TOPRAS Section: TGPS-E2 Page: 1128 Date June, 2001 Revision :0 TUPRAS izmit REFINERY DIESEL/KEROSENE HYDROPROCESSING AND CCR REFORMER PROJECT GENERAL PROJECT DESIGN SPECIFICATION ‘SHELL-AND-TUBE HEAT EXCHANGERS 4.0 SCOPE 2.0 3.0 241 The requirements given in this speci This specification outlines the major requirements for materials, design, fabrication, inspection and testing of unfired shell-and-tube heat exchangers for general refinery service, GENERAL ation and in the design data sheet approved by Owner, are mandatory, unless changes are approved in writing by Owner, 2.2 Heat exchangers (other than steam surface condensers) shall comply with Class R of Standards of Tubular Exchanger Manufacturers Association (TEMA), as modified by this specification or the design data sheet. 2.3. The requirements outlined herein are included under the appropriate TEMA subject headings. The corresponding TEMA paragraph numbers are given in parenthesis following the headings. ‘SCOPE AND GENERAL REQUIREMENTS (R-1) 3.1 Construction Codes (R-1.13) 3.4.1, Addition to R-1.13. Design and fabrication of pressure parts of exchangers used to generate steam shall comply with Section VIII of the ASME Boiler and Pressure Vessel Code and local regulations and codes. 3.1.2. Addition to R-1.13. Materials, design, fabrication, inspection and testing of heat exchangers shall comply with ASME Code unless otherwise specified on the design data sheet.TOPRAS T REFINERY Section : TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page: 2/28 AND CCR REFORMER PROJECT Date: June, 2001 5 Revision :0 3.2. Materials (R-1.14) 3.2.1 General 3.2.1.1 Addition to R-1.14, Materials may be specified by Owner without knowledge of many of the design details to be offered by Contractor. Contractor shall assume responsibilty for correct incorporation of materials in the design and, therefore recommend alternatives, if required, giving the reason for the suggested change. All changes are subject to approval in writing by Owner. .2Addition to R-1.14, Materials for each component of an exchanger shall be as specified on the design data sheet. 3.2.1.3 Addition to R-1.14. If materials conforming to ASTM Specifications are not readily available, Vendor may offer equivalent substitute materials. The type of material, complete specification and ASTM equivalent shall be given. All substitutions are subject to approvat in writing by Owner. 3.2.1.4 Addition to R-1.14. The proposed material for test rings shall be specified by @ Vendor. Cast materials shall not be used, 5 Addition to R-1.14. No bottom or side air or air/oxygen blown converter steels shall be used. Oxygen blown steels may only be used below the creep range. 3.2.1.6 Addition to R-1.14. Uniess otherwise specified, only the non-ferrous alloys listed in Table 1 shall be used for water service. All copper-zinc alloy materials used in construction shall be arsenically inhibited grades of material. Materials shall be selected to minimize the possibility of galvanic attack, e.g to avoid combination such as Monel and brass. Where hydrocarbon pH is less than 7.2 aluminium brass shall be used; above pH 7.2 (due only to presence of free ammonia), 70-30 Cu Ni alloy shall be used. If lead-lined steel is used, chemical lead 1/8" thick shall be bonded homogeneously. Suitable non-ferrous flange facings that permit proper bonding of the lead, e.g, 70-30 Cupro-Nickel, shall be used. Special care shall be taken to ensure complete bonding of the lead with the flange face ‘material; this recommendation is particularly important if aluminium bronze used.TUPRAS ae een Section: TGPS.£2 DIESEL / KEROSENE HYDROPROCESSING Page: 3728 ‘AND CCR REFORMER PROJECT Ro Cae Revision :0 3.2.1.7Addition to R-1.14. Materials for equipment containing hydrogen or hydrogen/hydrocarbon mixtures shall be resistant to hydrogen attack under the design parameters in accordance with Drawing TD-20253. 3.2.1.8 Addition to R-1.14. When cladding is used, the backing steel and the material used for bonding purposes shall have adequate resistance to hydrogen attack under the design conditions. 3.2.1.9 Addition to R-1.14. The use of copper base alloys in direct contact with Ethylene Plant process streams or any other streams where acetylene or homologues may be present is prohibited, 3.2.1.10 Addition to R-1.14, Where carbon steel is specified, the following materials shall be used: a. Pressure plates: SA-516, any grade b. Internal and external plates welded to pressure parts: SA-616, any grade ©. Internal and external plates not welded to pressure parts: SA-36, SA- 283, SA-285 GrC, SA-516-any grade d. Forgings: SA-181, SA-105 (except tubesheets and main cylinders), of ‘SA-266 Grade 2 @. Pipe : SA-106B or SA-538 f. Exchanger Tubes: SA-214 or SA-179 3.2.1.1 Addition to R-1.14, Where carbon steel, silicon killed, is specified , the following materials shall be used: a. Pressure plates: SA-516, any grade b. Internal plates welded to pressure parts: SA-516, any grade ©. External plates welded to pressure parts: SA-36, SA-283, SA-285 GrC, SA-516 any grade d. Forgings: SA-105 (except tubesheets and main cylinders), or SA-266 Grade 2 e. Pipe : SA-106B or SA-53B £ Exchanger Tubes: SA-179 Si killed, Sa 192 Si killedTUPRAS izMiT REFINERY DIESEL / KEROSENE HYDROPROCESSING. Section: TGPS-E2 Page 4/28 AND CCR REFORMER PROJECT Date: June, 2001 Revision :0 3.24.12SA-36 or SA-283 materials for attachments to parts with design 3.2.2 temperatures in excess of 650 °F shall not be used. Tubes 3.2.2.4 Addition to R-1.14. Ferrous tubes, including austenitic stainless steel, will be seamless. 