FF-178-12-2211-S003 Shell & Tube Heat Exchanger Specification - B PDF
April 19, 2023 | Author: Anonymous | Category: N/A
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DESARRROLLO DE LA INGENIERA CONCEPTUAL Y B#SICA DEL PROYECTO DE EXPANSI%N DE PRODUCCI%N DE 105 9) MBD A 160 MBD (ARIAL 9)
N Documento PSSA :
N Proyecto : P!gina :
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5083E
DESIGN BASIC DESIGN
Rev.
5083E-1-FFX-D-2310-M4DETN-0001
B
SHELL & TUBE HEAT EXCHANGER SPECIFICATION FS
B A REV.
16/04/12 23/03/12 23/03/12 FECHA
14 14 P &G
NCORPORACI$N DE COMENTARIOS EMISI$N PARA COMENTARIOS DESCRIPCI$N
DERECHOS RESERVADOS Este documento es propiedad de PSSA. No se permite la divulgaci (n u otro uso de este documento sin la previa autorizaci( autorizaci ( n escrita de PSSA.
LXB LXB
WW / ZXG
WW / ZXG REV. APROB. ELAB. APROB ICHQ No. Documento HQCEC
APROB. PSSA
5083E-04-2000-M20-111-002 Archivo Electr (nico:
FF-178-12-2211-S003_ SHELL & TUBE HEAT EXCHANGER SPECIF ICATION _Rev B.
FF-178-12-2211-S003_B
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DESARRROLLO DE LA INGENIERA CONCEPTUAL Y B#SICA DEL PROYECTO DE EXPANSI%N DE PRODUC PRODUCCI CI%N DE 105 9) MBD A 160 MBD (ARIAL 9)
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CONTENT 1 GENERAL GENERAL ........................................................... ...................................................................................... .....................................................3 ..........................3 1.1 Scope ..................................................... ............................................................................... ........................................................ ..................................... .......3 3 1.2 Codes, Standard and Specifications......................... Specifications....................................................... .............................................3 ...............3 2 DESIGN............................. DESIGN....................................................... ........................................................ ........................................................... ............................... ..5 5 2.1 General................................ General............................................................. ........................................................ .....................................................5 ..........................5 2.2 Shell and Channel ....................................................... .................................................................................. ..........................................5 ...............5 2.3 Tubes ..................................................... ............................................................................... ........................................................ ..................................... .......6 6 2.4 Tubesheets.......................... Tubesheets....................................................... ........................................................ .....................................................6 ..........................6 2.5 Tubebundle .............................................. ............................................................................ ........................................................... ............................... ..7 7 2.6 Connections Connections ........................................................ ...................................................................................... ..................................................7 ....................7 2.7 Gaskets .................................................. ............................................................................ ........................................................ ..................................... .......9 9 2.8 Structural.......................................................................... Structural........................................................................................................... ..................................... ....9 9 2.9 Bolting .............................................. ............................................................................ ........................................................... ..................................... ........10 10 3 INSPECTION AND TESTS TESTS ................................................. ............................................................................ ................................... ........11 11 4 PREPARATION PREPARATION FOR SHIPMENT..................................... SHIPMENT.................................................................. .....................................1 ........12 2 5 NAME PLATES ........................................................... ...................................................................................... ...........................................13 ................13 6 GUARANTEE GUARANTEE .............................................. ............................................................................ ...........................................................14 .............................14
FF-178-12-2211-S003_ SHELL & TUBE HEAT EXCHANGER SPECIFI CATION _Rev B.
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DESARRROLLO DE LA INGENIERA CONCEPTUAL Y B#SICA DEL PROYECTO DE EXPANSI%N DE PRODUCCI%N DE 105 9) MBD A 160 MBD (ARIAL 9)
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1.
GENERAL
1.1.
