Pdvsa: Engineering Design Manual

PDVSA
ENGINEERING DESIGN MANUAL

VOLUME 8
ENGINEERING SPECIFICATION
PDVSA N° TITLE
EA–201–PR SHELL AND TUBE HEAT EXCHANGE EQUIPMENT
1 JUL.94 GENERAL REVISION 18 L.T. E.J. A.N.
0 MAR.87 FOR APPROVAL 17 J.G. A.O.
REV. DATE DESCRIPTION PAG. REV. APPD. APPD.
APPD.BY José Gilarranz DATE MAR.87 APPD.BY Antonio Ortiz DATE MAR.87
E PDVSA, 1983 ESPECIALISTAS

ENGINEERING SPECIFICATION PDVSA EA–201–PR
REVISION FECHA
PDVSA SHELL AND TUBE HEAT 1 JUL.94
EXCHANGE EQUIPMENT Página 1
.Menú Principal Indice manual Indice volumen Indice norma
Index
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Data Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Data requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 System of Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Codes, Standards and Regulatory Requirements . . . . . . . . . . . . . . . . . . . . 5
2.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Design Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Design Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Corrosion Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.9 Alloy Protective Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 Shell Expansion Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 DESIGN DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Shells and Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Tubes and Tube Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Supports and Lifting Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 FABRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Weld Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Post weld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 TESTING AND NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 PREPARATION FOR SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REVISION FECHA
1 GENERAL
1.1 Scope
1.1.1 This specification, together with the Exchanger Data Sheets and purchase
documents, indicates the minimum requirements to be met by the Seller in the
design, fabrication, inspection, testing, and supply of shell and tube type
exchangers. Owner’s approval shall be required to resolve any conflict between
the Exchanger Data Sheets and this specification.
1.1.2 This specification does not include steam condensers operating at a vacuum,
double pipe exchangers, suction tank heaters or tubular exchangers for turbines,
engines, pumps, compressors and other mechanical equipment normally
furnished by the supplier of such equipment.
1.2 Data Requirements

1.2.1 Seller shall furnish all data required to complete Owner’s Shell and Tube Heat
Exchanger Data Sheet.
1.2.2 Designs which are not fully defined by the nomenclature in Tubular Exchanger
Manufacturers Association (TEMA) Standards, Section 1, shall be accompanied
by detailed engineering sufficient to describe the construction.
1.3 Drawings
Outline drawings shall be certified correct and shall show the following
information:
1.3.1 Applicable code, TEMA class, and Owner’s specifications.
1.3.2 Nozzle size, rating, facing, reinforcing pad, location, and flow direction.
1.3.3 Support mounting dimensions and location.
1.3.4 Overall exchanger dimensions.
1.3.5 Thickness of shell and heads.
1.3.6 Tube bundle removal clearance, if applicable.
1.3.7 Weights exchanger empty, full of water, and removable tube bundle.
1.3.8 Design pressure, test pressure, design temperature, and corrosion allowance for
both sides of the exchanger.
1.3.9 Identification: service, Owner’s item number, project name and location, Owner’s
order number, and Seller’s shop order number.
REVISION FECHA
1.3.10 Post weld heat treatment, radiographic and other examination requirements.
1.3.11 Surface preparation and painting requirements.
1.3.12 Construction material specification for major parts.
1.3.13 Effective tube surface area, number of tubes and tube rows.
1.3.14 Heat Exchanger service.
1.3.15 Number and location of lifting lugs.
1.3.16 Gasket details, including type and material
1.3.17 Name–Plate details.
1.3.18 Bundle details including tubes and tube supports.
1.3.19 Headers details including nozzles.
1.4 References
1.4.1 The latest edition of the following codes, standards and specifications, including
applicable addenda shall form part of this specification to the extent specified
herein.
a. Tubular Exchanger Manufacturers Association (TEMA)
b. American Society of Mechanical Engineers (ASME)
Section I Power Boilers
Section II Material Specifications
Section V Nondestructive Examination
Section VIII, Div.1 Pressure Vessels
Section IX Welding and Brazing Qualifications
c. American National Standards Institute (ANSI)
B2.1 Pipe Threads
B16.5 Steel Pipe Flanges, Flanged Valves and Fittings
B16.11 Forged Steel Fittings, Socket Welding and Threaded
d. Steel Structures Painting Council (SSPC)
SP2 Hand Cleaning
SP3 Power Tool Cleaning
SP5 Blast Cleaning tp “White” Metal
SP10 Blast Cleaning to “Near White” Metal
e. American Society for testing of Materials – (ASTM)
REVISION FECHA
f. American Welding Society (AWS)