3.2.2.2 Addition to R-1.14. All tubing material shall be in the full-length annealed 3.2.3 3.2.4 temper except arsenical copper, which shall be light drawn temper, and aluminium, which shall be half-hard temper. Tubes of 70-30 Cupro-Nickel shall have a maximum hardness of 140 DPH or equivalent Shells, Channels, Covers, Floating Heads, Tubesheets, and Flanges Addition to R-1.14, Cast iron pressure containing parts shali not be used in process fluid service but may be used in fresh cooling water service, subject to approval by Owner. Fully killed steel of good welding quality shall be used for tubesheets when strength-welded tube jcints are required. For good weldabilty, tne tubesheet shill preferably have the following composition Carbon 0.15 max. Manganese —1.0-1.4 Sulphur 0.035 max. Phosphorus 0.035 max. Nozzles shall be made of a material corresponding to that used for the part to Which they are attached. Bolting 3.2.4.1 Addition to R-1.14. Unless other materials are required because of design or service considerations, pressure-containing parts shall have stud bolts of ASTM A 193 (Grade B7 for bolt temperatures up to 850 °F and B14 or B16 for higher temperatures) and nuts of ASTM A 194 , grade 2 or 2H. Thermal expansion of flange material and bolting shall be considered in selecting adequate materials.® TOPRAS iZMIT REFINER REFINERY Section: TGPS-E2 DIESEL/ KEROSENE HYDROPROCESSING Page: 5/28 AND CCR REFORMER PROJECT Date + June, 2001 Revision :0 3.3 3.4 3.2.4.2 Addition to R-1.14, Bolting for internal parts shall have corrosion resistance comparable to that of the internal shell material and not be subject to galvanic corrosion. Stee! bolting may be used for non-ferrous parts in hydrocarbon service if there is no danger of galvanic corrosion. Aluminium bronze or other suitable materials shall be used with copper-base alloys when there is danger of galvanic corrosion. 3.2.4.3,Addition to R-1.14, When steel stud bolts are specified to be specially tempered to a maximum hardness of 24 Rockwell C because of danger of hydrogen sulfide corrosion cracking the appropriate allowable stress in bolt design shall be used . Bolts specially tempered shall be stamped B7-S to so indicate. 3.2.4.4 Addition to R-1.14. A high temperature thread lubricant of recognized quality shall be applied to all bolts, prior to installation. Thread lubricants for austenitic stainless steel bolting are subject to approva! by Owner. Design Pressure (R-1.2) 3.3.1 Addition to R-4.21. The design pressure for both sides of the exchanger shall be as specified in design data chet. The minimum design pressure for either side, however, shall be 75 psig. The exchanger shall be stamped for the true maximum allowable working pressure hot and corroded condition if it is greater than the design pressure. 3.3.2 The design of exchanger intemal pressure parts for a differential pressure less than the shell and/or tube design pressure shall not be allowed unless approved by Owner. When such a differential pressure design is permitted, 2 ‘special nameplate or warning tag shall be attached to the exchanger so as to make this condition known, Testing (R-1.3)TOPRAS IZMIT REFINER BEEINERY Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page 628 AND CCR REFORMER PROJECT Date: June, 2001 Revision :0 3.4.1 Standard Test (R-1.31), 3.4.1.4 Addition to R-1.31. For exchangers with tubesheets designed for differential Pressure, hydrostatic testing shall be in accordance with (a) and (b) below, and the appropriate test presessures shall be recorded on the design data sheet. a. For tubeside or sheliside tightness tests, pressure test to minimum of the following ~ 1.5 times the design differential presesure. - Appropriate tube or shell test pressure, b. For strength test of shell or channel, pressure both tube and shall sides simultaneously both to their respective strength test pressures. 3.4.1.2 Addition to R-1.31. Normal service gaskets shall be used for final hydrostatic tests. 3.4.1.3 Addition to R-1.31. Exchangers with austenitic stainless stell paris (excluding 3.4.2 gaskets ) shai be hydrostatically tested with water containing not more than 50 ppm of chioride. Exchanger must be throughly drained and dried after hydrostatic test. Air Or Gas Test (R-1.32) Addition to R-1.32. Reinforcing pads and alloy liners shall be air tested with soap suds. 3.5 DesignTemperature of Heat Exchangers Parts (R-1.42) 3.5.1 Addition to R-1.42. The design metal temperature shall be 25 °F above the calculated value for exchangers operating above ambient temperatures, The calculated metal temperature shall be used for the design of exchangers operating at temperatures below ambient.TOPRAS iZMiT REFINERY DIESEL / KEROSENE HYDROPROCESSING Section: TGPS-E2 Page 7/28 AND CCR REFORMER PROJECT Date June, 2001 Revision °0 3.6 Standard Corrosion Allowance (R-1.5) 3.6.4 3.6.2 Addition to R-1.5. Corrosion allowance shall be as specified on the design data sheet and be provided for all parts of exchanger except tubes and baffles. Unless otherwise specified, 3 mm minimum corrosion allowance is required for all carbon steel parts. Addition to R-1.5. The specified corrosion allowance shall be added to all confined female faces and faces under male tongues for body, head, and tubesheet flanged joints (not nozzles) 4.0 TUBES (R-2) 44 Tube Diameters and Gauges (R-2.2) 444 41.2 443 41.4 Addition to R-2.2. The diameters and lengths shall be as specified on the design data sheet. Addition to R-2.2, Tubes shall normally be 3/4" O.D unless a larger size is required Addition to R-2.2. The tube gauge may be either minimum or average wall Average wall tubes shall be the next heavier commercially available gauge above the minimum wall requirement Addition to R-2.2. The minimum tube wall thickness shall be as follows Carbon steel and low alloy 14 BWC. (up to and incl. 5 Cr-% Mo) tubes High alloy (above 5 Cr-¥4 Mo and up 16 BWG through austenitic stainless steel) tubes Non-ferrous (Admiralty, Cu-Ni, etc.) tubes. 