DEC 01 DESIGN AND MANUFACTURE OF GEMS E-1M19

SHELL AND TUBE HEAT EXCHANGERS

TABLE OF CONTENTS
PAGE

1. SCOPE ............................................................. 3

2. REFERENCES ........................................................ 3
2.1 Purchaser Specifications .................................... 3
2.2 Purchaser Drawings .......................................... 3
2.3 Industry Codes and Standards ................................ 3

3. GENERAL ........................................................... 5

4. DEFINITIONS ....................................................... 5
4.1 General Definitions ......................................... 5
4.2 Service Definitions ......................................... 5

5. PROCESS DESIGN .................................................... 6

5.1 General ..................................................... 6
5.2 Surface ..................................................... 6
5.3 Heat Transfer Rate .......................................... 6

6. MECHANICAL DESIGN ................................................. 7

6.1 General ..................................................... 7
6.2 Corrosion Allowance (CA) .................................... 8
6.3 Design Pressure ............................................. 8
6.4 Design Temperature .......................................... 8
6.5 Minimum Design Metal Temperature (MDMT) ..................... 8
6.6 Maximum Allowable Working Pressure (MAWP) ................... 8
6.7 Allowable Stresses .......................................... 9

7. DESIGN DETAILS .................................................... 9

7.1 Shell Supports .............................................. 9
7.2 External Attachments ........................................ 10
7.3 Tubes ....................................................... 10
7.4 Shells and Shell Covers ..................................... 10
7.5 Baffles and Support Plates .................................. 11
7.6 Floating Heads .............................................. 11
7.7 Gaskets ..................................................... 12
7.8 Tubesheets .................................................. 13
7.9 Channels and Channel Covers ................................. 13
7.10 Nozzles ..................................................... 14
7.11 End Flanges and Bolting ..................................... 15

8. MATERIALS ......................................................... 16
8.1 General ..................................................... 16
8.2 Tubes ....................................................... 16
8.3 Shell and Shell Covers ...................................... 16
8.4 Bolting ..................................................... 17

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8.5 Forgings .................................................... 18

9. FABRICATION ....................................................... 18
9.1 Welding ..................................................... 18
9.2 U-Bends ..................................................... 18
9.3 Tube Joints ................................................. 19
9.4 Gasket Contact Surfaces Other than Nozzle Flange Facings .... 20
9.5 Heat Treatment .............................................. 20
9.6 Component Identification .................................... 21

10. INSPECTION AND TESTING ............................................ 21

10.1 Radiography ................................................. 21
10.2 Hydrostatic Testing ......................................... 21
10.3 Shop Testing ................................................ 21
10.4 Field Testing (By Others) ................................... 22
10.5 Inspection .................................................. 22

11. PAINTING .......................................................... 22

12. PREPARATION FOR SHIPMENT .......................................... 22

ATTACHMENTS
E-1M19S1 Data Sheet
E-1M19I Inspection and Testing Requirements Sheet (ITRS)
E-1M19R Documentation Requirements Sheet (DRS)

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SHELL AND TUBE HEAT EXCHANGERS

1. SCOPE

This specification defines minimum technical requirements for design,

materials, fabrication, inspection, and testing of shell and tube heat
exchanges, including tank suction heaters and double pipe exchangers.

2. REFERENCES

2.1 Purchaser Specifications

This specification contains references to the following Purchaser
specifications:
1. GEMS GC, “General Conditions - General Equipment and Material
Specifications”.
2. GEMS G-2D, “Refinery Process Unit Layout (PIP PNC00003)”.
3. GEMS G-3D, “Climatic Design Data”.
4. GEMS G-6M, “Packaged Systems”.
5. GEMS G-7M, “Welding and Post Weld Heat Treating (API RP 582)”.
6. GEMS J-1P, “Leak Tests of Piping (PIP PNSC0021)”.
7. GEMS J-2D, “Selection and Limitation of Piping Materials”.
8. GEMS M-1D, “Fireproofing”.
9. GEMS V-1P, “Application of Industrial Coating Systems”.
2.2 Purchaser Drawings
This specification contains references to the following Purchaser
drawings:
1. 4S-5846, “Standard Anchor Bolt Detail”.
2. 7S-2757, “Weld and Nozzle Details for Alloy Lined Vessels”.
3. 7S-3054, “Shell and Tube Exchanger Handling Lugs and Tube Sheet
Taps”.
4. 9S-7581, “Vent and Drain Nozzles for Shell and Tube Exchangers”.
5. 9S-7686, “Typical Piping Layout and Clearances at Exchangers”.
2.3 Industry Codes and Standards
This specification contains references to the following industry codes
and standards:
2.3.1 American Petroleum Institute (API)
1. Std 650, “Welded Steel Tanks for Oil Storage”.
2. Std 660, “Shell and Tube Heat Exchangers for General
Refinery Service”.
2.3.2 American Society of Mechanical Engineers (ASME)
1. B16.5, “Pipe Flanges and Flanged Fittings”.
2. B31.3, “Chemical Plant and Petroleum Refinery Piping”.
3. B36.10, “Welded and Seamless Wrought Steel Pipe”.