D1.1 Structural Welding Code
g. Especificaciones de Ingeniería PDVSA
PDVSA O–201 Painting Material and Application Requirements
h. American Petraleum Institute (API)
605 Large Diameter C.S. Flanges
660 Standard Heat Exchangers for Genral Refinery
Services
1.5 System of Measurements

1.5.1 All drawings and documents must be in Metric dimensions, except pipe and tube
sizes and bolting.
1.5.2 Ratings and dimensions of flanges shall be in accordance with ANSI B16.5
Standard.
2 DESIGN
2.1 General
2.1.1 Specific performance, design requirements and type of exchanger shall be
indicatede by the Owner on the Exchanger Data Sheet.
2.1.2 Generally, the following exchanger design types shall be used for low–fin or bare
tubes.
a. For non–fouling service on the shell side (Fouling factor 0,0002
hr–m2–°C/Kcal or less), fixed tube sheet or U–tube exchangers with
triangular pitch layouts may be used.
b. For fixed tube sheet type exchangers, the shell diameter shall be limited to
2032 mm (6,75 ft) unless otherwise specified on individual data sheet.
c. For fouling service on the shell side, use floating head or U–tube exchangers
with square pitch layouts.
d. For a non–fouling service on the tube side (fouling factor 0,0002
hr–m2–°C/Kcal or less), u–tubes may be used..
2.1.3 Other types of exchangers, such as fin or bare double pipe, tank suction heaters,
spiral exchangers, impervious graphite units, brazed aluminum, plate type
exchangers, etc., may be specified by the Owner or may be offered by the Seller
as an alternate where design service conditions will permit.
REVISION FECHA
a. These special types of units shall be of the manufacturer’s standard design.

2.1.4 Water cooled units shall be designed for the cooling water to flow through the
tubes unless specified otherwise by the Owner on the Exchanger Data Sheet.
a. The minimum water velocity through tubes shall be 1,0 m/s (3,28 ft/s).
b. The maximun water velocity through carbon steel tubes shall not exceed 2,5
m/s (8,2 ft/s).
In tube materials other than steel, velocity shall be kept within the range
1,0 – 2,5 m/s and any deviation, considered in a particular service, shall be
approved by the Owner or his designee.
2.2 Codes, Standards and Regulatory Requirements

2.2.1 All exchangers shall be designed, fabricated, inspected an tested in accordance
with the requirements of this specification and the requirements of TEMA.
2.2.2 The TEMA class designtion shall be Class R unless specified otherwise by the
Owner on the Exchanger Data Seet.
2.2.3 The requirements of the standards, codes and regulations set forth on this
specification shall be considered as minimum requirements.
2.2.4 All requirements, as indicated under 2.2.1 and 2.2.3, shall comply with all
applicable Venezuelan Laws and regulations, including the applicable PDVSA
standards.
2.3 Materials
2.3.1 The materials of construction for exchanger components shall be indicated by the
Owner on the Exchanger Data Sheets and shall be selected to produce an
economical design for the specified design service conditions.
2.3.2 Materials shall conform to the specifications tabulated in the TEMA Standards,
and all materials subject to internal or external pressure shall also conform to the
specifications given in ASME Code Section II or other governing codes.
2.3.3 Exception to Paragraph 2.3.2 may be taken where the Owner allows materials or
alloy
a. In this case, the Seller shall obtain design data from the supplier of such
material, verify all calculations, show source of data and obtain regulatory
approvals.
2.3.4 Pressure holding components shall be of the same or comparable material as that
used for the shell or heads.
REVISION FECHA
2.3.5 The material of internals such as baffles, tie rods, etc. may be similar to the shell
material; if the shell is cladded, those internals shall be similar to the cladding.
2.4 Bolting
2.4.1 Unless indicated otherwise on the Exchanger Data Sheet, all external bolting shall
conform to the following ASME specifications:
Design Temperature Stud Nuts
°C
–100 to –30 SA–320 Gr. L–7 SA–194 Gr. 4
– 30 to 500 SA–193 Gr. B–7 SA–194 Gr. 2–H
500 to 600 SA–193 Gr. B–16 SA–194 Gr. 4
600 to 800 SA–193 Gr. B–8 SA–194 Gr. 8
2.4.2 External bolting smaller than 3/4 inch shall not be used.
2.4.3 Internal bolting shall be selected on the basis of shell material (clad or solid) AND
MOIST H2S CONTENT as follows:
Shell Material Stud Nuts
Cardon Steel ASME SA–193 Gr. B7 ASME SA–194 Gr. 2H
(Less than 100 PPM H2S)
Carbon Steel SA–193 Gr. B7M SA–194 Gr. 2M
(More than 100 PPM H2S)
Low Alloy Steel SA–193 Gr. B7 SA–194 Gr. 2H
5% Chrome SA–193 Gr. B5 SA–194 Gr. 3
Bonnet Material
13% Chrome SA–193 Gr. B8 SA–194 Gr. 8
18–8 All Types SA–193 Gr. B8 SA–194 Gr. 8
Nickel Copper (Monel) Monel Monel
Aluminum SA–193 Gr. B8 SA–194 Gr. 8
NOTE:
Internal bolting of exchangers in alkaline sour water or mea services should be
ASME SA–193, GR. B8M (Class 2).
2.4.4 Material for bolting in units with design temperatures below –30 °C shall be
selected from a suitable grade of ASME SA–320.
2.5 Gaskets
2.5.1 Gaskets shall be furnished in accordance with the specified TEMA Standards.
REVISION FECHA
2.5.2 Materials for metal clad gskets shall be selected by the Seller for the design
service conditions and shall be subject to Owner’s approval.
2.5.3 One complete set of spare gaskets shall be furnished.
2.6 Design Pressure

