Data Base of Design Code

A. Shell & Tube Heat Exchanger (DECO-RX-M-SP-2111 Rev.C2)

B. Pressure Vessels (DECO-RX-M-SP-2009 Rev C3)

Sl No. Description ASME TEMA API 660 Mustang Spec IBR

A B
1.0 Design Data for Wind Load
1.1 Standard IS 875 Part 3 (3.3.4)
(A.) Basic wind speed (Vb) = 47m/s (B.) Risk Coefficient
1.2 Basic Details (K1) = 1.0 (C.) Terrain Category 1 (D.) Topography Factor
(K3) =1.0 (3.3.4)

2.0 Design Data for Siesmic Load

2.1 Standard IS 1893 Part 4 (3.3.5)
(A.) Zone III (B.) Structure Category =2 (C.) Importance
2.2 Basic Details
Factor = 1.75 (3.3.5)

3.0 Piping Loads on Nozzles Refer (3.3.11)

4.0 Cover Flange

4.1 Thick 85.879mm (Appendix-2) 94.367mm (RCB-9.21) NA
Equal To Corrosion Allowance (7.2.1)
4.2 Cladding or Overlay thick
NA as single pass Min Cladding of 3.2mm (R-9.22) Min Cladding - 2.5mm Thk & Min Overlay - 1.6Thk (7.2.2)
5.0 Channel Flange
5.1 Thick 77.155mm (Appendix-2) NA NA
Equal To Corrosion Allowance (7.2.1)
5.2 Cladding or Overlay thick
Min Cladding - 2.5mm Thk & Min Overlay - 1.6Thk (7.2.2)

6.0 Channel NA
6.1 Min Thick 6.8599mm (Appendix 1-1-a-1) 7.9 (Table R-3.13) 7.531mm Regl. 366
6.2 Pass Partition thick NA since single pass (Table RCB-9.131)
6.3 Dividing Plate Thick NA since single pass (Table RCB-9.131)

7.0 Shell
7.1 Min Thick 13.3mm (Appendix 1-1-a-1) 12.7mm (Table R-3.13) NA NA NA 11.47mm Regl. 366

8.0 Tube Sheet

(A.) 53.23mm is the required thick (RCB-7.132) (B.) Min
thick should be equal to Tube OD+ Corr. Allo. & not less
(A.) 55mm is the required thick (B.) Both the tube sheet is than 19.1mm including Corr. Allo. (R-7.131) (C.) Both the
8.1 Min thick of same thick (UHX-13) tube sheet is of same thick (RCB-7.13) NA
8.2 Tube hole NA Dia 25.7mm +0.05mm,-0.1mm (RCB-7.41 & Table 7.41)
8.3 Pass Partition groves NA NA (fixed tube sheet) (R-7.6)

9.0 Nozzles UG-37 to UG -45 NA

AS Per UG-45, Manufacturer Tolerance of ± 12.5% of
9.1 Sch. / Thick NA nozzle thick (3.5.6)
9.2 RF Pad Thick NA 9mm (
9.3 Nozzle Flange NA
NA

10.0 Baffles NA NA
10.1 Min Thick 9.5mm (Table R-4.41) Twice the corrosion allowance of shell I.e 6.4mm (7.6.3.1) 6.4mm (3.5.5)
Min Spacing- 0.2 Times of Shell ID or 51mm which ever is
greater I.e 229mm (RCB-4.51) Max Spacing - Table
10.2 Spacing RCB-4.52 I.e 1880mm NA
10.3 Notches NA Min 10mm Height (7.6.3.2)
Clearance between BaffleOD &
10.4 Shell ID 6.4mm (Table RCB-4.3) As per the TEMA Std. Table RCB 4.3 (9.1.3)
OD + 0.4mm I.e Dia 25.8mm & Over Tolerance of 0.3mm
10.5 Tube Holes (RCB-4.2)

11.0 Tie Rods NA

11.1 No. of 8 (TableR-4.71) NA
11.2 Dia 12.7mm (TableR-4.71) NA

12.0 Spacers NA
12.1 No Of. 8 NA
12.2 OD & BWG 19.05mm & 14 BWG (Table D7-M) NA

13.0 Impingement Plate NA 6.4mm (3.5.5)

13.1 Prepared 1 NA Plate or Rod (7.6.4.1)
13.2 Projection NA Min 25mm beyond the Nozzle bore. (7.4.6.2)
13.3 Shell & Tube Bundle Entrance Recommended good practice (Pg. 274) Shall not be less than flow area of the Inlet Nozzle (7.6.4.3)
13.4 Thick NA Min Nominal Thick 6mm (7.6.4.4)
13.5 Location NA Welding to at least two spacers. (7.6.4.5)

14.0 Shell Supports NA As per Dennies moss hand Book

14.1 Bearing Surface of saddle 1/3 of Circumference of Shell (7.3.2.b)
14.2 Bearing Plate vent holes Min 6mm dia located At the vertical Centerline (7.3.2.d)
14.3 Bearing Plate Thick Min 6mm & All corners rounded to 25 mm Radius (7.3.2.e)