14BWG 4.2 U-tubes (R-2.31) 4.24 4.2.2 Addition to R-2.31.U-tubes shall be of one-piece construction, Addition to R-2.33. All U-tubes shall be stress relieved after bending. Carbon steel U-tubes in amine or caustic service and all austenitic stainless steel and non-ferrous U-tubes shall be stress relieved over their full length. All other U-tubes may be stress relieved in the bend section plus a minimum tangent length of 1 meter.TUPRAS izmir REFINERY Sectio;, : TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page, 8/28 AND CCR REFORMER PROJECT Date June, 2001 Revision :0 4.2.3 Addition to R-233. Complete details of the Vendor's proposed stress 4.24 4.25 relieving heat treatment for austenitic stainless steels shall be submitted to Owner for approval. The heat treatment selected shall not produce sensitization that will be harmfull in the service environment. Types 321 and 347 shall be stress relieved at 1600 - 1650 °F for 2 hours minimum, followed by air cooling, Addition to R-2.33, Stainless steel tubes shall be supported to minimize distortion during heat treating. Straightening shall not be permitted for tubes that are stress relieved prior to insertion in to the tubesheet. Addition to R-2.33. The minimum mean radius of U-bends shall be 1.5 times the .D. of the tube. Flattening at the bends shall not exceed 10% nominal .D. of straight portion of tube. 5.0 BAFFLES AND SUPPORT PLATES (R-4) 5.4 5.2 Special Precautions (R-4.43) 5.4.4. Longitudinal battles for two pass shells are only permitted for non critical and non fouling services, and where shell side pressure drop does not exceed 5 psig. In addition if "lamiflex" type baffles are used, they shalt not be subjected to a temperature differential of more than 300 °F. Use of longitudinal baffles is subject to Owner's approval. Impingment Baffles (R-4.6) 5.24 5.22 5.2.3 Addition to R-4,6. Shell-side inlet impingement plates shall be provided on heat exchange equipment that has salt water on the tubeside. Addition to R-4.6. The design of impingement baffles shall be such that they can be relocated when the bundle is rotated 180 degrees on its longitudinal axis. Addition to R-4.6. All impingement plates shall be of sufficient size to prevent direct impingement on the tubes. Impingment plates shall be supported by at least two tie rods, or the equivalent. Perforated impingment plates are not acceptable.© - TOPRAS teat ZMIT REFINERY Section: TSPS-E? DIESEL / KEROSENE HYDROPROCESSING Page 9/28 AND CCR REFORMER PROJECT Date June, 2001 Revision :0 5.3. Bundles 5.3.1 Removable bundles shall be provided with skid bars when bundle weight exceeds 12 000 Ibs. These shall be adequate to provide protection to the tubes and buffles and shall, as a minimum, be (two bars) 1 inch by 2 inches, mounted 15 degrees each side of the bottom centerline. In addition, all bundles shall have adequate handling bars to permit handling the bundle with 5 a.cable'sling without damage to the tubes or baffles. Bars shall be welded to all intersecting baffles. 5.3.2. For bundles with an empty weight in excess of 12 000 tbs and for all bundles of vertical exchangers, jack screws shall be provided to separate the bundle from the exchanger shel. 6.0 FLOATING HEADS (R-5) 6.1 Postweld Heat Treatment Exception to R-5.12. Fabricated floating heads need only be stress relieved as required by the ASME code unless otherwise specified on the design data sheet. 7.0 GASKETS (R-6) 71 Gasket Material (R-6.2) 7.4.1 Addition to R-6.2. For water service, gaskets for channel to channel cover and channel to stationary tube sheet shall be 1/8" thick full face compressed asbestos composition. 7.1.2 Addition to R-6.2. Any gaskets supplied by Vendor for flanged nozzle connections shall be spiral-wound asbestos-filed gaskets through 900 Ib. ANSI rating, octagonal ring joint shall be used above 900 Ib. ANSI rating. 7.1.3 Vendor shall supply 3 sets gaskets for construction spares 8.0 TUBESHEETS (R-7) 81 Applied Tubesheet Facing (R-7.121) Exception to R-7.121. Applied tubesheet facings shall not be usedTOPRAS iZMiT REFINERY Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page 10728 AND CCR REFORMER PROJECT Date June, 2001 Revision :0 8.2 Intergrally Clad Tubesheets (R-7) 8.2.1 Exception to R-7.122. Cladding shalll not be used for aqueous service. 8.2.2 Addition to R-7.8. The cladding thickness of clad tubesheets shall be at least 3/8" on the shell side. In the case of partition grooves, the thickness of the cladding af the bottomrof the groove shall-be atleast 1/8". The cladding thickness shall not be included in the effective tubesheet thickness. 8.3 Tube Hole grooving (R-7.44) - Exception to R-7.44.When shell side face of tube sheet is clad or overlayed, one groove shall be in the clad or overlayed portion, 8.4 Welded Tube Joints (R-7.52) 8.4.1 Seal Welded Joints (R-7.521) When tube to tubesheet seal welds are specified in the design data sheet, they shall be in accordance with Figure PFT-12.1 (e), Section | of the ASME Code. For exchanger designs where the tubes are considered as stays, only strength (not seal) welds shall be used. 8.4.2. Strength Welded Joints (R-7.522) Addition to R-7.522 Tubes shall be strength welded to tubesheets when any of the folowing design conditions exist : a. The pressure differential exceeds 1.000 psi, b. Any temperature of differential exceeds 500 °F cc, The temperature of either the tube or shell side exceeds the following Austenitic stainless steels 700 °F Carbon steel 850 °F Chromium-molybdenum steels, 950 °F including C-¥4 Mo.TUPRAS IZMIT REFINERY . Section: 16PS-€2 DIESEL / KEROSENE HYDROPROCESSING Page :11728 AND CCR REFORMER PROJECT Date: June, 2001 Revision :0 . When there is a hazard resulting from leakage, such as may occur when a hydrogen stream leaks to a non-hydrogen stream. ©. When high pressure steam (40 kg/cm2g) is used as a heating medium in reboilers. {When leakage .at-rolied joints would very seriously affect satisfactory operation. 9. When the temperature is within the creep range of the tube material Strength welds shall be in accordance with Figure PFT-12.1 (g), Section | of the ASME Code. 8.4.3 Fabrication and Testing Procedure (R-7.523) "8.4.3.1 Addition to R-7.523. When strength welding is required, the joint design, @ welding procedure (including heat treatment if needed) and methods of inspection and testing shall be submitted to Owner for approval. When Possible, the internal bore welding method shall be used for austenitic Stainless steels. The possible economic advantage of internal bore welding shall be given consideration for all high alloy materials. 