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ES No.

ENGINEERING SPECIFICATION E-101


Revision
4
HEAT EXCHANGERS
Project ; SEP PAGE 1 OF 32

* REVISION HISTORY SHEET *

REV. NO. DATE DESCRIPTION

0 May. 21, 2008 Newly Issued For S-OIL’s Approval

1 Aug. 28, 2008 Reissued for S-Oil’s Approval

2 Sep. 17, 2008 Reissued for S-Oil’s Approval

3 Sep. 25, 2008 Reissued for S-Oil’s Approval

4 Nov. 5, 2008 Reissued for S-Oil’s Approval

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ES No.
ENGINEERING SPECIFICATION E-101
Revision
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HEAT EXCHANGERS
Project ; SEP PAGE 2 OF 32

CONTENTS
PAGE
1. GENERAL
1.1 Scope 3
1.2 Codes, Standards and Regulations 3
1.3 Units 3
1.4 Purchaser’s Drawings and Documents 3
1.5 Vendor’s Drawings and Documents 4

2. DESIGN
2.1 Design Pressure 6
2.2 Design Temperature 6
2.3 Corrosion Allowances 7
2.4 Materials 7
2.5 Loading Conditions and Strength Calculation 7
2.6 Tolerances 8

3. DETAILED DESIGN
3.1 Shells and Channels 8
3.2 Tubes and Tube Bundles 9
3.3 Nozzles 9
3.4 Opening 10
3.5 Alloy Lining 10
3.6 Bolts, Nuts and Gaskets 11
3.7 Supports 11
3.8 Miscellaneous 11

4. FABRICATION
4.1 Plate Layout 12
4.2 Forming 12
4.3 Welding 13
4.4 Heat Treatment 13
4.5 Hardness 14
4.6 Miscellaneous 14

5. INSPECTION AND TESTS 14

6. NAMEPLATE, PAINTING AND MARKING


6.1 Nameplate 14
6.2 Painting 14
6.3 Marking 15

7. PACKING AND SHIPPING


7.1 General 15
7.2 Packing and Preparation for Shipping 15
7.3 Shipping 15

Appendix A Basic Design Requirements 17


Appendix B Inspection Requirements 21
Appendix C Painting Requirements 27
Appendix D Special Design Code Requirements 28
Appendix E Requirements for specific corrosion environment 29

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
Revision
4
HEAT EXCHANGERS
Project ; SEP PAGE 3 OF 32

1. GENERAL

1.1 Scope

1.1.1 This specification together with the drawings or data sheets covers the requirements for the
materials, design, fabrication, inspection, testing and supply of shell and tube heat exchangers.

1.1.2 This specification shall also apply to suction tank heaters or auxiliary heat exchangers for turbines,
engines, pumps, compressors and other mechanical equipment wherever applicable.
For such auxiliary heat exchangers, the heat exchangers shall be designed in accordance with the
basic design requirements in Appendix A.

1.2 Codes, Standards and Regulations

1.2.1 Heat exchangers shall be designed, fabricated, inspected and tested in accordance with the
requirements of the following codes, standards and regulations of latest edition.

(1) Applicable regulations in Republic of Korea


(2) ASME Boiler and Pressure Vessel Code Sec. VIII Div. 1 or Div.2
2007 Edition without Addenda
(3) TEMA Standard Ninth edition without Errata

1.2.2 Unless otherwise specified, TEMA Standard Class R shall be applied.

1.2.3 Vendor shall be responsible for making all aspects of materials, design, fabrication, inspection and
testing conform to the requirements of the specified codes, standards and local regulations.

1.2.4 Where there are conflicts between the requirements in Purchaser’s drawings/specifications and the
specified codes/standards or local regulations, the order of precedence shall be as follows:

(1) Local regulation


(2) Requisitions and Minutes of Meeting
(3) Engineering drawings or data sheets
(4) Engineering specifications
(5) Codes and standards

In such a case, Vendor shall promptly refer the conflicts to Purchaser in writing to obtaining
Purchaser’s instruction.

1.3 Units

Unless otherwise specified, SI units shall be applied as the measurement system for the drawings and
documents to be submitted. However, nominal sizes of piping components shall be in accordance
with inch system.

1.4 Purchaser’s Drawings and Documents

1.4.1 Purchaser will provide the Engineering Drawing for each heat exchanger which contains such
information as the shape, basic dimensions, estimated thickness and weight, design conditions,
materials for primary parts, nozzle specifications, tube arrangement as required by Vendor to
accomplish his mechanical design of the heat exchanger.

When sketches or data sheets are provided, Vendor shall prepare Engineering Drawings covering
the same contents as specified above. Such drawing may be used as Vendor’s assembly drawings
with necessary information that may be added.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
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1.4.2 Engineering Drawings will be issued in the following steps, and at each step additional information
and/or revisions will be incorporated. Vendor shall proceed with his work in accordance with
purpose of each issue.

(1) Preliminary or For Approval : Preliminary information of design conditions, basic


dimensions,
thickness for major parts and weight estimation are
indicated.

(2) Approved for Design (AFD) : Almost all design information are settled and confirmed
except
nozzle locations. No further major revisions are expected.

(3) Approved for Construction (AFC) : Nozzle location is fixed and Vendor can start the fabrication
based on this issue.

1.4.3 Purchaser will provide R-505 “Vessel Standard” which supplements the above drawing and
determines the detail construction of heat exchangers. Applicable drawing numbers in Vessel
Standard will be shown in each Engineering Drawing.
When data sheets are provided, Vendor shall confirm Purchaser the application of each drawing in
Vessel Standard.

1.4.4 The related Engineering Specifications to supplement this specification are as follows. These
specifications, when indicated on Purchaser’s requisition sheets or Engineering Drawings, shall form
an integral part of the requirements.
D-112 “Marking for Vessels & Heat Exchanger”
D-115 “Platform & Ladder”
D-121 “Pressure Vessels of Low Alloy Steel”
D-202 “Inspection and Tests of Vessel and Heat Exchanger”
H-103 “Piping Materials”
L-101 “Thermal Insulation Design”
O-301 “Painting”
O-304 “Inspection of Painting”
R-201 “General Inspection Requirements”
R-453 “Shipping and Packing Instruction”
R-503 “Rust Preventive Instruction”
R-505 “Vessel Standard”

1.5 Vendor’s Drawings and Documents

1.5.1 Vendor shall submit to Purchaser drawings and documents as called for in Purchaser’s requisition
sheets.

1.5.2 All drawings and documents shall give the name of Client (end user), Purchaser’s Work No., Item
No. and service of the commodity.

1.5.3 Drawings shall be prepared to scale and in third angle projection.

1.5.4 Drawings shall contain:

(1) Title block (Purchaser’s Work No., Requisition No., Item No. and service of the commodity)
(2) Design Data (conforming to Purchaser’s drawings or data sheets)
(3) Material list (material specifications and quantities for all parts including spare parts)
(4) Nozzle list (conforming to Purchaser’s drawings or data sheets)
(5) All weld seams, and weld and surface finish symbols
(6) Detailed dimensions and thickness

1.5.5 Strength calculations shall cover:

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
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(1) Code calculations for all pressure retaining parts including reinforcements for nozzle openings
(2) Structural calculations for internals, lifting lugs and transportation fittings
(3) Stability check of heat exchanger and support for wind/seismic load
(4) Stability check of heat exchanger and support at transportation, loading & unloading and
erection
(5) Flow induced vibration of bundle when specified
(6) Local stress analysis against external loading on nozzles

1.5.6 For heat exchangers fabricated and/or assembled at job site, Vendor shall submit the instruction for
the work.

1.5.7 Purchaser’s “Approved” on Vendor’s document means that Vendor may proceed his work without re-
submitting the documents unless further revisions are made. “Approved as noted” on Vendor’s
document means that Vendor may proceed his work provided the notes are concurred by Vendor.
Re-submission of the revised documents are required for confirmation. “Not approved” on the
document means that Vendor may not proceed the work without re-submission of the corrected
document for approval. Purchaser’s approval for Vendor’s drawings and documents shall not relieve
Vendor of his responsibility to meet all requirements of the purchase order.

