Discussion Point With LT - Packinox Bundle Replacement (VA) PDF

DISCUSSION POINTS WITH L&T FOR BUNDLE REPLACEMENT WORK OF ISOM-A PACKINOX-EXCHANGER AT JAMANAGAR PX4 SITE
Date: 28th Nov 2017
RIL: L&T:
Steady State : S Ramchandran, Suraj Tipirneni, D Banerjee, B Pant, C H Anand Rajesh Singh
Pravat Chattopadhyay, Chirag Kelaiya, Ketan P Prajapati Chandrakant Chinchole
Project : Arun Vijaykumar, Nitin Jain Nilesh Shah
Construction : Mehul Panji, Ajay Kumar, Vivek Jain Alpesh Ukani
Sr. No. Query Discussion Notes

1. Pneumatic or vacuum test shall be done for the bare bundle (new) Discussion point: No additional testing is required to be done
before insertion i.e. on arrival at site, to ensure no damage is occurred on the new Bundles, before insertion.
in transit.
Identification and rectification of Plate pack leaks is easier outside as Visual inspection will be done by ALP and RIL once the bundles
compared to carrying out the same testing & rectification inside the are received at site.
Vessel.
2. Guide rails for Cold cutting machine shall be supplied by Vendor. Discussion point : L&T will supply guide rails with tack welded
on shell.
Support of the Guide rail to be explained by L&T i.e. from structure or
welded to the Vessel shell. RIL requested L&T to use demagnetising machine for cold
cutting & during welding of dome.
L&T explained that they are checking out the option of

metallic wheels as well as abrasive wheels for the operation.
Once the selection is completed, they will conduct a test run
at their shop at Hazira on a similar profile of adequate
thickness.
RIL asked for demo testing at L&T Hazira shop.

Date: 28th Nov 2017

RIL also requested L&T to explore the possibility of using
Destec or equivalent machines, which can do cutting and
bevelling in single operation. L&T will check and revert.
3. Wedges as spacer to be arranged while doing Cold cutting Discussion point: Confirmed by L&T
4. WPS/PQR shall be qualified prior to welding. Discussion point: RIL has provided testing requirement, L&T to
check and submit WPS/PQR for RIL approval.
5. Inspection & Testing requirements shall be as per ALP procedure L&T Confirms compliance.
SESCAZA3001 Revision H and its acceptance criteria shall be per API 934
C/ RIL specification ME-002 / ASME Code Section VIII Div-1.
PQR / PTC shall be simulated for minimum & maximum PWHT condition L&T Confirms compliance. PQR ( at Hazira shop) to meet
( maximum shall include 1 additional cycle for site repair) ASME Section IX requirements, also weld position to be
simulated.
L&T to provide all documents including ITP and welding documents for L&T Confirms Compliance
working at site.
For PTC, ageing coupon(if available)of Packinox can be used, if the same RIL could not confirm ageing coupon availability and agreed
is not available inside the vessel, L&T shall arrange for the PQR material, for non-requirement of PTC.
same can be kept ready before hand.
L&T will submit ITP for RIL approval.

6. All Inspection, NDT, including NDT agency and consumable shall be in Discussion point: RIL confirmed that R stamp not required, all
the scope of L&T, This includes LAS consumable in line with L&T inspection docs will be submitted by L&T for RIL /TPI review.
WPS/PQR. Document no SESCAZA3001_Alpha general procedure of
TPI or RIL shall be third party for quality checks. inspection shall be used for all testing and inspection
requirements.
TPI is in RIL scope.
Date: 28th Nov 2017

7. RT by iridium. RT source will be arranged by L&T. Discussion point: L&T agreed to perform UT only and accepted
Contractor taking up RT job will have to bring the legal approvals from by RIL. UT methodology procedure will be submitted by L&T
AERB for carrying out RT at site. Endorsement for source movement will for RIL approval.
be done by REAM
8. NDE prior to PWHT & NDE after PWHT shall be carried out by L&T (NDE Discussion point: RT/UT to be confirmed by L&T for bellow,
shall be same before & after i.e. RT/UT). Only one type of NDT (RT or RIL will provide non-purge electrode for bellow joint to avoid
UT) shall be done pre and post PWHT. Argon purging.
RIL-REAM will witness and certify.
L&T to submit PWHT procedure for RIL acceptance.
RIL asked L&T to perform FEA analysis also, L&T will include
the same in their scope.
9. Manpower for Hard Barricading will be provided by L&T, Material Discussion point: Hard barricading not required, fire blankets
supply shall be in RIL scope. to be supplied by RIL.
For Bevelling operation, hard barricading may be required and

the entire area will be covered and cordoned off by L&T
during the operation.
10. Hydro-test, Differential Hydro-test is required & same shall be done Discussion point: RIL will check with ALP and will come back
under ALP (Alfa Laval) Supervision. with exact test requirement & procedure. RIL to provide
steady state safety procedure/requirement to L&T.
Post meeting Notes :

ALP has confirmed that no Limpet Coil testing is required for
the head to shell joint.
Testing of the exchanger shall be done as per the procedures

SAIEXWA0011 - Hydrotest Vertical and SAIEXWA0010 -
Tightness Test. Copies of both documents attached.
Date: 28th Nov 2017

11. Pneumatic test at 200 mbar is required after Hydro-test & same shall be Discussion point: Pneumatic testing is in RIL/ALP scope.
done under ALP Supervision.
12. List of Hydro Blinds, gasket and fasteners required for testing & service Discussion point: Eqp blinding de-blinding to be performed by
shall be provided by L&T as per the Nozzle drawings (Doc.no.: 10010- RIL - O&M.
4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0003), for RIL to arrange.
13. Bolt tensioning as required shall be performed by L&T, Bolt tensioner Discussion point: Will be performed by RIL - O&M.
(/Contractor) shall be arranged by L&T.
14. Dummy shell for resting the top Dome ( in inverted position) to prepare Discussion point: no dummy shell required, stool will be
WEP shall be fabricated & supplied by L&T provided by RIL for dome resting. WEP shall be done in
overhead condition.
RIL to confirm bellow cut length for top & bottom.
Please refer to Appendix No 5 of document SMSCAZAS002 for

bellow cutting.
15. Utility air connection for drying is available near the equipment, Discussion: RIL will arrange necessary material for drying, if
necessary hose/fittings shall be arranged by L&T. required and will perform air drying.
Time estimate for drying to be furnished.

16. Weld & HAZ area shall be prepared with emery paper & painted. All Discussion point: Blasting not required and only buffing to be
paints as per RIL specification shall be arranged by L&T. performed before painting.
Option for blasting is being checked with REAM-RIL
17. L&T proposed DHT at 350 degree C for 4 hours against the requirement Discussion point: RIL agreed to perform DHT at 350 degree for
of 450 degree C for 3 hours by ALP. 4 Hr, L&T to confirm on H2 bake out & toughness
L&T to confirm total H2 Bake out & toughness requirement of API-934 C requirement.
can be met with 350 Degree for 4 hrs.
18. Power connection from feeder to machines in L&T Scope. Discussion point: L&T to inform KW required and no of
welding machines & PWHT requirement. L&T will come back
within 15 days of order placement. RIL will provide feeder
source and shutdown DB at platform.
Date: 28th Nov 2017

19. Old bottom guide support (Cold side) shall be cut & removed, new Discussion point: RIL will provide guide support & same need
guides shall be installed, and same shall be supplied by ALP/RIL. to installed by L&T.
20. In case vacuum test of vessel is anticipated, L&T to arrange for the Discussion point: RIL will arrange if required
vacuum pump.
21. DHT & Pre heating should all be performed by Electric coil/pad. Discussion point: L&T will perform by electric coil/pad.
22. RIL confirmed old bundle to be cut and will inform place to be kept after L&T will do the cutting and disposal of the old bundle as
wards. RIL will inform cutting size requirement. RIL will provide stool for directed by RIL.
bundle placement.
23. Top Dome Insulation removal & again application is in RIL scope. RIL will hand over the Hx to L&T after removing the pipes and
structure above the Hz and also after removing the Insulation.
L&T and RIL will jointly walkthrough the Hx to freeze the

removal requirements.
24. Other Points L&T will perform welder qualification as per code in L&T
Hazira shop. WPQ will be submitted.
Bellow & support duct material to be confirmed by RIL.
Mitre pipe will be provided by RIL, L&T will fabricate as per

requirement.
Post Meeting Notes

Please refer to drawing no 10010-4Z1JAY-MEY0001-FWR-F-00-
AYZ271-F01-0005 (Nozzle E2 S1 and S2 Details)
Bellow are supplied with Extra length as marked in drawing.

So Existing Mitres to be used.
RIL to provide spray bar and Bellow drawing & details to L&T.
Date: 28th Nov 2017

Post Meeting Notes : Following drawings attached to this
MOM
10010-4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0011 (Spray
Bar Assembly)
10010-4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0013 (Spray
Bar Details)
10010-4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0012
(mounting tool)
10010-4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0008 (Bellow
Nozzle E2)
10010-4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0009 (Bellow
Nozzle S1)
10010-4Z1JAY-MEY0001-FWR-F-00-AYZ271-F01-0010 - Bellow
Nozzle S2
All material supply for permanent installation will be in RIL
scope
Bundle lifting point & lifting lug details to be provide by RIL.
Rigging plan will be submitted by L&T.
Post Meeting Notes

Please refer to drawing no 10010-4Z1JAY-MEY0001-FWR-F-00-
AYZ271-F01-0001 (Bundle Drawing) attached.
25 Safety Procedures Please refer to Exhibit_D (SITE SAFETY AND SECURITY
GUIDELINES)
&
SEZ Aromatics Night Shift Construction Work Permit
management Rev_01
L&T shall fully comply to the safety requirements.
SMSCAZAS002
REVISION D
Page 1 sur 32
BUNDLE REPLACEMENT ON SITE
Nom Entité Date

REVISION D Name Entity Date
Rédacteur Thierry BOSSUT Méthodes 6/6/2005
Writer
Vérificateur(s) Madeleine KMIEC Qualité 14/6/2005

Reviewer(s) Pierre TANCA Méthodes 9/6/2005
Approbateur Pierre TANCA Méthodes management 14/6/2005

Approver
Document validé électroniquement conformément au système qualité et applicable sans visa
Document validated electronically in accordance with quality system and applicable without signatures
Ce document est la propriété exclusive de Alfa Laval Packinox SAS. Il ne pourra, sans l'autorisation préalable écrite de Alfa Laval Packinox SAS, être utilisé à d'autres fins
que celles expressément prévues ni être communiqué à des tiers. Toutes précautions utiles seront prises pour éviter sa divulgation. Loi n°57298 du 11-3-1957.
This document belongs and is the exclusive property of Alfa Laval Packinox SAS. Any use other than those expressly authorised and any copy is strictly forbidden
without Alfa Laval Packinox SAS prior written consent. Users of this document shall take all necessary precautions to prevent its disclosure
SMSCAZAS002
REVISION D
Page 2 sur 32
REVISIONS DU DOCUMENT
REVISIONS TO THE DOCUMENT
Révision Date d’application Objet de la révision

Revision Application date Subject of the revision
A 8/3/2004 Création / First issue
B 8/3/2004
C 20/4/2005 Création du document sous VDOC
D 14/6/2005 Mise a jour suivant commentaire PKS
SMSCAZAS002
REVISION D
Page 3 sur 32
SOMMAIRE
1. SUBJECT .............................................................................................................. 5
NDE = Non Destructive Examination ..................................................................... 5
PT = Dye Penetrant examination........................................................................... 5
MT = Magnetic Particle examination...................................................................... 5
UT = Ultrasonic examination.................................................................................. 5
RT = Radiographic examination............................................................................. 5
2. HANDLING AND STORAGE OF THE NEW BUNDLE................................... 5
3. PREPARATION OF THE EXCHANGER BEFORE REPAIR ......................... 6
4. REMOVE THE OLD BUNDLE........................................................................... 6
4.1. Cut the top head ..................................................................................................... 6
4.2. Remove the old bundle ........................................................................................... 6
5. PREPARATION OF THE VESSEL, THE TOP HEAD AND THE BUNDLE
BEFORE INSERTION........................................................................................................ 6
5.1. Preparation of the vessel and the top head............................................................. 6
5.2. Bundle preparation ................................................................................................ 7
6. INSERTION OF THE BUNDLE INTO THE VESSEL ...................................... 8
6.1. Handling recommendations (see §2)...................................................................... 8
6.2. Insertion ................................................................................................................. 8
6.2.1. Bundle with spray-bar(s): (1 or 2 spray bars) .............................................. 8
6.2.2. Bundle without spray bar ............................................................................ 8
7. FITTING UP AND WELDING OPERATION OF THE TOP HEAD ............... 9
7.1. Fit up the top head ................................................................................................. 9
7.2. Weld the top head................................................................................................... 9
8. COMPLEXION OF THE CONNECTIONS BETWEEN THE BUNDLE AND
THE VESSEL ...................................................................................................................... 9
9. EXAMINATION AND REPORTS (TO SENT TO PACKINOX FOR
INFORMATION) .............................................................................................................. 10
10. HYDRO-TEST .................................................................................................... 10
APPENDIX Nbr 1.............................................................................................................. 11
Appendix Nbr 2.................................................................................................................. 12
Appendix Nbr 3.................................................................................................................. 13
Appendix Nbr 4.................................................................................................................. 14
Appendix Nbr 5.................................................................................................................. 15
Appendix Nbr 6.................................................................................................................. 16
Appendix Nbr 7.................................................................................................................. 17
Appendix Nbr 8.................................................................................................................. 18
SMSCAZAS002
REVISION D
Page 4 sur 32
Appendix Nbr 9.................................................................................................................. 19

Appendix Nbr 10................................................................................................................ 20
Appendix Nbr 11................................................................................................................ 21
Appendix Nbr 12................................................................................................................ 22
Appendix Nbr 13................................................................................................................ 23
Appendix Nbr 14................................................................................................................ 23
Appendix Nbr 15................................................................................................................ 24
Appendix Nbr 16................................................................................................................ 25
Appendix Nbr 17................................................................................................................ 26
Appendix Nbr 18................................................................................................................ 27
Appendix Nbr 19................................................................................................................ 27
Appendix Nbr 20................................................................................................................ 27
Appendix Nbr 21................................................................................................................ 28
Appendix Nbr 22................................................................................................................ 29
SMSCAZAS002
REVISION D
Page 5 sur 32
1. SUBJECT
This specification, based on the Packinox experience, defines the minimum operations of
fabrication and checking (see appendix Nbr 21) which must be carried out (and planned)
to replace a bundle into a vessel, in vertical position, on site, in order to make sure that:
• The position of the bundle in the vessel is correct (supports, guides, spray bars if existing)
• A mesalignment between the nozzles of the bundle and the nozzles of the vessel, allows a
fitting up of the expansion bellows according to the calculation note of them (tansmitted
by Packinox).
Remark :
All the temporary accessories welded on the vessel must be the same material
as the vessel
It gives also some recommandations about handling and storage of the bundle before and
during the repair.
Abbreviations :
NDE = Non Destructive Examination
PT = Dye Penetrant examination
MT = Magnetic Particle examination
UT = Ultrasonic examination
RT = Radiographic examination
PWHT = Post Welding Heat Treatment
GAD = General Arrangement Drawing
2. HANDLING AND STORAGE OF THE NEW BUNDLE

See Appendix Nbr 1 to Nbr 4
• The bundle is delivered in the box or protected with cover, anyway, it lies on the « wall »
• If the bundle is delivered in a box, respect all the indications for handling, marked on the
box.
• The hanging of the new bundle should be done with the lifting lugs, (2 lifting lugs are
calculated to handle the bundle)
• The handling of the new bundle could be done with nylon ropes or flat ropes in a cradle
position, if the lifting lugs are not used.
If metallic wire-ropes are used, flexible protections must be employed. Take
care with metallic protections which should damage the bundle.
• The bundle laying on the « wall », must be put down on shimming which warrants a
none pollution of the bundle by ferritic particles.
• During the storage and the work, the bundle must be protected against knocks and the
surrounding pollution.
SMSCAZAS002
REVISION D
Page 6 sur 32
Take care with the handling operation of the old bundle, the lifting lugs are not able to
handle the bundle.
3. PREPARATION OF THE EXCHANGER BEFORE REPAIR
After the unit shut down, cold down the exchanger (see operation manual) and perform
a chemical cleaning in order to be sure that all the safety conditions allowed the work.
Remove the insulation out of the work area.
Disconnect all the process pipings out of the exchanger.
4. REMOVE THE OLD BUNDLE
4.1. Cut the top head
• Remove the spray bars if existing

