Inspection of Heat Exchangers

Saad G.AL-Dufairi
BGP-Inspection Unit
July4,2005

Outline

Objective. Types of Heat Exchangers. Saudi Aramco Specifications, F175 Forms. Industrial Standards & Codes.

TEMA Classifications.
Air-Cooled Heat Exchangers. Primary Process Functions of Heat Exchangers.

Fabrication steps through ITP.

Objective

Identify the main types of heat exchangers and their

primary components..

Inspection, and testing procedures for heat exchangers.

Saudi Aramco Specifications and F175 Forms. Industry Standards And Codes.

Evaluate vendor fabrication drawings for suitability, using 32-SAMSS-007, 32-SAMSS-011, TEMA, and API standards. industry codes and standards to determine heat exchanger inspection and testing requirements.

Describe the use of 32-SAMSS-007, 32-SAMSS-011, and

Types of Heat Exchanger

The main types of heat exchangers that are used by Saudi Aramco are as follows:

Shell-and-tube heat exchangers Air-cooled heat exchangers Double-pipe heat exchangers Plate-and-frame heat exchangers

Types of Heat Exchanger Shellside Flow In Tubeside Flow Out Shell

Tube Bundle

Shellside Flow Out Tubeside Flow In

Shell-and-Tube Heat Exchanger

Types of Heat Exchanger

Tube Keeper (top) Lifting Lug Air Seal Header

Air Seal

Tube Nozzle

Air Seal

Header
Tube spacer Side Frame
Typical Air-Cooled Heat Exchanger

Fins Tube Support (bottom)

Types of Heat Exchanger

Shell Cover Gasket Vent Shell Cover Shell External Fin Pipe

Return Bend (welded) Drain Sliding Support Twin Flange Fixed Support Shell End Piece

Double-Pipe Heat Exchanger

Types of Heat Exchanger

Separating Sheet

Bin

Aout

Nozzle Header

Cin

Corrugated Sheet

Effective Width

Heat Transfer Section Effective

Side Bar Distributor

Length

Cout

Distribution Section

Ain

Bout

Plate-and-Frame Heat Exchanger2

SA Specifications
32-SAMSS-007 32-SAMSS-011 32-SAMSS-028
Exchangers SAES-E-004 Manufacture Of Shell And Tube Heat Exchangers Manufacture Of Air-Cooled Heat Exchangers Inspection Manufacture of Double Pipe Heat Design Criteria Of Shell And Tube Heat Exchangers Design Criteria of Double Pipe Heat Exchangers Design Criteria Of Air-Cooled Heat Exchangers Design Criteria Of Plate And Frame Heat Exchangers Design Criteria Of Electric Heat Exchangers

SAES-E-006
SAES-E-007 SAES-E-014 SAES-E-015

Saudi Aramco Inspection Requirements Forms SA F 175

Form 175-323100 Form 175-323500 Form 175-323600 Form 175-323300

Manufacture of Shell And Tube Heat Exchangers Floating Heads or Tube Bundles Manufacture of Air-Cooled Heat Exchangers Manufacture of Plate & Frame

Industrial Standards

ASME SEC VIII

D1/D2

Rules for Construction of Pressure Vessels Standards of the Tubular Exchanger Manufacturer's Association

TEMA

API 660
API 661

Shell and Tube Heat Exchangers for General Refinery Services

Air-Cooled Heat Exchangers for General Refinery Service

TEMA Classifications
TEMA Class Application Example
__________________________________________________________________________________________________________________________________________

R
C

Severe environments
Moderate service

Refineries
Building services, commercial, and general process industries

Chemical process

Chemical manufacturing

TEMA Classifications
Design Item Corrosion Allowance (carbon steel) Minimum Thickness of Shell Minimum Tie-Rod Diameter Gasket Contact-Surface Tolerance Class/Service R/Refinery 1/8 in. See Table R3.13 3/8 in. 1/32 in., max. in. C/General 1/16 in. See Table CB-3.13 in. None in. B/Chemical 1/16 in. See Table CB-3.13 in. None 5/8 in.

Minimum Bolt Size

TEMA Size and Type Normally Written: 23192 AES

23 Shell I.D.

Straight Tube Length 192 (16 0)

Type A Channel

Type E Shell Single-Pass

Type S Split-Ring Floating Head

TEMA Designation System Example

TEMA Types

Acceptable Exchanger Components Materials for Carbon and Alloy Steels

Design Temperature
Exchanger Component
(Note: The numbers in ( ) refer to the specific notes at the end of the table)

-100C - 47C (-150F - 51F) SA-203 Grades D or E

-46C - 0C (-50F - 32F) SA-516 Grade 70N, or SA-537 Class 1

1C - 425C (33F - 800F) SA-516 Grade 70 or SA-537 Class 1 or SA-285 Grade C (1)

351C - 645C (651F 1200F) SA-387 Grade 11

Shells, Channels, Dished Heads, Tube sheets, Rolled Nozzle Necks, Covers, and Reinforcing Pads Pips, Nozzle Necks

SA-333 Grade 3 SA-333 Grade 6 SA-106 Grade B SA-53 Grade B (1)

SA-335 P11, 12 or 22

Shell and Tube Heat Exchangers

Air-Cooled Heat Exchangers

Forced-draft
Air forced across tube bundle by fan located in air plenum

below bundle.