2.6.1 Design pressure shall be based on the normal operating pressure, with
consideration given to expected abnormal system operation PLUS 10% OR 2,0
kg/cm2 (29,4 psi) (Whichever is greater).
a. The design pressure shall be indicated by the Owner on the Exchanger Data
Sheet.
2.6.2 Exchangers operating under a vacuum and in steam service shall be designed for
an external pressure of 1,054 kg/cm2 (14,7 Psi) (FV).
2.6.3 The minimum design pressure for the exchanger shall be 3,5 kg/cm2 (51,45 psi)
both for the tube side and/or the shell side.
2.7 Design Temperature

2.7.1 The maximum anticipated operating temperature or minimum for exchangers
operating below 0 °C shall be indicated by the Owner on the Exchanger Data
Sheet.
2.7.2 Exchangers which will operate at temperatures above 0 °C shall be designed for
a temperature at least 15 °C above the maximum anticipated operating
temperature, but not less than 65 °C.
For parts subject to different fluid temperatures, the design temperature shall be
the metal temperature under working condition. Unless otherwise specified, the
metal temperature shall be aqual to the higher of the shell and tube side design
temperature.
2.7.3 Exchanger which will operate at temperatures 0 °C and below shall be designed
for the minimum anticipated operating temperature.
2.7.4 When loss of flow of the cooling medium is possible, as indicated by the Owner
on the Exchanger Data Sheet, the internal components shall be designed for the
maximum anticipated operating temperature of the hotter medium plus 15
°C.
2.7.5 In the selection of design temperatures for multiple ex changers in series,
consideration shall be given to the maximum temperature on each side of each
exchanger resulting from either fouled or clean operation.
2.8 Corrosion Allowance

2.8.1 No corrosion allowance shall be added to alloy parts unless otherwise indicated
on the Exchanger Data Sheet.
REVISION FECHA
2.8.2 The corrosion allowance for carbon steel shall be 3 mm (0,125 inch) minimum
unless otherwise indicated on the Exchanger Data Sheet.
2.8.3 No corrosion allowance shall be added to baffles, supports, partition plates,
internal bolting, floating head backing devices, or nonferrous parts.
2.9 Alloy Protective Lining

