): Exchangers that have been postweld heat treated shall have the following notation painted on the
exchanger prior to shipment:

"NO WELDING OR BURNING PERMITTED ON THIS EXCHANGER"


TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 12 OF 13

11. SUPPLEMENTAL REQUIREMENTS

11.1 GENERAL

11.1.1 (Substitute): This section includes additional design, fabrication, and examination requirements that shall
apply when the design pressure exceeds 2000 pounds per square inch gauge (13,800 kilopascals), when the
plate thickness of a box-type header of an air-cooled heat exchanger exceeds 2 inches (50 millimeters), and
when an exchanger is to be placed in a critical service.

11.3 EXAMINATION

11.3.1 (Revise): Ultrasonic examination shall be performed for plate material thicker than 4 inches (101 mm)
shall be ultrasonically examined in accordance with SA-435, supplement S1.

11.3.13 (New): All tubes shall be hydrostatically tested at the mill to a pressure at least equal to the exchanger
test pressure. Vendor is to specify the minimum test pressure when ordering the tubes.

11.3.14 (New): Weld surface examination shall be conducted in accordance with Table 4 on all accessible
surfaces after any required postweld heat treatment or after pressure testing when the wall thickness is greater
than 2 inches (50 mm), using the following methods:

a. by either the MT or the PT method for ferritic materials

b. by the PT method for austenitic materials

TABLE 4 - EXAMINATION OF WELD SURFACES

REQUIRED SURFACE EXAMINATIONS (MT OR PT)


TYPE OF LONGITUDINAL NOZZLE
EXCHANGER MATERIAL LEVEL OF ATTACHMENT
AND GIRTH WELDS
RADIOGRAPHY WELDS
WELDS (Note 2)
(Note 1) (Note 3)
Carbon & low alloy Not postweld Spot No No No
steels with 1/2% heat treated Full No Yes No
(max.) nominal Postweld Spot No No No
chromium content heat treated Full No Yes Yes
Low alloy steels over 1/2% nominal Spot or
Yes Yes Yes
chromium content Full

Austenitic steels with design metal Spot No No No


temp. up to 750°F (399°C) Full No Yes No
Austenitic steels with design metal
Spot or
temperature warmer than 750°F Yes Yes Yes
Full
(399°C)
TECHNICAL SPECIFICATION

AIR COOLED HEAT EXCHANGERS


MC45-1E

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 13 OF 13

NOTES TO TABLE 4:

1. The level of radiography which is specified for longitudinal and circumferential butt welds

2. Nozzle welds include the welds between nozzle and the reinforcing pad, exchanger and the reinforcing pad,
and the nozzle and exchanger under the reinforcing pad. Welds under the reinforcing pad shall be
examined before the pad is attached.

3. Attachment welds include structural support, external clips, and saddle attachment welds.

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