8.4.3.2 Addition to R-7.523. The following manufacturing procedure shall be used when tubes are strength welded by conventional means a. Tube ends and tubesheet holes shall be cleaned to remove moisture and solid contamination and shall be solvent degreased prior to welding, b. If necessary, position the tubes by drifting lightly with a clean, dry beaded drifting tool ©. Preheat as required for the materials welded. d. Weld in accordance with the approved procedure Tubes shall be welded to the tube-sheet in a sequence that will minimise tube sheet distortion,TUPRAS iZMiT REFINERY Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page 12/28, AND CCR REFORMER PROJECT Deere coud Revision :0 €. Stress relieve as required for the materials welded (e.g. tube to tube sheet welds for 2%Cr-1Moly. steel or higher alloy) {. Pneumatically test the welds for leakage. No rolling shall be done until after the weld joints are proven by air test. g. Expand the tubes lightly into the tubesheets, just sufficiently to close the annulus. h. Hydrostatically test the completed unit 8.4.3.30n completion of welding; tubesheet gasket faces shall be checked for trueness and shall be skimmed where necessary 9.0 CHANNELS AND CHANNEL COVERS (R-3) 9.1 Postweld Heat Treatment (R- 4) @ 9.1.1 Exception to R-9.14. Fabricated and forged steel channels need only be stress relieved as required by the ASME Code untess otherwise specified on the design data sheet. 10.0 NOZZLES (R-10) 10.1 Nozzle Construction (R-10.1) Oo 10.1.1 Addition to R-10.1. Connections to shell-and-tube exchangers size 1%" and larger shall be flanged. Dimensions shall be in accordance with ANSI B 16.5. ‘Above ANSI 900 Ib. rating fianges shall be ring joint, 10.1.2 Flanged nozzles through 2" size inclusive shall be forged steel long welding necks. Nozzles over 2° size may be built-up using forged stee! welding neck flanges, with rolled plate or pipe necks. 10.1.3 Nozzle lengths shall be long enough to permit the removal of a standard length stud bolt from the back side of the flange to clear the exchanger body and insulation. If not specified, a minimum of 4” insulation shall be assumed 10.1.4 Nozzle necks through 8" shall be minimum sch. 80 pipe. Larger nozzles shall be minimum 1/2 inch thick.TOPRAS izMiT REFINERY wen Section: TGPS-2 DIESEL / KEROSENE HYDROPROCESSING Page 13928 AND CCR REFORMER PROJECT Date : dune, 2001 Revision :0 10.1.5 Nozzle welds including pads shall be full penetration in accordance with the details (c), (d), (e), (9). (F-1), (f-2) of (F-4) of figure UW 16.1 of the ASME. Code. All nozzle welds shall be back chipped to sound metal before welding from the opposite side. 10.1.6 Couplings weld shall be in accordance with details (2-1) or (2-2), (scarfing of plate for single vee can be from the outside), of figure UW 16.1 of the ASME Code. When possible, coupling welds shall be back chipped to sound metal before welding from the opposite side. All coupling welds shall be full penetration, s 10.1.7 The use of nozzles fabricated from integrally clad plate or alloy protected with deposited weld metal is preferred. For carbon and low alloy steel exchangers, solid alloy nozzles are not recommended and stainless steel nozzles are not permitted. 10.1.8 Addition to R-10.1, Nozzles 2" size and smaller may be fabricated using a loose sleeve type liner welded to the face end of the nozzles and to an expansion ring welded to the shell liner. Rolled liners for nozzles are not Permitted. Details of ioose sleeve type liners must be approved by Owner. 10.1.9 Addition to R-10.1. Each section of a reinforcing pad shall contain a test hole tapped 1/8 inch NPT (ANSI B2.1) prior to installation. After air testing, the holes shall be left unplugged and filled with grease. 10.1.10 Class 150 flanges of carbon steel are not permitted for design temperature over 700 °F or for pressure relief valve connections; the 300 Ib series shall be used as a minimum instead 10.2 Nozzle Installation (R-10.2) Addition to R-10.2. Nozzles or other openings shall be located so that no part of the neck, added reinforcement or attachment welds intersect any welded seam in the exchanger wall. 10.3 Pipe Tap Connection (R-10.3) 10.3.4 Addition to R-10.3. Vent and drain connections plugged with 6" long bar stock plugs shall be provided on the shell and tube side of each exchanger. Sufficient connections shall be provided to insure adequate venting and draining of pass compartments. Drains shall be provided at the channel end and vents at the floating head end,TOPRAS iT REF} izMiT REFINERY secion -T6Ps¢2 DIESEL / KEROSENE HYDROPROCESSING Page 1478 AND CCR REFORMER PROJECT Date: June, 2001 Revision: 0 10.3.2 When hydrogen service construction is required, the high and low points of the shell and tubesides of the exchanger, not otherwise vented or drained by the nozzles, shall be provided with 1" RF LWN flanged vent(s) or drain(s) connections. 10.3.3 Addditon to R-10.3 Blind flanges shall be provided for flanged vent and drain connections, 10.3.4 Threaded conections shall not be used in hydrogen service. RF LWN flanges (min. 300 tb rating) shall be used for necessary vents, drains, pressure, and temperature connections in hydrogen service. 10.3.5 For alloy and alloy clad exchangers and hydrogen service exchangers connections on the exchangers nozzle are not required. 10.3.6 When the tubeside fluid is steam, a 114" 300 Ib minimum fianged operating vent connection shail be provided in the side of the channel or bonnet at the high point of the last past. 10.3.7 For total condensing shell side service a 1%" 300 Ib minimum flanged vent shall be provided on the top of each shell at the end oppesite to the shell inlet. For stacked units in series provide a vent nozzle in each shell. 