2. DESIGN

2.1 Design Pressure

2.1.1 Design pressure shall be as specified on Purchaser’s drawing or data sheet.

2.1.2 When design pressure of “F.V. (Full Vacuum)” is specified, exchangers shall be designed to
withstand for external pressure of 101.3 kPa.

2.1.3 Unless otherwise specified, exchangers normally subject to internal pressure shall be designed to
withstand for external pressure of 50.7 kPa at 150 ºC.

2.1.4 Unless otherwise specified, parts in contact with both shell and tube side fluids such as tubes,
tubesheets and floating heads shall be designed for the pressure on one side only or the
combination of the pressure, whichever that requires the maximum material thickness for the part.

2.1.5 Maximum Allowable Working Pressure (MAWP) is the maximum gauge pressure at each side of a
completed exchanger, which is obtained from the calculation for every element of the exchanger
based on the used thickness under corroded condition. Vendor shall calculate the MAWP of each
exchanger.

2.2 Design Temperature

2.2.1 Design temperature shall be as specified on Purchaser’s drawing or data sheet. Two kinds of
design temperature, one for maximum design temperature (called as “Design Temperature”) and the
other for minimum design temperature (called as “Minimum Design Metal temperature” = MDMT) are
specified.

2.2.2 When operating temperature is 15 °C and below, the design temperature shall be the minimum
anticipated operating temperature.

2.2.3 When design temperature or MDMT cannot coincide with the maximum pressure, the corresponding
design pressure shall be designated together with the temperature.

2.2.4 Exchanger parts in contact with two fluids having different temperatures shall be designed for both
higher and lower design temperatures.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
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Project ; SEP PAGE 6 OF 32

2.2.5 When the exchanger inside is insulated from high temperature fluid, the design temperature may be
determined by heat transfer calculation.

2.3 Corrosion Allowances

2.3.1 The corrosion allowance for the shell and channel sides shall be as specified on Purchaser’s
drawing or data sheet.

2.3.2 The necessity of corrosion allowances for various heat exchanger parts shall be in accordance with
applicable codes and standards.

2.3.3 No corrosion allowance is required for such parts not in contact with the inside fluid as outside
surface of exchanger, support, anchor bolt and so on.

2.3.4 Unless otherwise required by the governmental regulations, no corrosion allowance is added to
tubes.

2.3.5 Corrosion allowance is not usually required for non-pressure parts such as tie-rods, spacers, baffles,
support plates and pass partition plates. (See also paragraph 3.2.6)

2.3.6 When it is not practicable to provide corrosion allowance by increasing the thickness of base metal,
a corrosion resistant material shall be used in solid, lining, cladding or weld overlay construction.
Any change of these construction materials shall be referred to Purchaser for approval.

2.4 Materials

2.4.1 The materials for primary parts shall be as specified on Purchaser’s drawing or data sheet.

2.4.2 Materials of the parts not specified on Purchaser’s drawings, data sheet or Vessel Standard shall be
decided by Vendor and shall be submitted by showing them on the Vendor’s drawings for
Purchaser’s approval.

2.4.3 Vendor may propose the use of alternative materials. Such alternatives shall be clearly indicated on
his proposal giving official material designation or the chemical composition and physical properties
for such materials having only a trade or supplier designation, and shall be submitted for Purchaser’s
approval.

2.4.4 Gaskets, bolts and nuts for blind nozzles and manholes shall be as specified in Purchaser’s drawing
or data sheet.

2.4.5 Carbon steel materials for the service with design temperature over 350 ℃ shall be coarse grain
killed steel.

2.4.6 External bolting material for design temperature not less than -10 ℃ shall generally be A193GrB7 for
bolts, and A194Gr2H for nuts. For design temperature over 425 ℃, the material shall be A193GrB16
for bolts and A194Gr4 for nuts.

2.5 Loading Conditions and Strength Calculation

2.5.1 The thickness indicated on Purchaser’s drawings are those proposed by Purchaser. Vendor shall
check and confirm under his guarantee that such thickness provide the proper strength under the
specified conditions. Any lesser thickness considered by Vendor shall immediately be referred to
Purchaser, but in no case, any proposed thickness will be decreased without Purchaser’s prior
approval, even if it has an extra margin beyond the required thickness.

2.5.2 Lining, cladding and weld overlay thickness shall not be considered to contribute to the strength of
pressure parts.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
Revision
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HEAT EXCHANGERS
Project ; SEP PAGE 7 OF 32

2.5.3 The following loading conditions shall be considered in designing heat exchangers including its
support and anchor/setting bolts.

(1) Operating condition

The loadings shall include those from:

(a) internal or external design pressure


(b) weight of exchangers and contents at operating condition (including static head of liquids)
(c) weight of insulation and fire proofing
(d) weight of combined equipment, if specified
(e) reactions from piping systems, if specified
(f) cyclic or dynamic reactions from combined equipment, if specified
(g) wind or seismic load whichever is greater

(2) Erection condition

The loading shall include those from:

(a) weight of exchangers and contents at erection


(b) weight of other attachments, if any
(c) weight of combined equipment, if specified
(d) wind or seismic load whichever is greater

(3) Testing condition (in the installed position and corroded condition)

The loadings shall include those from:

(a) test pressure


(b) weight of exchangers and contents at testing condition (including static head of liquids)
(c) weight of piping and other attachments
(d) weight of combined equipment, if specified

2.5.4 Wind load shall be determined in accordance with the requirements of ASCE 7-05 with the following
conditions.

Basic Wind Speed : 60 m/sec (three second guest speed in ASCE 7-05)
Exposure Category :C
Equipment Category : II (Normal Buildings) as per ASCE 7-05 Table 1-1
3 Importance Factor : 1.10 as per ASCE 7-05 Table 6-1

2.5.5 Seismic load shall be determined in accordance with the requirements of UBC 97 with the following
conditions.

Seismic Zone : 2A
Exposure Type : No exposure type required in UBC 97
Importance Factor : 1.0 (Category / Standard Occupancy)
Soil Profile Type : SE (Soft Soil)

2.5.6 Classification and evaluation of stresses at various loading conditions shall be done in accordance
with the applicable codes and standards. Higher allowable stresses may be used according to the
category of the stresses for short time and local loads.

2.5.7 Allowable tensile stress of foundation bolts of A307 Gr.B shall be 100 N/mm2 for long-term and 120
N/mm2 for short-term loading conditions.

2.5.8 Local stresses at shell around attachments such as nozzle, exchanger support and lifting lug and so
on, shall be calculated and evaluated when requested by Purchaser.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
Revision
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Project ; SEP PAGE 8 OF 32

The following generally accepted calculation procedure, or the equivalent, may be applied.

(a) Bulletin of Welding Research Council No.107 or 297


(b) BS 5500 Appendix G
(c) Pressure Vessel Handbook (By E.F. Megyesy)
(d) Process Equipment Design (By L.E. Brownell & E.H. Young)

2.6 Tolerances

2.6.1 Tolerances shall be in accordance with Appendix B “Inspection Requirement” unless otherwise
specified on Purchaser’s drawings.

2.6.2 The thickness after forming of any pressure holding parts shall not be less than the calculated
thickness. Plates with an under tolerance of not more than the smaller value of 0.25 mm shall be
used, unless requested otherwise by the applicable code.

3. DETAILED DESIGN

3.1 Shells and Channels

3.1.1 When shell diameter is 600 mm and under, pipes may be used.

3.1.2 The minimum nominal shell thickness including corrosion allowance shall be in accordance with
TEMA including RECOMMENDED GOOD PRACTICE.

3.1.3 The shape of the formed head shall be as specified on Purchaser’s drawing or data sheet. 2:1
ellipsoidal or hemispherical head are used, in general.

3.1.4 The nominal thickness of 2:1 ellipsoidal or hemispherical head shall be selected to assure that the
minimum thickness after forming shall not be less than the minimum required thickness of head.
Also, the nominal thickness shall not be less than the minimum required thickness of connecting
2 cylindrical shell for 2:1 ellipsoidal head.

3.1.5 Except for kettle and U-tube types, exchangers with removable tube bundles shall be provided with
bolted shell covers.