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4. Boiler and Pressure Vessel Code.

a. Section II, “Materials”.
b. Section VIII, “Pressure Vessels”, Division 1, and
Division 2, “Alternate Rules”.
5. SA-20/SA-20M, “General Requirements for Special Plates for
Pressure Vessels”.
6. SA-193, “Alloy-Steel and Stainless Steel Bolting Materials
for High-Temperature Service”.
7. SA-194, “Carbon and Alloy Steel Nuts for Bolts for High-
Pressure and High-Temperature Service”.
8. SA-214, “Electric-Resistance-Welded Carbon Steel Heat-
Exchanger and Condenser Tubes”.
9. SA-249, “Welded Austenitic Steel Boiler, Superheater, Heat-
Exchanger, and Condenser Tubes”.
10. SA-263, “Corrosion-Resisting Chromium Steel Clad Plate,
Sheet, and Strip”.
11. SA-264, “Stainless Chromium-Nickel Steel-Clad Plate, Sheet,
and Strip”.
12. SA-265, “Nickel and Nickel-Base Alloy-Clad Steel Plate”.
13. SA-285, “Pressure Vessel Plates, Carbons Steel, Low- and
Intermediate-Tensile Strength”.
14. SA-358, “Electric-Fusion-Welded Austenitic Chromium-Nickel
Alloy Steel Pipe for High-Temperature Service”.
15. SA-515, “Pressure Vessel Plates, Carbon Steel, for
Intermediate- and Higher-Temperature Service”.
16. SA-516, “Pressure Vessel Plates, Carbon Steel, for
Moderate- and Lower-Temperature Service”.
17. SA-671, “Electric-Fusion-Welded Steel Pipe for Atmospheric
and Lower Temperatures”.
18. SA-672, “Electric-Fusion-Welded Steel Pipe for High-
Pressure Service at Moderate Temperatures”.
19. SA-691, “Carbon and Alloy Steel Pipe, Electric Fusion-
Welded for High-Pressure Service at High Temperatures”.
20. SA-788, “Steel Forgings, General Requirements”.
2.3.3 American Society for Testing and Materials (ASTM)
1. A 153, “Zinc Coating (Hot-Dip) on Iron and Steel Hardware”.
2. A 473, “Stainless and Heat-Resisting Steel Forgings”.
3. F 436, “Hardened Steel Washers”.
2.3.4 Process Industry Practices (PIP)
VEFV1103, “Vessel; Grounding Lug”.
2.3.5 Tubular Exchangers Manufacturers Association (TEMA)
“Standards of the Tubular Exchanger Manufacturers Association”.

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2.3.6 Other
Zick, L.P., “Stresses in Large Horizontal Cylindridal Pressure
Vessels on Two Saddle Supports”, Welding Journal Research
Supplement, 1971.

3. GENERAL

1. Shell and tube heat exchangers shall comply with API 660, TEMA, and
this specification.
2. Mechanical design, materials, and fabrication shall comply with ASME
Code, Section VIII, Division 1.
3. Equipment whose pressure containing parts do not fall within scope
of ASME Code, Section VIII, shall comply with ASME B31.3.
4. ASME Code, Section VIII, Division 2, designs shall be used if this
code produces a more economical design than Section VIII, Division
1.
5. Unless specified otherwise, heat exchangers shall comply with TEMA
Mechanical Standards Class R.
6. Barometric condensers shall be constructed in accordance with
Supplier’s standard practice.
7. Shell and tube exchangers furnished as auxiliaries with mechanical
equipment or other package type equipment shall comply with GEMS
G-6M and ASME Code, Section VIII. Such exchangers are not required
to comply with this specification.
8. General conditions shall comply with GEMS GC.
9. Conflicts among this specification, drawings, data sheet, or
attachments will be resolved by Purchaser.

4. DEFINITIONS

4.1 General Definitions

1. ASME Code - Boiler and Pressure Vessel Code, Section VIII, Division
1 or 2, as applicable.
2. MAWP - Maximum allowable working pressure.
3. MDMT - Minimum design metal temperature.
4. N.B. - National Board of Boiler and Pressure Vessel Inspectors.
4.2 Service Definitions
4.2.1 Hydrogen Service
Hydrogen service is defined as service in which normal
operating contents contain hydrogen partial pressure equal to
or greater than 100 psia.
4.2.2 Cyclic Service
Cyclic service is defined as service in which operating
conditions during exchanger’s design life exceed number of
cycles that require fatigue analysis in ASME Code Section VIII,
Division 2, Paragraph AD-160.2.

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4.2.3 Wet H2S Service

Wet H2S service is defined as service that contains free liquid
water with H2S concentration equal to or exceeding any one of
the following values:
1. Partial pressure in vapor phase of 0.25 psi or more.
2. Content in water phase of 50 weight parts per million
(wppm).
3. Content in liquid hydrocarbon phase of 250 wppm.

5. PROCESS DESIGN

5.1 General
1. Unless approved otherwise, water cooled units shall be constructed
with water on tube side.
2. Except for exchangers defined in paragraph 1. or if fluid is
assigned to tube side because of fouling problems, shell and tube
side fluid assignments may be interchanged for the most effective
heat transfer and most economical overall design.
3. To minimize corrosion and fouling, water velocities in shell and
tube coolers and condensers shall not fall outside ranges listed
below. Exceptions may be made where pressure drop limitations
govern. Notation shall be made on data sheet if minimum velocity
requirement causes unit to be significantly oversized.

Tube Material Minimum Velocity (ft/s)

Inhibited Admiralty 4 to 6
Aluminum Brass 4 to 8
90-10 Cu-Ni 6 to 10
70-30 Cu-Ni 6 to 14
Red Brass 3 to 6
Monel 6 to 14
Carbon Steel 6 to 8

5.2 Surface
1. Minimum effective surface will be specified on data sheet.
2. Proposals may be based on effective surface of 95% or more of
specified minimum effective surface, provided Supplier's smaller
standard shell size can be used. Supplier shall not be released from
any part of its responsibility for performance guarantee.
3. If Supplier uses shell size larger than required by paragraph 2. or
by heat transfer rate for vapor disengagement or impingement baffle
clearance, an alternate proposal based on amount of surface required
to fill shell as completely as possible shall be submitted.
4. Surface basis, gross or effective surface of tubes, shall be stated
in proposal.
5.3 Heat Transfer Rate
1. Required heat transfer rate shall be calculated. Quotations shall be
based on more than specified minimum surface if such is necessary to
guarantee that surface offered is satisfactory for duty, fouling
factors, pressure drop, minimum velocities, and acceptable flux rate.