Scope
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This Specification together with referenced codes and standards, Data Sheets, standard drawings and requisition defines technical requirements for the design, material, fabrication, testing and inspection of shell & tube heat exchangers for *Expansion of the Area of Morichal and Jose Blending Plant from 105 MBD to 160MBD+. Any deviations deviations from these specifications specifications are not acceptable, acceptable, unless prior notification of such has been submitted, received and approved by the CLINENT or its representative only, in writing. Therefore the VENDOR shall be held responsible for the required engineering design, material procurement, fabrication, testing and shipment of all equipment assigned to him by the CLINENT in accordance with these specifications. Any special requirements requirements not covered by by the scope scope of these these specifications specifications shall be clearly indicated on Data Sheets. Where conflict occurs between special requirements, these specifications, or the requirements of the Code, it shall be the duty of the VENDOR to call such discrepancies to the attention of the CLINENT, who shall make final disposition of the problem. This specification covers the general requirements for shell & tube heat exchangers. 1.2.
Codes, Standard and Specifications All shell & tube heat exchangers exchangers shall be designed, fabricated, fabricated, tested and inspected in accordance with the requirements of this specification and the Code, Standards and Specifications listed in following paragraphs. All shell & tube heat exchangers exchangers in this class c lass shall bear a nameplate properly stamped with the Code Symbol. The requirements of the ASME Pressure Vessel Code referred to in the preceding paragraph shall be considered as the minimum requirements. All shell & tube heat exchangers shall be registered with the National National Board of Boiler and Pressure Vessel Inspectors, except as noted on Data Sheets The specification requires compliance with all applicable Venezuelan and international Codes. The following codes, standards and specifications, at latest edition, including applicable addenda, shall form a part of this specification
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5083E
BASIC DESIGN DESIGN
Rev.
5083E-1-FFX-D-2310-M4DETN-0001
B
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) (ASME) l
SECTION II, Material Specification SECTION V, Non-Destructive Examination. Examinat ion.
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SECTION VIII,DIV.1&2,
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Rules for Construction of Pressure Vessels,
SECTION IX, Welding And Brazing Qualifications. Qualificat ions.
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ASME B46.1 Surface Texture (Surface Roughness, Waviness, and Lay)
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ASME B16.5 Pipe Flanges and Flanged Fittings Fitting s
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ASME B16.47 Large Diameter Steel Flanges(Series A)
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ASME B16.20 Metallic Gaskets Gaskets For Pipe Flanges - Ring-Joint,Spiral-Wound, Ring-Joint,Spiral-W ound,
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And Jackete Jacketed d ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
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TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA) PETROLEOS DE VENEZUELA (PDVSA) PDVSA D-211 Pressure Vessel Design and Fabrication Specification
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PDVSA EA-201-PR Shell and and Tube Heat Exchange Equipment.
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PDVSA JA-221 Dise,o Sismorresistente de instalaciones industriales
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PDVSA JA-222 Dise,o sismorresistente de recipientes y estructuras
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PDVS PDVSA A MD MDPP-05 05--01 PRIN PRINCI CIPI PIO OS BASI BASIC COS
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PDVSA O-201 SELECCI SE LECCI$N Y ESPECIFICACIONES DE APLICACI$N DE SISTEMAS PROTECTIVOS DE P INTURAS
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PDVSA L-212 * Aislamia Aislamianto nto Termico para Tuberias Tuberias y Equipos Equipos de Servicio Servicio en Caliente
PDVSA 90617.1.041 *Intercambiadores de Calor de Carcasa y Tubo
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Metallic Gaskets Gaskets for Raised-Face Pipe Flanges and Flanged Connections Connections (Double-Jacketed Corrugated and Spiral Wound)
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API Standard Standard API 660 Shell and Tube Exchangers For general Refinery Service.
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PROJECT SPECIFICATIONS: FF-1 FF-178 78-12 -12-2 -2211211-S0 S001 01 Mecha Mechani nical cal Equipm Equipmen entt de desig sign n Criter Criteria ia
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FF-1 FF-178 78-1 -122-22 2211 11-S -S00 002 2
Pr Pres essu sure re Ve Vesse ssell Spec Speciifica ficati tion on
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FF-1 FF-178 78-12 -12-2 -2311311-S0 S006 06
Engin Engineer eerin ing g Specifi Specificat catiion for for Painti Painting ng
FF-1 FF-178 78-12 -12-2 -2311311-S0 S005 05
Engin Enginee eeri ring ng Speci Specifi ficati cation on for Insul Insulati ation on
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2.