3.1.6 The angle of a conical section of kettle type exchangers shall generally be 30°

3.1.7 For fixed tube sheet construction, Vendor shall determine the necessity of expansion bellows
according to ASME and TEMA standard. The metal temperatures of shell and tubes will be specified
on Purchaser’s drawings or data sheets. Subtract 20 °C from those temperatures in calculation in
general. Unless otherwise specified, the necessity of expansion bellows shall be evaluated for the
normal operating condition.

3.1.8 Girth flanges shall have a confined gasket joint to hold the gasket in place during assembling.

3.1.9 Gasket contact surface of girth flange shall have a finish equivalent to the following in μm:

(1) For non asbestos sheet gasket : Ra 3.2


(2) For spiral wound gasket : from Ra 1.6 to Ra 3.2
(3) For metal jacket, solid metal gasket : Ra 1.6 and finer

3.1.10 All girth flanges shall be of welding neck construction.

3.1.11 Vent and drain holes of approx. 6 mm in diameter shall be provided at the highest and lowest points
of each pass partition plate.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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3.1.12 Thickness of floating head backing device shall be determined from formula based on bending
calculation.

3.2 Tubes and Tube Bundles

3.2.1 Each U-tube shall be formed from a single length, and mean radius of U-tube bend shall not be less
than 1.5 times the tube outside diameter.

3.2.2 Tube- to- tubesheet Joints shall be strength welded followed by heavy expanding with two grooves,
except that heavy expanding with two grooves are applied when all of the following conditions apply.

(1) Design pressure does not exceed 5 000 kPa


(2) Design temperature, both maximum and minimum, are from -10 °C up to 350 °C
(3) Hydrogen partial pressure is 600 kPa and smaller

3.2.3 Vendor shall submit the welding procedure, welding methods and inspection methods of strength
welded tube-to-tubesheet joints for Purchaser’s approval. WPS and PQR for tube to tubesheet
welding shall be prepared separately from other fillet welding.

3.2.4 Tubesheets shall be designed in accordance with the TEMA Standard, provided that calculated
thickness meet the code requirement. Extended Tubesheet shall be applied to removal type tube
bundle.

3.2.5 Baffles and support plates shall be tied together with rods and spacers, and for horizontal
exchangers they shall be provided with notches at the lowest point to permit full drainage of the
shell.

3.2.6 When the specified shell-side corrosion allowance exceeds 3 mm, the minimum baffle and support
plate thickness specified in the TEMA standard shall be increased by the shell-side corrosion
allowance in excess of 3 mm.

3.2.7 For exchangers which do not require baffles, support plates of 45 % vertical cut shall generally be
provided. Support plates need not be cut for kettle type exchangers. These support plates shall be
so spaced that unsupported tube length does not exceed the value indicated in the TEMA Standard.

3.2.8 When longitudinal baffles are welded to the shell, the welding seams shall not be close to the
longitudinal welded seams of the shell.

3.2.9 Clamp bands shall be installed for kettle type exchanger with the shell diameter of 400 mm and over,
and the tube length 1 500 mm and over.

3.2.10 Tubes shall be extended by 3 mm beyond the channel side surface of each tubesheet. For vertical
exchangers, minimum one tube per each tube block shall be flush with top tubesheet surface to
facilitate drainage.

3.2.11 For the heavy expanded joints, tubesheet holes shall be provided with square grooves conforming to
the TEMA standard.

3.3 Nozzles

3.3.1 Nozzle and manhole size shall not be changed by Vendor. However, if nozzles, reinforcement pads,
and main seams should interfere with each other, these dimensions may be changed upon
Purchaser’s approval.

3.3.2 The type, rating and facing of nozzle flanges shall conform to those specified in Purchaser’s drawing
or data sheet.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
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3.3.3 Each blind cover with mass over 200 N shall be supported by a davit or hinge as specified on
Purchaser’s drawing. The details of davit or hinge shall be in accordance with Vessel Standard.

3.3.4 Nozzle flange standard shall generally conform to Engineering Specification H-103. Nozzle flanges
24 inch and smaller shall be as per ASME B16.5. Nozzle flanges larger than 24 inch nominal shall
be as per ASME B16.47 Series B or designed per ASME Sec. VIII Div.1 when ASME B16.47 Series
B is not applicable. In case a non standard flange is designed by vendor, the companion flange with
bolt, nut and gasket shall be supplied with by vendor.

3.3.5 The nozzle neck thickness shall be selected in accordance with Vessel Standard as per materials,
nominal size, flange rating and corrosion allowance. The pipe material for nozzle neck shall be
seamless, unless otherwise approved by Purchaser.

3.3.6 - DELETED -

3.3.7 When male and female (M&F) or tongue and groove (T&G) type flanges are specified, the nozzle
flange facing of the exchanger shall be of female or groove type.

3.3.8 Drain, vent and draw off nozzles shall be trimmed flush with the inside surface of the exchanger.
Other nozzles may extend inward within the limits necessary for welding.

3.3.9 Nozzles to be welded directly to the connecting piping will be indicated on Purchaser’s drawings.
Caps for pressure testing shall be attached to the nozzles by welding. After the pressure testing the
caps shall be cut off, and the nozzles shall be machined to form the specified welding bevel.

3.3.10 The highest and lowest points on shell and tube sides, not otherwise vented or drained, shall be
provided with 3/4 inch nominal size drain and vent in the following manner.
(1) For general service : 3/4" 6000# coupling w/plug of 150mm length
(2) For hydrogen service (partial H2 P ≥ 7kgf/cm2 abs.)
- 600# & less : 1" flange, SW gasket w/blind flange
- 900# & less : 1" flange, RTJ gasket w/blind flange".

3.3.11 The nozzle facing of the intermediate nozzles between the units which are to be stacked shall be
raised face (RF) type unless ring type joint (RTJ) is specifically specified.

3.3.12 Level gauge nozzles of kettle type exchangers shall be supported from the shell.

3.3.13 Flanged nozzles larger than 2 inch nominal shall be provided with one instrument connection in the
following manner.
(1) For general service : 3/4" 6000# coupling w/plug of 150mm length
(2) For hydrogen service (partial H2 P ≥ 7kgf/cm2 abs.)
- 600# & less : 1" flange, SW gasket w/blind flange
- 900# & less : 1" flange, RTJ gasket w/blind flange"

3.4 Opening

3.4.1 The opening reinforcement shall be so designed as not to limit the maximum allowable working
pressure of the heat exchanger.

3.4.2 Nozzles made of pipe or plate and sized 2 inch nominal and larger shall generally be provided with
reinforcement plates. Each reinforcement plate shall be provided with at least one tell-tale hole of
NPT 1/8 inch. Long weld neck (LWN) type nozzle may be used without reinforcement pad up to 3
inch nominal.

3.4.3 The reinforcement for the nozzle opening shall be of integral type, when required by the applicable
codes/standards or where any of the following conditions are met:

(1) Design temperature exceeds 450 °C

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
Revision
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(2) Design pressure exceeds 10 000 kPa


(3) Design temperature exceeds 350 °C and design pressure exceeds 3 000 kPa
(4) Plate thickness exceeds 50 mm
(5) Size 1-1/2 inch and below

3.4.4 In general, nozzles are subject to external loads. Vendor shall check the strength of the nozzles and
shells against external loads based on Purchaser’s information and shall provide additional
reinforcements if required. See Par. 2.5.3 for calculation procedures.

3.5 Alloy Lining

3.5.1 Alloy lining shall be either integrally clad plate or overlay weld metal. The minimum thickness shall
be 2 mm for cladding and 3 mm for weld deposit after machining. The minimum clad thickness for
tubesheet shall be 8 mm. For clad tubesheet, one groove shall be in the cladding and cladding shall
extend 3 mm beyond the groove. If seal or strength weld is specified, all groove shall be in base
material.

3.5.2 Nozzles attached to alloy-lined shell shall be alloy-lined by integrally cladding or overlay welding with
exception in Par. 3.5.3 and Par. 3.5.4.

3.5.3 Solid austenitic stainless steel nozzles may be welded to ferritic shells in case of the following.
When postweld heat treatment is required, such nozzles shall be made of stabilized stainless steel
or low carbon grade and welded by Inconel filler metal.