• Dismantle the deflectors (bottom side) if existing
• Cut the guides (bottom side).(see appendix 19)
• If the expansion joints are re usable, block and protect them (see appendix N°5)
• Cut all the connections between the bundle and the vessel, remove the expansion
joints (top and bottom side), Take care with the buttering zone (see appendix N° 5)
• Dismantle the centring system (top side)
• Search the existing seam, lay out the cut line
• Perform a Dehydrogenation Heat Treatment if a thermal process is used to cut
o Temperature : 450°C =>842°F
o Holding time : depends of the thickness, any way minimum 3h00
• Cut the top head (if a thermal process is used, preheat the cutting area: temperature
150° C =>302° F) and remove the top head.(see appendix17 and 18)
4.2. Remove the old bundle
Take care with the handling operation of the old bundle, the lifting lugs are not able
to handle the bundle.
5. PREPARATION OF THE VESSEL, THE TOP HEAD AND THE BUNDLE

BEFORE INSERTION
5.1. Preparation of the vessel and the top head

• Machine the bevel on the top head and the vessel, be sure to remove all the “HAZ”
(Heating Affected Zone)
• Check the bevels (Magnetic particle examination)
• If necessary, modify internal accessories and / or fit up new equipment:
SMSCAZAS002
REVISION D
Page 7 sur 32
o If there is any thermal operation on the vessel (flame cutting, welding,…) a

Dehydrogenation Heat Treatment must be done before the intervention, and all
these types of operation must be done under preheating (temperature: 150°C =>
302°F(1.25Cr) - 175°C =>347°F(2.25Cr))
o The scope of fitting up an equipment on the vessel is always :
Grind the area (surface or bevel)
Check the area (dye penetral test or Magnetic particle examination)
Preheating (150°C => 302°F(1.25Cr) - 175°C =>347°F(2.25Cr))
Welding
Post heating (300°C => 543°F holding time 1H00 minimum)
Grind smooth concave profile (if it is a definitive equipment)
Check the welding (Dye penetral test or Magnetic particle examination,
+ ultrasonic test or/and RT test) according to the code and the rules on force
Post Weld Heat Treatment
Temperature for material 1.25 Cr

maximum: 705°C =>1301°F
minimum: 685°C => 1265°F
Holding time: according to the code and the legal rules in force, any way,
02h30mn minimum.

maximum : 710°C =>1310°F
minimum : 690°C => 1274°F
Holding time : according to the code and the legal rules in force, any way,
10h00mn minimum.
o Check the welding (Dye penetral test or Magnetic particle examination, +

ultrasonic test or/and RT ) according to the code and the rules on force
o If it is a temporary equipment, the area must be well grind and checked (Dye
penetral test or Magnetic particle examination) after removing the equipment
o If a welding operation is perform on the vessel (except temporary attachments),
the full penetration is required.
o Clean the vessel.
5.2. Bundle preparation

• Measure the position of the bracket supports in the vessel, lay out the position of them
on the bundle
• Fit up, adjust (overlength existing on the supports) and weld the brackets stainless-
steel supports on the bundle (fillet weld )
• Dye penetral test of the weld
• Clean the bundle.
SMSCAZAS002
REVISION D
Page 8 sur 32
6. INSERTION OF THE BUNDLE INTO THE VESSEL
6.1. Handling recommendations (see §2)

Use the lifting lugs of the new bundle, adjust the wire ropes to have a perfect vertical
position of the bundle before insertion into the vessel.
6.2. Insertion
Insert, set up an adjust the bundle in such way that:
6.2.1. Bundle with spray-bar(s): (1 or 2 spray bars)

• The axes of the spray bar(s) nozzles on the vessel (N1, N2) and the axes of the
rings of the spray bar(s) on the cold (bottom) header are well positioned (vertical
and horizontal position) (take care with the offset position of the spray bars if
necessary)
• The alignment of the bellow expansion joints is correct, regarding the position
of the bundle and of the vessel nozzles.(The value of the tolerances is given by the
calculation sheet of the bellows, transmitted by packinox)
• Fit up and weld the news bundle gudances.(see appendix 20)
• The gap between the guides (cold side = bottom side) and the bundle respects
the tolerances : maxi : 10mm, mini : 5mm
• The fitting up and the welding of the stainless-steel supports on the bundle (hot
side = top side) guarantee 3 contact points minimum between the bundle
supports and the vessel supports, if not, set up shims in order to get these 3
contact points (tack weld the shims on the stainless steel supports).
• The gap on the mobile part of the centring system (hot side = top side) is
correct to allow a movement of the bundle in operation.
• Note :
o Take care with the direction of the flow during the fitting up of the
bellow expansion joints.
o After complexion of the insertion job, before the hydro-test of the vessel,
the shrouds and protections of the bellows must be removed, except for
the spray bars bellows.
6.2.2. Bundle without spray bar

• The nominal size of the bundle position (position of the bundle (LRE) to the
tangent line of the vessel) is well respected. (see the drawing at the applicable
revision)
• The alignment of the bellow expansion joints is correct, regarding the position
of the bundle and the vessel nozzles.(The value of the tolerances is given by the
calculation sheet of the bellows, transmitted by packinox)
• Fit up and weld the news bundle gudances.(see appendix 20)
• The gap between the guides (cold side = bottom side) and the bundle respects
the tolerances : maxi : 10mm, mini : 5mm
• The fitting up and the welding of the stainless-steel supports on the bundle (hot
side = top side) guaranty 3 contact points minimum between the bundle
SMSCAZAS002
REVISION D
Page 9 sur 32
supports and the vessel supports, if not, set up shims in order to get these 3
contact points (tack weld the shims on the stainless steel supports).
• The gap on the mobile part of the centring system (hot side = top side) is
correct to allow a movement of the bundle in operation.
• Note :
Take care with the direction of the flow during the fitting up of the bellow
expansion joints.
7. FITTING UP AND WELDING OPERATION OF THE TOP HEAD
7.1. Fit up the top head

• Fit up and adjust the top head regarding the vessel and the position of the bundle
nozzles
• If not done before, perform the Dehydrogenation Heat Treatment:
o Temperature : 450°C => 842°F
o Holding time depends of the thickness, any way minimum 3h00.
7.2. Weld the top head

• Preheat the head and the vessel on the welding area (150°C => 302°F(1.25Cr) -
175°C =>347°F(2.25Cr))
• Weld the top head
• Postheat the head and the vessel on the welding area (300°C => 543°F, during
1h00 minimum)
• Check the weld according to the code and local rules in force (magnetic particle
examination or Dye penetral test, US, RT, …)
• Perform the PWHT (Post Weld Heat Treatment):

maximum : 705°C =>1301°F
minimum : 685°C => 1265°F
02h30mn minimum.

maximum : 710°C =>1310°F
minimum : 690°C => 1274°F
10h00mn minimum.
• Check the weld according to the code and local rules in force (magnetic particle
examination or Dye penetral test, US, RT, hardness test, …).
8. COMPLEXION OF THE CONNECTIONS BETWEEN THE BUNDLE AND THE

VESSEL
SMSCAZAS002
REVISION D
Page 10 sur 32
• Machine the bevels on the bellows expansion joints, transition sleeves, nozzles of the
bundle
• Check the bevels (Dye penetral test)
• Fit up, adjust the connections (bellows, transition sleeves) between the bundle and the
vessel
• Weld the connection
• Check the welds (Packinox recommends a Dye penetral test)
• Well clean the vessel and the bundle
• Remove the shrouds and all protections of the bellow expansion joints (except of the spray
bars if existing).
9. EXAMINATION AND REPORTS (TO SENT TO PACKINOX FOR INFORMATION)
Perform and set up dimensional reports (before hydro-test)
• Spray bar(s) position (if existing): see Appendix Nbr 6 and 7

• Position of the L.R.E. line to tangent line Hot (Top) side (if no spray bars): see
Appendix Nbr 8
• Bellow expansion joints alignment: see Appendix Nbr 9 to 12
• Guidance system (gap between the guides and the bundle)at the “cold side”
(bottom) (check with a “Go, No Go” gauge): see Appendix Nbr 20
• Contact points between the bundle supports and the vessel supports, position and value
of the shims if necessary : see Appendix Nbr 13
• Position of the supports of the vessel regarding the spray bars axes (if existing): see
Appendix Nbr 14
• Position of the supports of the vessel regarding the tangent line cold (bottom) side (if no
spray bar): see Appendix Nbr 15
• Clearance between the bundle and the vessel, hot side (top) and cold side (bottom): see
Appendix Nbr 16.
10. HYDRO-TEST
• Preparation of the hydro-test (see Packinox’s specification)

• Perform the hydro-test
• Perform the differential pressure test if required (see the specification)
• Perform the air test if required (see the specification)
• Drain the water.
SMSCAZAS002
REVISION D
Page 11 sur 32
APPENDIX Nbr 1
Using the lifting lugs to handle the bundle
Oreilles de levage
Lifting lugs
Coté chaud Coté froid (bas)

Hot (top) side Tole externe Cold (bottom) side
External plate
SMSCAZAS002
REVISION D
Page 12 sur 32
Appendix Nbr 2
Handling the bundle without use lifting lugs
Faisceau > 10m Bundle > 10m
Faisceau < 10m Bundle < 10m
= =
2500 to 3000
SMSCAZAS002
REVISION D
Page 13 sur 32
Appendix Nbr 3
Handling the bundle without use lifting lugs - Warning
YES NO
Elingues ou sangles
Slings
Elingues ou sangles
Slings
Cales en bois
Wood shims
Bundle
Protection métalliques
Metallic protection
SMSCAZAS002
REVISION D
Page 14 sur 32
Appendix Nbr 4
Bundle storage - Warning
50 50
Calage et vérins autorisés

Shimming & jacks allowed
Calage et vérin interdits

Shimming & jack forbidden
Type 2 cannes / 2 Spray bars type
50 50
Calage et vérins autorisés

Shimming & jacks allowed
Calage et vérins interdits

Shimming & jacks forbidden
Type 1 canne ou 4 compensateurs / 1 spray bar or 4 bellows type
SMSCAZAS002
REVISION D
Page 15 sur 32
Appendix Nbr 5
How to cut the old bellows
Before cutting the

Bellows expansion
Lignes de coupe joints,block them
Cut lines with 4 rods
Also protect the

wawes
Stainless-steel
Supports (may
be existant)
Bellow expansion joint
Nozzle
Buttering zone Cut lines

Transition sleeve
OU / OR
30 Bellow expansion joint
Nozzle
Transition sleeve
Cut lines
SMSCAZAS002
REVISION D
Page 16 sur 32
Appendix Nbr 6
2 Spray bars
Spray bars’s ring axes

Axes des anneaux de
passage des cannes
∆ B2+
∆ B2-
∆A2+ ∆ A2-
Cold Side (Bottom)

Coté Froid (bas
Coté Chaud
(Haut)
AXE CALANDRE
VESSEL ‘S AXIS
Spray bars’s ring axes

Axes des anneaux de
passage des cannes
∆ B1-
∆ B1
∆A1+ ∆A1-
Axes N
N Axis
Tub N
Nozzle N
A1 A2 B1 B2
Appareillage utislisé:
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 17 sur 32
Appendix Nbr 7
1 Spray bar
Axes l’annea de canne

Ring of the pray bar
∆ B+
∆Β −
∆Α+ ∆Α− Tubulure N

Nozzle N
Coté Chaud (Haut)
Hot Side (Bottom)
Cold side (Bottom)

Coté Froid (bas)
AXE CALANDRE
VESSEL AXES
A B
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 18 sur 32
Appendix Nbr 8
Bundle position
Echangeur Type 4 compensateurs
4 Bellows expansion joint exchanger type
L.T
T.L
Vérifiée après insertion

To be checked after
insertion
L.R.E
Ligne de
référence, tracée
par PKX
Reference Line,
marked by PKX
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 19 sur 32
Appendix Nbr 9
Bellows (Exchanger with 3 bellows)
Nozzle Nbr : Nozzle Nbr : Nozzle Nbr :
A Plumber A
B
B B
C
C C Plumber
Nozzle Nbr : 0° 90° 180° 270°

A
B
C
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
C
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
C
Observations :
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 20 sur 32
Appendix Nbr 10
Nozzle Nbr : Nozzle Nbr : Nozzle Nbr : Nozzle Nbr :
A A
A Plumber A
B B
B B
C C
C C Plumber
Nozzle Nozzle
0° 90° 180° 270° 0° 90° 180° 270°
Nr : Nr :
A A
B B
C C
Observations Observations
Nozzle 0° 90° 180° 270° Nozzle 0° 90° 180° 270°

Nr : Nr :
A A
B B
C C
Observations Observations
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 21 sur 32
Appendix Nbr 11
Nozzle Nbr : Nozzle Nbr : Nozzle Nbr :
Plumber A
A B
B
B A
Plumber
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 22 sur 32
Appendix Nbr 12
Nozzle Nbr : Nozzle Nbr : Nozzle Nbr : Nozzle Nbr :
Plumber A A
A B
B
B
B A
Plumber
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Nozzle Nbr : 0° 90° 180° 270°

A
B
Observations :
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 23 sur 32
Appendix Nbr 13
Contact points between supports
Ep. mm Ep. mm
Ep. mm Ep. mm
Ep. mm Ep. mm
Ep. mm Ep. mm
Faisceau/Bundle
Calandre/Vessel
Support soudé sur
Ajuster et pointer les cales inox (si faisceau
necessaire) sur le support faisceau Support welded on the
Adjust and tack-weld stainless-steel (if bundle
necessary) on the bundle’s support
Support soudé sur calandre

Support welded on the vessel
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 24 sur 32
Appendix Nbr 14
Exchanger with Spray bar(s)
L2
L1
L1 L2
L1
L2
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 25 sur 32
Appendix Nbr 15
Exchanger without Spray bar
L1 L2
L1 L2
L.T.
T.L
L1
L2
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 26 sur 32
Appendix Nbr 16
Clearance between bundle and vessel
0°
H B
A
270° G C
90°
E
F D
180°
A B C D E F G H
Coté Froid/Cold side
Coté Chaud/Hot side
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
SMSCAZAS002
REVISION D
Page 27 sur 32
Appendix Nbr 17
Top head cutting
Position of the grinding machine
Top Head
1° (to allow gap
during operation)
SHELL
Air grinding machine (manual
or automatic)
Adjustable ( ) transition piece
Wheel Rail : fixed up all around the shell
Appendix Nbr 18
SMSCAZAS002
REVISION D
Page 28 sur 32
Top head cutting
1st Step
Don’t cut
Don’t cut
Don’t cut
Don’t cut
2sd Step
After cutting, insert wedges between Top Head and Shell into the cutting zone and
then finish the cutting operation
Top Head
cut
cut
Shell Wedge
cut
cut
The mechanical cutting does not need a dehydrogenation heat treatment.