Width is equal to Anchor Bolt dia plus 8mm Length

14.4 Slotted Holes Dimension is equal to Anch. Bolt dia + longitudinal Movement + 8 mm. (7.3.4)
15.0 Tube To Tube Sheet Joint
15.1 Type As per Appendix A, Table A-2 (Type Joint " f " ) NA Seal Welded & Expanded (Since Customer Specify)
15.2 Reduction in Tube Sheet thick NA NA

16.0 Nozzle & Other Connection NA

Nozzle Size is 40NB & greater it Shall be of Flanged (7.7.1) Flange
Shall be of Forged or Centrifugally-Cast Long Welding Neck Flange.
16.1 End Connection NA NA (7.7.4.a)
Slip-on Flanges Shall not be used when (A.) Pr. Exceeds 2070 Kpa;
(B.) Design Temp. Exceeds 400° C; (C.) Corr. Allowance Exceeds
3mm (1/8in). (7.7.5)
Nozzle Projection outside the Min space to be provided for the removal of bolting form either side
16.2 Vessel NA NA of Flange with out removing insulation (7.7.7)
Nozzle Should not be protrude beyond the inner surface of Nozzle Should not be protrude beyond the inner surface of Vessel
16.3 Nozzle Projection inside the Vessel NA Vessel (RCB-10.1) (9.3)

17.0 Flanged External Girth Flanges

Forged Weld Neck Unless other wise agreed by the Purchaser
17.1 Flange Type NA NA (7.8.2)
17.2 Nubbins NA NA Not to be used (7.8.3)

18.0 Gaskets
Gasket width is of Min 25mm for Flange ID upto 900mm &
Min 32mm from 900mm to 1500mm & Min 38mm over 9.5mm for Shell Nom. Dia of < 584mm & 12.7mm for Shell
18.1 Gaskets width 1500mm Nom. Dia of > 584mm (RC-6.31) NA
6.4mm for Shell Nom. Dia of < 584mm & 9.5mm for Shell
18.2 Pass partition gasket width NA Nom. Dia of > 584mm (RCB-6.4) NA
18.3 Gasket Joint NA Confined type Should be of One Piece Design (7.10.3)
18.4 Asbestos fill NA NA Should not used (8.2.1)
Such that Base & Filler material should with stand Max. Design temp
18.5 Material Selection As Per Appendix - 2 Table 2-5.1 NA (8.2.5)

19.0 Corrosion Allowance

19.1 Carbon Steel 3.2mm or As per Data Sheet (3.2.1)
19.2 Alloy Material AS per Data sheet (3.2.1)

20.0 Lifting Device NA

Shall be weld on lug or ring to be Provided with hole of min 38mm
20.1 Location NA NA Dia (7.11.1)
20.2 Lifting Lug to be Designed for NA Recommended Good Practice (Pg. 272) Twice the mass of Component (7.11.1)

21.0 Tubes
21.1 Tube Dia NA (Table RCB-2.21) Min 19.05mm
21.2 Tube Wall Thick NA 1.65mm (Average) (alloy material) (7.6.1.2) 2.3mm Min Regl. 631
21.3 Tube Length NA
To be Carried out for the welded tubes in finished Condition over full
21.4 Eddy Current test NA Length (8.3.2)
Extansion of tube beyond the May be Flush with tubesheet or Should not more than 0.5
21.5 tube sheet times of tube OD (RB-7.513) NA 4 mm Extansion & 15° Flering to be done on the edge
21.6 Tube Pitch NA 1.25 times the tube OD (R-2.5) NA
50.8mm or tubesheet thick minus 3.2mm which ever is
21.7 Length of expansion of tubes smaller (RB-7.511)

22.0 General
Castings Shall not be used un less approved by the Purchaser
22.1 Casting materials NA NA (8.1.2)
MOC of parts Connecting to Heat
22.2 Exchanger NA NA Same material of Connecting Parts (8.1.3)
Weld Overlay, integrally-Clad Or Explosion bond are Permitted. But
Loose Liners or Sleeves Shall not be used with out Approval of
22.3 Alloy Lining NA Purchaser (8.1.4)

23.0 Welding
23.1 Welding Process NA Oxyacetylene gas welding. Should not used (9.5.1)
(A.) Category A & B and shall be comply with pressure design code
23.2 Full Penetration weld NA (9.5.2); (B.) All attaching connections to the Vessels (9.5.3)
When the nozzle is Fab. From plate shall be Examined By means of
23.3 Examine for lamination Magnetic particle or liquid penetrent method. (9.5.4)
23.4 Continuous Weld for the no pressure parts such as (such as lugs or supports) (9.5.8)
Repair-associated Welding
23.5 Procedure To be submitted to the purchaser (9.5.9)

24.0 Post weld Heat Treatment

(A.) With six & more tube passes (9.6.4.a); (B.) With one tube pass
whose Nozzles are not axial & Cylinder-to-nozzle diameter ratio are
24.1 Fab. CS Channel & Bonnet NA As per Code 2 or less. (9.6.4.b) NA