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2. Unless other requirements govern, all of specified allowable pressure

drop shall be fully utilized.
3. Actual fouling factor shall be based on clean transfer rate
calculated by Supplier and shall equal or exceed specified fouling
factor.
4. For vaporizing duty, heat flux shall not be sufficient to cause
vapor binding of tube surface.

6. MECHANICAL DESIGN

6.1 General
1. Proposals shall be based on types of construction specified by
Purchaser. If more economical, alternate proposals may be submitted
as follows:
a. Split-ring floating head exchangers with removable channel and
cover (TEMA Type A and S). Split ring shall be designed in
accordance with ASME Code, Section VIII, Division 1, Article 2-9.
b. All TEMA type shells are acceptable, except two pass shell with
longitudinal baffle.
c. U-tube bundles with stationary heads in accordance with TEMA Type
A or B with throughbolt tubesheets.
d. Pull through floating head exchangers with removable channel and
cover (TEMA Type A and T) may be used with Purchaser approval.
e. Exchanger bundle weights are limited by mobile crane capacity.
Bundle handling requirements shall comply with GEMS G-2D.
f. U-tubes are not allowed in fouling service.
g. If approved by Purchaser, multitube double pipe exchangers may be
proposed.
2. Proposal shall be based on specified maximum bundle weight. An
additional proposal may submitted wherein bundle weight exceeds
specified maximum, provided a definite reduction in cost can be
realized.
3. Exchanger clearances shall comply with Drawing 9S-7686.
4. Horizontal exchangers greater than 48 inches internal diameter or
full of water weight of 30,000 pounds shall have supports designed
in accordance with L.P. Zick’s article referenced in Section 2.3.6.
Calculation shall be submitted for Purchaser review.
5. Staybolts shall not be used without prior Purchaser approval. If
used, staybolts shall be protected from corrosion by sealing from
contact fluid. Complete design details shall be submitted.
6. Acoustic and flow induced vibrations shall be analyzed for each
exchanger, if specified by Purchaser. Results shall be submitted to
Purchaser for review.
7. Flange insulation shall be specified. If insulation is specified,
Supplier shall verify that flanges and bolting have been designed
for resulting higher flange temperature.
8. Pressure/temperature range, frequency, and exchanger design life
will be specified for exchangers in cyclic service.

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6.2 Corrosion Allowance (CA)

1. CA will be specified by Purchaser.
2. Carbon steel tubes shall have minimum corrosion allowance of 1/6 of
calculated wall thickness required to withstand design pressure.
6.3 Design Pressure
1. Parts subjected to pressure from shell and tube sides shall be
designed in accordance with differential pressure only if specified
by Purchaser.
2. Differential pressure tubesheet design, if selected, shall be
subject to Purchaser review of system(s) to identify and correct
potential causes of overpressure of tubesheet(s).
6.4 Design Temperature
1. If mechanical design temperature is limited by flange pressure class
rating, Purchaser shall be consulted on whether or not to change
pressure rating of flanges. If flange rating is not changed,
mechanical design temperature shall be highest temperature for
flange rating coincident with mechanical design pressure.
2. If approved by Purchaser, heat transfer can be taken into account in
tubesheet design temperature in services with gas on shell side and
uninterruptible tube side cooling water flow.
3. Design temperature for bolting shell to channel joints shall be the
more severe of shell or channel design temperatures.
6.5 Minimum Design Metal Temperature (MDMT)
1. Impact testing requirements shall comply with applicable ASME Code,
Section VIII, Division 1 or 2, and most severe low temperature and
coincident pressure conditions. Only carbon steel, P1, Group 1, up
to 1/2 inch thick, ASME Code, Section VIII, Division 1, exchangers
shall be exempt from impact testing in accordance with Paragraph
UG-20(f).
2. MDMT and coincident pressure shall be determined by manufacturer
using applicable ASME Code, selected plate material type, plate
thickness, impact testing performed, and tensile stress level.
Tensile stress shall include pressure and nonpressure loads, such as
wind, seismic, or other mechanical loads.
3. The following MDMTs and coincident pressures shall be indicated on
exchanger nameplate and Supplier's data report:
a. MDMT at maximum allowable working pressure (MAWP).
b. Lowest allowable MDMT and coincident maximum pressure.
6.6 Maximum Allowable Working Pressure (MAWP)
1. After actual components to be used to fabricate exchanger are
selected, MAWP shall be calculated by manufacturer at design
temperature for both corroded and uncorroded conditions. MAWP shall
not arbitrarily be set at design pressure.
2. MAWP specified on ASME Manufacturer’s Data Report for Pressure
Vessels shall be after loss of specified corrosion allowance.
Corrosion allowance shall be specified on data report.

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6.7 Allowable Stresses

1. Maximum allowable stress for carbon steel anchor bolts shall comply
with Drawing 4S-5846.
2. Internal nonpressure containing parts, such as baffles and
impingement plate and their attachment welds to exchangers, shall be
designed using allowable stress for material and temperature
specified in ASME Code, Section II, Part D, for Division 2, as
applicable, for selected material and design temperature.
3. Stress in any part of exchanger, including flanges and bolts
resulting from hydrostatic test pressure, shall never exceed 0.9
times minimum yield stress at 100°F.
4. If two allowable stresses are listed in ASME Code, Section II, Part
D, higher value may be used in design of exchanger heads and shells.
Lower value shall be used for flange design.