2.9.1 Alloy protective linings may be used in the design of ex changers in services for
which severe corrosion can be predicted.
2.9.2 Lining for exchanger shells, tube sheets and channels shall be of the integrally
clad type in accordance with or equivalent to the SA material designations for
integrally clad plate specified in Part UCL of ASME Code Section VIII.
Lined tube sheets shall be integrally clad material and thickness of cladding 10
mm (0.375 inch) minimum.
b. When integrally clad type is not available, weld overlay lining may be used
with the Owner’s approval.
2.9.3 The minimum thickness of applied liners shall be 3 mm (0.125 inch) and the
thickness of alloy cladding, for parts other than tube sheets, shall approximate
3 mm (0,125 inch), as closely as standard mill practices will permit.
2.9.4 Pass partition grooves in lined tube sheets and channel covers shall have the
specified lining thickness on all surfaces.
2.9.5 Applied alloy liners shall be considered as corrosion allowance only, not as part
of the base metal, when calculating the thickness of pressure parts.
2.9.6 Integrally clad plate may be considered part of the base metal, for thickness
calculation purposes, in accordance wth ASME Code section VIII, Div. 1, and
Owner’s approval.
2.9.7 When cladding is specified by internal bonding or weld overlay, all surfaces
exposed to the fluid, including gasket seating surfaces, shall have at least 3 mm
(0,125 inch) nominal thickness of cladding.
2.10 Shell Expansion Joints

2.10.1 Where fixed tube sheet construction is used as permitted under Paragraph 2.1.2
of this specification, suitable provision shall be made for expansion to prevent
overstressing of the tubes of shell.
2.10.2 Stresses due to thermal expansion shall be analyzed by investigating the normal
operation in the clean and fouled conditions to determine the necessity of using
expansion joints.
REVISION FECHA
2.10.3 Other conditions such as startup, shutdown, steam cleaning, etc., when specified
by the Owner, shall also be investigated.
2.10.4 The types and material of construction of expansion joint recomended by the
Seller shall require the Owner’s approval.
2.10.5 For fixed tube–sheet exchangers without expansion joints, the average shell
metal temperature and the average metal temperature of any one tube pass shall
not exceed 28.
a. When the temperature differential exceeds 28 °C, an expansion joint shall
be furnished.
3 DESIGN DETAILS
3.1 Shells and Channels
3.1.1 Shells shall be of one piece construction whenever practical and shall be
fabricated of pipe or rolled plate.
3.1.2 All shells on floating head units, except kettle reboilers, shall be provided with
forged or welded removable bolted shell covers
3.1.3 Channels may be of forged, or built–up welded construction.
a. Partition plates shall be provided with 6 mm (0,25 inch) drain and vent holes.
3.1.4 Shell and channel girth flanges, ring or hub type, shall be designed for thru–bolt
joint construction.
3.1.5 To facilitate disassembling the gasketed joint of main girth flanges when the
assembled flange has a clearance less than 5 mm at the periphery, either of the
two following methods shall be employed:
b. Jack screws shall be provided on one of each pair of main girth flanges, or,
c. Along the periphery of the male flange, a cutback of 5 mm (0,2 inch) to a
depth of approximately 8 mm (0,315 inch) shall be made.
3.2 Tubes and Tube Bundles

3.2.1 Outer tube limit diameter for removable bundles shall be 1.220 mm unless
otherwise specified on the individual data sheet.
d. Removable exchanger bundles shall be designed to a maximum weight of
13.600 kg.
3.2.2 The preferred tube lengths shall be 4.900 mm (16 ft) and 6.100 mm (20 ft);
however tube lengths of 2.400 mm, 3.000 mm, 3.700 mm and 7.300 mm may be
used for specific requirements.
REVISION FECHA
3.2.3 Except for exchangers of manufacturer’s standard design or special requirements