(1) Nozzle size is 2 inch and smaller with design temperature 400 °C and lower
(2) Nozzle size is 4 inch and smaller with design temperature 250 °C and lower

3.5.4 Loose metal lining may be used for the nozzles of the following.

(1) Nozzle size is 6 inch and smaller with design temperature 400 °C and lower

Expansion ring shall be provided when the design temperature exceeds 250 °C. Each segment of
liner welds shall be provided with tell-tale holes with threaded end for plugging.

When postweld heat treatment is required, such sleeve liner shall be made of stabilized stainless
steel and welded by Inconel filler metal. One end of loose sleeve liner shall be welded after
postweld heat treatment.

3.6 Bolts, Nuts and Gaskets

3.6.1 Unless otherwise specified, all bolting threads to be used for heat exchangers shall be ANSI Unified
System. When bolt size are U1-1/8 and over, unified screw threads of 8 threads per inch shall be
used. When bolt size are U1 and less, unified coarse screw threads shall be used. Girth flange
boltings shall be of stud bolt type, threaded full length, and at least U 5/8 for flange of 600 mm and
smaller inside diameter and at least U7/8 for over 600 mm inside diameter flange.

3.6.2 The hardness of metal gaskets shall not exceed the values in the following table. Vendor shall
confirm these hardness are lower than those of gasket contact surface.

Gasket Materials Brinell Hardness


Soft iron, Low Carbon Steel and Nickel 120
5 % Cr - 1/2 % Mo Steel 130
Austenitic Stainless 160
410SS (13Cr) 170

Asbestos gasket is not permitted, Non-asbestos type gasket shall be used.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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3.6.3 Threads of bolts and nuts shall be coated before installation with anti-galling agent.

3.7 Supports

3.7.1 Saddles or lugs for exchangers shall be as per the tables in Vessel Standard. For exchangers which
meet all the conditions stipulated in the tables such as maximum weight or saddle height, strength
calculations may not be submitted to Purchaser.

3.7.2 Units which are to be stacked shall be provided with the required additional intermediate supports
and liners for elevation adjustment.

3.7.3 Supports for low temperature horizontal exchangers with the operating temperatures -20 °C or below
shall be provided with wooden pillows according to Vessel Standard.

3.7.4 Load at bundle extraction shall be considered in design of saddle and anchor bolts. Loading data at
bundle extraction shall also be submitted.

3.7.5 Units which are to be stacked shall be designed so as to withstand the load at stacked condition. For
nozzles connected each other and intermediate saddles, thermal expansion shall also be considered
in design

3.8 Miscellaneous

3.8.1 To facilitate breaking gasketted joint of main girth flanges, jack screws or at the periphery of the
male flange a cutback of 5 mm to a depth of approximately 30 mm and width of 30 mm shall be
provided.

3.8.2 Guide rails shall be provided for kettle type exchangers and the horizontal exchangers with the
removable bundle weighing 100 kN and over.

3.8.3 Each channel, channel cover and shell cover shall be provided with plate type welded-on lifting lug
with 25 mm diameter hole.

3.8.4 Tapped holes for insertion of eyebolts shall be provided on the outer face of tubesheets of
removable bundles and floating head cover flanges.

3.8.5 Alignment marks shall be provided to prevent mis-assembly of channel covers, channel flanges,
shell flanges, shell cover flanges and floating heads.

3.8.6 According to Purchaser’s information, Vendor shall check the strength of the heat exchangers during
transportation and field erection, and provide necessary reinforcements prior to shipment. The
shock factor of 1.25, as minimum, shall be considered in these design, Vendor shall submit such
strength calculation to Purchaser.

3.8.7 For vertical heat exchangers, plate type lifting lugs shall be provided in general. Trunnion type lifting
device needs Purchaser’s prior written approval. Lifting lugs shall be designed taking account of
heat exchanger weight and lifting method, etc. The shock factor of 1.25, as minimum, shall be
considered in the design of lugs and shell.

3.8.8 In general, exchangers shall be provided with two earth lugs.

3.8.9 For U-tube or floating head type with a bonnet channel, stationary tubesheet shall be of extended
construction. In this case, a test ring for the stationary tubesheet is not required

4. FABRICATION

4.1 Plate Layout

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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4.1.1 Shell plates shall be laid out so that there will be a minimum of welded seams.

4.1.2 Longitudinal and circumferential welded seams shall not interfere with nozzle openings,
reinforcement plates and saddle pads, as far as possible. If the seams is covered with
reinforcement plates or saddle pads under Purchaser’s approval, they shall be ground flush with
shell surface and radiographically examined in full length prior to welding of plates or pads.

4.1.3 Longitudinal welded seams on adjacent shell segments shall be separated by at least 4 times the
wall thickness of the thicker plate but not less than 100 mm.

4.1.4 Longitudinal and circumferential welded seams shall be kept out of the internal welds insofar as
practical, and shall be so located that they can be easily inspected with internals in place.

4.2. Forming

4.2.1 Selection of hot or cold forming of materials may be made by Vendor, but heat treatment after
forming shall conform to the requirements of applicable code.

4.2.2 Despite of Par. 4.2.1, low alloy steel of 50mm and over in thickness shall be subjected to hot
forming. Cold forming shall not be employed unless otherwise approved by Purchaser.

4.2.3 Despite of Par. 4.2.1, austenitic stainless steel including clad plate shall generally be subjected to
cold forming. Hot forming shall not be employed unless otherwise approved by Purchaser.

4.2.4 A formed head shall generally be made of single plate.

4.2.5 When temporary attachments are required during the forming work, they shall be welded to the shell
plate using the same welding procedures as for the main seams. After removing these attachments,
the surface shall be ground flush and examined by magnetic particle method. In case of high alloy
steel or non ferrous materials, liquid penetrant method can be substituted.

4.2.6 When forming of clad steel is required, Vendor shall submit prior to operation, the procedure for
Purchaser’s approval.

4.3 Welding

4.3.1 Vendor shall obtain Purchaser’s approval for start of welding.

4.3.2 As a rule, exchangers shall be welded by fusion arc process. Electroslag welding for overlay weld
may be applied with Purchaser’s prior approval.

4.3.3 Welding procedures and welders shall be qualified in accordance with the specified code or
standard.

4.3.4 Pressure holding seams shall normally be full-penetration double-welded butt joints. Single-welded
butt joints which ensure full-penetration may be used, where double-welded butt joints are
impractical.
Butt joint with backing strip needs to obtain Purchaser’s prior written approval.

4.3.5 Welding electrodes and wires shall have chemical compositions and mechanical properties equal to
or of higher grade than the base material.

4.3.6 Welding procedures shall be selected to minimize the residual stresses insofar as practical.

4.3.7 Preheating shall be carried out for carbon and low alloy steel welding where required. Preheating
temperature shall be kept uniform from the start to the end of welding.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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4.3.8 Welding procedure for any dissimilar metal welds of stainless steel to carbon steel or low alloy steel
shall be presented in full detail to Purchaser for approval.

4.3.9 Dissimilar metal welding of stainless steel to carbon steel or low alloy steel in pressure retaining butt
weld shall be carried out in the following manner.

(1) Filler metal of Inconel 182 : For joints where PWHT is required or design temperature over
350 ºC

(2) Filler metals of E309, E309L : For first layer of joints where no PWHT is required and design
309Mo, 309MoL temperature is less than 350 ºC

Note: The welding method and welding parameters of the dissimilar weld overlay shall be carefully
selected to control the dilution and micro-structure of weld deposit to avoid any cracks. 20
000 J/cm is allowable maximum heat input for the first layer of pressure retaining dissimilar
butt weld.

4.3.10 The minimum bead length for low alloy and high alloy steel shall be 80 mm.

4.3.11 When joining alloy-clad plate, the alloy layer shall be stripped for a minimum distance of 8 mm from
the bevel to assure the sound weld joint of base materials. If Vendor would propose other
procedure, the details of it to assure the sound weld joint of the base material shall be referred to
Purchaser for approval. The thinning of base metal due to this clad stripping is not necessary to
consider in the shell thickness calculation if the thinning is within the smaller of 1.0 mm or 10 % of
the base metal nominal thickness.