7. DESIGN DETAILS

7.1 Shell Supports

1. Tank suction heaters shall have nonattached cradle support under
free end of shell. Shell support shall be rested on floor of tank
and have extended base to prevent tilting.
2. Exchangers shall as a minimum have two attached supports suitable for
carrying weight of entire unit full of water plus at least 15% of
such weight to accommodate attached piping.
3. Unless other means are taken to allow for thermal expansion of
shell, attached shell supports for horizontal units shall have
circular holes at stationary head end and slotted holes at rear head
end.
4. Fixed shell support at stationary head end shall be adequate to
resist longitudinal bundle pulling load of 150% of bundle weight.
5. Supports shall be located to provide sufficient clearance to swing a
wrench when removing nuts from nozzle flange bolts.
6. Vertical height of supports shall be minimized to permit maintenance
without scaffolding. Saddle supports shall be fireproofed in
accordance with GEMS M-1D.
7. Stacked multiple shell units shall comply with the following:
a. Lower shells shall have support members to carry upper exchangers
in accordance with paragraph 2. and resist axial loads required
to pull upper bundles in accordance with paragraph 5.
b. Lower shells shall be adequate to accommodate superimposed load
from shells above without distortion that might cause binding of
tube bundle. Effects of differential thermal expansion between
interconnecting nozzles and support shall be investigated to
determine that stresses are within allowable limits.
c. Upper shells with flanged intermediate shell nozzles shall have
minimum allowance of 1/4 inch for shims between intermediate
supports. Shims shall be tack welded to upper baseplate of lower
shell after accuracy of fitup is checked.
d. Stacked units shall be shop assembled to check saddle and nozzle
fit up.

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e. Maximum stacking height of shells shall comply with the

following:

Shell Diameter No. of Shells High

< 24 in. 4
> 24 in. < 40 in. 3
> 40 in. 2
7.2 External Attachments
1. Lifting Lugs - Shell covers, floating head covers, and channel
covers shall have cast or welded lifting lugs in accordance with
Drawing 7S-3054.
2. Grounding Lugs – Grounding lugs shall be provided and designed in
accordance with PIP VEFV1103.
7.3 Tubes
1. Tubes may be supplied on average wall basis if such average wall
tubes are:
a. Otherwise in accordance with applicable ASME specification.
b. Actually one gage heavier than specified gage.
2. Cleaning Lanes
a. Cleaning lanes for vaporizing services shall be oriented in
horizontal and vertical rows.
b. Cleaning lanes for condensing services may be oriented in
horizontal and vertical rows or may be set at 45 degrees to flow
on shell side, depending upon service involved and manufacturer
design standards.
c. Cleaning lanes for all other services shall be oriented at 45
degrees to flow on shell side. Channel pass ribs may be set at 45
degrees to vertical to permit 45 degree orientation without
increasing shell diameter.
3. Tube pass layout shall be such that there are minimum lanes for
bypassing of fluid on shell side.
4. Tubes may be finned. Overall transfer rate in terms of both finned
and bare tube shall be given. Critical dimensions of fin shall also
be provided.
5. Subject to Purchaser approval, high heat flux tubing where fouling
factors are low, particularly in condensing and reboiler services,
may be considered.
6. Unless approved by Purchaser, tubes shall not be circumferentially
welded. U-tubes or tubes in hydrogen service shall not be
circumferentially welded.
7.4 Shells and Shell Covers
1. Welds or other rough spots on inside of shell shall be finished or
ground smooth and flush with inside surface. Shell thickness shall
meet thickness requirements after such finishing.
2. Shell Cover
a. Shell covers shall be designed to provide clearances for thermal
expansion without binding.

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b. Exchangers with pull-through floating head bundles shall have

fixed shell covers if leakage problems dictate maximum
elimination of flanged joints or use of fixed shell covers yields
cost reduction.
3. Tank suction heaters shall be provided with shell to constrain fluid
to tube bundle. End of shell shall be cut inside tank at
approximately 45 degrees to favor flow from above. Lower part of
shell shall be projected beyond end of bundle. Portion of shell that
is inside and outside tank shall have same thickness.
7.5 Baffles and Support Plates
1. Unless specifically approved by Purchaser, condensers (whether on
compressor discharge or not) or exchangers (if pulsating conditions
are indicated in exchanger data sheet) shall comply with TEMA hole
over tolerance for pulsating service.
2. Increase in transverse baffle and support plate clearance permitted
by TEMA Class R shall be limited to services that have gas or vapor
on shell side.
3. Baffles in vertical reboiler bundles with boiling fluid in shell
shall be perforated with 1/4 inch diameter holes on same pitch as
tubes to reduce stagnant areas adjacent to baffles.
4. Impingement or Deflector Baffles.
a. Shell inlet connections on all exchangers shall have impingement
or deflector baffles.
b. Baffles shall be at least diameter of nozzle and located such
that minimum flow area around baffle is at least 1-1/3 times
cross sectional area of nozzle at flange.
c. Minimum flow area around baffle shall be taken as baffle
perimeter times average clearance between baffle and shell at
baffle perimeter.
d. Impingement sleeves shall be tack welded to tubes of double pipe
exchangers adjacent to inlet nozzles.
5. Baffles shall not be located between inlet or outlet nozzle and
their respective tubesheets unless deflector baffle is provided to
direct flow across tubesheet.
6. Longitudinal baffles for split flow exchanges in services
susceptible to severe fouling shall be perforated with 1/4 inch
diameter holes on 1-1/4 inch triangular pitch to reduce stagnant
areas.
7. Impingement, deflector, and longitudinal baffles shall as a minimum
be 1/4 inch thick for carbon steel or 3/16 inch thick for high alloy
or nonferrous materials.
8. In liquid service, space between tubes and shell shall be blanked
off with longitudinal sealing strips in accordance with API 660.
Antichanneling strips shall as a minimum be 1/4 inch thick.
7.6 Floating Heads
1. Bolts and nuts in floating head assembly shall be fully accessible
if shell cover is removed.
2. Floating heads shall be designed and dimensioned in accordance with
Figure 1-6(d) of ASME Code, Section VIII, Division 1.