defined on the individual Exchanger Data Sheet, tubing normally shall consist of
the following: (except service)
a. Carbon steel, C–1/2 Mo steel or 3 1/2 Ni steel tubes: Welded, 3/4” OD x 14
BWG thick or 1” OD x 12 BWG thick, average wall.
b. Low chrome moly steel (up to 9% Cr) Tubes: Seamless, 3/4” OD x 14 BWG
thick or 1” OD x 12 BWG thick, average wall.
c. High chrome moly steel or copper–alloy tubes: Seamless, 3/4” OD x 16
BWG thick or 1” OD x 14 BWG thick, average wall.
d. High alloy steel, titanium, hastelloy, etc. tubes: Welded, 3/4” OD x 18 BWG
thick or 1” OD x 16 BWG thick, average wall.
e. Nickel Alloys or monel tubes: Seamless, 3/4” OD x 18 BWG thick or 1” OD
x 16 BWG thick, Average wall.
f. Ferritic and austenitic stainless steel tubes: seamless or welded, 3/4” OD
x 18 BWG thick OR 1” OD x 16 BWG thick, average wall.
g. Other sizes and thickness may be acceptable in selected areas, with
Owner’s approval.
h. Tube wall thickness to 11, 13, 15, 17 and 19 bwg average wall shall not be
used.
i. ASTM A–214 welded tubes (ERW) may be used as subdtitutes of ASTM
A–179, only under service/design limitations and conditions set forth by
Owner on the Exchanger Data Sheet.
3.2.4 For horizontal reboiler or vaporizing services, tubes shall be arranged with a
triangular pitch unless otherwise specified on the Exchanger Data Sheets.
Consideration may be given to triangular pitch for services with very clean process
fuids combined with a low heat flux.
3.2.5 Rolled only tubes shall project 3 mm (0,125 inch) + 1,6 mm (0,063 inch) beyond
the tube side face of the tube sheet.
3.2.6 Each U–tube shall be formed from a single length, and the length specified shall
be the straight length measured from end to return bend tangent.
a. All u–bends shall be properly annealed after bending, as specified by the
Owner.
3.2.7 On vertical removable bundle units with channel down, a full diameter stationary
tube sheet with at least four collar bolts shall be provided, or other means
approved by the Owner, to hold bundle with channel off.
REVISION FECHA
3.2.8 When gasket grooves are required on tube sheets, the minimum design distance
between the edge of the tube hole and the edge of the gasket groove shall be
normally 1.6 mm (1/16 inch).
3.2.9 A positive means of assuring alignment and prevention of misassembly of the
following shall be provided: floating head cover, channel, channel cover having
grooved partitions, stationary tube sheet, and shell flange.
3.2.10 Baffles shall be of the cross flow segmental type, tied together with rods spacers
and provided with notches, only when necessary, to permit drainage of the shell.
3.2.11 Baffle clearances between design ID of shell and baffle OD shall be as shown in
the table listed in TEMA, but these maximum clearances may be increased to
twice the tabulated values only when isothermal vaporization or isothermal
condensing occurs on the shell side of an exchanger.
3.2.12 The use of a two–pass shell employing a continuous longitudinal baffle shall
require the Owner’s approval of the baffle design.
a. Packed type or groove–in–shell type baffles are not acceptable.
3.2.13 Impingement baffles are not required for nonabrasive liquids, gases or
superheated vapors when, at the smallest cross sectional area of the nozzle, the
value of (density in kg/m3) x (velocity in m/s)2 is less than that stipulated in the
TEMA class referred to in Paragraph 2.2.2.
a. For all other conditions, impingement protection is required.
3.2.14 Impingement protection shall be provided by either a plate baffle, a distributing
belt or by an enlarged inlet nozzle with an internal distributor plate.
3.2.15 Plate baffles shall extend beyond the projection of the nozzle bore.
a. This baffle shall be located at a distance from the nozzle to provide a
minimum free cylindrical entrance area at the projected nozzle bore equal
to the nozzle bore area.
3.2.16 The entrance area into the shell of enlarged inlet nozzles containing an internal
distribution plate shall be the cylindrical area of the projected enlarged diameter
plus the free area between the tubes.
a. This entrance area shall be at least equal to the inlet line bore area.
b. The maximum fluid velocity at the cross sectional area of the enlarged
nozzle section shall not exceed: (density in kg/m3) x (velocity in m/s)2 =
2232.
c. Enlarged inlet nozzles shall not be used for mixed phase fluids.
3.2.17 A minimum of two longitudinal sealing strips shall be provided for cross–baffled
exchangers when the radial clearance between the outer row of tubes and the
inside of the shell is as follows:
REVISION FECHA
Radial Clearance Shell Diameter