Induced-Draft
Fan located above hood covering tube bundle. Air pulled across tube bundle and exhausted through hood.

Humidified Forced-Draft
Air humidified before forced across tubes. Evaporation draws heat from air and cools air below

temperature of process fluid.

Air-Cooled Heat Exchangers

Inlet Nozzles Tube Bundle Return Header(s) Inlet Headers Outlet Headers Outlet Nozzles

Supports

Fan Drive Assembly

Plenum Fan Ring

Typical Forced-Draft Air-Cooled Heat Exchanger

Air-Cooled Heat Exchangers

Hood or Plenum Fan Ring Fan Inlet Nozzles Return Headers

Inlet Headers

Outlet Headers

Outlet Nozzles

Tube Bundle Drive Assembly

Supports Horizontal Tube, Induced-Draft Air-Cooled Heat Exchanger

Air-Cooled Heat Exchangers

Hot Air Tube Bundle Process Nozzle Partition Plate Header
Fine Water Mist

Header

Plenum Chamber

Process Nozzle Water Header Nozzles (above fan Typical)

Forced Draft Fan

Water Header Nozzles (below fan Sometimes)

Humidified Forced-Draft Heat Exchanger

Acceptable Materials for Fin fan cooler

Design Metal Temperature Exchanger |Component Header Plates, Pass Partition Plates and Stiffener Plates
(Note: The numbers in ( ) refer to the specific notes at the end of the table)

-46C to 0C (-50F to 32F)

SA-516 Grade 70N or SA-573 Class 1

1C to 425C (33F to 800F)

SA-516 Grade 70, or SA-537 Class 1 or SA-205 Grade C (1) SA-106 Grade B SA-53 Grade B (1) SA-179 or SA-214 SA-105N

351C to 645C (651F to 1200F)

SA-387 Grades 11, 12 or 22

Nozzle Necks Tubes (inner) (2) Forged Flanges, Forged Fittings, and Plugs Wrought Fittings

SA-333 Grade 6 SA-334 or SA-249 Type 304 SA-350 LF2

SA-335 P11, 12 or 22 SA-179 or SA-214 or SA-213 Type 304 SA-182 F11, 12, or 22 SA-234 F11. 12. pr 22

SA-420 WPL6

SA-234 WPB

Studs/Nuts for Pressure Connections

SA-320 L7 w/ SA-194 Grade 2H

SA-193 B7/ SA-194 Grade 2H

SA-193 B5, or B16/SA-194 2H, or 3

Primary Process Functions of Heat Exchangers

Change temperature of a fluid

Change phase of a fluid.

Fabrication steps through ITP

Fabrication drawing should be issued for constriction. Welding Procedure Specification (WPS) & Procedure
Qualification Record (PQR) shell be approved by CSD.

Material certificates to be 3.1B for pressure parts plus

NACE TM0284 for HIC service.

Certificate should include material chemical analysis &

mechanical test.

Verification of heat number between certificate and

actual material.

Material traceability. (hard punching prior to cutting)

Fabrication steps through ITP (2)

Layout marking for cutting of shell and header box. Rolling & edge preparation of long seam & circ seams. Re-rolling after long seam. Fit-up of long seams then circ seams. Layout marking of all nozzles pipe. Fit-up of flange to neck pipe. Marking of all nozzles on shell & channels.

Bevel edge preparation of nozzle opening.

Fit-up of nozzles to shell & Channels.

Fabrication steps through ITP (3)

Layout & drilling of baffle plate & tube sheet . Tube bundle preparation & assembling of tubes, tierods, spacers etc, to tube sheet.

Tube expansion to be between 5.0% to 10%. Post Weld Heat Treatments (PWHT) if required. NDE (RT, UT, MT & PT) and Hardness test. Final visual & dimensional test. Pneumatic test of all reinforcements pads at 30 KPA. Hydrotest of shell side, tube side then channels side.

Fabrication steps through ITP (4)

Draining the whole equipment. Verification of U stamp and name plate. Surface preparations, blasting then coating. Fin-fan coolers shall be completely drained with dry air to an exit dew point of less than -1C. as CORTEC VCI-309, VCI-307 or 5 PSIG of nitrogen blanket.

Internal surface protection by corrosion inhibitor such Shipment release.

Thank you