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3. Design of floating heads shall consider gasket seating area of pass

ribs.
4. Floating heads, flanges, and bolting shall be designed for the most
severe design temperature condition and most severe internal and
external design pressures.
5. TEMA Types S or T floating heads shall have transverse support
baffle.
7.7 Gaskets
1. Gaskets shall be selected in accordance with limitations outlined in
this specification.
2. An extra set of heat exchanger gaskets shall be provided.
3. Gaskets shall be selected on basis of operating conditions, not on
exchanger design pressures and temperatures.
4. If gasketed joints are in opposing services, gaskets shall be
selected for the more severe service.
5. Exchangers greater than 12 inches in diameter shall not have sheet
gaskets.
6. Gaskets shall not contain asbestos.
7. Permissible types or gaskets are:
Service Permissible Gasket Type
Hydrogens - all pressures MJ, SW
Hydrocarbons - all pressures M, MJ, SW
Steam - all pressures M, MJ, SW
Water and Air - 150 psi and below M, MJ, S (see Note)
- Above 150 psi M, MJ
Special Services Supplier recommendation
subject to Purchaser
approval
M - Metal (corrugated, solid, flat, or grooved)
MJ - Metal jacketed (ceramic fiber, nonasbestos inorganic
millboard, or graphite filled)
SW - Spiral wound metal (flexible graphite filled)
S - Sheet gasket - Aramid fiber with suitable binder
Note: Type S shall not be used for internal floating head
joints.
8. Permissible gasket materials are:
Service Permissible Gasket Matls
Hydrogen Stainless steel
Hydrocarbons - all pressures Iron (see Note 1)
Hydrocarbons - corrosive or unusual Supplier recommendation
conditions (see Note 2)
Steam - noncorrosive Copper, Stainless steel
Steam - corrosive (see Note 3) Stainless steel,
Admiralty, Monel
Notes:
(1) Iron shall not be used in gaskets for water or steam
service.
(2) Subject to Purchaser approval.

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(3) Contains contaminants, such as ammonia or CO2.

9. Maximum temperature limitations for gasket materials are:
Material Max. Temp. °F
Sheet (Aramid fiber) 350
Admiralty 400
Copper 400
Nonasbestos inorganic millboard (MJ) 500
Iron 750
Monel 700
Special alloys ASME Code limits
Stainless steel (spiral wound) 1100
Flexible graphite (SW or MJ) 1100
Ceramic fiber (MJ) 1100
7.8 Tubesheets
1. Unless greater minimum thickness results from requirements of TEMA
Class R, minimum tubesheet thickness (including corrosion allowance)
measured at bottom of pass partition groove shall be 1 inch.
2. Tube holes in tubesheets shall comply with requirements for
“Standard Fit” in TEMA Class R.
3. Cladding
a. If clad tubesheets are used, minimum thickness of cladding shall
be 3/8 inch.
b. If tubes are to be seal welded to tubesheet, both grooves shall
be in base material.
c. If tubes are not to be seal welded, outer groove shall be in
cladding.
d. Cladding shall be weld overlay.
e. Other methods of cladding shall be subject to Purchaser approval.
4. Tube holes in tubesheets with austenitic steel tubes for corrosion
resistance shall comply with requirements for “Special Close Fit” in
TEMA Class R.
5. Unless approved for special cases, fixed tubesheets shall not be
used.
6. Exchanger bundles that are to be pulled and handled with mobile
equipment shall have tapped holes in edges of channel end tubesheets
in accordance with Drawing 7S-3054.
7. Full diameter tubesheets may be used with TEMA Type B stationary
heads, subject to Purchaser approval. Optionally, fully threaded
tubesheet bolt holes or shoulder bolts may be used.
8. Tube holes at shell side face of tubesheet shall have at least
1/32 inch 45 degree chamfer.
9. Tubesheets shall not consist of solid bronze or other similar soft
materials. If such materials are required for corrosion resistance,
carbon steel shall be clad or overlaid with the soft material.
7.9 Channels and Channel Covers
1. Stationary heads shall be removable channel and cover type (TEMA
Type A), except as stipulated under paragraphs 3., 4., and 5.
2. Double pipe exchangers of multitube type shall have stationary heads
with removable channel and cover (TEMA Type A).

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3. Bonnet (integral cover) channels (TEMA Type B) or integral tubesheet

channels (TEMA Type C) with throughbolt flanges shall be used if
leakage problems (such as in hydrogen service) require maximum
elimination of flanged joints.
4. Bonnet (integral cover) channels (TEMA Type B) shall be used for
tank suction heaters with shells less than 24 inches in diameter.
5. Bonnet (integral cover) channels shall be used for vertical
reboilers and other vertical evaporators. Such bonnets shall be
similar to TEMA Type B but shall be designed such that face of
outlet nozzle is in vertical plane and flow is streamlined. If
fabricated, axes of adjacent conical segments shall not differ by
more than 30 degrees.
6. Except on tank suction heaters, bonnet channels (TEMA Type B) shall
have test rings. If there is more than one exchanger for which test
ring is interchangeable, number of test rings will be specified.
Test rings shall be provided as follows(in accordance with
Purchaser’s field hydrotest requirements):
a. Multiple shell units stacked in series flow shall have one test
ring for each shell within a stacking. If multiple stackings are
involved (series or parallel), only the first stacking shall have
test rings.
b. Multiple shell units in parallel flow shall have one test ring
per shell size.
c. If full diameter tubesheets are specified, test rings shall be
quoted as an option.
7.10 Nozzles
7.10.1 General
1. Nozzles shall be flanged, welded, and radially oriented.
Multipass units may have hillside nozzles.
2. With prior Purchaser approval, shell nozzles between
stacked units may be provided without flanges and welded
integral in shop, provided that shipping, handling, and
erecting facilities are adequate for such construction.
3. Vent and drain connections shall comply with Drawing
9S-7581. Vents and drains shall have blinds.
4. Use of solid alloy nozzles shall be restricted. Application
shall be subject to Purchaser review and approval.
5. Elbow orientation will be specified. Unless specified
otherwise, bottom nozzles shall have 90 degree elbows for
single exchanger or lowest exchanger in stacked exchangers.
6. Nozzle tolerances for stack assembly shall comply with TEMA
tolerances for single individual exchanger.
7.10.2 Flanges
1. ASME B16.5 slip-on flanges or ASME Code, Section VIII,
loose or optional type flanges may only be used with the
following restrictions:
a. Carbon steel.
b. Pressure-temperature conditions not exceeding ratings of
ASME B16.5 class 300 flanges.