over 19 mm (0,75 inch) to 690 mm (2,25 Ft)
over 25 mm (1 inch) 710 mm (2,33 Ft) & over
3.3 Connections
3.3.1 The inlet and outlet stream connections shall be flanged, faced and drilled to the
ANSI pipe rating specified on the Exchanger Data Sheet.
3.3.2 Flange face finishes per ANSI B16.5 shall apply for Class 150 and 300 flanges
operating between –100 °C and 400 °C.
a. For all other service conditions, a 0.003 mm (125 microinch) flange face
finish shall apply.
3.3.3 Nozzle sizes shall be indicated by the Owner on the Exchanger Data Sheet.
a. The Seller shall not alter these nozzle sizes without Owner’s specific
approval.
3.3.4 Flanged nozzles shall be one of the following types:
a. Integrally flanged forged (long welding necks).
b. Pipe neck or plate rolled and longitudinally welded, full penetration, with a
full penetration welded attachament to a forged welding neck flange.
c. Forged carbon steel slip–on type flanges may be for Class 150 and 300 only
used at design temperatures between –30 °C and 260 °C.
Slip–on flanges for services with operating hydrogen partial pressures above 7,0
kg/cm2 (100 Psi) shall be furnished with a 3 mm (0,125 inch) diameter hole to vent
the space between the od of the pipe and the bore of the flange.
d. Nozzles of alloy material may be fabricated from alloy pipe with forged
carbon steel slip–on flange faced with alloy on gasket seat (this is not
acceptable in Hydrogen Service or Cold Temperature Service).
3.3.5 The Seller shall provide necessary reinforcement in exchanger shell due to
externally imposed loads on exchanger connections when and if advised of such
loads by the Owner.
a. The Owner will only request the Seller to investigate external loads on
exchanger connections that might induce a combined stress greater than
80% of yield stress at maximum operating temperature.
b. The reinforcement due to external loads on exchanger connections should
limit the combined stress in exchanger shell to 80% of yield stress at
maximum operating temperature.
REVISION FECHA
c. The combined stress is defined as the maximum stress in the exchanger

shell due to maximum operating pressure and temperature plus localized
stresses due to externally applied load on exchanger connection.
3.3.6 All high and low points on shell and tube sides not otherwise vented or drained
shall be provided with 19 mm (3/4 inch) minimum sized drain and vent
connections.
d. Expansion joints in horizontal units shall be separately vented and drained.
3.3.7 Each flanged nozzle 4 inches and larger shall be provided with a 1/2 inch pressure
gauge connection and a 1 inch thermometer connection.
a. Nozzles larger than 1 1/2 inches and smaller than 4 inches shall be provided
with 1/2 inch pressure gauge connections only.
b. Pressure gauge and thermometer connections shall be included in the
mating connections of units connected in series.
3.3.8 The vent, drain, pressure and thermometer connections shall be constructed of
couplings or bosses threaded with ANSI standard pipe threads.
a. Each coupling shall be supplied with a forged steel bull pulg.
b. Flanged connections with covers shall be furnished only when specified by
the Owner.
3.3.9 Flanges of interconnecting nozzles of stacked units shall be of same rating and
facing as for external piping connections except that when the external piping
connections have ring type joints, the interconnecting flanges shall have raised
faces.
a. Seller shall supply bolts, nuts, and gaskets for interconnecting exchanger
connections.
3.3.10 Minimum nozzle size connection shall be 2 inches; all connections shall be
flanged.
3.3.11 Aluminum alloy flanges shall not be used
3.3.12 When chemical cleaning connections are specified on the exhanger Data Sheets,
the connections shall be provided per the following:
a. Connections shall be installed only in nozzles 4 inches and larger.
b. The minimum size connection shall be 2 inches flanges connections complete
with cover, bolts and gasket.
c. Connection shall be installed horizontally.
d. For exchangers in series arrangement, only one chemical cleaning connection is
required in the inlet nozzle and one in the outlet nozzle.
REVISION FECHA
3.4 Supports and Lifting Lugs

3.4.1 Rear saddle support and intermediate supports for horizontal units shall be
provided with slotted holes to allow for expansion.
3.4.2 Units which are to be stacked shall be provided with the required additional
intermediate supports and bracing.
a. The shells shall be reinforced as required to carry the imposed loads.
3.4.3 Each cover shall be provided with a plate type welded on lifting lug with 1 inch
diameter hole located on top centerline, wherever possible.
3.4.4 On the bottom exchanger of stacked exchangers, two lifting lugs each located 45°
from the top centerline shall be provided on floating head covers, shell covers and
bonnet type channel covers.
3.4.5 Pulling lugs or tapped holes for insertion of eyebolts shall be provided on the outer
face of tube sheets of removable bundles to permit removal of bundles from shell.
3.4.6 Where clad tube sheets are used, pulling lugs or tapped holes shall be located
on the outside edge, not in the cladding.
4 FABRICATION
4.1 Welding
4.1.1 Welding procedures, welder performance and welding processes shall be
qualified in accordance with ASME Code Section IX and subject to Owner’s
approval.
4.1.2 Pressure holding seams, nozzle attachments and similar joints shall be full
penetration double welded butt joints.
4.1.3 Single welded butt joints may be used only where double welded butt joints are
impractical.
4.1.4 Backing strips may be used only with Ownenr’s written. Consumable inserts are
not considered as backing strips.
4.1.5 All fillet welds for saddles, supports, lugs, etc. shall have a continuous weld.
4.2 Weld Inspection