10.3.8 Provide 1’4" flanged neutralizing connections in all main shell and tube side Nozzles of exchangers constructed of austenitic stainless stee! material 11.0 END FLANGES AND BOLTING (R-11) 11.1 Addition to R-11. Flat-lace flanges are acceptable for components in water service. Sizes 12" and over shall be equipped with jack screws for parting “11.2 Addition to R-11. When shells of stacked units are flanged together or are Connected with a spool piece, the connection shail be fitted with a spectacle blind. 14.3 Addition to R-11. All bolt holes in flanges shall straddle centre lines. 11.4 Addition to R-11. Consideration shall be given to the problems involved when materials with markedly different coefficients of expansion are bolted together, e.g ferritic and austenitic steels. 11.5 Addition to R-11. In the case of design pressures of more than 100 bar or bolts having a diameter of more than 1%", bolts shall be suitable for tightening using hydraulic tensioning equipment, and the bolting design shall provide clearance dimensions that permit use of tensioning equipment.TUPRAS iZMIT REFINERY Section: TGPS-E2 DIESEL/ KEROSENE HYDROPROCESSING Page: 15/28 AND CCR REFORMER PROJECT Date: June, 2001 Revision :0 12.0 SHOP OPERATION (G-1) 12.4 General 12.1.4 Addition to G-1, The fabricating requirements specified herein are mandatory, unless otherwise agreed to in writing by Owner. 12.4.2 Addition to G-1. The entire length of the shell shall be checked for tube bundle clearance by means of a riding, accurately calipered template consisting of two baffle diameter discs 12" apart. All welds shall be ground ‘smooth on the inside of the shell to facilitate removal of the bundles. The transverse baffle and support plate clearance between shell ID and baffle OD shall not exceed the values shown in TEMA Table RCB 4.3 for the various classes unless specifically waived by Owner. 12.1.3 Addition to G-1. When a difference in thickness exists between shell plates or plates and heads, the inside diameter shall be held. 12.2 Welding 12.2.1 Adcition to G-1. Vendor shall submit al! welding procedures, including those for weld overlay and tube to tube sheet welds for approval by Owner. The qualifications shall be in accordance with the designated code or specification. 12.2.2 Addition to G-1, All welds subject to pressure shall have full penetration and shall be double welded wherever possible. Where access precludes the use of double welded joints, single welded joints with backing strips may be used, only as approved by Owner. 12.2.3 Addition to G-1. Welding electrodes shall conform to ASTM specifications. In general, the deposited weld metal shall have a composition corresponding to that of the material being welded. The mechanical properties shall conform to the minimum requirements specified for the parent material, 12.2.4 Addition to G-1. Welded overlay shall be deposited in at least two passes, and the composition of the top 1/16" of the finished thicknesses shall be equal to or better than the specified metallurgy for cladding, 12.2.5 Addition to G-1. Automatic submerged arc welding of main seams will be permitted provided the following conditions are complied with a, Maximum weld deposit per pass shall not exceed 1/4". b. All intersections of seams, and all stopping and starting points of weld beads shall be radiographically examined+ TOPRAS iMir REFINERY Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page: 16/28, AND CCR REFORMER PROJECT Re ec ) Revision :0 12.2.6 Addition to G-1. Back chipping of double welded butt joints is generally required for manually welded joints. When back chipping is required for the fabricator's welding procedure, the chipping shall be carried out down to ‘sound metal to the satisfaction of Owner's inspector, 12.2.7 Addition to G-1. All nozzles and ‘small connections and their reinforcement shall be attached with full penetration welds, if Possible, Back strips (if approved) shall be removed wherever possible. 12.2.8 Addition to G-1. No welding shall be permitted after stress relieving except as ey approved by Section Vill, Division 1 of the ASME Boiler and Pressure Vessel Code. 12.3 Heat Treating 12.3.1 Addition to G-1. Postweld heat treatment shall be given to various exchanger Parts as specified in Paragraphs UCS-56 and UHA-32, Section Viti, Division | of the ASME Boiler and Pressure Vessel Code. a 12.3.2 Addition to G-1. All welded joints in caustic service shall be stress relieved when the operating temperature exceeds the value derived from the following formula Ts =170-°Be Where, Ts = Stream temperature °F . “Be = Density of the caustic-water solution in degrees Baume. 12.3.3 Addition to G-1. Heads on which the knuckle or flange has been cold formed shall be stress relieved prior to welding, 12.3.4 Addition to G-1. The complete stress relieving procedure for welds joining austenitic steel to dissimilar materials and for clad or lined exchangers shall be submitted to Owner for approval 12.3.6 Addition to G-1. All flange facings and threaded connections shall be protected against oxidation during heat treatment.TUPRAS Jznir REFINERY Section = TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page 1728 AND CCR REFORMER PROJECT pee enc . Revision :0 12.4 Repairs Addition to G-1. Owner shall be consulted concerning all repairs and shall witness all repair work, 12.5 Non-pressure Attachments Addition to G-1. The edges of all structural members in contact with pressure parts of the exchanger shall be completely seal welded to prevent atmospheric corrosion C4 between the structural element and the shell of the exchanger. Corners of non- Pressure attachments shall be rounded to 1/4" min. radius. All continuously welded + attachments, such as saddles and reinforcing pads shall have 1/4" NPT tapped hole. 12.6 Dimensional Tolerances Addition to G-t. Dimensional tolerances shall conform to TEMA standards, except that stacked units shall be assembled together in the shop to assure correct fit. ®@ 13.0 INSPECTION(G-2) 13.1 General 13.1.1 Addition to G-2. Owner reserves the right to carry out partial or complete inspection of the materials and equipment during the course of fabrication and to inspect the finished article for compliance with the terms of the order and specifications. 