This one will be performed before welding.
Appendix Nbr 19:cold side guidance cutting
SMSCAZAS002
REVISION D
Page 29 sur 32
10 maxi
5 mini
Fix part of the guide
Mini 50 mm Cut location
Appendix Nbr 20:cold side guidance system
SMSCAZAS002
REVISION D
Page 30 sur 32
4 2
5 mini 10 maxi
1 2 3 4
5 mm “Entre” / “Go”
10 mm “N’entre pas” / “No
Go”
Equipment used:
Observations :
Remarks :
Contrôleur
NDT Inspector
Nom :
Name :
Date :
Date :
Signature :
Signature :
Appendix Nbr 21
Typical sketch of fabrication and checking operations which must be planned and carried
out to perform the replacement of the bundle
SMSCAZAS002
REVISION D
Page 31 sur 32
⇒ Shut down the unit

⇒ Cold down the exchanger (see Packinox procedure)
⇒ Chemical clean of the exchanger
⇒ Remove insulation out of working area
⇒ Lay out axis, cut line and reference mark on the head and the shell
⇒ Disconnect and remove process nozzles
⇒ Disconnect and remove spray bar(s) if existing
⇒ Dismantle and remove the deflectors (bottom side) if existing
⇒ Lay out, protect, block the expansion joints (top and bottom side), cut and
remove them
⇒ Cut the bundle guides (bottom side) if necessary (preheating)
⇒ Dehydrogenation Heat Treatment must be done on each area which will be
affected by thermal cutting or welding process
⇒ Cut and remove the top head (if thermal process used, preheat)
⇒ Remove the old bundle (take care with handling operation, verify that the lifting
lugs in place are able to lift the old bundle)
⇒ Machine the bevel on the shell and on the top head (the “HAZ” (Heated Affected
Zone) must be totally removed)
⇒ Magnetic particle examination of the bevels (head and vessel)
⇒ Modify existing vessel according to Packinox drawing if necessary (supports,
guides and so on…)
⇒ Clean up the vessel
⇒ Lay out the position of the stainless steel bracket supports on the bundle
regarding the position of the supports on the vessel
⇒ Fit up, adjust and weld the bracket supports on the bundle
⇒ Dye penetral test of the welds
⇒ Insertion of the new bundle
⇒ Adjust the bundle, fit up the centring system and the guides
⇒ Fit up and adjust the top head
⇒ Weld the top head (preheating and postheating recommended)
⇒ Check the weld : Dye penetral test or magnetic particle examination + UT or/and
RT) according to the code and the rules on force
⇒ Post Weld Heat Treatment
⇒ Check the weld : Dye penetral test or magnetic particle examination + UT or/and
RT) according to the code and the rules on force
⇒ Fit up, adjust and weld all the connections between the bundle and the vessel
(Transition sleeves, expansion joints)
⇒ Dye penetral test of the welds
⇒ Assemble, weld the spray bar(s) if existing (see Packinox procedure)
⇒ Dye penetral test of the weld
⇒ Visual, dimensional examination and reporting (as explain in this specification)
⇒ Prepare the hydro and differential hydro test(See Packinox procedure)
⇒ Perform the hydro-test (See Packinox procedure)
SMSCAZAS002
REVISION D
Page 32 sur 32
⇒ Perform the differential hydro-test (if required) (See Packinox procedure)

⇒ Prepare and perform the pneumatic test (if required) (See Packinox procedure)
⇒ Report the tests(See Packinox procedure)
X
Ian Ponton (B2574) 17/Dec/13
STATIC EQUIPMENT
MEAYZ271Y000001
4 Z 1 J A Y ME Y 0 0 0 1 FWR F R P
DSN 44
10010 4 Z 1 J A Y ME Y 0 0 0 1 F WR F 0 0 AY Z 2 7 1 B 0 2 0 0 0 1 0 3
3
DSN 44 5150/2001 4 4
Guillaume Gilbert Gilbert

COLIN GRAILLE GRAILLE
26/11/13 26/11/13 26/11/13
Document validated electronically in accordance
with quality system and applicable without signatures

DSN 14
DSN 15
DSN 12
VENDOR DOCUMENT REVIEW FEEDBACK
Permission to proceed does not constitute acceptance or approval of Design Detail, Calculations, Analysis, Test Methods or
Materials developed OR selected by vendor, and does NOT relieve Vendor from FULL compliance with Contractual Obligations
X 1 Work may proceed 5 Cancelled / Superseded
Revise & resubmit. Work may proceed,

2 subject to incorporation of comments F Final Certified
3 Revise & resubmit. Work shall not Proceed
4 For Information Only
Ian Ponton (B2574)

_______________________________________________ 6th May 2014
By : _ Date : ________________________________________________
Discipline
Equipment
No. ME-AYZ271-Y000001 A
MR No. 4 Z 1 J A Y - M E Y 0 0 0 1 - F W R - F - 0 0
Project
MR No. Unit No(Plant WBS) Cat. No. Seq. No. Rev. No.
No.
1 0 0 1 0 4 Z 1 J A Y - M E Y 0 0 0 1 - F W R - F - 0 0 A Y Z 2 7 1 - F 0 1 - 0 0 0 1 0 2
DSN 47
DSN 16
X
Ian Ponton (B2574) 9th June 2014
DSN 30
X
DSN 29
X
DSN 28
NO PIPING COMMENT
Ian Ponton (B2574) 11/Jul/13
STATIC EQUIPMENT
MEAYZ271Y000001
4 Z 1 J A Y M E Y 0 00 00 11 FF W
WRR FF R
RPP
10010 4 Z 1 J A Y M E Y 0 00 00 11 FF W
WRR FF 00 00 AY
A Y ZZ 22 77 11 FF 00 11 00 00 11 33 00 00
DSN 1089
DSN 1089 5150/2001
5150/2001 5 11

18/6/13 18/6/13 18/6/13

X
Ian Ponton (B2574) 11/Jul/13
STATICEQUIPMENT
STATIC EQUIPMENT
MEAYZ271Y000001
MEAYZ271Y000001
4 4ZZ1 1J JAAYY MMEEYY00000011 FFW

WRR FF RRPP
1100001100 WRR FF 00 00
4 4ZZ1 1J JAAYY MMEEYY00000011 FFW AA YY ZZ 22 77 11 FF 00 11 00 00 1 2 0 0
DSNDSN
21 21 5150/2001
5150/2001 5 11

18/6/13 18/6/13 18/6/13

X
Ian Ponton (B2574) 6th May 2014
DSN 22

27/3/14 27/3/14 27/3/14

SESCAZA3001
REVISION H
Page 1 sur 35
PRESSURE VESSEL GENERAL SPECIFICATION
Nom Entité Date

REVISION H Name Entity Date
Rédacteur Laurent FRALONARDO Etudes 2/11/2015
Writer
Vérificateur(s) Alain BOURGEON Etudes 2/11/2015

Reviewer(s) Emilie TEYSSIER Qualité 9/11/2015
Approbateur Antoine PECHBERTY Etudes Management 19/11/2015

Approver
SESCAZA3001
REVISION H
Page 2 sur 35

A 24/11/2008 First issue
B 16/12/2009 Modification of gasket design, edges and bevels preparation,
PWHT values for 1.25Cr-0.5Mo material, spraybars
adjustement, painting, marking and appendix 1.
C 15/6/2010 Flanges calculation, bolting length, gaskets material and PWHT
temperature.
D 20/1/2012 Accessories material, loading combination, flange facing, weld
types of accessories, NDE personnel qualification, hardness
measurement and ageing sample.
E 5/4/2013 Accessories material, loading combination, nozzle internal
radius, flange calculation, WPS data, preheating of bi-metallic
junction.
F 16/9/2013 Welding book data, welding of temporary attachments, hardness
measurements.
G 5/9/2014 Ring gaskets type, production test coupons, design of
transportation saddles, Appendix 4.
H 19/11/2015 Loading conditions and combinations, limitation of electrode
diameter, impact test requirement on PQR, local PWHT,
internal surface preparation, Appendix 4.
SESCAZA3001
REVISION H
Page 3 sur 35
SUMMARY
1. PRESENTATION ........................................................................................................................................ 5
2. APPLICABLE DOCUMENTS & STANDARDS ...................................................................................... 5
2.1. CLIENT’S DOCUMENTS ................................................................................................................... 5
2.2. STANDARDS....................................................................................................................................... 5
3. REQUIRED DOCUMENTS ........................................................................................................................ 6
4. STAMPING OF THE VESSEL .................................................................................................................. 6
4.1. ASME STAMP ..................................................................................................................................... 6
4.2. PRESSURE EQUIPMENT DIRECTIVE STAMP (PED 97/23) .......................................................... 7
5. MATERIALS ................................................................................................................................................ 7
5.1. SHELLS & HEADS .............................................................................................................................. 7
5.2. INTERNAL & EXTERNAL ELEMENTS ........................................................................................... 7
5.3. LIFTING LUGS .................................................................................................................................... 8
5.4. TRANSITION PIECES ........................................................................................................................ 8
5.5. BOLTING ............................................................................................................................................. 9
6. VESSEL DESIGN AND CALCULATION ................................................................................................ 9
6.1. CORROSION ALLOWANCE ............................................................................................................. 9
6.2. JOINT EFFICIENCY ............................................................................................................................ 9
6.3. ALLOWABLE STRESS VALUES ...................................................................................................... 9
6.4. DESIGN TEMPERATURES ................................................................................................................ 9
6.5. DESIGN PRESSURE ........................................................................................................................... 9
6.6. LOADING CONDITIONS AND COMBINATIONS ......................................................................... 10
6.7. SHELL COURSES & HEADS ........................................................................................................... 10
6.8. OPENINGS & CONNECTIONS ........................................................................................................ 11
6.8.1. Design requirements ....................................................................................................................... 11
6.8.1.1. General ................................................................................................................................................ 11
6.8.1.2. Specific requirements for parts at design temperature higher than 427°C ........................................... 12
6.8.2. Calculation requirements ................................................................................................................ 12
6.8.2.1. Flange calculation................................................................................................................................ 12
6.8.2.2. Opening calculation ............................................................................................................................. 13
6.9. INTERNAL & EXTERNAL ELEMENTS ......................................................................................... 13
6.10. LIFTING DEVICES ........................................................................................................................... 14
6.11. BOLTING ........................................................................................................................................... 14
6.12. GASKETS .......................................................................................................................................... 15
6.13. AGEING SAMPLE ............................................................................................................................. 15
7. FABRICATION.......................................................................................................................................... 15
7.1. WELDING .......................................................................................................................................... 15
7.1.1. General ........................................................................................................................................... 15
7.1.2. Low alloy steel welding ................................................................................................................. 16
7.1.3. Bi-metallic junctions ...................................................................................................................... 17
7.1.4. Stainless steel welding ................................................................................................................... 18
7.2. WELD GRINDING & BRUSHING.................................................................................................... 18
7.3. POSTWELD HEAT TREATMENT (PWHT) IN FURNACE ............................................................ 18
7.3.1. 1.25Cr – 0.5Mo .............................................................................................................................. 19
7.3.2. 2.25Cr – 1Mo ................................................................................................................................. 20
7.4. LOCAL HEAT TREATMENT ........................................................................................................... 20
7.5. PRODUCTION SAMPLES ................................................................................................................ 20
7.6. EXPANSION BELLOWS WELDING ............................................................................................... 20
SESCAZA3001
REVISION H
Page 4 sur 35
8. INSPECTION & TESTING ...................................................................................................................... 21

8.1. GENERAL .......................................................................................................................................... 21
8.2. VISUAL EXAMINATION ................................................................................................................. 21
8.3. X (OR GAMMA)-RAY EXAMINATION .............................................................................................. 21
8.4. ULTRASONIC EXAMINATION ...................................................................................................... 22
8.5. MAGNETIC PARTICLE EXAMINATION ....................................................................................... 22
8.6. PENETRANT TEST EXAMINATION .............................................................................................. 22
8.7. HARDNESS MEASUREMENT ........................................................................................................ 22
8.8. POSITIVE MATERIAL IDENTIFICATION (PMI) .......................................................................... 22
8.9. DIMENSIONAL CHECKING ........................................................................................................... 23
9. INTERNAL & EXTERNAL SANDBLASTING - INTERNAL CLEANING....................................... 23
10. BUNDLE INSERTION .............................................................................................................................. 23
11. SPRAYBARS ADJUSTMENTS ............................................................................................................... 23
12. HYDROSTATIC AND AIR TESTS ......................................................................................................... 24
13. DRYING ...................................................................................................................................................... 24
14. PAINTING .................................................................................................................................................. 24
15. MARKING .................................................................................................................................................. 24
16. FINAL VISUAL INSPECTION ................................................................................................................ 25
17. SPARE PARTS ........................................................................................................................................... 25
18. PREPARATION FOR SHIPMENT- TRANSPORTATION ................................................................. 25
APPENDIX 1 : FORCES & MOMENTS ON NOZZLES................................................................................ 27
APPENDIX 2 : TYPICAL BRACING AND WEDGING DURING PWHT .................................................. 29
APPENDIX 3 : LOCAL PWHT ......................................................................................................................... 31
APPENDIX 4 : PRODUCTION AND AGEING SAMPLES ........................................................................... 33
SESCAZA3001
REVISION H
Page 5 sur 35
1. PRESENTATION
This general specification covers the standard mandatory requirements governing the design,
materials, fabrication and inspection of pressure vessels containing an AL Packinox’s plate
heat exchanger.
This specification shall be used in addition to the following documents :
 The Job Specification applicable to the Order. It contains :
o the scope of supply ;
o the scope of work ;
o the list of the applicable additional specifications ;
o the additional information and deviations.
 The additional Specifications concerning :
o the material requirements
o the specific requirements of the licensor and/or of the Client ;
 The Vessel Data Sheet with the main technical data ;
 The General Arrangement Drawing with the main geometrical characteristics.
The intention of this specification is not to supersede the specified Codes and standards, but to
supplement them with certain conditions not fully covered by the codes.
This specification shall not apply to other equipments (such as filters, strainers, etc), except
when indicated in the Purchase Order.
2. APPLICABLE DOCUMENTS & STANDARDS

The vessel shall be designed, fabricated, inspected and tested in accordance with the
construction Code, named hereafter the Applicable Code, indicated in the Vessel Data Sheet.
In case of conflict between these applicable documents and standards, or any variation from
and/or additions to these documents, a clarification or deviation request shall be made and
written approval obtained before starting fabrication.
2.1. CLIENT’S DOCUMENTS

 Documents listed in the AL Packinox’s Sub-Contractor Purchase Order.
2.2. STANDARDS
 ASME CODE II, V, VIII & IX: Edition and Addenda indicated in the data sheet.
 Local laws & regulations indicated in the Vessel Data Sheet.
 ASTM standards.
 ANSI standards (edition allowable by referenced ASME Code).
 ASME B 16 5 – edition referred in applicable code.
 ASME B 16.47 - edition referred in applicable code.
 WRC Bulletin 107/297.
 API 934 latest edition.
 API 941 latest edition.
 API Standards (edition allowable by referenced ASME Code).
SESCAZA3001
REVISION H
Page 6 sur 35
 ASCE 7: Minimum Design Loads for Buildings & other Structures - latest
edition, or IBC.
 AWS: Specification of welding electrodes (edition allowable by referenced
ASME Code).
 PED: Pressure Equipment Directive PED 97/23 CE (if applicable).
3. REQUIRED DOCUMENTS
The documents as listed in the Job Specification shall be submitted for approval and for
review to AL Packinox in quantities, format and at the dates indicated in the purchase order.
All documents (including calculation sheets, drawings, certificates, reports, etc...) and
communications (letters, fax, etc...) shall be in the language specified in the Vessel Data Sheet
as Official Language.
SI units shall be used in the drawings & calculation sheets with, in addition :
 The pipe and nozzle diameters in inches.
 The pressure in MPa and Kg/cm2.
 The impact test in Joules and in Kg.m/cm2.
In case of ASME stamp, units shall be as described in para. 4.1.
Calculation sheets shall include all inputs necessary for review.
The vessel manufacturer’s procedures shall be based on the AL Packinox’s specifications.
AL Packinox review and the final client's approval of these documents shall in no way relieve
the vessel manufacturer of its obligations & responsibilities.
The Client’s sticker and/or front page form will be transmitted by AL Packinox to the Vessel
Sub-contractor for insertion in the documents.
The numbering of documents shall be in accordance to AL Packinox system.
Documents between the Vessel Sub-contractor and AL Packinox shall be transmitted and
returned in PDF format through Extranet according to the AL Packinox’s procedure.
4. STAMPING OF THE VESSEL

This article is applicable only when stamping is required, as indicated in the Vessel Data
Sheet.
4.1. ASME STAMP

The required Authorised Inspector shall stamp the documents and data report shall be
registered with the National Board.
For US and Canada countries, the values in Imperial units shall be added into
brackets, to the SI units, in documents and drawings.
All welding operations, including tack welding and temporary attachments, and non
destructive examinations shall be done according to ASME Code requirements by U
Stamp holder and qualified personnel.
SESCAZA3001
REVISION H
Page 7 sur 35
The nameplate and U-1 form shall be filled in units negotiated with client.
Indications to fill : see ASME VIII Div 1 Code para. UG-115.
For countries where the SI units have been selected, the documentation including
name plate and data report shall be in SI units.
Vessel marking, nameplate, and U-1 form shall be as required by the ASME Code.
4.2. PRESSURE EQUIPMENT DIRECTIVE STAMP (PED 97/23)