DESIGN
2.1.
General
Rev.
B
Heat Exchangers shall be designed, fabricated, tested and stamped in accordance with the latest edition of ASME Section VIII, Division 1 and TEMA class *R+ requirements. Mechanical design shall be also in accordance with the referenced Pressure Vessels Specification Specificat ion FF-178-12-2211-S00 FF-178-12-2211-S002. 2. Heat exchangers shall be stamped with a MAWP equal to that of the limiting component at the specified design temperature. Nozzle reinforcement shall not be the pressure limiting component in the exchanger design. The pressure limiting component shall be identified on VENDOR drawings. Pressure used for the design of tube-sheets, floating head, covers and other internal pressure containing parts shall use the value specified at specified temperatures for either the shell or tube side design that results in the greater thickness of the part being considered. Tube-sheets, floating head covers and other internal pressure containing parts shall have their minimum design metal temperature less than or equal to the minimum value that is specified for shell or tube side design. Expansion joints shall not be used unless approved by CLIENT. No corrosion allowance shall be added to baffles, supports, partition plates, internal bolting, floating head backing devices, or nonferrous parts. Stainless steel nameplate shall be supplied and installed on a readily visible part of the exchanger, in accordance with the referenced Pressure Vessels Specification Specificat ion FF-178-12-2 FF-178-12-2211-S00 211-S002. 2. Stacked units shall be shop-assembled to check saddle and nozzle fit up. 2.2.
Shell and Channel Channels shall be forged, or built-up welded construction. Shell and channel girth flanges shall be of forged steel, only hub type flanges shall be used.
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B
Thru-bolt joint construction shall be used for all shell and channel girth flanges. Jack screws shall be provided to aid in breaking all assembled girth flanges. Vertical units with removable bundles mounted with the channel down shall be provided with a system for supporting the tube-sheet when the channel is removed which shall be at least four collar bolts, or other means approved by CLIENT to hold bundle with channel off. Shells having longitudinal baffles (TEMA configurations *F+ and *G+) shall not be used unless approved by CLIENT. 2.3.
Tubes 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: l Carbon Steel, C-12 Mo steel or 3 0 Ni Steel tubes: Seamless, 1+ OD x 14 BWG thick or 1+ OD x 12 BWG thick, average wall Low chrome moly steel (up to 9% Cr) tubes: Seamless, 1+ OD x 14 BWG
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thick or 1+ OD x 12 BWG thick, average wall High chrome moly moly steel or copper-alloy copper-alloy tubes: tubes: Seamless, Seamless, 1+ OD x 16 BWG
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thick or 1+ OD x 16 BWG thick, average wall. Each U-tube shall be formed from a single length of tubing. Carbon and low alloy steel U tube bends having a mean radius smaller than 5 times thebe nominal shall not used. tube diameter shall be stress relived. Copper based alloys Seamless tubes shall be used. 2.4.
Tubesheets Tube to tube-sheet joint shall be as indicated on data sheet. Rolled only tubes shall project a minimum of 2 mm beyond the tube side face of the tube-sheet. tube-sheet. Fabrication and welding procedures for seal welding of tube-to-tube-sheet joints shall be approved by by CLIENT. CLIENT. Removable bundle U-tube tube-sheets shall be full diameter designs.
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Tube-sheets shall be fabricated from forged materials when integral tube-sheet with shell and/or channel will be used or when extended for use as a flange. For removable bundles four tapped holes for eyebolts shall be provided in the face of the stationary tube sheet for use in pulling the bundle. In operation these shall be protected by removable threaded plugs of tube-sheet material. When the tube-sheet is too small to allow four holes, two are sufficient. 2.5.