25.0 Dimensional Tolerances NA F-1 (Pg No. 6) NA

(A.) For Elevation ± 1.6mm, (B.) 0.5° for orientation, & (C.)
25.1 Nozzle For projection ± 1.6mm (6.7.2)
25.2 Seam to Seam 0.13mm per 300mm of length

26.0 Gasket Contact Surface Finish

26.1 Double jacketed To be as per Appendix 2, Table 2-5.1 NA 1.6 to 3.2 micrometers ( 63 to 125 microinches) (9.8.1 table-2)

27.0 Flatness Tolerance on Peripheral Gaskets Contact Surfaces

27.1 751 to 1125 Nom. Dia NA ± 0.8mm (R-6.23) Tolerance is ± 0.20 mm ( ± 0.008 in) (9.8.3 table-3))
27.2 >1125 Nom. Dia NA Tolerance is ± 0.20 mm ( ± 0.008 in) (9.8.3 table-3)

28.0 Tube Hole Grooves

28.1 Edge Preparation Free from burs (RCB-7.43) Square Edged, Concentric & free from burs (9.9.1)
28.2 Machined of tube holes Dia 25.7mm +0.05mm-0.1mm (RCB-7.41 & Table 7.41) As per TEMA Std. Table RCB-7.41 column (b) (9.9.3)
At Least 2 grooves of at least 3.2mm wide & 0.4mm deep
28.3 No. of Grooves in tubesheet (RB-7.44)

29.0 Assembly
29.1 Match marks or dowels NA To be provided for Channel cover to Channel (9.11.1.c)

30.0 Quality Control

(A.) As per the Pressure Design code (10.2.1) (B.) At least one
radiograph to be made for of each category A & B welded joints,
nozzle welds are Exempted. (10.2.1.a). (C.) shall include each start
& stop of welds made by the automatic sub merged arc welding.
30.1 Radiography Full Radiography (100%) As per UW-11-a-3 & UW-11-a-4 As Per Code (10.2.1.b). (D.) Shall be carried at lest 250mm long (10.2.1.c)

(A.) Weld metal and heat affected zone of pressure retaing welds to
be tested (10.2.5.a) (B.) Examination Shall be made after any
required PWHT (10.2.5.b) (C.) Brinell hardness For CS-225
HBW(10.2.5.c), Hardness to be termained by using 10mm Dia ball
(10.2.5.d) (D.) One longitudinal weld, one cicumferetial weld, &
connection-to-component weld if the connection is Greater than 2"
shall be tested (10.2.5.e). (E.) If more thn one welding procedure is
used , hardness readings shall be made of weld deposited by each
30.2 Weld Hardness Test NA procedure (10.2.5.f)
(A.)Striped section of base material & the weld shall be examined by
magnetic particle method prior to applying weld overlay. (10.2.6) (B.)
Prior to the Fab. Integrally clad material to be subjected to ultrosonic
Examination from clad side as per the Pressure design Code.
30.3 Alloy clad construction NA (10.2.10).

31 Pressure Testing
31.1 Tube to tube sheet joint
31.2 Hydrostatic test
31.3 Pneumatic test
31.4 Paint & other Coating
Tube weld integrity to be verified before expanding the tubes by a
pneumatic test from shell side at a gauge Pr. Between 50 Kpa to
NA 100Kpa. Using soap water (10.3.1)
(A.) Independent hydrostatic test of shell side & tube side shall be
(A.) Test Pr. to be held for at least 30 Minutes (B.) Shell performed. Min Temp. for testing is as per the pressure design code.
side 7 Tube Side are to be tested seperatly (C.) Min (10.3.2) (B.) Hydrostatic test pressure shall be maintained for at
UG99-B Hydrotest Pr. Is As per code (RCB-1.31). least 1Hr. After the completion of test. (10.3.3)
(A.) Nozzle reinforcement pad to be tested for 170Kpa.(10.3.6). (B.)
If any supplementary pneumatic test shall be carried at a nominal Pr.
NA Of 170 Kpa.(10.3.7)
NA Shall be applied over welds before the final hydrostatic test. (10.3.9)

32.0 Name Plate & Stamping RT-2

32.1 Name plate material SS 300 series (G-3.1) SS plate (to be visible after the insulation) (10.4.1)
32.2 Location To be on the shell near the channel end (10.4.2)
32.3 Min data to be entered As per ASME code & Eqpt No. & Order No. NA
32.4 Stamp of Manufacturer's serial No. To be stamped on Channel flange, Channel Cover, Tube sheet (10.4.3)

Drawing

33.0 Outline Drawing for Review to the purchaser see the Attachments (6.1)

34.0 Information to be sent after drawing reviewed see the Attachments (6.2)

35.0 Documents to be submitted for review to purchaser see the Attachments (6.2.4)

36.0 Reports & Records see the Attachments (6.3)