In case of PED stamp, the ASME Code shall be used except otherwise specified,
using the following requirements of Directive :
 selection of a Notified Body ;
 selection of ASME materials with additional requirements ;
 complete design with ASME Code ;
 for hydrotest pressure : application of the greatest between 1.43 x p and
1.25 x p x higher yield ratio (except otherwise specified) ;
 WPS/PQR qualified as per Directive by TPI ;
 NDE Personnel qualified as per COFREND for France for example.
When European code is exceptionally specified instead of ASME Code, the
material selection shall be made on the basis of European standards (EN 10028)
with stress based on 100 000 hours creep range values.
Usually, AL Packinox keeps the responsibility of pressure equipment. So the
Notified Body chosen by AL Packinox will be APAVE, TÜV Nancy or Lyon, ETC.
5. MATERIALS
Material grade and class : see Vessel Data Sheet.
5.1. SHELLS & HEADS

Heads shall be preferably seamless. In case of welded heads, the Supplier has to
inform and obtain written approval from AL Packinox prior to plate’s procurement.
5.2. INTERNAL & EXTERNAL ELEMENTS

For elements directly welded on pressure parts, the material shall be strictly the same
as pressure vessel material.
For elements none directly welded on pressure parts, material shall be at least the
same grade as the ASME designation of the material of the shell or head to which it
is welded (impact tested at the temperature indicated in the vessel data sheet). Except
the impact test requirements, no other specific requirements will be applied to these
internal and external elements.
Material requirements for internal and external elements are summaries in table
below:
SESCAZA3001
REVISION H
Page 8 sur 35
Material as per
ASTM material
DESCAZA0003
Type of accessory impact tested
specification
Bundle support brackets welded on shell x
Bundle cold guides on shell With pad Without pad
Guide clips to maintain tools in right
x
position during bundle insertion
Lifting & Tailing lugs With pad Without pad
Davit or hinge elements welded on
x
shell/nozzle & blind
Skirt ring x
Skirt x
Skirt anchor boxes and skirt stiffeners x
Fireproofing lugs x
Nameplate support On skirt On shell
Earthing lug x
Insulation support lugs On skirt On shell
Piping and platform supports x
Internal accessories x
Pads x
Temporary attachments x
For davit or hinge parts not directly welded on blind or on flange, carbon steel
impact tested material at the MDMT or colder can be used instead of identical grade
of the pressure vessel material.
For external elements in 2.25Cr-1Mo, no step cooling is required.
In case of use of bi-metallic skirt shell (after approval by AL Packinox), a minima
length of 610mm shall be provided in the same material as the shell. WPS and PQR
shall be sent to AL Packinox for approval prior manufacturing. It shall include
macrographic and micrographic examinations and mechanical tests after PWHT
(holding time taking into account the simulation of one repair after initial PWHT).
These mechanical tests shall include the tensile tests, KCV impact tests and hardness
tests in the HAZ of low alloy steel / carbon steel junction.
5.3. LIFTING LUGS

The material grade for lifting blind flanges and lifting lugs shall be either carbon
steel (ASTM or EN designation) or low alloy steel, impact tested at temperature
specified in the Vessel Data Sheet, and PWHT.
5.4. TRANSITION PIECES

The stainless steel transition pieces (short pipes, reducers, etc.) between the vessel
nozzles and the bellows shall be of the same grade as the bundle headers.
When the design temperature is  550°C, the carbon content for SS 300 series
(including welding consumables) shall be between 0.04 and 0.06%.
Ferrite content as per Schaeffler diagram shall be controlled with acceptance criteria
between 3 and 8%.
SESCAZA3001
REVISION H
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5.5. BOLTING
External bolting materials shall be as indicated in the Vessel Data Sheet.
Internal bolting material shall be SA 193-B8 or B8T or B8M (Grade A2 or/and A4
are acceptable).
6. VESSEL DESIGN AND CALCULATION

The exchanger is not subjected neither to cyclic service, nor thermal fatigue.
The exchanger does not contained lethal substances.
Anchor bolts shall be sized even if excluded from the scope of supply.
6.1. CORROSION ALLOWANCE

The corrosion allowance of pressure retaining parts and supports shall be as per
Vessel Data Sheet.
Internal components welded to the vessel shall be provided with a total corrosion
allowance equal to twice the corrosion allowance of the vessel (including fillet and
seal welds).
6.2. JOINT EFFICIENCY

The required joint efficiency is: 1.
6.3. ALLOWABLE STRESS VALUES

The allowable stress values shall be taken in accordance with the Applicable Code.
6.4. DESIGN TEMPERATURES

The graded design temperatures are indicated on AL Packinox General Assembly
Drawing.
Note : the shell course length associated with a design temperature on the General
Assembly Drawing can be different from the real shell length, when tapering is
required for welding to an adjacent shell of lower thickness.
The Minimum Design Metal Temperature (MDMT) is indicated in the Vessel Data
Sheet.
6.5. DESIGN PRESSURE

The internal and external design pressures are indicated in the Vessel Data Sheet.
The Hydrostatic Test Pressure, based on ASME VIII Div 1 paragraph UG 99 (b),
shall take into account the vertical position of the vessel on site and shall be
calculated according to the Applicable Code and Local Regulations indicated in the
Vessel Data Sheet.
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6.6. LOADING CONDITIONS AND COMBINATIONS

The bulk densities are as follows:
 Hot insulation (mineral wool) : 250 Kg/m3 (up to 550°C)
 Fireproofing : 2200 Kg/m3
Wind, snow and earthquake data : refer to the document indicated on the Vessel Data
Sheet.
The following combinations of loads and forces shall be considered for the design of
the vessel and of the supports:
H Design case
Erection -
As erected Normal Operation Test on site
Lifting
Weight of exchanger x
Dynamic x x x
Incl. Insulation & fireproofing
coef : 1.5
Platform (If applicable) x x x
x (Design x (Test
Pressure
Pressure) Pressure)
Wind load x (100%) x (100%) x (50%)
(whichever is
(whichever is greater)
Seismic load greater)
Snow load x x
Efforts on nozzles and x x x
support reactions pipes Mechanical part Mechanical and Mechanical part
(See Appendix 1) (33%) thermal parts (100%) (33%)
Water weight x
Vessel shall also be checked against transverse bending during horizontal hydrotest
as per CODAP French Code or PD5500 English Code.
6.7. SHELL COURSES & HEADS

Shell plates shall be preferably laid out so that there shall be a minimum of welded
seams.
The welded longitudinal and circular seams shall be arranged so that welded
attachments, such as nozzles, insulation supports, etc., shall not overlap or interfere
with them.
For longitudinal welds : see joint orientations on GAD.
The minimum distance between mean seams shall be 200 mm or two (2) times the
wall thickness, whichever is greater.
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The minimum plate thickness (before forming) of the head shall not be smaller than
the thickness of the shell to which it is welded, except when approved by AL
Packinox.
6.8. OPENINGS & CONNECTIONS

6.8.1. Design requirements
6.8.1.1. General
The following insulation thicknesses shall be taken into account for the
determination of the stand-out of the flanges, except when other values
are indicated on GAD.
Country
Russia Other countries
Temp (°C)
T > 538 250 mm 165 mm
315 < T  538 250 mm 152 mm
T  315 190 mm 102 mm
The minimum distance between the outside of the nozzle weld edge and
other weld edges shall be 50 mm or one (1) time the wall thickness,
whichever is greater.
Bolt holes of bolted connections shall straddle the natural vertical and
horizontal centrelines.
Flanges shall not be located inside of vessel support skirts or other
confined areas.
Every nozzle shall be flanged except otherwise specified.
Slip-on flanges shall not be used.
Nozzles 2” shall be at least 300# serie.
Flanges whose diameter is 24" or smaller shall be according to ASME
B 16.5.
Flanges whose diameter is over 24" shall be according to ASME B 16.47
with Series A for the RTJ faces and Series B for the RF faces.
For RF type, the gasket contact surface shall be done by a serrated-spiral
groove generated by a 1.5 mm radius round-nosed tool at a feed rate
between 0.45 and 0.55 mm per revolution. This shall result in a
roughness between Ra 3.2 and 6.3 µm (125 to 250).
Ring joint flanges grooves shall have a minimum radius as per code at
the intersection between flat bottom and sides.
Faces shall be machined before nozzle installation and shall be protected
by efficient means against any shock and deterioration during the
complete fabrication of the vessel.
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Flange surface shall be checked by visual comparison with surface finish

roughness standards.
Junction radius between back of flange and hub : maxi of 0.25g1 (fig. 2-4
of Appendix 2 of ASME VIII Div.1) and 5mm.
Long Welding Neck or self reinforced nozzles ("integrally reinforced"
flanges) shall be used.
As an alternative, reinforced stud end + forged flange could be used after
checking of flanges by calculation including external forces and moments
if an economic advantage is demonstrated. This design shall be submitted
to AL Packinox for approval.
Every nozzle shall be forged and its branch thickness shall be at least the
corresponding LWN type thickness. Machining shall respect strictly the
radius of the surface transitions and the radius of the nozzle projection
ends as required by the applicable code and documents.
The minimum value of the radius r1 (fig. UW-16.1 of ASME VIII Div.1)
of a set in or set on nozzle shall be the lowest of 3 mm and thickness/4.
The forgings shall be forged to a shape close as practical as the final
dimensions.
Nozzles that are not connected to the bundle shall be flush ground to the
surface of the vessel, except the instrumentation nozzles that may project
internally with the prior written agreement of AL Packinox.
Nozzles ends to be connected to the expansion bellows ends shall be
machined in order to perform buttering in accordance with AL Packinox
details.
Nozzles shall be welded to shell or head with full penetration.
Nozzles type shall be according to ASME VIII Div. 1, fig. UW-16.1 (d),
(e), (f-1) to (f-4) or (g). Set on nozzles may be applied for nozzles less
than 4", according to ASME VIII Div. 1, fig. UW-16.1 (a) or (b), when
installed on component with thickness greater than 50 mm.
6.8.1.2. Specific requirements for parts at design temperature
higher than 427°C
Reinforcement plates, or pads are not allowed.
Fillet welds of nozzle to shell /head junctions and nozzle to nozzle
junctions shall be ground smooth to a 10 mm radius.
6.8.2. Calculation requirements

The rating and facing of flanges are indicated in the General Arrangement
Drawing.
6.8.2.1. Flange calculation
The rating shall be checked according to ASME B 16.5 and ASME B
16.47 latest edition, regarding to equivalent pressure.
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This equivalent pressure taking into account external loading is taken

according to Dennis R.MOSS, CODAP French code, or equivalent :
Peq = 16xM / xG3 + 4xF / xG2 + P
with axial load F and bending moment M taken in Appendix 1. Only the
mechanical part (33%) of these loads is considered in the calculation of
the equivalent pressure.
All flanges (standard as well as non-standard flange) shall be checked by
calculation by applying the equivalent pressure above defined.
The calculation has also to be done for weld overlaid flanges due to the
non standard nozzle bore before weld overlay. Overlay shall not be taken
into consideration for flange strength.
6.8.2.2. Opening calculation
Forces and moments indicated in Appendix 1 shall be taken into account
for the openings in head calculations. A load equivalent to the bellows
reaction shall be added to the nozzles loading. This load shall be equal to
the axial load defined in Appendix 1 (mechanical load only). The
calculations shall be done at the head-to-nozzle junction.
WRC 107 and 297 may be used for stress calculations, except for nozzles
parallel to main axis and for ligaments under 2.5 Rm t between two
discontinuities. In this case, finite element analysis shall be performed for
the top head. However WRC 107 may be acceptable for bottom head.
6.9. INTERNAL & EXTERNAL ELEMENTS

The vessel support type (brackets, conical or cylindrical skirt) is indicated in the
Vessel Data Sheet.
Insulation support rings, support of nameplate, clips and lugs shall be as per
applicable standards.
Vacuum stiffening rings may be used only where design Temperature < 427°C and
after AL Packinox’s approval.
Pads are not allowed on parts where design temperature is  427°C.
Minimum thickness for clips shall be 10 mm for low alloy steel.
The minimum distance between two weld edges shall be 50 mm or one (1) time the
wall thickness, whichever is greater.
The weld types for internal and external accessories shall be as follows :
Continuous fillet Full penetration

Type of accessory
weld weld
Bundle support brackets welded on shell x
Bundle support brackets welded on bundle x
Bundle cold guides on shell With pad Without pad
Guide clips to maintain tools in right x
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Continuous fillet Full penetration

Type of accessory
weld weld
position during bundle insertion (if
necessary)
Lifting & Tailing lugs With pad Without pad
Davit or hinge-to-shell/nozzle & davit or
x
hinge-to-blind welds
Skirt-to-ring weld x
Ring-to-shell weld x
Skirt anchor boxes and skirt stiffeners x
Fireproofing lugs x
Nameplate support x
Earthing lug x
Insulation support lugs x
Piping and platform supports x
Internal accessories x
Nota : provide a vent hole ¼” NPT in case of use of pad

The shell/conical skirt or bracket junction welds are located at the cold side (design
temperature less than 427 °C).
Bundle support brackets (including the fixed point) and bundle guides shall be
calculated under rotation (during welding of the enclosure seam) condition and
transportation condition with dynamic coefficients of 1.5 in longitudinal direction,
0.7 in transverse direction and 2 in vertical direction and submitted to AL Packinox
for review. They shall be also calculated in operating conditions.
Provide extra length on stainless steel bundle brackets for adjustment before welding.
The fillet welds shall be checked by calculation.
6.10. LIFTING DEVICES

The lifting devices shall consist in two lifting lugs full penetration welded on blind
flanges installed on the upper nozzles plus one tailing lug welded on the bottom
head. The tailing lug shall be welded on pad if required by local calculation.
The blind flanges shall be designed for the hydrotest pressure. The lifting devices
shall be calculated with a dynamic coefficient of 1.5.
The blind flanges shall be equipped with a compression ring.
A PQR is required for the welding. Lifting devices shall be post weld heat-treated.
UT examination of weld is required.
6.11. BOLTING
Bolting type shall be ISO except for US, Canada or otherwise specified.
Bolting shall be full threaded studs, with heavy series hexagonal nut at each end.
Overlength of bolting shall be :
 12 threads + 1 bolt diameter for process nozzles and manholes,
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 6 threads for others nozzles.

In case of U stamped vessels for US or Canada, the bolting shall be UNC or 8 UN
class 2A/2B for diameters greater than 1” in compliance with ASME B 1.1.
6.12. GASKETS
The gaskets type shall be appropriate for the flange faces indicated on the AL
Packinox’s General Arrangement Drawing.
Spiral wound gaskets shall be as follows :
 Thickness : 4.4 mm
 Material : SS type 304, 316 or 321
 Filler : Graphite
 Internal & external center rings : SS type 304, 316 or 321.
For spray bar nozzles (M side) where are installed conical grids, inner ring is
prohibited.
Oval or octagonal ring gaskets material shall be in 5% Cr with HB < 130.
In case of flange gasket face overlaid, the ring gasket shall be in stainless steel.
Asbestos is prohibited.
6.13. AGEING SAMPLE

A 600 mm x 300 mm piece of the final closure seam production test shall be fixed to
the bundle stainless steel internal brackets. This sample shall be post weld heat
treated as described in the Appendix 4.
7. FABRICATION
7.1. WELDING
7.1.1. General
Welding shall be conforming to the applicable Code (WPS/PQR, production
test, welder’s qualification, etc).
Welding book shall include all pressure vessel joints (mean seams, internal and
external accessories, skirt, etc.), internal stainless steel welds and lifting lugs
welds. Welding book shall also include a welding map of temporary
attachments.
For new PQR, HV10 hardness shall be located, according to API934 figure 7.1,
plus measurement on the root pass.
Each welded joint shall be suitable for interpretation of non-destructive
examinations.
Edges and / or bevels, when performed by thermal cutting shall be ground in
order to eliminate affected zone: minimum 3 mm.
Edges shall be shaped to the final welding geometry.
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All categories A, B, C, and D welds shall be of full penetration type.