4.4 Heat Treatment

4.4.1 Heat treatment after bending of U-tubes shall be carried out prior to bundle assembling for the
following conditions:

4 (1) Carbon steel U-tubes in wet H2S service, HIC service, caustic service or amine service

(2) Austenitic stainless steel U-tubes when stress corrosion cracking may be expected

(3) Al-killed steel U-tubes of which mean bending radius is less than or equal to 5 times the tube
outside diameter in low temperature service

(4) Cr-Mo steel U-tubes in all services

4.4.2 Unless otherwise stated, postweld heat treatment shall be carried out in accordance with the
applicable codes or standards.

4.4.3 No welding shall be performed on heat exchangers after the final postweld heat treatment without
Purchaser’s approval.

4.4.4 When clad steel or dissimilar metal welded parts are heat treated, the heat treatment procedure shall
be submitted for Purchaser’s approval.

4.4.5 The gasket faces of shell and channel girth flanges shall be machined after final heat treatment.

4.4.6 When fixed tubesheet exchanger bundles are heat treated, the heat treatment procedure shall be
submitted for Purchaser’s approval.

4.4.7 When post weld heat treatment is specified on channel side, tube to tubesheet weld shall also be
heat-treated in case that tube and tubesheet are made of carbon steel or low alloy steel.

4.5 Hardness

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
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Hardness of base metal, weld metal and heat affected zone shall not exceed the limits given below.

Material (P-Number) Brinell Hardness


Carbon Steel (P-1) 225
Low Alloy Steel (P-3, 4) 225
Low Alloy Steel (P-5, 6, 7, 9) 235

4.6 Miscellaneous

Materials for heat exchangers shall be carefully stored at shop not to be heavily rusted or damaged.
Stainless steel shall be stored under roof and protected from the contamination of any harmful
substances such as chloride and zinc.

5. INSPECTION AND TESTS

5.1 All heat exchangers shall be inspected and tested in accordance with the applicable local regulations,
applied code, Appendix B “Inspection Requirements” and D-202 “Inspection & Tests of Vessels &
Heat exchangers”, unless otherwise specified on Purchaser’s drawings.

5.2 Vender shall submit a detailed procedure of inspection and test for Purchaser’s approval.

5.3 Purchaser and his designated representative shall have the right to witness inspection and test to be
performed by Vender.

5.4 Units which are to be stacked shall be examined by pneumatic test in the stacked condition to check
leakage from the connected nozzle flange

6. NAMEPLATE, PAINTING AND MARKING

6.1 Nameplate

A nameplate as shown in the Vessel Standard shall be mounted on each exchanger. Mounting on the
removable parts is prohibited.

6.2 Painting

6.2.1 As a rule, all external surface of vessels shall be painted in accordance with Painting Requirements
in Appendix C, except the following.

A. Surface of Stainless Steel and high alloy steels; Not painted.


B. Gasket sheet surface; See Par. 6.2.2

6.2.2 All flange faces and other machined surfaces shall be coated with a readily removable rust
preventive paint.

6.2.3 Weld bevels on the ends of carbon steel and low alloy steel nozzles which are to be welded at site
shall be coated on the inside and outside for a distance of 75 mm from the end of the nozzle with
Deoxyaluminite, Taseto Silver or equivalent.

6.2.4 Vendor shall submit a detailed procedure of applicable painting system (Painting Specification) for
Purchaser’s approval.

6.3 Marking

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ENGINEERING SPECIFICATION E-101
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Project ; SEP PAGE 16 OF 32

Each Heat Exchanger and its parts shall be marked in accordance with VS-55 of R-505 and D-112
“Marking for Vessels and Heat Exchangers”.

7. PACKING AND SHIPPING


7.1 General

Packing and shipping shall be in accordance with Engineering Specification R-453 “Shipping and
Packing Instruction” , R-503 “Rust Preventive Instruction” and the following additional requirements.
Packing specifications and sketches shall be submitted.

7.2 Packing and Preparation for Shipping

7.2.1 All exchangers shall be dried up by draining and air blowing, thoroughly cleaned inside and outside
and free of all dirt and loose foreign materials before shipping.

7.2.2 All flanged openings shall be provided with bolted steel cover of minimum 4.5 mm thickness with
gaskets. Number of bolting is one fourth of the service bolt but not less than 4 sets.

7.2.3 All beveled openings shall be covered or capped to protect the inside from rust and moisture. The
welded cover or cap shall be so designed to protect the weld bevel and to be removed easily at site.

7.2.4 Nitrogen filling or volatile corrosion inhibitor such as DICHAN* shall be applied for carbon or low
alloy steel heat exchangers.

* Dicyclohexylammonium nitrite

7.2.5 Spare parts shall be packed separately from the exchangers.

7.2.6 Tell-tale holes on the outside of exchangers shall be greased up. Plugging of holes is prohibited.

7.2.7 Demisters shall be free of wire pieces in so far as possible.

7.2.8 Unless otherwise specified on Purchaser’s document, girth flanges shall not be loosed after final
hydrostatic test and shipped as it is, provided service gasket is used for the hydrostatic test.

7.3 Shipping

7.3.1 Templates and foundation bolting shall be shipped separately from the exchangers according to
Purchaser’s instruction.

7.3.2 No exchangers shall be released for shipment from Vendor’s shop until it has been approved by
Purchaser’s inspector.

7.3.3 Units which are to be stacked may be shipped in the combined condition, if approved by purchaser.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 17 OF 32

Appendix A Basic Design Requirements

This appendix describes the basic requirements of the design of the shell and tube heat exchangers and are
reflected into Purchaser’s drawing or data sheet, in general. When Purchaser issues only the duty
specification and the basic design is executed by vendor, in such a case of heat exchanger in package units,
the requirements of this appendix shall be followed in addition to the body of this specification.

A.1 Type Selection


A.2 Basic Dimensions
A.3 Design Temperature (Minimum)
A.4 Corrosion Allowance
A.5 Material Selection
A.6 Gasket Selection
A.7 Minimum Shell Thickness
A.8 Pipe Shell
A.9 Minimum Nozzle Size
A.10 Nozzle Flange Design
A.11 Nozzle Protrusion
A.12 Girth Flange Design
A.13 Support Design of Vertical Heat Exchangers
A.14 Fire Proofing
A.15 Extent of Radiographic Examination

A.1 Type Selection

A.1.1 TEMA Standard type shell and tube heat exchangers shall be used except for high pressure &
temperature or other special services.

A.1.2 Normally, heat exchangers shall be designed with corrosive or fouling fluid in the tube side. Cooling
water shall be serviced in the tube side to prevent C.W corrosion. If cooling water should be serviced
in shell side, approval of purchaser is needed.

A.1.3 Fixed tubesheet exchangers shall be used for little-fouling service on the shell side, or when
chemical cleaning device is provided. Special considerations must be given to fixed tubesheet
exchangers that are in dry-out or steam-out conditions.

A.1.4 U-tube exchangers shall be used for little-fouling service (fouling factor is less than 0.00034
m2·°C/W) on the tube side, or when fixed tubesheet or floating head exchangers are not practicable.

A.1.5 In case of cooling water or fouling fluid(fouling factor is equal and larger than 0.00034 m2·°C/W) on
the tube side, removable flat covers (TEMA Type A) shall be provided on the channel.

A.2 Basic Dimensions

A.2.1 Nominal shell inside diameters shall be selected on every 50 mm, and limited, except for kettle type
exchangers, to the maximum of 1800 mm, as a rule.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
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ENGINEERING SPECIFICATION E-101
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A.2.2 Tube lengths will be selected from 3 000, 5 000 and 6 000 mm.

A.2.3 Standard tube outside diameters and tube pitches shall be as follows:

Unit: mm
Tube Outside Diameter Pitch
19.0 25.0
25.4 32.0

A.2.4 Standard tube patterns shall be of triangular and square. Square pattern shall be applied in case of
boiling service in shell side or fouling fluid(fouling factor is equal and larger than 0.00034 m2·°C/W)
on the shell side.