4.2.1 Regardless of code requirements, a minimum of one spot radiograph shall be
made of pressure holding butt welds on the channel assembly, one spot
radiograph of the shell assembly (which includes shell cover where applicable)
and one spot radiograph on the return channel or floating head assembly.
REVISION FECHA
4.2.2 The Owner’s Inspector shall have the prerogative of determining the two or three
minimum radiograph locations and designating additional locations as judged
required.
4.2.3 Radiographing other than required by the specified code and paragraph 4.2.1 and
4.2.2 shall be as specified on the Exchanger Data Sheet.
4.2.4 Radiographic examination of pressure holding but welds shall be per the
following:
a. Examination methods shall be per ASME Code Section V, Article 2 (t–270).
b. Acceptance criteria shall be per ASME Code Section VIII, par. uw–51.
4.2.5 Radiographic film dhsll be equivalent to type 1 or type 2 per ASME E94, except
that fluorescent intensifying screens, such as calcium tungstate, shall not be
used.
4.2.6 Pressure holding tee and other fillet welds shall be magnetic particle inspected or
checked by other approved methods to determine soundness of welds.
4.2.7 Brinell hardness of the base metal, the weld metal and the Heat Affected Zone
(HAZ) of all welds shall not exceed the limits given below:
a. These tests shall be made with a Brinell testing machine or a portable
hardness tester such as telebrineller using a 10 mm (0,4 inch) ball. The
hardness test of the HAZ shall be made with the ball centered in the HAZ
(representing a composite of weld metal, HAZ, and base metal).
MATERIAL BRINELL HARDNESS
P–Number (See ASME Code Section IX)
P–1 (NOTE 1) 225 (NOTE 2) (NOTE 3)
P–3, P–4, P–9 225 (NOTE 3)
P–5, P–6, P–7, P–10 235
NOTES:
1. Base metal hardness tests are not required on P–1 materials.
2. For units in hydrogen service, hardness value shall be limited to 200.
3. Except for sour water service, to be 200.
b. Examinations shall be made in the presence of the Owner’s inspector to
verify compliance with the above hardness values.
4.3 Post weld Heat Treatment

4.3.1 Post weld heat treating than required by the specified code shall be as indicated
on the Exchanger Data Sheet.
REVISION FECHA
4.3.2 The exemption provided in ASME Code Section VIII, table USC–56 note 1,
allowing postweld heat teating at lower temperature for longer periods of time is
not permited.
4.3.3 Welding on the base metal (including such items as repairs to base metal) shall
be completed and accepted by the inspector prior to postweld heat treating.
4.3.4 All gasket faces and other machined surfaces shall be checked after heat treatmet
and/or fabrication for freedom from warpage, distortion, oxidation and unbroken
serrations.
4.3.5 If heating with induction or resistance elements is employed, the Owner’s prior
written approval is required.
4.4 Tolerances
4.4.1 Dimensional tolerances shall be in accordance with the TEMA Standards.
4.4.2 Special care shall be exercised in truing up interconnecting nozzle flanges when
exchangers are stacked in series.
4.5 Stamping
The following exchanger parts shall be stamped with Seller’s ex changer serial
number: shell, shell cover, channel, channel cover, fixed tube sheet, floating head
cover and floating head backup device.
5 TESTING AND NAMEPLATE