Welding process such as GTAW, SMAW & SAW are recommended.
Pressure containing welded seams shall be full penetration double-welded butt
joints, except the final enclosure seam that may be a single-welded butt joint
made by submerged arc process with a minimum of two passes. Double-
bevelled welded seams made by submerged arc process shall have a minimum
of two passes per side.
GMAW & FCAW processes are not permitted for pressure retaining welds
(categories A, B, C, and D), except for the first pass if removed by gouging and
controlled after grinding (visual examination + PT or MT).
GMAW & FCAW processes can be used for local weld overlay on process
nozzles for bi-metallic junctions.
FCAW process shall use an external shielding gas and is not permitted for root
pass except if removed by gouging and controlled after grinding.
GMAW-S process in the short-circuiting mode can be used in the following
applications only :
 The root pass for any material thickness ;
 Complete groove or fillet welds providing that the wall thickness does
not exceed 6 mm ;
 Tack welds, temporary attachments and other applications when the
weld made by this process is completely removed.
GMAW process in the spray transfer mode shall not be used for the root pass.
Temporary attachments shall be of the same material grade as the pressure part.
The use of different material is submitted to prior AL Packinox’s approval.
Their welding shall be supported by a WPS. These requirements include
preheating and post heating of the welds as required in specifications.
Arc strikes on the pressure parts are forbidden.
H Electrodes diameter used for vertical upward manual welding shall be 4mm
maxi.
7.1.2. Low alloy steel welding

Only Hydrogen controlled filler metal shall be used ; the hydrogen content
diffused on deposited metal shall be maximum 5 ml per 100 g for electrodes
and maximum 8 ml per 100 g for wire/flux combination.
Each PQR shall be qualified with the two following cases of heat treatment:
 1 x PWHT holding time
 4 x PWHT holding time
For SMAW, SAW & FCAW welding process, welding consumables used for
manufacturing shall be on the same brand name and trademark than those used
for PQR. Brand name and trademark shall be reported on the WPS. It is
forbidden to mix brand names and trademark per welding process.
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H PQR for 2.25Cr-1Mo material shall include transition curves and step-cooling
tests excepted for operating temperatures lower than 340°C. Impact tests to
develop transition curves and step-cooling treatments shall be as defined in
plate purchasing specification DESCAZA0003 and DESCAZA0005.
In addition to requirements of ASME Section IX, specimen sets for the impact
toughness of the welds and heat affected zones of the procedure qualification
test plates shall be removed at least from depth define in below table :
Test Depth from Single-sided weld Two-sided weld
PWHT
location (1) top surface t ≤ 19mm 19 < t < 38 t ≥ 38mm t ≤ 19mm 19 < t < 38 t ≥ 38mm
Under skin X X X X X X
Weld Metal
qualification test plates
¾t X X
Welding procedure
1
½t X X X X X X
HAZ
¾t X X X
Under skin X X X X X X
Weld Metal
4 ¾t X X
½t X X X X X X
HAZ
¾t X X X
GENERAL NOTES :
(1)
For each location, one set of three impact tested specimens shall be done, according to ASME UG-84.(c).
A low alloy steel buttering shall be performed on top part for thermocouple
fitting.
Preheating shall be performed at a temperature of 150 °C for 1.25Cr-0.5Mo
mini and 200 °C for 2.25Cr-1.0 Mo mini for thermal cutting, gouging, tack
welding and welding.
Post heating shall be performed at a temperature of :
 315°C mini for 1 hour mini for 1.25Cr-0.5Mo
 350°C mini for 2 hours mini for 2.25Cr-1.0Mo.
7.1.3. Bi-metallic junctions

This section concerns especially the internal junctions between the low alloy
steel vessel nozzles and the stainless steel connecting pieces, and buttering for
thermocouple boss.
Any buttering shall be in accordance with QW 492 + QW283 of ASME IX.
ER Ni-Cr3 (SFA 5.14), or E Ni-Cr-Fe 2 (SFA 5.11) shall be used as welding
consumables.
PQR/WPS of the complete welding, including welding of the stainless steel
sleeve to the buttered nozzle end, shall be performed. Each PQR shall be
qualified with 2 x PWHT holding time (AL Packinox’s recommendation : 10
hours for 1.25Cr and 20 hours for 2.25Cr).
When buttering thickness is 6 mm or lower, preheating at 150°C mini for
1.25Cr-0.5Mo and 200°C mini for 2.25Cr-1Mo shall be applied.
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7.1.4. Stainless steel welding

When the design temperature is  550 °C, the carbon content for filler metal
shall be 0.04 %  C  0.06%.
The ferrite content on the deposited metal and the HAZ shall be between FN3
and FN8 as per WRC diagram given in ASME II (included values).
7.2. WELD GRINDING & BRUSHING

The stainless steel welds shall be SS wire brushed. In case of weld grinding, the
material used shall be appropriated to stainless steel.
7.3. POSTWELD HEAT TREATMENT (PWHT) IN FURNACE

PWHT shall be carried out in accordance with the applicable documents.
All accessories welded on manhole blind flange shall be PWHT in the same time of
pressure vessel.
Lifting lugs shall be post weld heat treated.
Production test coupons shall be post weld heat treated as described in Appendix 4.
Flange facings shall be protected against oxidation during PWHT by mean of high
temperature resistant grease (CASTOMASK, or similar).
The vessel or part of the vessel to be heat treated shall be supported and stiffened by
braces in order to avoid any deformation (sufficient shoring stiffeners inside shell,
skirt or support wedging, ...etc ). Brace material shall be at least 1.25Cr material,
except if sub-supplier can demonstrate the correct behaviour of other material at
PWHT temperature, and shall be indicated in the PWHT procedure.
Braces and supports shall be located as follows :
 PWHT in horizontal position :
1 on upper shell near the closure seam, 1 between spray bars and bottom head
seam on lower shell, 1 per shell, and 90° saddles supports with radius allowing
thermal expansion at 700 °C (braces at the same location of saddles).
 PWHT in vertical position :
under nozzles and / or other loaded protruding parts.
In order to ascertain that the temperature variations never exceed the specified limits
in any part of the vessel, a sufficient number of thermocouples shall be connected to
the vessel or parts of the vessel and the temperatures shall be continuously recorded
during the complete PWHT time (heating, holding and cooling) using a chart
recorder.
The thermocouples shall be attached to pressure vessel by means of tack welded nuts
or by condenser capacity discharge. The attachment and removal method, including
preheating temperature at mini 100°C, shall be indicated in the PWHT procedure.
The location and quantity of thermocouples shall be as follows :
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REVISION H
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internal external
Per head welded to
2T
courses
Per course 1T
Per part of 6 meters
1T
length of courses
Per separate head 1T 2T
Per production sample 2T
Typical details are given in Appendix 2

For example : for 1 part made of 4 courses of 3000mm and 1 head with 1 production
sample,
10 thermocouples are required as follows :
 Internal thermocouple : 2T
 External thermocouples : 2T + 4T = 6T
 On production sample : 2T
In case of vacuum stiffening rings welded to the vessel, a sufficient number of

thermocouples shall be attached to the rings.
Heating and cooling rates shall be determined according to the Applicable Code but
shall never been greater than 100 °C / hour. For band of local PWHT, not including
nozzle, heating and cooling rates can be according to the applicable code.
PWHT temperature and holding time are indicated in the corresponding Material
Specification.
Holding times, holding temperatures, heating and cooling rates shall be as per
para.7.3.1 and para.7.3.2, except if otherwise specified in material procurement
specifications.
7.3.1. 1.25Cr – 0.5Mo

The test specimens shall undergo a post weld heat treatment simulation at a
holding temperature as indicated in the table hereafter for a holding time 1 time
and 4 times the time required by the code, but never less than 2 hours 30
minutes and 10 hours for 4 times.
 For example :
- Up to shell thickness of 63.5 mm : mini holding time 2 H 30 ' for 1
simulated PWHT, and 10 H for 4 simulated PWHT
- For shell thickness greater than 63.5 mm : mini holding time = mini
required by code (1 H per inch) for 1 simulated PWHT, and 4 times the
mini required by code for 4 simulated PWHT, so for thickness of 4 " :
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mini holding time 4 H for 1 simulated PWHT, and 16 H for 4 simulated

PWHT.
The holding temperature shall be 69010°C.

This temperature has to be fixed between Mill and ALP regarding to material
thickness, impact test values to guarantee and maximum holding time.
7.3.2. 2.25Cr – 1Mo

The test specimens shall undergo a post weld heat treatment simulation at a
holding temperature of 700°C ± 10°C, for a holding time 1 time and 4 times
the time required by the code, but never less than 8 hours and 32 hours for 4
times.
7.4. LOCAL HEAT TREATMENT

Local PWHT shall be performed by electric resistances.
Local PWHT shall be carried out in accordance with a specific procedure submitted
to AL Packinox for prior approval. The procedure shall include the width of heating
and insulation bands and shall give the location of resistances, thermocouples
associated to resistances and production tests.
Typical details are given in Appendix 3
The quantity of thermocouples shall be as a minimum 3 external at 90° + 1 internal.
The heating band shall be at least equal to 2 times the wall thickness from the weld
edge on both sides and the insulation band shall be at least 4 times the thickness from
the weld edge on both sides.
H During heating, a stabilization step shall be done at 400°C. This step shall be
maintained at least one hour and until temperature difference between thermocouples
is below 20°C.
When a nozzle is included in the heating band, all the band including nozzle shall be
post weld heat treated with the same extension as defined above. Sufficient
thermocouples shall be placed on the nozzle.
The thermocouple attachment and removal method shall be similar to PWHT in
furnace.
7.5. PRODUCTION SAMPLES

For number and locations, refer to Appendix 4.
In case of head construction is dome and petals type, one production test coupon is
required for each head. Coupons shall be taken in the overlength of head plate.
Tests on head coupons shall be done before the welding of heads on the shell. The
welding of head is not permitted until satisfactory results on production tests are
available.
7.6. EXPANSION BELLOWS WELDING

The expansion bellows could be welded before insertion.
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Before definitive welding, the bellows shall be fitted in place and tack welded in
order to check the misalignment.
The maximum lateral offset shall be 10 mm in all directions.
The fitting tolerances for expansion bellows and sleeves shall be as per applicable
AL Packinox standard.
The wave spaces after installation shall be greater than the size indicated by the
bellows manufacturer. This value shall be given by AL Packinox at Sub-contractor’s
documentation receipt.
This operation shall be indicated on ITP with a hold point.
8. INSPECTION & TESTING

8.1. GENERAL
Equipment shall be subject to inspection during the process of fabrication and upon
completion.
All NDE personnel shall be qualified in accordance with ASNT SNT-TC-1A.
Personnel interpreting and reporting results shall also be qualified to the same
practice.
NDE shall be performed at least 24 hours after weld cooling and until vessel
temperature came back to room temperature.
Prior to the final inspection of the vessel, all slag, loose scale, dirt, grit, weld spatter,
paint, oil and other foreign matter shall be thoroughly removed to ensure the
applicable inspection can be performed readily.
The extent of Non Destructive Examination (NDE) shall be in accordance with the
Vessel Data Sheet.
8.2. VISUAL EXAMINATION

The visual examination shall be performed and reported according to the Applicable
Code.
8.3. X (or gamma)-RAY EXAMINATION

When a weld is rejected according to the radiograph acceptance criteria, the cause of
the non-conformity shall be investigated.
When X (or gamma)-Ray examination is not feasible, UT shall be performed to the
same extent after Client approval.
The manufacturer shall keep the radiographs for 10 years retention.
Radiographic examination can be replaced by TOFD UT or PA UT before and after
PWHT in accordance with Code. Before using TOFD UT or PA UT, pressure vessel
manufacturer shall obtain Client's approval and has to submit NDE procedure prior
to use.
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8.4. ULTRASONIC EXAMINATION

The reference block shall be of the same grade and in the same range of thickness as
the vessel.
8.5. MAGNETIC PARTICLE EXAMINATION

Magnetic particle examination by probe method is prohibited unless AL Packinox
approval.
8.6. PENETRANT TEST EXAMINATION

See vessel data sheet.
8.7. HARDNESS MEASUREMENT

When PWHT is required, Brinell hardness measurements shall be taken on the inside
and the outside of each longitudinal & circumferential weld and nozzle weld with
Equotype hardness tester or equivalent. No hardness value shall exceed 225 HB,
except otherwise specified.
Hardness measurement shall be done after PWHT on area of temporary attachment
welds. These measurements include weld area after removal of stay used during the
PWHT.
Each measurement shall consist on checking HAZ & deposited metal : 4 locations or
1 each 3m length, which is greater, for the longitudinal & girth welds and 2 locations
for the nozzle welds.
8.8. POSITIVE MATERIAL IDENTIFICATION (PMI)

When PMI is required in the Vessel Data Sheet, the components and welds in low
alloy steel shall be examined before PWHT. PMI shall be performed by means of
portable analyser type. Metascope is not permitted.
The measured alloy elements shall be Cr and Mo for low alloy steels.
Extent of PMI shall be as follows:
 For each pressurized component : one material identification per
component;
 For each internal attachment : one material identification per attachment;
 For external attachments : one material identification on 10% for each
type of attachment;
 For each pressurized component weld, one material identification on each
side of the welded seam with a minimum of one per meter in case of
manual welding process and of one per weld in case of automatic welding
process ;
 For internal accessory welds and skirt welds, one material identification
per weld ;
 For external accessories welds, one material identification on 10% for
each type of attachment;
PMI is also required for buttering (Ni alloy) : 1 material identification per buttering.
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REVISION H
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Where access to the internal side of the seam is not feasible, the material
identification of the external side of the seam only is acceptable.
After the PMI, a report with a sketch indicating the location of the check points shall
be included in the manufacturing report.
8.9. DIMENSIONAL CHECKING

A general dimensional examination shall be performed at different stages of
construction and reported on the "As built" drawing.
Tolerances of exchanger shall be in accordance with applicable code plus Client
and/or AL Packinox tolerances.
9. INTERNAL & EXTERNAL SANDBLASTING - INTERNAL CLEANING

Flange facings shall be protected during sandblasting.
H Internal sandblasting shall be minimum SSCP - SP 6 SA2.
External sandblasting shall be as indicated in the Vessel data sheet.
After sandblasting and the completion of the inspection, the inside of the vessel shall be
thoroughly cleaned and free of loose mill scale, grease, oil & other foreign matter.
10. BUNDLE INSERTION

The centering system tightening torque shall be controlled to avoid creep fracture in service
applying a friction coefficient of 0.10. Tightening torque has to be calculated and indicated on
drawing where the system is defined.
The extra lengths provided on stainless steel bundle brackets shall be adjusted during
insertion.
11. SPRAYBARS ADJUSTMENTS

The spray bars will be supplied by AL Packinox in separate elements. It shall be adjusted to
the bundle according to the AL Packinox specification.
These spray bars shall be completely fitted, blank mounted on nozzle M and identified with
the nozzle concerned.
Welding of spray bars shall be performed with same welding consumables that those used for
internal stainless steel sleeves.
Dimensional check shall be reported on an "As built" drawing.
This document has to be sent back to AL Packinox and included in the data book.
The spray bars including spray bar holders (blind N + nozzle M) shall be removed from the
vessel and installed in wooden boxes for shipment.
SESCAZA3001
REVISION H
Page 24 sur 35
12. HYDROSTATIC AND AIR TESTS