A.2.5 Standard tube thickness shall be as follows:

Unit: mm
Tube Thickness
Tube Outside C.S. & Low Copper &
High Alloys
Diameter Alloys Copper Alloys
(Minimum thickness) (Minimum thickness) (Minimum thickness)
19.0 2.11 1.65 1.65
25.4 2.77 2.11 2.11
Note:
a. 25.4 mm tube shall be applied when fouling factor on tube side is equal and larger than 0.00034
m2·°C/W)
b. For Al brass, Ti tubes, 19mm diameter with 1.65 average thickness may be used.

A.2.6 The effective heat transfer surface shall be defined as the outside surface of the tubes between the
inner faces of tubesheets. Bent portions may be considered as the heat transfer surfaces in U-
tube exchangers.

A.2.7 - DELETED -

A.2.8 Maximum un-supported length shall be 0.8 times of TEMA specified values.

A.3 Design Pressure and Temperature

A.3.1 Internal design pressure shall be whichever greater from the following.
Calculation formula In case
a) Pmax.op. + 0.15 MPa Pmax.op. < 1.500
b) Pmax.op. x 1.1 1.5 ≤ Pmax.op. ≤ 10.000
c) Pmax.op. + 1.0 MPa Pmax.op. > 10.000
d) 0.350 MPaG as minimum design pressure
Note: Pmax.op. (MPaG) is maximum pressure of normal operation

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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A.3.2 The design temperature (maximum) shall be Tmax.op. + 15 ℃, with minimum 80 ℃.


Note: Tmax.op. (℃) is maximum temperature of normal operation.

2 A.3.3 Design temperature minimum for operating temperatures below 0 ℃, shall be minimum operating
temperature minus 5 ℃ or minimum ambient temperature (-18 ℃), whichever is lower.

A.4 Corrosion Allowance

A.4.1 The necessity and the values of corrosion allowances shall be determined depending on the
material, inside fluid characteristics, operating conditions and applicable codes and standards.

A.4.2 Minimum corrosion allowances for pressure parts shall be as follows.


(1) Carbon steel : 3.0 mm
(2) Carbon steel under Wet H2S Service : 6.0 mm
(3) Low Alloyed Steel (up to 2.25% Cr included) : 3.0 mm
(4) Low Alloyed Steel (above 2.25% Cr and up to 9% Cr included) : 1.5 mm
(5) Stainless steel (11% Cr and above) and high alloy steel : 0.75 mm
(6) Non-ferrous metals : 0.0 mm

A.5 Material Selection

A.5.1 Materials shall be selected from those listed in ASTM/ASME Standards considering the inside fluid
characteristics, design conditions and applicable codes and standards. However, considering the
availability in the market, equivalent materials of country of origin may be selected with Purchaser’s
approval.

A.5.2 Unless otherwise specified girth flanges and flat covers shall be forged steel. Plate construction shall
be subject to Purchaser’s approval.

A.5.3 Materials for the low temperature service shall be selected considering the impact properties of the
material and MDMT specified for the heat exchanger. The requirements of the impact test shall be
as specified in UCS-66 of ASME Boiler and Pressure Vessel Code Section VIII, Div.1.

A.5.4 A283 Gr.C may be used for pressure retaining parts when all of the following conditions are met.

(1) Design pressure does not exceed 1 000 kPa


(2) Design temperature, both maximum and minimum, are from 10 °C up to 350 °C
(3) Utility service such as cooling water, steam, steam condensate, air, N2, etc.
(4) Shell plate nominal thickness is equal or less than 16 mm

A.5.5 Seamless tubes shall be used.

A.6 Gasket Selection

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ENGINEERING SPECIFICATION E-101
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A.6.1 Gaskets for girth flange shall be determined depending on the inside fluid characteristics, design
conditions and applicable codes and standards. As a rule, spiral wound with carbon steel inner ring
shall be selected except that non-asbestos sheet gasket may be used when all of the following
conditions apply.
(1) Flange inside diameter does not exceed 1 200 mm
(2) Design pressure does not exceed 1 000 kPa
(3) Design temperature, both maximum and minimum, is from 0 ºC up to 180 ºC
(4) Flange rating is 150# and below
(5) Utility service such as cooling water, steam, steam condensate, air, N2, etc.

A.6.2 When spiral wound gasket is used, spiral wound gasket with inner ring shall be used for confined
type flange, and spiral wound gasket with outer ring shall be used for raised face flange.

A.7 Minimum Shell Thickness

A.7.1 The minimum nominal shell thickness including corrosion allowance shall be in accordance with
TEMA including RECOMMENDED GOOD PRACTICE.

A.8 Pipe Shell

A.8.1 When shell diameter is 600 mm and under, pipes may be used.

A.9 Minimum Nozzle Size

A.9.1 In general, nozzles shall be flanged and minimum 1-1/2 inch nominal size.

A.10 Nozzle Flange Design

A.10.1 Nozzle flange shall be of welding neck type.

A.11 Nozzle Protrusion

A.11.1 Nozzle protrusion shall be decided considering the minimum clearance of 50 mm between the
bottom of bolt to the surface of the shell or surface of the insulation cover. Purchaser’s Vessel
Standard VS-49 shall be referred.

A.11.2 For the nozzles to be connected to piping, the distance of the flange face to the center of the heat
exchanger shall be rounded up to each 10 mm by adjusting the nozzle protrusion.

A.12 Girth Flange Design

A.12.1 All girth flanges shall be of welding neck construction.

A.13 Support Design of Vertical Heat Exchangers

A.13.1 Vertical heat exchangers shall generally be supported by lugs.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ENGINEERING SPECIFICATION E-101
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A.14 Fire Proofing

A.14.1 Fire proofing shall be provided for the heat exchangers installed in the fire hazardous area in the
following manner. Application of fire proofing to heat exchangers installed on elevated structure shall
be decided for each case.

For lug type support, fire proofing shall not be provided.


For saddle type support, fire proofing shall be provided for saddles of the non-insulated lowest height
is greater than 300 mm.

A.15 Extent of Radiographic Examination

A.15.1 The extent of radiographic examination of the shell, shell cover and channel seams shall be spot
examination, as minimum.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 22 OF 32

Appendix B Inspection Requirements

B.1 Material

B.1.1 Ultrasonic Examination of the base metal shall be done in accordance with the following criteria.

(1) Plate material and thickness over 50 mm ASTM A435


(2) Forging material, plate-like one such as tubesheet, forging shell, ASTM A578 Level B
and thickness over 100 mm
(3) Forging material, not included in (2) above, and thickness over 100 mm ASTM A508 Par. 7.3
(4) Cladding material, any thickness ASTM A578 Level S6

B.1.2 Charpy impact test shall be done in accordance with the Code, based on MDMT specified on the
Purchaser’s engineering drawings or data sheet. For carbon steel and low alloy steel, when the
nominal thickness of plate or forging exceeds 100 mm., charpy impact test as specified in Table B-1
is mandatory.

Table B-1

Item CRITERIA
Sampling - Min. 1 set from each heat
- Min. 3 specimen in 1 set
- Sampling from 1/4T (Thickness) depth
Test Temperature 0 °C or MDMT whichever is lower
Absorbed Energy ASME Div.1, Fig. UG-84.1

B.1.3 Integrally cladding material shall conform to ASTM A263, A264 or A265 whichever applicable, and
shear test is mandatory.

B.2 Welds

B.2.1 Welding edge shall be inspected by MT or PT when any of the following conditions met.

(1) Carbon steel and thickness of base metal is 75 mm and over.


(2) Low alloy steel (Cr-Mo) and thickness of base metal is 50 mm and over.
(3) Low alloy steel (Ni) and thickness is 38 mm and over.
(4) Dissimilar welding, any material and any thickness

B.2.2 Welding backchip surface shall be inspected by MT or PT when any of the following condition met.

(1) Carbon steel and thickness of base metal is 50 mm and over.