5.1 Testing
5.1.1 The hydrostatic test pressure shall be as specified on the Exchanger Data Sheet
and shall be not less than 1–1/2 times the design pressure corrected for
temperature.
a. An approved rust inhibitor and wetting agent shall be added to the test water.
b. When testing exchangers with stainless steel materials, the maximum
allowable chloride content of the test water shall be 50 ppm.
5.1.2 Reinforcing pads shall be pneumatically tested at a pressure of 1.054 kg/cm2 (15
Psi)
a. The telltale holes in the reinforcing pads shall be left open after testing.
5.1.3 Exchangers which are to be stacked in service shall be shop assembled for fit up
and inspection prior to shipping.
REVISION FECHA
5.1.4 Test rings required for testing floating head exchangers shall be furnished with
the exchanger only when specifically called for in the purchase documents.
5.2 Nameplate
5.2.1 A stainless steel nameplate shall be provided with the following minimum
information:
a. The Owner’s name, purchase order and item number.
b. The serial number and the year built.
c. The design pressure (both sides).
d. The maximum allowable working pressure (both sides).
e. The design temperature (both sides).
f. The test pressure (both sides).
g. The effective surface.
h. The ASME Code stamp.
i. Seller’s identification.
5.2.2 The nameplate will be mounted on a bracket welded to the shell, near the channel
end, with a minimum of 75 mm (3 inches) projection from the shell for design
temperatures above –30 °C and 125 mm projection from the shell for design
temperatures below –30 °C.
6 PREPARATION FOR SHIPMENT

6.1 The exchanger shall be thoroughly drained, cleaned inside and outside and free
of all dirt and loose materials.
6.2 Carbon steel surfaces other than flange faces and other machined surfaces shall
have scale removed, be cleaned of oil, grease or other foreign matter, and be
painted in accordance with Engineering Specification “Painting Materials and
Application Requirements, PDVSA O–201”.
6.3 All exposed gasket surfaces shall be protected with rust preventive coating before
applying protective shipping covers. Protective cover type shall be specified by
the Owner.
6.3.1 Unpainted machined surfaces shall be protected from corrosion during shipment
and subsequent outdoor/indoor storage by coating with rust preventive equal to
those shown below.
REVISION FECHA
RUST–BAN GRADE (1)

SURFACE PETROLATUM BASE SOLVENT– OIL (3)
(HOT APPLICATION) CUTBACK TYPE
EXTERIOR, MACHINED 324 373, 392 –
INTERIOR, MACHINED OR THREADED – – 343
SPARE PARTS (2) 324, 326 373, 392 343
NOTES:
1. Grade selection to be based on expected exposure, removability requirements, etc.
2. After coating, suitable time shall be allowed for the protective film to set (cooling down of hot–dip
products and solvent evaporation of solvent–cutback products). The coated parts shall then be
wrapped in heavy, moisture–proof paper.
3. The oil–type rust preventives listed are viscosity (79 SSU at 100 °F or 14 CST at 40 °C) products
that provide a suitable coating for normal conditions.
6.4 Weld end and socket weld connections will be coated with deoxaluminite prior to
adding the protective covers.
6.5 The Owner’s order number and exchanger number shall be prominently marked
on the side of the shell with white paint in legible block letters at least 300 mm (12
inches) high.
6.6 Marking paint used on austenitic equipment shall contain no metallic pigments or
free chlorides.
6.7 Post weld heat treated shells, shell covers and/or channels shall be marked “DO
NOT WELD”.

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PDVSA

ENGINEERING DESIGN MANUAL

EA–201–PR SHELL AND TUBE HEAT EXCHANGE EQUIPMENT

1 JUL.94 GENERAL REVISION 18 L.T. E.J. A.N.

0 MAR.87 FOR APPROVAL 17 J.G. A.O.

REV. DATE DESCRIPTION PAG. REV. APPD. APPD.

E PDVSA, 1983 ESPECIALISTAS

1.2 Data Requirements

f. American Welding Society (AWS)

1.5 System of Measurements

a. These special types of units shall be of the manufacturer’s standard design.

2.2 Codes, Standards and Regulatory Requirements

2.6 Design Pressure

2.7 Design Temperature

2.8 Corrosion Allowance

2.9 Alloy Protective Lining

2.10 Shell Expansion Joints

3.2 Tubes and Tube Bundles

3.2.3 Except for exchangers of manufacturer’s standard design or special requirements

Radial Clearance Shell Diameter

c. The combined stress is defined as the maximum stress in the exchanger

3.4 Supports and Lifting Lugs

4.2 Weld Inspection

4.3 Post weld Heat Treatment

5 TESTING AND NAMEPLATE

6 PREPARATION FOR SHIPMENT

RUST–BAN GRADE (1)

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