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c. Temperatures below 850°F.

d. Sizes NPS 2 and larger.
e. Noncyclic and non-erosive services.
f. Nonhydrogen service.
2. Intermediate shell and channel nozzles of stacked units
shall have raised face flanges. Facings of remaining
flanges will be specified.
3. Screwed flanges shall not be used.
7.10.3 Length
1. Stacked units shall have flanged intermediate nozzles that
are long enough to permit bolt removal from either side of
flanges with assumed 3 inch thickness of insulation on
shells and channels.
2. Nozzle length for flanged intermediate nozzles for stacked
units shall be sufficient to allow for shimming.
3. Nozzles other than intermediate nozzles shall have flange
faces at least 8 inches from outside of shell or channel to
which they are attached.
7.10.4 Wall Thickness
1. Minimum wall thickness for unlined nozzles, including
corrosion allowance shall be:
Wall Thickness (ASME B36.10)
Diameter (NPS) Carbon Steel Solid Alloy (Note 1)
1, 1-1/2, 2 Schedule 160 Schedule 160
3 Schedule 160 Schedule 80
4 Schedule 120 Schedule 80
6, 8 Schedule 80 Standard
10 and larger Extra strong Standard
Note 1: Solid nonferrous alloys and solid ferrous alloys
with chromium content greater than 9%. Use of solid alloy
nozzles shall be subject to Purchaser approval.
2. Minimum wall thickness for lined nozzles, excluding
thickness of lining shall be:
Diameter (NPS) Wall Thickness (ASME B36.10)
1-1/2, 2 Schedule 160
3, 4 Schedule 80
6 and larger Standard
7.11 End Flanges and Bolting
1. Flanges for stud bolting shall not be tapped, except for channel
flanges opposite channel nozzles where clearance does not permit
throughbolting.
2. Tank connection flange on tank suction heaters shall be drilled in
accordance with NPS 20, NPS 24, NPS 30, or NPS 36 standard manway
flanges shown in API Std 650.
3. Sufficient clearances shall be maintained such that wrenches can be
used on both ends of throughbolting. Stud bolts 2 inches and larger
in diameter shall be designed for tightening with bolt tensioners.

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Wrench clearances shall as a minimum be equal to twice stud diameter

plus 1/2 inch.
4. Hardened bolt washers shall be provided for bolt diameters larger
than 1-1/2 inches or if service temperature exceeds 900°F.
5. Bolt hole for nozzles and body flanges shall straddle normal
centerlines.

8. MATERIALS

8.1 General
1. Material for pressure containing parts shall have adequate notch
toughness as specified in Section 6.5.
2. Materials are specified in exchanger data sheet and shall comply
with one of applicable specifications listed in TEMA standards and
this specification.
3. Exchanger parts shall not be cast iron.
4. Steels (including structural members) of 70 ksi minimum tensile
strength or greater shall comply with the following additional
requirements:
a. Mill reports shall verify that limits for “Unspecified Elements”
(Copper, Nickel, Chromium, Molybdenum, Vanadium, and Columbium)
do not exceed limitations stated in ASME SA-20/SA20M, Par. 7,
Table 1.
b. Welds shall be inspected in accordance with code that governs
fabrication and GEMS G-7M.
8.2 Tubes
The following restrictions shall apply:
1. Cupro-Nickel shall be C71500 (70-30).
2. N04400 (Monel) shall be annealed.
3. Austenitic stainless steel tubes shall comply with Section 9.5.2.
4. Welded carbon steel tubes in the following services shall be ASME
SA-214 (normalized):
a. Rich or lean amine, wet H2S, and caustic service defined by GEMS
G-7M.
b. Critical cooling water service that would cause operating unit
shutdown if a leak occurs.
8.3 Shell and Shell Covers
8.3.1 General
1. Provisions of this section shall also apply to other
exchanger parts (such as floating heads, channels, channel
covers, nozzles, and flanges) for which TEMA standards
stipulate that materials specified under shells and shell
covers are acceptable for such parts.
2. Vessel material specifications will be specified by
Purchaser. Unless specified by Purchaser, vessel fabricator
shall select material grade to provide the most economical
vessel.