13.1.2 Addition to G-2. The hydrostatic test will be witnessed by Owner's inspector, : unless Contractor is otherwise advised. Notice of such tests shall be given at least ten days in advance. 13.2 Testing 13.2.1 All heat exchangers shall receive a shop hydrostatic test in accordance with the ASME Boiler and Pressure Vessel Code. 13.2.2 Exchangers designed for stacking shall be hydrotested in the stacked Position, 13.2.3 For solid or clad austenitic stainless steel! exchangers the chloride content of the hydrotest fluid shall not exceed 50 ppm.TUPRAS iZMIT REFINE] MITREFINERY Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page: 18128 AND CCR REFORMER PROJECT Date: June, 2001 Revision :0 13.2.4 The hydrotest fluid shall be at least 30 °F above the ductile-britle transition temperature of the material. The minimum hydrotest temperature shall be stated on the outline drawing. It is the Vendor's responsibility to carry out any tests necessary to establish the transition temperature. 13.2.5 Welded attachments shall be tested with 25 psig air and soap solution prior to PWHT and final hydrotest of the exchanger. Vent holes shall remain open during hydrotest. 13.3 Non-destructive Examination 13.34 Addition to G-2. Vendor shall prepare a diagram showing the position of radiographic examinations performed and a radiographic report giving his interpretation of radiographic examinations and radiographic methods used andlor requested. 13.3.2 Addition to G-2. All radiographs shali be made and interpreted in conformity with the ASME Code. When full radiography is not a code requirement, all exchangers shall be spot radiographed in accordance with paragraph UW-52 of the Code. Also, the manufacturer shall take additional radiographs as requested by Owner's inspector. When a part is fully radiographed, it shall be 50 indicated on the Contractor's Data report and on the name plate. 43.3.3 All strength welds shall be spot radiographed when carbon steel and 100% radiographed when alloy. All welds in hydrogen service shall be fully radiographed. 13.3.4 Addition to G-2. Spot radiograph examination shall be made at all starts, stops, intersections and repairs of automatically welded seams, plus other locations designated by Owner's inspector. Spot radiograph examination shall be made at all junctions and repairs of manually welded seams plus other locations designated by Owner's inspector. 13.3.5 Addition to G-2. Acceptance radiography shall be performed after PWHT. 13.3.6 Addition to G-2. Nozzle and coupling welds shall be examined for crack detection using magnetic particle or liquid penetrant methods. 13.3.7 Ultrasonic examination is required for all strength welds after PWHT in material 2 inches and greater in thickness.TOPRAS izMiT REFINERY DIESEL / KEROSENE HYDROPROCESSING Section: TGPS-E2 Page: 1928 AND CCR REFORMER PROJECT Date June, 2001 Revision :0 13.3.8 Addition to G-2. For components in hydrogen service with thickness equal to 13.4.1. Addition to G-2. Chemical analyses of welds of molybdenum and chro or greater than 1% inch, the base metal shall be ultrasonically examined in accordance with SA-578, Level 1, Supplementary Requirement $1 “13.4 Special Requirements for Alloy or Lined Exchangers m- molybdenum steels intended for hydrogen service shall be made to ensure that the alloy content is not less than that specified for the base metal. At least one chemical analysis shall be made for each welding procedure and each major weld seam. Samples shall be taken from the equipment at a location selected by Owner's inspector. Additional analyses shall be made as required by Owner's inspector. 13.4.2 Addition to G-2. Stainless steel weld overlay on nozzles, weld seams of other paris of ciad vessels shall have 2 composition and corrosion resistance ‘comparable to that of the cladding. A chemical analysis shall be made when indicated on the Purchase Order, or when required by Owner's inspector. 13.4.3 Additicn to G-2. Stainless steel weld deposit iinings shall be dye penetrant inspected. All cracks and other harmful defects shall be repaired 13.4.4 Addition to G-2. Alloy mili cladding shall be ultrasonic examined for lack of bond at the mill over a minimum of 10 percent of the clad area. if the material is formed or in hydrogen service, the clad area shall be examined 100 percent after forming. For either examination, the acceptance criteria shall be in accordance with ASME Code SA-578, Acceptance Level $6. However, if the clad material is for tubesheets, the acceptance level shall be S7. 13.5 Thickness Measurements. 43.5.1 Addition to G-2. The actual measured minimum thicknes of formed heads, shell plates and channel sections shall be recorded on Vendor's data report. 13.5.2 Addition to G-2. Eight minimum thickness readings shall be determined for the completed shell at both the floating head and channel-section ends, Each set of eight measurements shall be taken at equally spaced radial positions, starting from the zero degree orientation of the exchanger in its normal operating position. Each minimum reading shall be determined by measuring with a "C" caliper gauge over a distance of 12" along the longitudinal axis of the shell at the designated location.TUPRAS izMiT REF INERY Section : TGPS-E2 * DIESEL / KEROSENE AYDROPROCESSING Page 2028 AND CCR REFORMER PROJECT Date: June, 2001 Revision: 0 13.6 Impact Testing 13.6.1 Addition to G-2. The minimum average atmospheric temperature in winter is -2 °C. The impact testing exception for material shall be in accordance with Para, UCS-66 of ASME Sect. Vill, Div.1 13.6.2 Addition to G-2. In addition to mechanical tests laid down in the steel specification, every plate more than 50 mm thick and forming part of shell . shall be subject to a Charpy V impact test with three specimens in accordance with ASTM A 370 (type A specimen). All pressure containing parts and every plate not only for more than 50 mm thick parts, if required by code. Specimens shall be taken in the longitudinal direction of plate rolling at a depth of not less than 1/4 of the thickness and the notch shall be perpendicular to the plate surface. 