(2) Carbon steel and MDMT ≤ -10 °C and thickness of base metal is 25 mm and over.
(3) Low alloy steel (Cr-Mo) and thickness of base metal is 25 mm and over.
(4) Low alloy steel (Ni), any thickness
(5) Austenitic stainless steel and thickness is 25 mm and over.
(6) Dissimilar welding, any material and any thickness

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ENGINEERING SPECIFICATION E-101
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B.2.3 All butt weld joint shall be inspected by UT after PWHT in the following cases.

B.2.3.1 Spot UT (Min. 10% in length) is required for carbon steel of 38 mm and over in thickness.
Purchaser’s inspector will specify location to be examined with UT.

B.2.3.2 Full UT is required when any of the following conditions is met.


(1) Carbon steel and thickness of base metal is 50 mm and over
(2) Low alloy steel (Cr-Mo) and thickness of base metal is 50 mm and over.
(3) Low alloy steel (Ni) and thickness is 38 mm and over.
(4) Dissimilar welding

B.2.4 Welding surface shall be inspected by MT or PT after Hydrostatic test, when any of the following
conditions met. Inspection shall be done on all accessible interior and exterior surface.

(1) Carbon steel and thickness of base metal is 38 mm and over, or Full RT(100 %) is specified.
(2) Low alloy steel (Cr-Mo),any thickness include attachment welds
(3) Low alloy steel (Ni), any thickness include attachment welds
(4) High alloy steel, any thickness
(5) Welds in lining or cladding metal and weld overlay surfaces, include attachment welds
(6) Welds of tube to tubesheet
(7) Dissimilar welding, any material and any thickness
(8) Fillet welds of intermediate heads

B.2.5 All area where temporary attachment was welded and is removed shall be examined by MT or PT.

B.2.6 The extent of radiography is specified on Purchaser’s drawings.


When “Full RT (100 %)” is specified on Purchaser’s drawings, all length of butt weld joint, including
Category B seam, shall be RT. When “Full RT” without a description of “(100%)” is specified, RT
shall be done in accordance with UW-11 of ASME Div.1.

B.2.7 When Spot RT is specified, each intersection of longitudinal and circumferential welding seams in
the shell and heads, or alternative location specified by Purchaser’s inspector, shall be radiographed.
Acceptance standards for spot radiography are in accordance with UW-51 of ASME Div.1.

B.2.8 RT shall be done before final PWHT.

B.2.9 Acceptance criteria of MT, PT and UT is ;


(1) MT Appendix 6 of ASME Div.1
(2) PT Appendix 8 of ASME Div.1
(3) UT Appendix 12 of ASME Div.1

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 24 OF 32

B.3 Hardness Test

B.3.1 Hardness of base metal, weld metal and heat affected zone shall be checked as follows.

(1) For Non-PWHT vessel : One point per one vessel


(2) For PWHT vessel : Two points per one of circumferential welds, and
One point per one of longitudinal welds, and
One point per each nozzle weld

B.4 Dimensional Inspection

B.4.1 Main dimension of vessels shall be checked after PWHT. Unless otherwise specified, tolerances for
pressure vessel shall be in accordance with Fig. B-1, B-2.

B.4.2 Thickness of pressure retaining parts shall be checked after forming, at least one point of every 1
2
m.

B.4.3 Vessels to be field assembled shall be pre-assembled at shop, and miss-alignment, which shall be
less than those specified in UW-33, shall be reported.

B.4.4 The gap between interconnecting nozzles of stacked type heat exchangers shall be checked and
reported to the Purchaser. Tolerance of the gap shall be ±0.8 mm.

B.5 Hydrostatic Test

B.5.1 Hydrostatic test shall be done prior to painting at weld and/or coating.

B.5.2 Hydrostatic test shall be done by water and at the temperature of at least 16 °C above MDMT.

B.5.3 The hydrostatic test pressure shall be held at least 30 minutes.

B.5.4 When carbon and low alloy steel materials are exposed to test water, chloride content in the water
shall be less than 100 ppm. Corrosion inhibitor such as 500 ppm NaNo2 shall be dosed to the test
water.

B.5.5 When austenitic stainless steel materials is exposed to test water, chloride content of water shall be
less than 30 ppm.

B.6 Leak Test

B.6.1 Reinforcing pads shall be leak tested at least 10 kPa with air before hydrostatic test.

B.6.2 Sleeve type nozzle shall be leak tested at least 10 kPa with air after hydrostatic test.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 25 OF 32

B.6.3 When tube to tubesheet joint is expanded and not welded, leak test shall be done with the pressure
specified on purchaser’s drawing.

B.6.4 Stacked type heat exchangers having interconnecting nozzles shall be leak tested in the stacked
condition.

B.7 Inspection and Test Records

B.7.1 Inspection and test records for each vessel shall be supplied by Vender.

B.7.2 Inspection and test records shall include (where applicable);

(1) Manufacturer’s Data Report

(2) As-built sketch or tabulation for identification of the materials showing the location

(3) Certified Material Test Report, including data of impact tests and records/certificates of non-
destructive examination required for the materials

(4) Records of production weld tests

(5) Time-temperature charts of post weld heat treatment, and records of other heat treatments

(6) Records/certificates of non-destructive examination, such as radiographic, ultrasonic, magnetic-


particle and liquid-penetrant examination

(7) Data/results of dimensional inspection

(8) Certificates of hydrostatic test, pneumatic test or other pressure tests

(9) Rubbing of nameplates

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 26 OF 32

Fig. B TOLERANCES FOR HEAT EXCHANGERS

[EXTERNAL DIMENSIONS, NOZZLE AND SUPPORT LOCATIONS]


Standard tolerances for the external dimensions of heat exchangers and for nozzle and support locations are shown in Fig. B-1. All
dimensions to flange faces are to the gasket surface.

Fig. B-1
±3 (+6, -3)
±6 ±15
±3
±3 (±5)
(±5)
±3 (±5)

±3 (±5)
±3
(±5)

±3
(±5)

±3
(±5)
±3
±3 (±5)
(±5)
±6

±3
(±5) Nominal Nozzle Size, (in.) G Max.
2 - 4 Inclusive 1.5
6 - 12 Inclusive 2.5
G 14 - 36 Inclusive 5
±3
(±5) Over 36 Inclusive 6
Note: This table applies to nozzles
±3
(±5) connecting to external piping only.

±3 ±3
(±5) (±5)

±3 ±3 ±1°
(±5) (±5)
±3
(±5)
±3 ±3
(±5) (±5) Allowable Centerline True Centerline
Rotation

CONNECTION NOZZLE ALIGNMENT AND


SUPPORT TOLERANCES
ROTATIONAL TOLERANCE
ON NOZZLE FACES

NOTES TO Fig. B-1:


1. Tolerances given in parenthesis ( ) shall apply only to 4. For any pair of nozzles for liquid level gauge, additional
heat exchangers with inside diameters exceeding 1 500 tolerances shall be applied as follows:
mm. a Difference in nozzle length : Max. 1
2. For heat exchangers with inside diameters not exceeding 1 b Distance between nozzles : ±2
500 mm, this figure gives the same tolerances as TEMA
Standards (Six Edition). c Difference in location from reference centerline :
Max. 2
3. Tolerances of the inside diameters shall be as follows:
d Alignment of flange face : ±1/4°
(1) Pipe Shells:
d
The inside diameter of pipe shells shall be in
accordance with the applicable pipe specifications.
(2) Plate Shells: c a

The inside diameter of any plate shell shall not exceed b


the design inside diameter by more than 3 mm (4 mm:
See Note 1) as determined by circumferential
measurement.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 27 OF 32

[TUBESHEETS, PARTITIONS, COVERS AND FLANGES]


The standard clearances and tolerances applying to tubesheets, partitions, covers and flanges are shown in Fig. B-2.