No painting of the vessel is allowed before hydrostatic test.
The water used for testing shall contain 5 ppm chlorides maxi.
In order to reduce the risk of brittle fracture during the hydro test, the temperature of the
vessel wall shall not be less than 15°C.
Gaskets used for the pressure test shall be of the same type & quality as the service gaskets
used for non graded temperatures vessels. However for graded temperatures vessels, in case
of no Client’s requirements, carbon steel ring gaskets can be used for RTJ faces.
In case of flange gasket face overlaid, the ring gasket shall be in stainless steel.
Gaskets used for shop hydro test are not acceptable for operating use.
Operating blinds shall not be drilled or modified.
The pressure test shall be performed according to procedure issued by Supplier regarding to
AL Packinox’s specification. This procedure shall be submitted to AL Packinox for approval.
It shall describe the 3 stages of the pressure test:
 Hydraulic Pressure test of the vessel.
 Hydraulic Differential Pressure test of the exchanger.
 Air Differential Pressure test of the exchanger.
No repair, welding or heat treatment shall be carried out after the pressure test on pressure
vessel.
Hydraulic test shall not be performed on rolls used for rotating the vessel, except after local
calculation by the vessel manufacturer and approval by AL Packinox.
13. DRYING
After hydrotest and the completion of the inspection, the vessel shall be dried.
See applicable specification.
14. PAINTING
Painting shall be in accordance with the Vessel Data Sheet requirements.
Temporary equipments fitted on pressure vessel shall be yellow (RAL 1021 or equivalent)
painted.
Metallic saddles shall be painted with one coat of 50µm inorganic zinc.
15. MARKING
During all manufacturing process, the material traceability shall be maintained either by
marking with a low stress stamp, or by the Manufacturer Quality Assurance system.
SESCAZA3001
REVISION H
Page 25 sur 35
When the vessel is not stamped, the word “ASME” and the Code Symbol on the nameplate
shall be prohibited and replaced by the requisition number.
Marking has to comply with Alfa Laval Packinox marking specification as a minimum plus
Client requirements if any.
16. FINAL VISUAL INSPECTION

Before blanking off for shipment, the inside of the vessel shall be thoroughly visually
inspected in order to certify that it is free of moisture and of foreign matter.
17. SPARE PARTS

Spare parts shall be packed in wooden boxes. When installed in the same box, gaskets and
bolting shall be in separated compartments. Spare parts shall be identified with tags by item.
18. PREPARATION FOR SHIPMENT- TRANSPORTATION

The lifting covers shall be equipped of compression rings.
Flanged connections (that are not already equipped with blinds) shall have adequate steel
plate covers at least 6 mm thick secured with full quantity of bolts.
Bolts shall be protected with grease.
A pipe of minimum 2" diameter shall connect either the cleaning nozzles located on the
process nozzles, or the flange covers of 2 adjacent process nozzles installed on one of the
heads.
For rust prevention, the exchanger shall be purged and pressurised with nitrogen at 0.01
MPa.g at 20°C according to AL Packinox’s procedure. A pressure gauge coupled with a
temperature gauge shall be installed on pipe in order to check the nitrogen pressure. These
gauges shall be adequately protected to prevent damage. Blind flanges used in operation shall
not be drilled for nitrogen connexion.
Steel transportation saddles shall be calculated for the total weight of the exchanger (vessel +
bundle). Saddles shall be designed for transportation condition with dynamic coefficients of
0.4 in longitudinal direction, 0.4 in transverse direction and 2 in vertical direction. In case of
sea transportation, the maximum pressure on floor is 10 tons/m².
At the lifting locations and slinging locations, the vessel manufacturer has to provide
protection belts (minimum 6 mm thick rubber band) in order to avoid damages on paint.
Saddles shall be entirely made of steel.
Saddles shall be reinforced as necessary by braces in order to avoid deterioration during
transportation.
The conditioning of wooden boxes shall be of SEI 4C type.
Fumigation of all wooden parts shall be performed as per NIMP15/ISPM15. Fumigation
certificate shall be provided.
SESCAZA3001
REVISION H
Page 26 sur 35
Lifting of the vessel shall be performed either with slings according to the vessel marking, or
by means of the lifting and tailing lugs following to AL Packinox’s specification for lifting.
A visual inspection shall be made on site in order to check flange faces. Temporary gaskets
shall be mounted before nitrogen filling for shipment. The service gaskets shall be not
mounted in shop, but by Client after on site inspection.
SESCAZA3001
REVISION H
Page 27 sur 35
APPENDIX 1 : FORCES & MOMENTS ON NOZZLES
SCOPE
This annex is applicable for the determination of loading on nozzles welded on pressure
vessels in carbon steel or alloy steel with a nominal diameter greater than 2".
Nozzles shall be designed to withstand piping thermal expansion and dead weight loading.
In case of external loading defined by the Client, Client's requirements shall apply when more
stringent than AL Packinox’s loadings in this Annex.
EXTERNAL FORCES AND MOMENTS
Each nozzle shall be capable of withstanding forces from external piping under normal
operating conditions and considered to be acting at the intersection of nozzle and shell or head
in the corroded condition.
For each nozzle the forces and moments shall be calculated with the formulas of the following
table, where D is the nominal diameter in inches and the ß-value is extracted from the Table 2
hereafter.
Nozzles located on
Nozzles located on shells
dished heads
Axial tension or compression force FA = ß x 2,000 x D (N) FA = ß x 2,000 x D (N)
Axial force in plane of flange FL = ß x 2,000 x D (N)
Tangential force in plane of flange FØ = ß x 1,500 x D (N)
Resultant shear force Fr = (FL2 + FØ2)1/2 (N) Fr = ß x 2,500 x D (N)
Longitudinal bending moment ML = ß x 130 x D2 (N.m)
Circumferential bending moment MØ = ß x 100 x D2 (N.m)
Resultant bending moment MB = (ML2 + MØ2)1/2 (N.m) MB = ß x 164 x D2(N.m)

Torsional moment Mt = ß x 150 x D2 (N.m) Mt = ß x 150 x D2 (N.m)
Table 1 : Forces & Moments formulas
SESCAZA3001
REVISION H
Page 28 sur 35
Flange class Nominal pressure ß-value
150 PN 20 0.6
300 PN 50 0.7
600 PN 100 0.8
900 PN 150 0.9
1500 PN 250 1
Table 2 : ß-value
The above mentioned loading shall be considered as being caused by 67% thermal and 33%
dead weight load.
The basis stress limits shall be as per ASME Code Section VIII Div.2 Part 5 and the basis
stress values as per ASME Code Section VIII Div. 1.
SESCAZA3001
REVISION H
Page 29 sur 35
APPENDIX 2 : TYPICAL BRACING AND WEDGING DURING PWHT
TYPICAL THERMOCOUPLE LOCATIONS

TC2 TC6
TC 2
TC8
TC5
TC 6
TC 1 TC 4 TC 5 TC 8
TC 10 TC 9 TC3
TC 3
Production test
TC 7 TC1 TC4
TC7
Distance between 2 thermocouples : 4.6 m maxi
Ce document est la propriété exclusive de Alfa Laval Packinox SAS. Il ne pourra, sans l'autorisation préalable écrite de Alfa Laval Packinox SAS, être utilisé à d'autres fins que celles expressément prévues ni être communiqué à des tiers. Toutes
précautions utiles seront prises pour éviter sa divulgation. Loi n°57298 du 11-3-1957.
This document belongs and is the exclusive property of Alfa Laval Packinox SAS. Any use other than those expressly authorised and any copy is strictly forbidden without Alfa Laval Packinox SAS prior written consent. Users of this
document shall take all necessary precautions to prevent its disclosure
SESCAZA3001
REVISION H
Page 30 sur 35
T
C
T 11
C T
12 C
13
SESCAZA3001
REVISION H
Page 31 sur 35
APPENDIX 3 : LOCAL PWHT
ARRANGEMENT OF ELECTRIC RESISTANCE COIL, INSULATION AND

THERMOCOUPLES (FOR BUTT WELD)
INSULATION WIDTH = 4T
BEYOND THE TOE OF THE WELD:
CERAMIC WOOL
HEATING BAND WIDTH = 2T

BEYOND THE TOE OF THE WELD
NOTE : THERMOCOUPLE SHALL NOT TOUCH ELECTRIC RESISTANCE COIL
LOCATION OF
THERMOCOUPLES
SESCAZA3001
REVISION H
Page 32 sur 35
ARRANGEMENT OF ELECTRIC RESISTANCE COIL, INSULATION AND

THERMOCOUPLES (FOR BRANCH WELD)
INSULATION
WIDTH = MIN 4T
BEYOND THE
TOE OF THE
WELD
HEATING BAND
WIDTH = MIN 2T
BEYOND THE
TOE OF THE
WELD
HEATING BAND WIDTH

= MIN 2T
INSULATION WIDTH
= MIN 4T
NOTE : THERMOCOUPLE SHALL NOT TOUCH ELECTRIC RESISTANCE COIL
SESCAZA3001
REVISION H
Page 33 sur 35
H APPENDIX 4 : PRODUCTION AND AGEING SAMPLES

QUANTITY & MATERIAL
One production sample per PQR is required for joints of Categories A and B :
 Note 1 - Production sample A representative of the longitudinal weld.
 Note 2 - Production sample B representative of the circular weld. If the closure
circumferential joint is performed with the same welding procedure than longitudinal
joint, then the production sample B can be taken in the production sample A.
These production samples shall be taken in the overlength of the thickest plate used for the
shell constitution.
 Note 3 - In case of dome and petals heads, one additional production sample C shall
be taken from each head. These production samples C are taken in the overlength of
head plate.
PRODUCTION SAMPLE TREATMENTS
Step 1 - The production sample A is welded to the longitudinal joint of the upper shell and
post weld heat treated with the vessel part. The production sample C, if any, is post weld heat
treated with the upper head :
(see note 3)
1 PWHT
Step 2 - After PWHT, the production sample A and C are cut in two parts, respectively
A1/A2 and C1/C2 as below:
A1 A2 C2 C1
Reserved
for final
Production Production
Mechanical tests sample A sample C Mechanical tests
(see table 4-1) (see table 4-1)
A1 and C1 are used for mechanical tests.

Mechanical tests of samples C shall be done before the welding of dome and petals heads
on the shell. The welding of head is not permitted until satisfactory results on
production tests are available.
SESCAZA3001
REVISION H
Page 34 sur 35
H Step 3 - The production samples A2, C2 and B are post weld heat treated at the same time and
with the same devices than the local PWHT of the closure seam.
If applicable
(see note 2)
A2 and C2 B
Local PWHT
If applicable
(see note 3)
Step 4 - After local PWHT, the production sample A2 or C2 are cut in 3 parts, respectively
A2'/A2"/A2''' or C2'/C2"/C2''', and the production sample B is cut in 2 parts, respectively B1
and B2.
 One piece construction heads :
B1
Production A2
sample B
B2 A2' A2" A2"'
Mechanical tests Ageing sample

(see table 4-1) (see corresponding paragraph below)
 Dome and petals heads:
B1
Production A2 C2
sample B
B2 A2' A2'' C2' C2" C2"'
Mechanical tests (see table 4-1)
Ageing sample
(see corresponding paragraph below)
SESCAZA3001
REVISION H
Page 35 sur 35
H Step 5 - A2', A2'', B1 and B2 or A2', A2'', B1, B2, C2' and C2'', depending of vessel construction, are used for mechanical tests. A2"' or C2"' are
fixed in the vessel as ageing sample.
Mechanical tests
Mechanical tests performed on production samples shall be in accordance with ASME Code.
Impact tests performed on production samples shall include specimen sets removed from heat treatment condition and depth define in table4-1
below.
Table 4-1
Test Depth from Single-sided weld Two-sided weld
Coupons PWHT
location (1) top surface t ≤ 19mm 19 < t < 38 t ≥ 38mm t ≤ 19mm 19 < t < 38 t ≥ 38mm
A1 1 Weld Metal Under skin X X X X X X
C1 (furnace ½t X X X X X X
HAZ
B1 or local) ¾t X X X
Production test coupons
2 Weld Metal Under skin X X X X X X

A2'
(furnace ½t X X X X X X
C2' HAZ
+ local) ¾t X X X
A2'' As fabricated (2) Weld Metal ½t X X X X X X
B2 + simulated up
C2'' to 4 times (3) HAZ ½t X X X X X X
GENERAL NOTES :
(1)
For each location, one set of three impact tested specimens shall be done, according to ASME UG-84.(c).
(2)
Including PWHT after repair if any.
(3)
Additional simulated PWHT shall be done on production test coupons up to undergo a total of 4 PWHT times (including fabrication cycles).
AGEING SAMPLE
Ageing sample shall be taken from a production sample which has undergone 2 PWHT. In addition, in case of dome and petals heads, the ageing
sample shall be taken from the thickest production sample, which is usually the sample C taken from upper head. Number and size of ageing
samples are defined in the Job Specification DESCAZA0010.
Ce document est la propriété exclusive de Alfa Laval Packinox SAS. Il ne pourra, sans l'autorisation préalable écrite de Alfa Laval Packinox SAS, être utilisé à d'autres fins que celles expressément prévues ni être communiqué à des tiers. Toutes précautions utiles
seront prises pour éviter sa divulgation. Loi n°57298 du 11-3-1957.
This document belongs and is the exclusive property of Alfa Laval Packinox SAS. Any use other than those expressly authorised and any copy is strictly forbidden without Alfa Laval Packinox SAS prior written consent. Users of this document shall take
all necessary precautions to prevent its disclosure
SAIEXWA0011
REVISION A
Page 1 sur 11
PACKINOX INSTRUCTIONS FOR 3 EXPANSION BELLOWS

COMBINED FEED / EFFLUENT HEAT EXCHANGER ON-
SITE HYDROTEST IN VERTICAL POSITION
Nom Entité Date

REVISION A Name Entity Date
Rédacteur Alex SIMONATO Services 19/11/2004
Writer
Vérificateur(s) Dominique SABIN Etudes 19/11/2004

Reviewer(s)
Approbateur Gilles CAZIN Services management 8/12/2004

Approver
This document belongs and is the exclusive property of Alfa Laval Packinox SAS. Any use other than those expressly authorised and any copy is strictly forbidden without
Alfa Laval Packinox SAS prior written consent. Users of this document shall take all necessary precautions to prevent its disclosure
SAIEXWA0011
REVISION A
Page 2 sur 11

A 8/12/2004 First issue
SOMMAIRE
SUMMARY
1 - Introduction
2 – Reference
3 – Equipment
4 – Minimum Temperature
5 – Inspection(s) prior and after hydro test – Acceptance Criteria(s)
6 – Test Instructions
7 – Test Performance
8 – Examination during the test at Inspection Pressure
9 – Acceptance criteria
10 – Intervention of the Inspection agency
11 – Documents to be set up after the test
12 – Drying requirements
Appendix No. 1 : Schematic Drawing
Appendix No. 2 : Position of valves during test
Appendix No. 3 : Typical board for pressure increase / decrease record.
SAIEXWA0011
REVISION A
Page 3 sur 11
1 - Introduction
This procedure specifies the hydro test conditions & instructions of a 3 Expansion Bellows
PACKINOX Combined Feed / Effluent Heat Exchanger installed in vertical position.
This procedure reflects the field experience acquired by PACKINOX Services in numerous
installations.
PACKINOX Services is available to provide advice and assistance when necessary.
Note :
Hydro test may as well be performed with naphtha.
2- Reference
Fabrication drawings + Hydro test schematic drawing in appendix No. 1.