13.7 Hardness Testing 13.7.1 Addition to G-2. Hardness tests shall be carried out on welds of Cr-Mo low- alloy steel exchangers after the final heat treatment using a portable apparatus (Poldi or equivalent) to ensure that the following values are not exceed 215HB for steel having 2 Cr content of less than 2% 240 HB for steel having a Cr content equal to or more than 2% . The average of seven readings may be taken into account for every zone examined. If the above values are exceeded heat treatment shall be repeated. 13.7.2 Addition to G-2. The maximum hardness of weld and HAZ shall be 200 Brinell for wet H2S Service. 13.7.3 Addition to G-2. Weld hardness testing shall be performed on attachment of non pressure parts to pressure part welds.TOPRAS iz MIT REFINERY Section: TGPS-E2 DIESEL / KEROSENE HYDKOPROCESSING Page 21128 AND CCR REFORMER PROJECT Date June, 2001 Revision <0 14.0 NAME PLATES (G-3) 14.1. Name Plate Data (G-3.11) 14.1.1 Addition to G-3.11 in addition to the pertinent design data required by TEMA, the following data shall be included on the name plate ~ Code to which the exchanger is designed, with code stamping, ~ Tube and shell-side hydrostatic pressures. Tube sheet hydrostatic test pressure (for units designed for dfferantial pressure only.) - Radiography and stress relief performed ~ Inspectors stamp - Purchase Order Number > Year built - Exchanger mark number Registered number Warning “Tubesheet designed only for differantial pressure” where applicable 44.1.2 All ancillary equipments shall be securely and plainly marked with the Purchase Order number and exchanger mark number. 0 DRAWINGS AND ASME CODE DATA REPORTS (G-4) Addition to G-4, Contractor shall furnish drawings and data to Owner in accordance with relevant project specifications. 16.0’ GUARANTEES (G-5) 16.1 Performance (G-5.1) 16.1.1 Addition to G-5.1. The performance guarantee shall be effective for a period of 18 months after the equipment is in operation 16.1.2 Addition to G-5.1. Upon satisfactory proof that the performance of the exchanger is not as specified, Contractor shall, without cost to Owner,supply additional equipment or make the necessary alterations to the existing ‘exchanger to obtain the required performance. 16.1.3 Addition to G-5.1 Approval of the Vendor's drawings by Owner shall not be considered as allowing any deviation from the specifications and shall not relieve Contractor of any responsibility under guarantees.& TOPRAS izMiv REFINERY Seen ceser DIESEL / KEROSENE HYDROPROCESSING Page :22/28 AND CCR REFORMER PROJECT caer eae . Revision :0 16.2 Defective Parts (G-6.22) Addition to G-5.22. Exchangers shall be guaranteed against faults in material, design and workmnaship for a period of 18 months from taking into service, and Contractor shall promptly repair or replace at his own expense, any part of parts found defective within this period. 17.0 PREPARATION OF HEAT EXCHANGERS FOR SHIPMENT (G-6) 17.1 Flange Face Protection (G-6.3) Addition to G-6.3. Flanges shall be coated with grease and covered with wood or Steel plates. Permanent blind flanges or covers shall be bolted up with the specified gaskets 17.2 Damage Protection (G-6.5) Addition to G-6.5. Exchangers shall be suitably prepared for export shipment when applicable. One coat of primer shall be applied to the external parts of exchangers shipped as deck cargo. Exchangers with austenitic stainless steel parts shall be left Unpainted and shall not be shipped as deck cargo. 48.0 GENERAL CONSTRUCTION FEATURES OF TEMA STANDARD HEAT EXCHANGERS (G-7) 18.1 Supports (G-7.1) 18.1.1 Addition to G-7.1. Each exchanger shall be provided with at least two steel supports with saddles for cistributing the total design load. The fixed support shall withstand a’ bundle pulling force equal to 150 percent of the bundle weight, unless otherwise specified. 18.1.2 Addition to G-7.1. On stacked multiple shell units, each bottom mounted shell shall be provided with at least two additional steel supports to enable mounting one shell above the other. The Vendor shall provide all necessary stacking material, including bolting shims, and gaskets.. TOPRAS izMiT REFINERY Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page 23128 AND CCR REFORMER PROJECT Date June, 2001 Revision 0 18.1.3 Addition to G-7.1. The bolt holes in the saddle on one end of each exchanger shall be slotted to allow for expansion under the design temperature. 18.1.4 Addition to G-7.1. Vertical exchangers shall be supported by lugs welded to the shell in such a manner that the shell shall not be overstreassed or distorted 18.1.5 Addition to G-7.1. Jack screws or other means shall be provided for separating stacked units that are flanged together or connected by a spool piece 18.2 Lifting Devices (G-7.2) 18.2.1 Addition to G-7.2. Suitable lifting lugs, rings, or eyebolts shall be provided on the channel and shell covers, the floating head, in order to facilitate handling and bundle removal. For fixed tube sheet exchangers, lifting lugs shall be provided on the tube sheets, 18.2.2 Addition to G-7.2, Lifting lugs on stacked exchangers shall be given special attention. Two or more lifting lugs located at 45 degrees from the top centerline shall be provided so that any of the exchangers can be dismantled without undue diffcutly. 19.0 QUOTATIONS 19.1 Contractor shall receive quotations from Vendors in strict conformity with Owner's specification; however, Vendors may offer an alternate quotation based on his standard practices when they are considered superior to those of Owner's. The reasons for adopting his standard practices should be indicated. 