Fig. B-2
t t t t t t t t t
R1 R1 t R1 R2 R1 R1 R1 t
R2
R4
R4

D1 R4
R4 D1
A D3 A
D1 W3 W1
t A A
D=I.D. DESIGN t
A D5=(D3+3) D2=(D1+3)
D4=(D1+3) D2
±0.8
±0.4 D6=(D2+3)
W2=(W1+3) t

STANDARD CONFINED JOINT CONSTRUCTION

t t t t t t t t t
R3 R4 R3

t
A D1
D1 D1 A
W3 A
t D3 A
t
A D2
D=I.D. DESIGN

STANDARD UNCONFINED PLAIN FACE JOINT CONSTRUCTION

t t t DIMENSIONS TOLERANCES NOTES TO Fig. B-2:


R2 R2
A +6, -3 1. This figure is not intended to
R1
R1 prohibit unmachined tubesheet
D1, D2, D3, D4, D5, ±0.8 faces and flat cover faces.
D6 Therefore no plus tolerance is
D1 W1 t ±1.5 shown on “R4”.
(R1=5) +0, -0.8 2. Negative tolerances shall not be
W2=(W1+3) D4=(D1+3) construed to mean that final
(R2=6, R3=1.5) +0.8, -0 dimensions can be less than that
(R4=5) -0.8 (Note 1) required by design calculations.
W1, W2, W3 ±0.8 3. For peripheral gaskets, “Confined”
ALTERNATE TONGUE AND means “Confined on the O.D.”.
GROOVE JOINT
4. Details are typical and do not
preclude the use of other details
which are functionally equivalent.

NOTES:
1. Unless otherwise stated, all dimensions and tolerances are given in (mm).
2. Tolerances are not cumulative.
3. Tolerances indicated on Vessel Drawing shall govern.
4. This appendix shall be used in conjunction with TEMA Standards.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
Revision
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HEAT EXCHANGERS
Project ; SEP PAGE 28 OF 32

Appendix C Painting Requirements

C.1 Painting system shall be selected from Table C-1.

C.2 Corresponding designation of SSPC, NACE and SIS standards and specifications are as follows;

SSPC NACE SIS


SP-6 TM-01-70, No.3 05 59 00, Gr. Sa, Degree 2
SP-10 TM-01-70, No.2 05 59 00, Gr. Sa, Degree 2-1/2

C.3 Total dry film thickness shall be inspected and recorded as follows;

Number of points to be inspected; 1 point/ 10 m2, Min. 2 points


Acceptance criteria; over 90 % of specified thickness in average
over 70 % of specified thickness in Minimum.

C.4 Painting work shall be done in accordance Paint material manufacture’s recommendation. At least,
following information shall be included in Vender’s PAINT SPECIFICATION.

A. Lowest and highest temperature


B. Highest humidity
C. Cleanness of atmosphere

Table C-1 Painting System for Pressure Vessel and its Attachments

Exposed Operating Surface Paint Nos. of Thickness


Type
Condition Temp.(°C) Preparation Material Coat (μm/Coat)
V1 T≤80 SP-6 Epoxy Resin 2 50
V2 Not Insulated T>80 SP-10 Silicon Resin Heat 2 20
Resistant
V3 Insulated(Hot) T≤120 SP-6 Alkyd Resin 2 35
V4 or P/P T>120 SP-10 Silicon Resin 2 20
Heat Resistant
V5 Insulated(Cold) All temp. SP-6 Alkyd Resin 2 35
V6 Skirt, Saddle, Davit
and other attachment -- SP-6 Epoxy Resin 2 50
Platform / Ladder

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 29 OF 32

Appendix D Special Design Code Requirements

D.1 Application of ASME Boiler and Pressure Vessel Code Section VIII, Div.2 or AD Merkablatt or
BS 5500 shall be considered for construction of pressure vessel when any of the following
conditions are met;

(1) Design Pressure exceeds 10 000 kPa


(2) Plate thickness exceeds 38 mm

D.2 When a vessel unit consists of more than one independent pressure chamber, different code may
be applied to each chamber. In such a case, only the combination of ASME Boiler and Pressure
Vessel Code Section VIII, Div.1 and Div.2 is acceptable.

D.3 When the equipment is fabricated by ASME Boiler and Pressure Vessel Code Section VIII, Div.2,
Vender shall have the Certificates of authorization for use of ASME U2 Code Symbol Stamp,
although code stamping is not required for the equipment, as a rule.

D.4 When the design code is not ASME Boiler and Pressure Vessel Code Section VIII, Div.1 or Div.2,
Vender shall check the consistency of the code requirement and the requirement of the spec. D-
102 and E-102, and shall inform the any consistency to the Purchaser.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.
ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 30 OF 32

Appendix E Requirements for Specific Corrosive Environment

E.1 General
This attachment covers the minimum requirements required for materials, fabrication and testing of pressure
vessels and heat exchangers in the specific environments listed below.

(1) Wet hydrogen sulfide


(2) Caustic
(3) Amine
(4) Polythionic acid
(5) Elevated temperature

E.2 Requirements

E.2.1 General
E.2.1.1 Material shall be fully-killed steel.

E.2.1.2 Stabilized austenitic stainless steel, such as Type 321, 347, shall be solution annealed before fabrication.
2 Maximum temperature of solution annealing shall be 1060 ℃.

E.2.2 Wet Hydrogen Sulfide


E.2.2.1 H2S resistant steel (AXENS category 1) shall satisfy the following requirements.
(1) Materials shall conform to the requirements of NACE standard MR0175-03 (part 2).
(2) PWHT (post weld heat treatment) is mandatory.
(3) The maximum hardness of base material shall be 22 HRC.
(4) The maximum hardness of the weld after PWHT shall be 200 HB.
(5) The maximum hardness on WPQT shall be as follows.
- Weld root: 250 HV10 or 5
2 - Weld cap: 275 HV10 or 5
(including HAZ)
(6) Pressure holding parts used in the sour environment shall have a minimum of 6 mm corrosion allowance,
unless otherwise specified.
(7) Materials shall satisfy the following restriction on chemical composition.
-C 0.20 % max. for plate only
- Ni less than 1% for plate, pipe and forged material

E.2.2.2 HIC resistant steel (AXENS category 2) shall satisfy the following requirements.
(1) Materials shall conform to the requirements stipulated in the above paragraph E.2.2.1.
(2) Plate, pipe and tube (Note 1) materials shall be qualified by testing in accordance with NACE Standard
TM0177 solution A.
- CLR shall not exceed 15.0 %.
- CTR shall not exceed 5.0 %.
- CSR shall not exceed 2.0 %.
Note 1: If HIC test could not be performed for heat exchanger tubes pr air fin cooler tubes due to small size
(test coupon could not be obtained), the following requirements shall be applied of HIC test.
S 0.003 wt% max.
P 0.010 wt% max.
(3) Materials shall satisfy the following restriction on chemical composition.
-P 0.025 wt% max. for plate only
-S 0.003 wt% max. for plate
0.01 wt% max. for seamless pipe
0.025 wt% max. for forged material

E.2.3 Caustic
E.2.3.1 PWHT shall be performed when required by the caustic soda service graph in “Corrosion Data Survey” of
NACE. The temperature shown in the graph shall be operating temperature of equipment except that it shall
be metal temperature for tubes of heat exchanger.

E.2.4 Amine
E.2.4.1 PWHT shall be mandatory.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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ES No.
ENGINEERING SPECIFICATION E-101
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HEAT EXCHANGERS
Project ; SEP PAGE 31 OF 32

E.2.4.2 PWHT shall be performed at temperature from 595 ℃ up to 650 ℃ for 1 hour per 25 mm of thickness with a
minimum of 1 hour.

E.2.4.3 The maximum hardness after PWHT shall be 200 BHN.

E.2.5 Polythionic Acid


When austenitic stainless steel is selected in polythionic acid class equipment, the following restrictions are
mandatory.

E.2.5.1 Stabilized type stainless steel shall be used. If maximum metal temperature is less than 350 ℃, low carbon
type austenitic stainless steel may be approved.

E.2.5.2 For plate, pipe, tube and forged material, the following restriction on chemical composition shall be satisfied.
(1) For Type 321 steel: Ti/C ≥ 7
(2) For Type 347 steel: Nb/C ≥ 10

E.2.5.3 U-tubes after bending shall be solution heat treated. The maximum temperature of solution treatment shall be
1050 ℃.

E.2.6 Elevated temperature


When Type 304H stainless steel is used at elevated temperature above 450 ℃, ferrite content at weld shall be
from 3% up to 8%.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844 / Engg Spec E-101 Rev4.doc © TOYO ENGINEERING CORP.

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