Applicable local regulations.
The test pressure P1 is defined in General Arrangement Drawings.
3 – Equipment
Pressurising and display devices (see details and schematic drawing in Appendix No. 1) :
• Hydraulic pump with a 2" min. diameter outlet equipped with a pressure gauge
capable of a pressure greater than P1.
• 2" diameter hoses (as defined in schematic drawing) with sufficient length, and able
to operate at a service pressure equal to twice P1.
• Isolating valve and necessary connections for 2" diameter hose (service pressure =
twice P1).
• Valves, check valves and necessary connections able to operate at a service pressure
equal to twice P1.
• Seal gaskets for process nozzles (type of gasket defined on the fabrication drawings).
• Bolting material corresponding to the set of pressure vessel nozzle flanges.
Material : ASTM 193 B7 – ASTM B94.2H or equivalent quality (otherwise specified).
• The service blinds shall be used for the hydrostatic test on blind flanges such as
manhole(s) and nozzles, which these devices are intended for.
• On the other nozzles, test blinds shall be used.
• Skin thermowell for measurement of the vessel wall temperature.
• Calibrated test pressure gauges (one of them being mandatory and located at the
highest point of the vessel).
SAIEXWA0011
REVISION A
Page 4 sur 11
Notes :
1- The pressure gauges shall be selected so that their graduations cover preferably twice
the test pressure and as mandatory requirement 1.5 time P1. A calibration report issued
since less than 6 months is necessary at the date of the test.
2- The test blinds receiving the above described test equipment shall be equipped with a
2" diameter 6 000 lbs coupling, in which a Briggs or NPT 2" threaded hole shall be
drilled
3- The in service bolting material and gaskets shall not be used for the test unless
otherwise specified.
4- The water used for hydro-test shall have less than 5ppm chlorides.
5- Source of water to be used for hydro testing shall be tested for chlorides as close as
practical to the test date.
4 – Minimum Temperature
The minimum temperature of the water and wall vessel is defined under the conditions
required in the Code and/or local regulations.
5 – Inspection(s) prior and after hydro test – Acceptance Criteria(s)
Any inspection prior and after hydro test shall be performed under the conditions
required in the Code and/or local regulations.
Acceptance criteria(s) shall be in accordance to the conditions required in the Code
and/or local regulations.
6 - Test Instructions
Equipments described in paragraph 4 shall be installed according to the hydrostatic

sketch in Appendix 1.
The position of the valves during the test is described in Appendix No. 2.
Tables to record pressure increase and decrease are provided in Appendix No. 3.
SAIEXWA0011
REVISION A
Page 5 sur 11
The list of operations is as follows (Æ see schematic test diagram in point 7.) :
SAIEXWA0011
REVISION A
Page 6 sur 11
Operation No. Instruction(s)

Open valves V1, V3, V4 & V5.
1 The water fills up the Shell & Feed circuit of the
PACKINOX Heat Exchanger.
When some water flows out by top vent (valves V3 & V5),
2
Close V3 & V5 and V1.
Open valve V2.
3 The water fills up the Effluent circuit of the PACKINOX
Heat Exchanger.
When some water flows out by top vent (valve V4), then close
4
V2 and V4.
NOTE :
ANY AIR LOCK SHALL BE REMOVED.
Check the correct installation of the measuring equipment and
5
the connections on the blinds.
Check the pressure vessel wall temperature. Pressurisation shall
not be performed as long as the wall and water have not the
6 required temperature.
The outside vessel wall shall be dry and free of any mark of
humidity.
Open valves V1 & V2.
The Shell & Feed and Effluent circuits of the PACKINOX
Heat Exchanger are pressurised.
The Heat Exchanger shall be pressurised to a value not
exceeding 0.5 bars (7.25 Psi) and the tightness of all nozzles
shall be checked.
If any leakage is detected, the bolts shall be tightened until a
7
correct tightness is obtained.
Reach the P1 pressure at 1 bar/min (14.5 Psi/min) or with a 5
minutes step every 5 bars (72.5 Psi).
Note : The pressure read on gauge M4 should always be lower
than the pressure read on gauge M2.
In no case P(M2) – P(M4) shall be higher than Heat Exchanger
Design Differential Pressure.
8 When P1 is reached close valves V1 and V2.
Visual examination shall be performed by inspector with the
minimum time required by Code and/or Local regulation.
The holding time shall be in accordance to the conditions
9
required in the Code and/or local regulations (minimum 30
minutes).
Æ See test diagram.
SAIEXWA0011
REVISION A
Page 7 sur 11
With valves V1 & V2 & V6, depressurise to P2 : inspection

pressure (if needed by Local regulation).
Note :
10 The pressure read on gauge M3 should always be lower than the
pressure read on gauge M2.
Close valves V1 & V2 & V6 when inspection pressure is
reached and maintain the pressure during the time for inspection
11 (if required by Local regulation).
For acceptance criteria see paragraph 9.
With valves V1 & V2 & V6, depressurise to atmospheric
pressure.
Note : The pressure read on gauge M3 should always be lower
than the pressure read on gauge M2.
12
When atmospheric pressure is reached, open valves V3 and V4
to empty the Heat Exchanger by gravity.
Details on pressures :
P1 : Test pressure in Feed circuit and inside pressure vessel at the highest point of vessel
read on gauge M4.
P2 : Inspection pressure (generally equal to the Heat Exchanger design pressure) at the
highest point of vessel read on gauge M4.
P'1 : Test pressure in Feed circuit and inside pressure vessel on bottom read on gauge M2
P'1 = P1+ static pressure due to static height of water where :
Total height in meters

P static (in bars) = ------------------------------------- x g
10
with g = 9,81 (to be corrected with local conditions).
P'2 : Witness pressure in the same circuits on bottom, read on gauge M2

P'2 = P2 + static pressure due to static height of water.
Design differential Pressure : specific project by project and defined in General

Arrangement Drawing.
The values read on gauge M2 are only for operator help.
Pressures read on gauge M3 and M4 at the highest points of vessel are the values
concerned by the code (or local regulations) and shall be respected.
7 – Test Performance
SAIEXWA0011
REVISION A
Page 8 sur 11
The test shall be performed in presence of :

- Customer representative
- Representative of regulation in force.
The pressure shall be increased according to the following test diagram.
Pressure Holding Time
Test Pressure Inspection Time
Inspection Pressure
1 bar/min or 5 min. step every 5 bars

14.5 Psi/min or 5 min. step every 72.5 Psi
Time
8 - Examination during Test at Inspection Pressure
Throughout the inspection, the pressure shall be maintained at P2.

A visual examination of the welds and the entire surface of the component shall be
carried out.
9 - Acceptance Criteria

At minimum :
- At the inspection pressure P2, the vessel examination shall not reveal any
leakage.
However, sweating or slight leak due to poor tightness of the flange/blind gaskets
shall be allowed provided that the inspection agency and the regulation
representative accept them.
- Back at atmospheric pressure, the vessel examination shall not reveal permanent
deformation.
SAIEXWA0011
REVISION A
Page 9 sur 11
10 - Intervention of the Inspection Agency

At minimum when the pressure test has been proved to be satisfactory, a hydrostatic test
report shall be issued and signed by the authorized representative(s).
11 - Document to be set up after the test
Test report.
Minimum requirement on the report :
- Fluid used
- Fluid quality
- Temperature recording
- Test pressure recording
- Holding time recording
- Inspection Pressure
- Equipment used, pressure gauges references and calibration certificates
12 - Drying Requirements
The water shall be removed as completely as possible by draining, blowing with clean air
free of oil.
The surfaces are dried by purging with dry air free of oil or gaseous nitrogen at ambient
temperature to remove humidity.
During drying, nozzles marked E1 – S1 – E2 – S2 shall be opened.
SAIEXWA0011
REVISION A
Page 10 sur 11
Appendix No. 1 :
Schematic Drawing V3 V4
M3 M4
V5
S1 : Combined Feed Outlet U1 E2 : Effluent Inlet
A1 A2
TH
Feed
Circuit
Effluent Circuit
N or
N1/N2
E1 : Recycle Gas Inlet

M2
U2
V1
V2 S2 : Effluent Outlet
M1
V6
Drain
PUMP
SAIEXWA0011
REVISION A
Page 11 sur 11
Appendix No. 2 : Position of valves during test.
Steps Operation V1 V2 V3 V4 V5 V6
1 Feed & Shell Side filling up O C O O O C
2 Feed & Shell Side filling up completed C C C O C C
3 Effluent Side filling up C O C O C C
4 Effluent Side filling up completed C C C C C C
7 Pressurisation O O C C C C
8&9 Holding Time at Test Pressure C C C C C C
10 Depressurisation to Inspection Pressure O O C C C O
11 Holding Time at Inspection Pressure C C C C C C
Depressurisation to Atmospheric
12 O O C C C O
Pressure
13 Draining O O O O O O
Legend : O = Valve position "Open"

C = Valve position "Closed"
Appendix No. 3 : Typical board for pressure increase / decrease record.
Feed Pressure Effluent Pressure

(bar or Psi) (bar or Psi)
Start
5 min.
10 min.
15 min.
20 min.
25 min.
30 min.
35 min.
40 min.
Stage of 30 min.
75 min.
80 min.
85 min.
90 min.
SAIEXWA0010
REVISION D
Page 1 sur 17
PACKINOX ON SITE TIGHTNESS TESTING

FOR 3 EXPANSIONS BELLOWS COMBINED
FEED / EFFLUENT HEAT EXCHANGER
Nom Entité Date

REVISION D Name Entity Date
Rédacteur Laure GUICHARD Etudes 25/1/2008
Writer
Vérificateur(s) Dominique SABIN Services 25/1/2008

Reviewer(s)
Approbateur Dominique SABIN Services management 25/1/2008

Approver
SAIEXWA0010
REVISION D
Page 2 sur 17

B 15/04/2003 Change in leak rate calculation description and nozzles identification.
C 14/1/2005 Corrections
D 25/1/2008 Addition of the method using characteristics of the pump
Summary
1. Introduction ...........................................................................................................3
2. Purpose...................................................................................................................3
3. Test by Pressure in Shell and Combined Feed Side..............................................4
4. Test by vacuum in Effluent Side............................................................................5
5. Leak Rate Calculation ...........................................................................................7
6. Storage Conditions After Test .............................................................................14
SAIEXWA0010
REVISION D
Page 3 sur 17
1. Introduction
This procedure describes the on site tightness testing instructions of a PACKINOX

Combined Feed / Effluent Heat Exchanger installed in vertical position.
This procedure reflects the field experience acquired by PACKINOX Services in numerous
installations.
PACKINOX Services is available to provide advice and assistance when necessary.
For the execution of the first test, we strongly recommend to contact PACKINOX
Services.
2. Purpose
The purpose of this test is to evaluate any cross channel leakage between the combined
feed and effluent streams during shutdown.
This procedure describes 2 test methods :

1 – Under pressure in Shell + Combined Feed side,
2 – Under vacuum in Effluent side.
Recommended test is 2 – Under vacuum in Effluent side as this is exactly the same test
than performed at ‘end of fabrication’. The differential pressure to be used during this test
(0.2 bar or 2.9 Psi) is also the differential pressure used by PACKINOX for ‘end of
fabrication test’ and this will allow easy follow-up in the Heat Exchanger lifetime.
Note :
If the differential pressure within the plate bundle is reversed (effluent pressure higher than
combined feed pressure), mechanical damage may result.
The plate bundle is designed to resist to differential pressure in one direction only (P
Combined Feed > P Effluent).
Please note that the nozzles tags are sometimes customised by project and there could be
some differences between the tags in this procedure and drawings.
SAIEXWA0010
REVISION D
Page 4 sur 17
3. Test by Pressure in Shell and Combined Feed Side
See detailed schematic drawing in Appendix No.1.
Preparation
- The PACKINOX Heat Exchanger must be isolated from the other equipment of the unit.
- S1 (combined feed outlet), TH (manhole), U1 (vent), U2 (drain), M or M1 and M2
(liquid feed Inlet), A1 (Auxiliary) nozzles are blinded.
- The recycle gas inlet (El) is fitted with the pressurizing pump and with a water
manometer able to measure 2000 mm (6 ft 3/4 in.) of water column.
- The effluent system remains at atmospheric pressure : E2 (effluent inlet) and S2 (effluent
outlet) nozzles are opened to atmosphere.
- The pressurisation gas can be nitrogen or dry air : (dew point < - 20°C / - 4°F).
3.1. Measuring of Pressure Loss in the Shell + Combined Feed side
The list of operations is as follows :

1 Open valve V1 to pressurise the shell + combined feed side.
2 Increase pressure gradually from 0 to 0.2 barg / 2.9 psig / 2000 mm
(6 ft 3/4 in) H2O.
The pressurization rate shall be ≤ 0.01 barg/min / 0,145 psi/min / 100
mm/min (0,34 in/min) H2O.
Increase requires about 20 minutes if network air is used.
3 Once shell + combined feed side pressure has reached 0.2 barg / 2.9
psig / 2000 mm (6 ft 3/4 in.) H2O, close valve V1.
4 Wait 10 minutes for pressure stabilisation in the shell + combined
feed side.
5 Open valve Vl to compensate for any pressure loss (if needed).
6 Close valve Vl as soon as feed + combined feed side pressure reaches
again 0.2 barg / 2.9 psig / 2000 mm (6 ft 3/4 in) H2O.
7 Note temperature. The temperature may be recorded by thermocouple
Tl.
Start the test for a 20 minutes holding time.
SAIEXWA0010
REVISION D
Page 5 sur 17
8 During the test, record the loss of pressure in the table below :
Time (minutes) Shell + Combined Shell + Combined

Feed Pressure Feed
(mm of water) Pressure Loss
(mm of water)
0 2000 0
5 1900 100
10 1700 300
…
Should the pressure loss be fast (full pressure lost in less than 20
minutes), the test & calculation shall be stopped for a 50% pressure
loss (0.1 barg / 1.45 psig / 1000 mm (3 ft 3/8 in) H2O.
Time (minutes) Shell + Combined Shell + Combined

Feed Pressure Feed
(mm of water) Pressure Loss
(mm of water)
0 2000 0
z 1000 1000
9 According to temperature and pressure variation, the accuracy of the

test is variation of 10 mm (3/8 in) of water.
10 Open valve V1 to depressurise shell + combined feed side.
Depressurisation rate shall be ≤ 10 mbar/min / 0,145 psi/min / 100
mm/min (0,34 in/min) H2O.
11 Estimate the operating cross channel leakage between the feed and
effluent streams as per method described in point 5.
4. Test by vacuum in Effluent Side
See detailed schematic drawing in Appendix No.2.
4.1. Preparation
- The PACKINOX Heat Exchanger must be isolated from the other equipment of the unit.
- The Shell + Combined Feed side is at atmospheric pressure : E1 (Recycle gas inlet), S1
(Combined feed outlet), TH (Manhole), U1 (vent), U2 (drain), M or M1 and M2 (Liquid
feed Inlet) nozzles are opened.
- S2 (Effluent Outlet) nozzle is fitted with the vacuum pump and with a water manometer
able to measure 2000 mm (6ft 3/4 in.) of water column.
- E2 (Effluent Inlet), A2 and A4 (Auxiliary) nozzles are blinded.
SAIEXWA0010
REVISION D
Page 6 sur 17
4.2. Measuring of Pressure Increase / Vacuum Loss in the Effluent side
• The list of operations is as follows :

1 Open valve V1 to pull vacuum in the effluent side.
2 Decrease pressure gradually from 0 to 0.2 barg / 2.9 psig) / 2000 mm
(6 ft 3/4 in.) H2O.
The depressurization rate shall be ≤ 0.01 barg/min / 0,145 psi/min /
100 mm/min ( in/min) H2O.
Decrease requires about 20 minutes.
3 Once effluent side vacuum has reached 0.2 barg / 2.9 psig / 2000 mm
(6 ft 3/4 in.) H2O, close valve V1.
4 Wait 10 minutes for vacuum stabilisation in the effluent side.
5 Open valve Vl to compensate for any vacuum loss (if needed).
6 Close valve Vl as soon as effluent side vacuum reaches again 0.2 barg
/ 2.9 psig / 2000 mm (6 ft 3/4 in) H2O.
7 Note temperature. The temperature may be recorded by thermocouple
Tl.
Start the test for a 20 minutes holding time.
8 During the test, record the loss of vacuum in the table below :
Time (minutes) Effluent Pressure Effluent Pressure

(mm of water) Increase (mm of
water)
0 - 2000 0
5 - 1950 50
10 - 1900 100
…
Should the vacuum loss be fast (full pressure lost in less than 20
minutes), the test & calculation shall be stopped for a 50% pressure
loss (0.1 barg / 1.45 psig / 1000 mm (3 ft 3/8 in) H2O.
Time (minutes) Effluent Pressure Effluent Pressure

(mm of water) Increase (mm of
water)
0 - 2000 0
z - 1000 1000
9 According to temperature and pressure variation, the accuracy of the

test is variation of 10mm (3/8 in) of water.
10 Open valve V1 to pressurise effluent side. Pressurisation rate shall be
≤ 10 mbar/min / 0,145 psi/min / 100 mm/min ( in/min) H2O.
11 Estimate the operating cross channel leakage between the feed and
effluent streams as per method described in point 5.
SAIEXWA0010
REVISION D
Page 7 sur 17
• If the vaccum cannot be maintained at the value of -200 mbarg / 2000 mm H2O,
Rev D decrease the pressure as far as possible and maintain the value for at least 30
minutes.
5. Leak Rate Calculation
Two transpositions from test results to cross channel leak rate in operation are possible :
- Simplified method (Bernoulli equations) as described in point 5.1.
- Accurate method (Saint-Venant equations) as described in point 5.2.
The following process data and constant shall be used for the accurate method. The
simplified method requires less of these data (only a part of them).
5.1. Process data :
- Total effluent flow rate, M& effluent in kg/h,