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8.3.2 Plate
1. Plate material for vessels, internal load carrying
supports, and internal pressure containing parts shall
comply with requirements of Purchaser's design drawings.
2. Carbon steel plate for pressure containing parts shall be
ASME SA-285, SA-515, or SA-516.
3. Carbon steel plate in the following services shall be ASME
SA-516:
a. Pressure containing parts in hydrogen service.
b. Pressure containing parts in FCCU gas recovery section.
c. Equipment with an O.D. greater than 10 feet.
d. Pressure containing parts with metal thickness over
1-1/2 inches.
e. Shell thickness greater than 3/4 inch for locations with
an average monthly temperature less than 40°F as listed
in GEMS G-3D.
4. ASME SA-285 and SA-515 shall be impact tested if used for
shell thickness greater than 1/2 inch. Impact test
temperature shall be as determined in Section 6.5.
8.3.3 Lining
1. Lining materials will be specified.
2. The following manufacturing methods shall be considered:
a. Integral cladding in accordance with ASME SA-263,
SA-264, and SA-265, including shear tests. Vessels in
hydrogen service shall have weld overlay, Lukens clad
plate, or approved equal.
b. Strip or sleeve liners for nozzles in accordance with
Drawing 7S-2757, except in hydrogen service.
c. Weld overlay.
8.3.4 Pipe
1. Pipe for shells shall be seamless or double fusion welded.
2. Double fusion welded pipe shall be ASME SA-358, SA-671,
SA-672, or SA-691.
8.4 Bolting
1. External bolting for pressure containing parts shall be selected in
accordance with GEMS J-2D, Table 5. During assembly, bolt and stud
threads shall be coated with thread lubricant as specified in GEMS
J-2D, Table 4.
2. Bolting shall not be electroplated (such as cadmium plating).
3. If galvanizing is specified, bolts shall be hot dip galvanized in
accordance with ASTM A 153.
4. Galvanized bolts or bolts coated with paint that contains zinc shall
not be in contact with stainless steel or nickel alloy pressure
containing parts during service.
5. Internal bolts exposed to wet H2S service shall be SA-193, Grade 7M,
with SA-194, Grade 2HM, nuts.

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6. Washers required in accordance with Section 7.11, paragraph 4.,

shall comply with ASTM F 436, Type 1, circular, hardened. Surface
roughness shall not exceed 750 microinch in height, including flaws
in or on surface. Burrs shall not exceed 0.01 inch in height.
8.5 Forgings
1. Forgings shall comply with ASME SA-788.
2. Unless specified otherwise, forging material grade shall be selected
by exchanger fabricator and shall provide the most economical
exchanger.

9. FABRICATION

9.1 Welding
9.1.1 General
Welding and post weld heat treatment shall comply with GEMS
G-7M.
9.1.2 Welding Alloy Lined Exchangers
1. Nozzle construction and longitudinal, girth, and nozzle
welds shall comply with Drawing 7S-2757.
2. Lightly loaded or continuous supports (for partitions,
baffles, etc.) may be welded directly to alloy lining.
3. Attachment welds for supports to strip lining shall
coincide with welds attaching liner to shell.
4. The following precautions shall be taken if welding
austenitic stainless steel internals to austenitic
stainless steel overlay:
a. Stainless steel welds to overlay shall be made after
final post weld heat treatment.
b. Low heat input multi pass welding with small diameter
welding rods shall be used.
c. For operating temperatures greater than 750°F, full
penetration stainless steel welds to overlay and heat
affected zone shall be covered with 347 SS fillet cap
blended to smooth radius.
9.2 U-Bends
1. U-bends for U-tube exchanger bundles shall be smooth and free of
wrinkles.
2. Cross section of tube wall shall not be flattened in bending by more
than 10% of O.D.
3. Minimum bending radius shall be 1-1/2 tube diameters. Tube wall
thinning shall comply with TEMA R-2.31.
4. Purchaser may ask Supplier to submit sample bends for approval prior
to fabrication.
5. Lead-babbitt mixture shall not be used to keep tubes from collapsing
during forming of U-bends.

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9.3 Tube Joints

1. Unless specified otherwise, tubes shall be extended 1/8 inch beyond
outside face of tubesheet with tolerance of +1/8 inch or -1/16 inch.
2. Austenitic stainless steel tubes shall extend into tubesheet in
accordance with TEMA recommendations. Expansion shall stop at 1/8
inch from shell side.
3. Over rolling shall be avoided.
4. Purchaser shall be advised of details of such tube rolling to
minimize crevice corrosion attack on shell side of tubesheet to tube
joints.
5. Tube to tubesheet joints in services subject to leakage, such as
hydrogen service with partial pressure of hydrogen of 499 psi or
above and/or temperature of 800°F, shall be made as follows:
a. Tube holes shall be chamfered at tube ends to form weld grooves.
Grooves shall be suitable for seal welds around tubes that will
be essentially flush with face of tubesheet.
b. Tube projection shall be set as specified in paragraph 1. Tube
shall be tack welded to tubesheet by gas tungsten arc welding
process (GTAW).
c. Tubes shall be seal welded to tubesheet using GTAW.
d. Seal welds shall be dye penetrant inspected and repaired as
required.
e. Seal welds shall be bubble tested with 10 psi inert gas or air
and repaired as required. A minimum of 15 minutes shall be
allowed for gas dispersion. Household detergents and soaps shall
not be used.
f. Tubes shall be expanded, starting 3/8 inch back from end of tube
to within 1/8 inch of backside of tubesheet. Tubes shall not be
expanded beyond tubesheet.
g. Seal welds shall be dye penetrant inspected and repaired as
required.
h. Completed tube joint shall be examined using gross helium mass
spectrometer detector probe leak test with bundle in shell prior
to hydrotesting as follows:
(1) Face of tubesheet shall be covered with plastic sheeting and
sealed with tape.
(2) Shell side shall be pressurized to 40 psig with pure
commercial grade helium.
(3) A minimum of 2 hours shall be allowed for gas dispersion.
After 2 hour soak, test for indication of helium shall be
performed at 15, 30, 60, and 120 minutes. Mass spectrometer
leak detector sensitivity shall be at least 3.5 x 10E-10 std
cc/sec/division of helium.
(4) No indication of helium shall be detected. If helium is
detected, leak shall be pinpointed and repaired, and test
shall be repeated.
i. Detailed tube to tubesheet joint procedure shall be submitted to
Purchaser for review prior to start of work.