Tubebundle Kettle re-boilers shall have bundle hold down straps to prevent damage to the bundle during shipment, and shall be provided with slide rails and holding bars. Bundle diameter shall not exceed 60 inches diameter (1524 mm) unless approved by purchaser. Impingement protection shall be provided by a plate or distributing belt if indicated on the data sheet or required by TEMA. Preferred tube lengths shall be 16 ft or 20 ft however tubes lengths of 7.8 ft, 9.8 ft, 12 ft , 24 ft and 30 ft. may be used for specific requirements, unless approved by purchaser. Removable tube bundles weighing over 12000 Lbs (5445 Kg) shall be provided with skid bars to prevent damage to the shell or bundle when removing or installing the bundle. When requested by CLIENT, the VENDOR shall submit the flow induced vibration calculations per TEMA Section 6 for review. Modifications to the bundle design may be made upon mutual agreement between CLIENT and VENDOR. A minimum of two longitudinal 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 follow: Radial Clearances Shell Diameter
2.6.
Over 1+ (19mm)
To 27+ (690 mm)
Over 1+ (25 mm)
28+ (710) and over
Connections Nozzle sizes and type shall be as indicated on the data sheets, and in accordance with the Pressure Vessel Specification FF-178-12-2211-S002.
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Rev.
B
Nozzle lengths shall be long enough to permit the removal of a standard length stud bolt from the back side of the flange and clear the exchanger shell and insulation. Nozzles shall be installed by inserting the neck of the flange, the coupling or the pipe nipple through the vessel wall and welded with full penetration welds (Abutting Type). Reinforcements shall be attached at the nozzle with full penetration welds. Thread-o-lets, sock-o-lets and weld-o-lets shall not be used. All nozzle connections connections on exchangers exchangers in vibrating or pulsating pulsating services, shall have mechanical reinforcement in the form of weld pads at least equal to the cut away area. Vibrating or pulsating conditions shall be indicated in data sheets. Nozzles shall be one of the following types: l Integrally Integrall y reinforced long welding neck flanges. Seamless pipe neck jointed jointed to a standard forged Welding Neck flange.
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Slip on flanges shall not be used. Nubbin finishes on flange gasket surfaces are not acceptable. All threaded connections shall be furnished with a forged solid bull plug. Vent Ve nt and drain connections shall be in accordance with the TEMA Standards, unless specified on data sheets. All high and low points on shell and tube sides not otherwise otherwise vented or drained drained shall be provided with 1+ (19mm) minimum sized drain and vent connections. Minimum nozzle size connection shall be 2 inches; all connections shall be flanged. Vendor shall include nozzles for steam out and shall design for external pressure conditions in accordance with indicated in the heat exchangers data sheet. Each flanged nozzle shall be provided with a pressure gauge connection and a thermometer connection as defined in the heat exchanger data sheet. Pressure gauge and thermometer connections shall be included in the stacked connections of units connected in series. The vent, drain and thermometer connections shall be flanged. The pressure connections shall be constructed of couplings or bosses threaded with ANSI standard pipe threads. FF-178-12-2211-S003_ SHELL & TUBE HEAT EXCHANGER SPECIF ICATION _Rev B.
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Rev.
B
Each coupling shall be supplied with a forged steel bull plug. Flanged connections with covers shall be furnished only when specified by The Owner. 2.7.
Gaskets Flat metal, jacketed non asbestos filled shall be used for girth flanges, other type may be used if approved by CLIENT. Materials for metal clad gaskets shall be selected by the Vendor for the design service conditions and shall subject to Owner /s approval. approval. Spiral wound, 316 SS, shall be used for the nozzles flange. Gasket seating surface finishes for non metallic and jacketed metallic gasket shall be the Commercial Standard Spiral Serration. Spiral wound gaskets shall seat against finishes of surface 125-250 Imperfections extending radically acrosssurface the gasket seating areAARH. not acceptable. Two sets of spare gaskets for start-up shall be furnished by Vendor for each heat exchanger. exchanger. Gasket material shall be as indicated on data sheets. Based on service and design conditi co nditions. ons.
2.8.
Structural The heat exchanger shall be designed to withstand wind and earthquake loads calculated per ASCE and PDVSA. Units which are to be stacked shall be provided with the required additional Intermediate supports and bracing. The shells shall be reinforced as required to carry the imposed loads and allow pulling of removable bundles. An impact load of 1.5 will be used. Suitable lifting lugs shall be provided for supporting stationary channels, or bonnets and removable covers. On the bottom exchanger of stacked exchanger, two lifting lugs each located 45 from the top centerline shall be provided on floating head covers, shell covers and bonnet type channel covers. Saddle pads shall be installed between the equipment and its corresponding supports: external pads shall be fabricated from the same material as used for the shell s hell.. Shell and saddle reactions shall be checked using L.P Zick method.