19.2 The Vendor's quotation shall include the following spares a. Three spare sets of all gaskets such as the shell cover, floating head and channel cover; the channel tubesheet and shell-tubesheet joints for each exchanger. b. All necessary test rings. One floating head test ring for floating head type exchangers shall be furnished for each size and type of exchanger. Channel test tings are also required if all tubes are not visible with channel cover removed . ‘Supply O-ring type gaskets adequate for complete testing ©. Any special tube rolling equipment or cleaning tools required for maintenance purposes,TOPRAS iZMIT REFINERY DIESEL / KEROSENE HYDROPROCESSING AND CCR REFORMER PROJECT Section Page Date Revision :TGPS-£2 24128 June, 2001 0 20.0 MATERIAL STATUS AND SUB-ORDERS 20.4 Contractor shall make available for Owner's representatives full information on the ‘status of sub-orders for material and on the progress of shop work. 21.0 ATTACHMENT Table |. Material Specification References. 22.0 REFERENCES ~ 22.1 Owner's Standard Drawings - TE-20253-Operating Limits for Steels in Hydrogen Service 22.2 Licensors Project specifications. 22.3 Licensor's Standard specifications TEMA 22.5 API660‘Type 410 when welding is involved. TUPRAS Pee eee Section: TGPS-E2 DIESEL / KEROSENE HYDROPROCESSII«:: Page. :25/28 AND CCR REFORMER PROJECT ete a eco Revision :0 TABLE 1 MATERIALS SELECTION REFERENCES - CARBON AND FERRITIC ALL STEELS tof4 \crade Grade JA orB [23 or 27\(1) for 4(1) |WCB Grade 1 or 11 |Grade 268 iB (0.25% |B or C Imax. C) 2. Carbon|A S15 [i501 Atos fseo2si|- — | — | — | — | — | — : IGrade |151 Grade killed Silicon |55 —_|Grade |AorB |Grade Steel 264 or 123 or 27| 28A | 3. C- _|A204 |1501- jA335 A208 [305918 |A2I7 |ie04 A182 |1503 412Mo |Grade \240 — |Grade \Grade Grade |240 Grade |240 Steel [A P1 Ir wea Fi |Grade iB 4. 14/4 |Ade7 | — A335 |s604 Aisa | —- lAzi7 [i504 |Ate2 | — Cr-t2_|Grade Icrade |Grade |Grade |Grade [240 [Grade Mo |C P11 je2t ft \wcé Fat | Steel ls. 244 |Ase7 | -—— [A335 [3604 [A199 | 7626 A2I7 |1504- [A162 |1640- Crt |Grade IGrade |Grade |Grade | Grade |Grade |622 [Grade |622 Mo |D p22 fo22 22 A |wes F22, Steel_|. 6. 3Cr-t [A367 | — Ass | — Ai99 | i508. | — 1504 | — |i503- Mo — |Grade IGrade IGrade | 623 623 Grade |623 Steel_|E P2 tr24 F241 I7. 5.Cr- [A357 |i501- |Asss [3604 [A199 | 1628 |A2I7 [1504 A182 |1503- 112 Mo 625 |Grade |Grade |Grade | Grade |Grade 625 [Grade |626 Steel IPs ozs ts. B_ {cs F5a 8. Scr. [Ase | — |A335 lAzis [asoe- | — | —- [—- [| — 412 Mo |with Ti lGrade Grade | 625 Steel PSc [Se | with Ti with Is. 12Cr- [A240 |ts01- | — | — |A2i3 | — Assi 1504 [A162 |1503- Steet [Type [713 Type IGrade 713 [Grade |713 (2) |4050r |(Type [405 or ICA 15 Fe l410__[405) l4t0 Notes :(1) Electric resistance welded. (2) Type 405 stainless steel shall be used in preference toTOPRAS izMiT REFINERY DIESEL / KEROSENE HYDROPROCESSING AND CCR REFORMER PROJECT Section Page Date Revision 2 TGPS-E2 £2628 + June, 2001 20 TABLE 1 MATERIALS SELECTION REFERENCES - AUSTENITIC STAINELS STEELS 2of 4 Tubes Foraings } Alloy ‘ASTM Bs | astm. BS H. Type 3605 JA2130r| — |A351 |1504- [A182 |1503- 304: - IGrade A 249 (1) IGrade 801 [Grade [801 Stainles lg01 [Grade Icrs F304 s [TP 304 2. Type [A240 |1501- JA312 [3605 A213 or] —~ _ [A182 _ 304. [Type |801 Grade |Grade JA 249 (1) IGrade Stainles|304L |Grade |TP jgoiL Grade IG304L s Ic i304 [TP 304. 3. Type |A240 |i501- JA3i2 3605 |AZIS0r| — [A351 |1504- [A182 |1503- 316 |Type |@45 [Grade IGrade [A249 (1) IGrade 801 Grade e45 Staintes {316 [Grade {TP [845 IcFem |Grade |F316 |Grade s B iB B 4. Type = |ast2 [3605 [A2iSorf — | — | — A182 346L IGrade |Grade |A 249 (1)} IGrade Stainles Ie [e45L Grade F316L s I316L ITP 3t6L. iS. Type 1501- [A312 [3605 [A213 or [1508- = [1504- JA 182 |1503- 321 l821 [Grade |Grade JA 249 (1)|821 1821 Grade |a21 Stainles [321 |Grade [TP 321\822Ti |Grade [Grade |Grade F321 |Grade s Ti ire 321 [Ti [ti [Ti Is. Type [A240 |is01- |ASi2 [3605 [A213 or |i508- [A3e1 [1504 [A182 |1503- 347 {Type j821 [Grade |Grade |A249(1)|821 Grade 21 [Grade 821 Stainles |347 [Grade _|TP 347|822 No [347 |Grade |CF8C |Grade [F347 |Grade s Nb Nb Nb Nb Notes: (1) ASTM A-249 Covers welded tubes.TOPRAS iz rT REFINERY ‘Section TGPS-E2 DIESEL / KEROSENE HYDROPROCESSING Page: 27728 _ AND CCR REFORMER PROJECT Date: June, 2001 Revision :0 TABLE 4 MATERIALS SELECTION REFERENCES - NOTCH TOUGH STEELS . a. Pipe Tubes Castings Alloy Astm| “BS | ASTM} BS |ASTM| BS |ASTM| BS |ASTM| BS 1. Carbon- |A300 |1510- [A333 [3603 [A334 -- A352 ]1504- |A350 |1510- & Steel \Class 1]LT50 Grade |27LTSO |Grade |Grade |161 Grade |LTSO a 4 1 ILCB Grade |LP1 la limpact { Tested | 2. CaraMof — | — | — | — | — | — [A382 [1504 7 = Steel | | IGrade |240 | | LC1 impact e Tested 3. 34/2Ni |A300 |1510- |A333 [3603 [A334 =- A352 |1504- |A350 | 1510- Steel \Class 3ILT100 |Grade |S503LT |Grade IGrade |503 Grade LT100 | 3 Hoo 3 C3 impact |LF3 | (1503- Tested 503) 4. 9 Ni A 300 — (A333 - |A334 7 oad Steel \Class 4} |Grade Grade 8 8 Is. Type [A240 [te01- |A3i2 [3605 |a2is | — |A3e1 [1604- A 12 |1503- e 304 Type |801 |Grade |Grade |Grade Grade [821 |Grade |@01 Stainles |304 Grade |TP 304/801 ITP 304 \CF8C |Grade |F304 s iB INb-TOPRAS i IZMiT REFINERY Section “TGPS-2 DIESEL / KEROSENE HYDROPROCESSING Page :2828 AND CCR REFORMER PROJECT Sa ce Revision, :0 TABLE 1 MATERIALS SELECTION REFERENCES - NON-FERROUS METALS 4of4 “Castings Forgings Alloy astm | BS | astm | BS i. Arsenical = — [B111 [1306 Pan} — = = Copper l2 [Analysis 1174 |2. Admiralty = — (B11 frasacz yy — = = = | Metal (in ype j1tt 1} bited) 3. Aluminium | |i544CZ e111 _[146acz | — = = = Brass (in- 110 410 hibited) | I L | 4. Naval Brass |B 171 /1547Cz | = Po IB 124 112, lAlloy 3 IS. Aluminium |B 171 |1541CA | = 8148 | 4400- |B 124 = Bronze {Alloy _|106 |Grade 9B] AB1-C |Alloy 114 6. 70-30 B71 [1s41CN |B 111 fiaeacn | — = = = Copper Ho7 107 (1) Nickel \7. Monel Bia7 — |B 163Ni [3074NA | — [3071 NAT = : [Cu Alloy [13 i Notes (1) — Yorcoron manufactured by Yorkshire Imperial Metals Limited and Kunifer 30 . A manufactured by Imperial Chemical Industries Limited acceptable 70-30 Cupro nickel tube materials.