- Feed temperature at hot side, Top in °C,
- Feed absolute pressure at hot side, Pfeed op in bar a,
- Effluent absolute pressure at hot side, Peffluent op in bar a,
- Density of feed vapor at hot side, ρ op in kg/m3,
- Specific heat of feed vapor at hot side, Cpop in J/(kg.°C),
5.2. Constant :
- 20920 is a constant,
- r for air = 287 J/(kg.°C)
- r for Nitrogen = 297 J/(kg.°C)
- γ for Air & Nitrogen = 1.4
- Density of dry air at 0°C (32°F) ρ = 1,293 kg/m3 (0.0805 lb/ft3) @ 1 atm
P( Pa abs)
For other temperature and pressure : ρ =
287 × (T (°C ) + 273.15)
- Density of Nitrogen at 0°C (32°F) ρ = 1,250 kg/m3 (0.0805 lb/ft3) @ 1 atm
P( Pa abs)
For other temperature and pressure : ρ =
297 × (T (°C ) + 273.15)
5.3. Test Data :

- V is the volume (tested volume) occupied by the pressurisation/vacuum gas (m3),
- t is the time of the test (minutes),
- ∆Pmeasured is the difference of pressure from the beginning to the end of the test
(bar) :
SAIEXWA0010
REVISION D
Page 8 sur 17
the loss of pressure of shell + feed side (pressure test) - the loss of
vacuum of effluent side (vacuum test).
- Ttest is the temperature of the fluid during the test (°C),

- Peffluent test is the effluent pressure during the test (bar a),
- Pfeed test is the feed pressure during the test (bar a),
AV
- Ptest is the average of the tested volume (V) pressure during the test (bar a).
- vide (mbar) is the maximum void value reached and maintained in the case of
Rev D -200 mbar cannot be reached.
5.4. Formula for leak rate estimation (R) :
The formula for the leak rate calculation is :
R = FB × FC
Where :
• FB is the Basic Factor (the same for both simplified and accurate
method) :
- If the pressure has been decreased and maintained at -200
mbarg / -2000 mm H2O
V 1 ∆Pmeasured
FB = 20920 × × ×
Rev D t M effluent (Ttest + 273.15)
&
- Otherwise
FB = 100 ×
(− 0.109 × vide + 39.633) × ρ test × vide
1000 × rtest × (Ttest + 273.15)
N.B. : This formula is only valid for Packinox Services pumps Midiflex M200 or
PIAB Round or a pump with the same characteristics (see Appendix 3)
• FC is the Correction Factor to translate the test result in operating leak

rate. The calculation of this factor depends on the chosen method
(simplified or accurate)
5.4.1. FC calculation by simplified method (Bernoulli equations)
FC =
(P feed op − Peffluent op )× ρ op
(P feed test − Peffluent test )× ρ test
SAIEXWA0010
REVISION D
Page 9 sur 17
5.4.2. FC calculation by accurate method (Saint-Venant equations)
− (γ op +1)
 1 
  γ op  2
 γ op − 1  2 (γ op −1) 
(
 Machop . Pfeed op × 10
5
)
 
 r .(T + 273.15) 
1 +
2
Machop 
2

  op op    
FC =  
−(γ test +1)
 1 
  γ test  2  γ test − 1 2 
2(γ test −1) 
(
 Machtest . Pfeed test × 10
5
)  1 + Machtest  
  rtest .(Ttest + 273.15)   2  
 
where (for both test and operating values):

− (γ −1)
 
Peffluent 2  Peffluent 

γ

¾ If > 0.5283 ⇒ Mach = − 1 < 1,
Pfeed γ − 1  Pfeed 

 
Peffluent
¾ If ≤ 0.5283 ⇒ Mach = 1 ,
Pfeed
Pfeed × 10 5
¾ r= , [J.kg-1.°C-1],
ρ × (T + 273.15)
Cp
¾ γ =
Cp − r
5.4.3. Examples of leak rate calculations
Calculations for both test by pressure and test by vacuum will be done. For each of these
tests, calculations for both simplified and accurate methods will be described.
5.4.3.1. Process data for the PACKINOX Heat Exchanger tested
- M& effluent = 100000 kg/h,

- Top = 450 °C,
- Pfeed op = 10 bar a,
- Peffluent op = 6 bar a,
- ρ op = 4 kg/m3,
- Cpop = 3000 J/(kg.°C),
5.4.3.2. Calculations for test by pressure in shell and combined feed side
(with air)
5.4.3.2.1. Test data
- V = 6 m3,
- t = 20 minutes,
SAIEXWA0010
REVISION D
Page 10 sur 17
- ∆Pmeasured = 0.03 bar,

- Ttest = 25 °C,
- Peffluent test = 1 bar a
- Pfeed test = 1.2 bar a
5.4.3.2.2. Basic Factor (FB) calculation
V 1 ∆Pmeasured 6 1 0.03
FB = 20920 × × × = 20920 × × ×
t M& effluent (Ttest + 273.15) 20 100000 (25 + 273.15)
FB = 6.315 × 10 −6
We also calculate the average of feed pressure during the test :

AV ∆Pmeasured 0.03
Pfeed test = Pfeed test − = 1.2 − = 1.185 bar a
2 2
5.4.3.2.3. Correction Factor (FC) calculation by simplified method
FC =
(P AV
feed test )
− Peffluent test × ρ test
AV 5
Pfeed test × 10 1.185 × 10 5
ρ test = = = 1.385 kg / m 3
287 × (Ttest + 273.15) 287 × (25 + 273.15)
FC =
(10 − 6)× 4 = 7.902
(1.185 − 1)×1.385
5.4.3.2.4. Correction Factor (FC) calculation by accurate method
 1 ( − γ op +1 )
  γ op  2
 γ op − 1  ( )
( )
2 γ op −1
5   1 + Machop2  
 r .(T + 273.15)  2
  op op    
FC =  
− (γ test +1)
 1 
  γ test  2  γ test − 1 2 
2(γ test −1) 
(
AV
5
)  1 + Machtest  
  rtest .(Ttest + 273.15)   2  
 
−(γ test −1)
 
Peffluent test 1 2  Peffluent test 

γ test

= = 0.844 > 0.5283 ⇒ Machtest = − 1
AV
Pfeed 1.185 γ test − 1  Pfeed
AV 

test
 test

γ test = 1.4
−(1.4−1)
 
2  1  1.4  = 0.498 < 1
Machtest =   − 1
1.4 − 1  1.185  
 
SAIEXWA0010
REVISION D
Page 11 sur 17
−(γ op −1)
 
Peffluent op 6 2  Peffluent op  γ op 
= = 0.600 > 0.5283 ⇒ Machop =  − 1
Pfeed op 10 γ op − 1  Pfeed op  
 
Pfeed op × 105 10 ×10 5
rop = = = 345.7 J/(kg.°C)
ρ op × (Top + 273) 4 × (450 + 273.15)
Cpop 3000
γ op = = = 1.13
Cpop − rop 3000 − 345.7
−(1.13−1)
 
2  6  1.13  = 0.965 < 1
Machop =   − 1
1.13 − 1  10  
 
− (1.13+1)
 1 
5   2  1.13 − 1
 2 (1.13−1) 
1.13 2
 0.965. 10 × (
10  ) 
 345.7 × (450 + 273.15)   1 +
2
0.965  
     
FC =   = 6.137
− (1.4 +1)
 1 
 5  1.4  2  1.4 − 1 2
2 (1.4−1) 
( )
 0.498. 1.185 × 10  287 × (25 + 273.15)  1 + 2 0.498  
     
 
SAIEXWA0010
REVISION D
Page 12 sur 17
5.4.3.2.5. Leak rate calculation
R = FB × FC = 6.315 × 10 −6 × FC
R = 6.315 ×10 −6 × 7.902 = 4.99 ×10 −5 , by simplified

method
R = 6.315 ×10 −6 × 6.137 = 3.88 ×10 −5 , by accurate
method
5.4.3.3. Calculations for test by vacuum in effluent side
5.4.3.3.1. Test data
- V = 6 m3,
- t = 20 minutes,
- ∆Pmeasured = 0.03 bar,
- Ttest = 25 °C,
- Peffluent test = 0.8 bar a
- Pfeed test = 1 bar a
5.4.3.3.2. Basic Factor (FB) calculation
V 1 ∆Pmeasured 6 1 0.03
FB = 20920 × × × = 20920 × × ×
t M effluent (Ttest + 273.15)
& 20 100000 (25 + 273.15)
FB = 6.315 × 10 −6
We also calculate the average of effluent pressure during the test :

∆Pmeasured 0.03
PeAV
ffluent test = Peffluent test + = 0.8 + = 0.815 bar a
2 2
5.4.3.3.3. Correction Factor (FC) calculation by simplified method
FC =
(P feed test )
ffluent test × ρ test
− PeAV
Pfeed test × 105 1× 105

ρ test = = = 1.169 kg / m 3
287 × (Ttest + 273.15) 287 × (25 + 273.15)
FC =
(10 − 6)× 4 = 8.601
(1 − 0.815)×1.169
SAIEXWA0010
REVISION D
Page 13 sur 17
5.4.3.3.4. Correction Factor (FC) calculation by accurate method
− (γ op +1)
 1 
  γ op  2
 γ op − 1  2 (γ op −1) 
(
5
)
 
 r .(T + 273.15) 
1 +
2
Machop 
2

  op op    
FC =  
−(γ test +1)
 1 
  γ test  2  γ test − 1 2 
2(γ test −1) 
(
5
)  1 + Machtest  
  rtest .(Ttest + 273.15)   2  
 
− (γ test −1)
 AV 
 Peffluent test  γ test
PeAV 0.815 2  
ffluent test
= = 0.815 > 0.5283 ⇒ Machtest = − 1
Pfeed test 1 γ test − 1  Pfeed test 

 
γ test = 1.4
−(1.4−1)
 
2  0.815  1.4
Machtest =   − 1 = 0.549 < 1
1.4 − 1  1  
 
−(γ op −1)
 
Peffluent op 6  P 
2  effluent op  γ op 
= = 0.600 > 0.5283 ⇒ Machop =  − 1
Pfeed op 10  
γ op − 1  Pfeed op  
 
Pfeed op × 105 10 ×10 5
rop = = = 345.7 J/(kg.°C)
ρ op × (Top + 273) 4 × (450 + 273.15)
Cpop 3000
γ op = = = 1.13
Cpop − rop 3000 − 345.7
−(1.13−1)
 
2  6  1.13
Machop =   − 1 = 0.965 < 1
1.13 − 1  10  
 
− (1.13+1)
 1 
  1.13  2
 1.13 − 1  2 (1.13−1) 
 0.965 . 10 (
× 10 5
 )
 345.7 × (450 + 273.15)   1 +
2
0.965 2
 
     
FC =   = 6.808
−(1.4+1)
 1 
 5  1.4  2  1.4 − 1 2
2 (1.4 −1) 
 0.549 . 1 × (
10  )
 287 × (25 + 273.15)  1 + 2 0.549  
     
 
5.4.3.3.5. Leak rate calculation
R = FB × FC = 6.315 × 10 −6 × FC
R = 6.315 ×10 −6 × 8.601 = 5.43 ×10 −5 , by simplified
method
R = 6.315 ×10 −6 × 6.808 = 4.30 ×10 −5 , by accurate
method
SAIEXWA0010
REVISION D
Page 14 sur 17
6. Storage Conditions After Test
In order to avoid any ingress of moisture in the PACKINOX Heat Exchanger, it shall be
kept under dry air or nitrogen atmosphere before unit restart.
SAIEXWA0010
REVISION D
Page 15 sur 17
APPENDIX 1 : Isolation and connection Drawing for Airtightness test in Pressure
U1 E2 : Effluent Inlet
S1 : Combined Feed Outlet
A1 A2
TH
T1
Feed
Circuit
Effluent Circuit
M or M1/M2
Liquid Feed Inlet
Water Manometer A
S2 : Effluent Outlet
U2
Pressurizing system
or Air supply
SAIEXWA0010
REVISION D
Page 16 sur 17
APPENDIX 2 : Isolation and connection Drawing for Vacuum test in Effluent side
U1 E2 : Effluent Inlet
S1 : Combined Feed Outlet
A1 A2
TH
T1
Feed
Circuit
Effluent Circuit
M or M1/M2
Liquid Feed Inlet

A4
S2 : Effluent Outlet
U2
V1
Water Manometer
Vacuum Pump
SAIEXWA0010
REVISION D
Page 17 sur 17
APPENDIX 3 : Characteristics of the pump PIAB Round M200
Flowrate of sucked up air :
Rev D Feeding pressure : 0.6 MPa
Vacuum level (-kPa) 0 10 20 30 40 50 60 70 80 90

Flowrate of sucked 40 28 18.5 9.6 4.8 3.6 2.4 1.3 0.6 0.1
up air (Nl/s)

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DISCUSSION POINTS WITH L&T FOR BUNDLE REPLACEMENT WORK OF ISOM-A PACKINOX-EXCHANGER AT JAMANAGAR PX4 SITE

Date: 28th Nov 2017

Sr. No. Query Discussion Notes

L&T explained that they are checking out the option of

RIL asked for demo testing at L&T Hazira shop.

Sr. No. Query Discussion Notes

L&T will submit ITP for RIL approval.

Sr. No. Query Discussion Notes

For Bevelling operation, hard barricading may be required and

Post meeting Notes :

Testing of the exchanger shall be done as per the procedures

Sr. No. Query Discussion Notes

Please refer to Appendix No 5 of document SMSCAZAS002 for

Time estimate for drying to be furnished.

Sr. No. Query Discussion Notes

L&T and RIL will jointly walkthrough the Hx to freeze the

Mitre pipe will be provided by RIL, L&T will fabricate as per

Post Meeting Notes

Bellow are supplied with Extra length as marked in drawing.

Sr. No. Query Discussion Notes

Post Meeting Notes

BUNDLE REPLACEMENT ON SITE

Nom Entité Date

Vérificateur(s) Madeleine KMIEC Qualité 14/6/2005

Approbateur Pierre TANCA Méthodes management 14/6/2005

Révision Date d’application Objet de la révision

Appendix Nbr 9.................................................................................................................. 19

GAD = General Arrangement Drawing

2. HANDLING AND STORAGE OF THE NEW BUNDLE

3. PREPARATION OF THE EXCHANGER BEFORE REPAIR

4. REMOVE THE OLD BUNDLE

4.1. Cut the top head

• Remove the spray bars if existing

4.2. Remove the old bundle

5. PREPARATION OF THE VESSEL, THE TOP HEAD AND THE BUNDLE

5.1. Preparation of the vessel and the top head

o If there is any thermal operation on the vessel (flame cutting, welding,…) a

Temperature for material 1.25 Cr

Temperature for material 2.25 Cr

o Check the welding (Dye penetral test or Magnetic particle examination, +

5.2. Bundle preparation

6. INSERTION OF THE BUNDLE INTO THE VESSEL

6.1. Handling recommendations (see §2)

6.2.1. Bundle with spray-bar(s): (1 or 2 spray bars)

6.2.2. Bundle without spray bar

7. FITTING UP AND WELDING OPERATION OF THE TOP HEAD

7.1. Fit up the top head

7.2. Weld the top head

Temperature for material 1.25 Cr

Temperature for material 2.25 Cr

8. COMPLEXION OF THE CONNECTIONS BETWEEN THE BUNDLE AND THE

9. EXAMINATION AND REPORTS (TO SENT TO PACKINOX FOR INFORMATION)

Perform and set up dimensional reports (before hydro-test)

• Spray bar(s) position (if existing): see Appendix Nbr 6 and 7

• Preparation of the hydro-test (see Packinox’s specification)

Coté chaud Coté froid (bas)

Faisceau > 10m Bundle > 10m

Faisceau < 10m Bundle < 10m

Calage et vérins autorisés

Calage et vérin interdits

Type 2 cannes / 2 Spray bars type

Calage et vérins autorisés

Calage et vérins interdits