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Rear saddle support and intermediate supports for horizontal units shall be provided with slotted holes to allow for expansion. Each cover shall be provided with a plate type welded on lifting lug with 1 inch diameter hole located on top centerline, wherever possible. 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 bundles from shell. 2.9.
Bolting External bolting for manways, shell and channel girth flanges, and pipe connections shall be through bolts and hex nuts. Unless indicated otherwise on the Exchanger Data Sheets all external bolting shall conform to the following ASME specifications. Design Temperature,
Stud
Nuts
C
-101 to 228
SA-320 Gr. L 7
SA-194 Gr. 4
-29 to 454
SA-193 Gr. B 7
SA-194 Gr. 2H
454 to 593
SA-193 Gr. B16
SA-194 Gr. 7
593 to 816
SA-193 Gr. B8
SA-194 Gr. 8
Internal bolting shall be selected on the basis of shell material (clad or solid) and moist H2S content as follow:
Shell Material Materia l Carbon Steel
Stud
Nuts
SA-193 Gr B7
SA-194 Gr 2H
SA-193 Gr B7M
SA-194 Gr 2M
Low Alloy Steel
SA-193 Gr B7
SA-194 Gr 2H
5% Chrome
SA-193 Gr B5
SA-194 Gr 3
(less than 100 PPM H2S) Carbon Steel (more than 100 PPM H2S)
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Bonnet Material 13% Chrome 18-8 All types Nickel Copper (Monel) Aluminum Alumi num
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DESIGN BASIC DESIGN
Stud SA-193 Gr B8 SA-193 Gr B8 Monel SA-193 Gr B8
5083E-1-FFX-D-2310-M4DETN-0001
Rev.
B
Nuts SA-194 Gr 8 SA-194 Gr 8 Monel SA-194 Gr 8
Material for bolting in units with design temperatures below 230C (-22 F)() shall be selected from suitable grade of ASME SA-320. Welding procedures, welder performance and welding processes shall be qualified in accordance with ASME Code Section IX and subject to Owner /s approval. Backing strips may be used withstrips. Owner /s written approval. Consumable inserts are not considered as only backing All fillet fillet welds for saddles, saddles, supports, supports, lugs, lugs, etc. shall have a continuous continuous weld. weld. 3.
INSPECTION AND TESTS CLIENT will make inspections of exchangers during construction, inspect exchangers before and after final closure, witness hydro test and make final inspection of all exchangers prior to shipping. VENDOR shall give to CLIENT one week notice prior to closure, to test and for final inspection. VENDOR shall provide access and facilities to CLIENT to inspect all materials, certificates and work in progress. All radiographic films and the records of examinations shall be available for review. CLIENT may waive the right to witness whatever test and inspections. Personnel performing Non-Destructive Examination shall be qualified in accordance with ASNT-TC-1A. Post weld heat treating other than required by the specified Code, TEMA or this specification shall be indicated on the Exchanger Data Sheet. Exchanger shall be thoroughly cleaned. All dirt, weld splatter, mill scale and loose material, along with any grease, oil or other hydrocarbon contaminants, shall be removed prior to post weld heat treatment. The hydrostatic test pressure shall be as specified by Code and shall not be less than 1.3 times the MAWP (New and Cold) for shop and 1.3 times the
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5083E
DESIGN BASIC DESIGN
5083E-1-FFX-D-2310-M4DETN-0001
Rev.