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9.4 Gasket Contact Surfaces Other than Nozzle Flange Facings

1. Gasket contact surface shall have finish equivalent to 80-125 RMS.
2. For normal applications, flatness tolerance on peripheral gasket
contact surfaces shall be 1/32 inch.
3. If any of the following apply, flatness tolerance shall comply with
API 660, Article 6.8.3:
a. Service with pressure greater than 1000 psig.
b. Service with temperatures greater than 800°F.
c. Hydrogen service.
4. Girth flange flatness tolerance shall be measured after:
a. Flange is welded to shell or cover.
b. Post weld heat treatment.
5. Tubesheet gasket contact surface flatness tolerance shall be
measured after tube to tubesheet joints are expanded or welded.
9.5 Heat Treatment
9.5.1 General
Post weld heat treatment shall comply with GEMS G-7M.
9.5.2 Tubes
1. General
a. Stabilized austenitic stainless steel tubes, such as 321
and 347 SS, designed to operate at 700°F or above, shall
have stabilization heat treatment in accordance with
ASME SA-249-S4.
b. Heat treatment temperature range shall be 1600°F to
1650°F for minimum holding time of 2 hours.
2. U-Tubes
a. Copper alloy and monel tubes in U-tube bundles shall be
annealed after forming.
b. Stainless steel U-tubes shall be avoided. Such tubes, if
required, shall be heat treated to reduce susceptibility
to stress corrosion cracking.
(1) For unstabilized materials, complete U-tube shall be
solution annealed.
(2) For stabilized materials, complete U-tube or bend
area only shall receive stabilizing heat treatment
at 1600°F to 1650°F with air cooling.
(3) Stabilized stainless steel tubes that are treated at
manufacturer’s mill in accordance with paragraph 1.
may be stress relieved in bend area only, plus 12
inches on each side in accordance with ASME
SA-249-S1.
(4) If tube has not received stabilizing heat treatment
before bending, whole tube shall be stress relieved
at 1600°F to 1650°F for at least 2 hours.

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9.5.3 Tubesheet
1. Solid stabilized austenitic stainless steel grade
tubesheets shall be solution annealed and stabilization
heat treated in accordance with ASTM A 473, Paragraph 7.3.
2. Temperature range shall be 1600°F to 1650°F with minimum
holding time of 4 hours.
9.6 Component Identification
Individual exchanger components, such as channel cover, bonnet,
tubesheet, and shell, shall be permanently tagged or marked with
assigned plant equipment number.

10. INSPECTION AND TESTING

10.1 Radiography
1. Radiography, as required, shall be performed in accordance with
applicable code and as noted in paragraph 2. Minimum requirement is
spot radiography to obtain joint efficiency of 0.85.
2. Radiography shall be performed after post weld heat treatment.
Alternate weld inspection methods shall be subject to Purchaser
approval.
10.2 Hydrostatic Testing
1. Exchangers shall be hydrostatically tested in accordance with ASME
Code at pressures specified on design drawings.
2. Stress in any part of exchanger, including flanges and bolts,
resulting from hydrostatic test pressure shall not exceed 0.9 times
ASME Code specified yield stress.
3. Metal temperature during hydrotest shall be maintained at warmer of
the following:
a. 60°F.
b. 30°F above minimum design metal temperature at MAWP.
4. Water for testing of shells, internals, cladding, weld overlay,
tubes, or lining of austenitic stainless steel shall have lowest
chloride content available (not to exceed 50 ppm chloride).
5. Exchangers shall be drained immediately after testing. If complete
drainage is not possible, exchanger shall be flushed with chloride
free water, alcohol, petroleum distillate, or suitable flushing
solution. Exchanger shall not be hot air dried in lieu of flushing.
Unheated air can be used to blow water out of pockets.
6. Exchangers shall be tested after post weld heat treatment.
7. Tube to tube seal welds shall be examined as detailed in Section
9.3, paragraph 5.
8. Rolled tube to tubesheet joints of nondifferential pressure tubesheet
designs shall be tested at shell hydrotest pressure. Differential
pressure tubesheet designs shall be tested at 1.5 times differential
design pressure.
10.3 Shop Testing
1. Exchangers shall be hydrostatically shop tested in accordance with
TEMA standards.

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2. Stacked units shall be tested as assembled units.

3. If shop test exchanger is damaged during shipment, integrity of
exchanger shall be certified by Supplier and National Board
Inspector.
10.4 Field Testing (By Others)
1. In addition to shop hydrostatic testing required by TEMA, exchangers
shall be hydrostatically field tested for tightness.
2. Test may be systems type, if technique employed permits positive
detection of leaks.
3. Minimum hydrostatic field test pressure for tightness tests shall
not be less than operating pressure of side involved.
4. Tubesheets designed for differential pressure shall be taken into
account.
5. Field pressure testing shall comply with GEMS J-1P.
6. Pneumatic of combined pneumatic-hydrostatic testing shall be subject
to specific Purchaser approval.
10.5 Inspection
1. Dirt, weld splatter, loose scale, oil, paint, and other foreign
matter shall be removed from both inside and outside of exchanger
prior to testing and final inspection.
2. Weld overlay used for corrosion protection shall be examined with
liquid dye penetrant after post weld heat treatment.
3. Weld overlay and clad shall be inspected in accordance with GEMS
G-7M.

11. PAINTING

Exterior steel surfaces shall be prepared, primed, and painted in

accordance with GEMS V-1P.

12. PREPARATION FOR SHIPMENT

1. Exposed machined surfaces shall be thoroughly coated with rust

preventive compound before shipment.
2. Flange facings shall be protected with steel cover at least 1/4 inch
thick, suitable gasket, and minimum of four full diameter bolts.
3. Exposed bolt threads shall be coated with metallic based waterproof
lubricant to prevent aqueous corrosion during testing, shipping, and
storage.
4. Reinforcing pad weep holes shall be packed with grease before
shipment.

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