B
MAWP (Corroded and Hot) for field, corrected by temperature and held for 1 hour minimum. Test water temperature shall be 30 F above of the exchanger MDMT, unless approved by CLIENT. Potable water shall be used for hydro-test of all carbon and low alloy steel equipment. For hydro-testing of austenitic stainless steel exchangers or exchanger /s sections, the chloride content in water test shall be less than 50 PPM. Stacked Exchangers shall be hydrostatically tested in the stacked position. Testing rings required for the test of floating head exchangers, shall be furnished with the exchanger in accordance with quantity indicated in the data sheet. The VENDOR shall take precautions to avoid, localized hard spots of the type caused by arc strikes, ground clamp burns, tack welding of alignment aids, etc. VENDOR/s inspection of the pressure vessel shall assure that localized hard spots are avoided and removed prior to hydro-test. Heat exchangers shall be immediate draining and drying after hydro-test. Stainless steel or clad equipment shall be drying by blowing air through the exchanger section. As minimum the exchanger exchanger shall be spot radiographed. radiographed. CLIENT CLIENT inspector inspector shall have the prerogative of determining the two or three minimum radiography locations and designating additional locations as judged required. All tube-sheet made made from from plates shall shall be ultrasonically ultrasonically inspected per SA 2 435. Each welding procedure qualification record (PQR) shall include Brinnell hardness test results for the weld and H.A.Z. Brinnell hardness test may be performed or required by CLIENT Inspector, on the weld and H.A.Z to check if welding procedure has been properly applied. The individual hardness readings shall not exceed a hardness equivalent to Rockwell *C+ 13 or Brinnell 200 (steel ball). Gaskets and test rings shall be supplied by Vendor.
4.
PREPARATION FOR SHIPMENT
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DESIGN BASIC DESIGN
5083E-1-FFX-D-2310-M4DETN-0001
Rev.
B
The purchase order number and exchanger item number shall be prominently marked in the equipment nameplate, and on the side of the shell it shall be marked with white paint in legible block letters at least 12 inch high. Individual exchanger components, such as channel cover, bonnet, tube-sheet, and shell, shall be permanently tagged or marked with assigned plant equipment number. All exposed gaskets gaskets surfaces surfaces shall be protected with rust preventive coating before applying protective shipping covers. Protective cover type shall be specified by the owner. Unpainted machined surfaces shall be protected from corrosion during shipment and subsequent outdoor/indoor storage by coating with rust preventive. 5.
NAME PLATES A stainless stainless steel nameplate nameplate shall be supplied supplied and mounted on the heat exchangers in accordance with the instruction indicated on the drawings or Heat Exchanger Data Sheet. The official ASME Code symbol shall be stamped on the nameplate and as otherwise required by the respective division of the ASME Code, Section VIII, or local authorities having jurisdiction over the installation. The required ASME Code stamping information shall be on a nameplate of AISI Type 304 stainless steel attached to a bracket welded to the shell. The brackets shall extend 3 in. outside shell or insulation. Nameplate shall be provided with the following minimum information: Purchase order number. Item number. Item service. The serial number and the year built. Design pressure (both sides). The maximum allowable working pressure (both sides). The design temperature (both sides).
FF-178-12-2211-S003_ SHELL & TUBE HEAT EXCHANGER SPECIF ICATION _Rev B.
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DESARRROLLO DE LA INGENIERA CONCEPTUAL Y B#SICA DEL PROYECTO DE EXPANSI%N DE PRODUCCI%N DE 105 9) MBD A 160 MBD (ARIAL 9)
N Documento PSSA : FF-178-12-2211-S003 FF-178-12-2211-S003
N Proyecto : P!gina : 178
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N Proyecto ICHQ Fase del Proyecto N Documento ICHQ :
5083E
DESIGN BASIC DESIGN
5083E-1-FFX-D-2310-M4DETN-0001
Rev.
B
The test pressure (both sides). The effective surface. The ASME code stamp. Manufacturer /s name n ame and serial number. 6.
GUARANTEE VENDOR shall guarantee the mechanical design of the equipment when operating at the design conditions. This guarantee covers any fabrication defect or any problem due to improper mechanical design including vibration damage. VENDOR shall guarantee equipment to or be replace free fromatdefects in expense workmanship and/or material and shall all agree to repair his own any part proving defective within the period of time as specified on the commercial contract.
FF-178-12-2211-S003_ SHELL & TUBE HEAT EXCHANGER SPECIF ICATION _Rev B.
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