PETRONAS TECHNICAL STANDARDS

Heat Exchanger – Printed Circuit (PCHE) Type

PTS 12.21.05
September 2016

© 2016 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at ptshelpdesk@petronas.com.my
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 6
1.1 SCOPE ............................................................................................................................. 6
1.2 GLOSSARY OF TERMS..................................................................................................... 6
1.3 SUMMARY OF CHANGES ............................................................................................... 6
2.0 BASIC DESIGN REQUIREMENTS .............................................................................. 7
2.1 THERMAL DESIGN .......................................................................................................... 7
2.2 DESIGN MARGINS .......................................................................................................... 7
2.3 PRESSURE DROP............................................................................................................. 7
2.4 THERMOSYPHON REBOILER .......................................................................................... 7
2.5 TWO PHASE FLOW INLET DISTRIBUTOR........................................................................ 8
2.6 STRAINER ....................................................................................................................... 8
2.7 FOULING ......................................................................................................................... 8
3.0 MECHANICAL DESIGN ............................................................................................ 9
3.1 CODES AND STANDARDS ............................................................................................... 9
3.2 DESIGN CONDITIONS ..................................................................................................... 9
3.3 DESIGN CALCULATIONS ............................................................................................... 10
3.4 DESIGN ANALYSIS ........................................................................................................ 10
3.5 DESIGN LOADS CASES .................................................................................................. 11
3.6 HEADERS ...................................................................................................................... 11
3.7 NOZZLES, CONNECTIONS AND OPENINGS .................................................................. 11
3.8 NOZZLE LOADS ............................................................................................................. 12
3.9 SUPPORTS .................................................................................................................... 12
3.10 EARTHING..................................................................................................................... 12
3.11 INSULATION ................................................................................................................. 13
3.12 BLOCK-TO-BLOCK CONNECTIONS ................................................................................ 13
3.13 SHEATHING .................................................................................................................. 13
3.14 VENTING OF BLOCK-TO-BLOCK JOINTS ....................................................................... 13
3.15 VENTS AND DRAINS ..................................................................................................... 13
3.16 THREADED CONNECTIONS........................................................................................... 13
3.17 CLEANING CONNECTIONS............................................................................................ 13
3.18 INSTRUMENT CONNECTIONS ...................................................................................... 14
3.19 RELIEF SCENARIOS ....................................................................................................... 14
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3.20 SAFETY/RELIEF VALVE NOZZLE CONNECTIONS ........................................................... 14

3.21 LIFTING LUGS ............................................................................................................... 14
3.22 DIMENSION AND TOLERANCES ................................................................................... 14
3.23 DATA AND DOCUMENTS FURNISHED BY OWNER ...................................................... 14
3.24 DATA AND DOCUMENTS FURNISHED BY MANUFACTURER ....................................... 15
4.0 MATERIALS OF CONSTRUCTION ........................................................................... 16
4.1 GENERAL ...................................................................................................................... 16
4.2 PRESSURE PARTS SPECIFICATIONS .............................................................................. 16
4.3 NON-PRESSURE PARTS ................................................................................................ 16
5.0 FABRICATION ...................................................................................................... 17
5.1 DIFFUSION BONDING................................................................................................... 17
5.2 WELDING ...................................................................................................................... 17
6.0 INSPECTION AND TESTING ................................................................................... 18
6.1 GENERAL ...................................................................................................................... 18
6.2 NON-DESTRUCTIVE TESTING ....................................................................................... 18
6.3 LEAK TESTING ............................................................................................................... 19
6.4 PRESSURE TESTING ...................................................................................................... 19
7.0 PREPARATION FOR SHIPMENT ............................................................................. 20
7.1 CLEANING AND PACKING ............................................................................................ 20
7.2 MARKING ..................................................................................................................... 20
7.3 PROTECTION OF OPENINGS......................................................................................... 20
7.4 SPARE AND REPLACEMENT PARTS .............................................................................. 20
7.5 WEIGHING .................................................................................................................... 20
7.6 NAMEPLATE ................................................................................................................. 20
8.0 BIBLIOGRAPHY .................................................................................................... 22
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1.0 INTRODUCTION

This PTS provides design, fabrication, inspection and testing requirements for printed circuit
heat exchangers (PCHEs).The PCHE may be installed in the hydrocarbon and petro-chemical
processing, refining, refrigeration and oxygen services.

1.1 SCOPE

1.1.1 The detailed scope of PCHEs shall be as per the data/ requisition sheets for supply of the
equipment in compliance with this PTS including relevant codes & standards. Manufacturer
shall include all special features necessary for reliable and safe operation as well as
safeguarding and control of the equipment considering required operating conditions e.g.
start up, shutdown, any fluctuations of operating parameters as indicated in the data sheet.

1.1.2 The statutory requirements and registration, if any, at the location of installation of the
exchanger shall be complied with by Contractor / Manufacturer.

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definitions

No Terms Definition

1 Printed Circuit Heat Exchanger Printed circuit heat exchangers is a compact

diffusion bonded heat exchanger and generally
used for clean services where a small foot print
and lighter weight is required.
Table 1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 PCHE Printed Circuit Heat Exchanger

Table 2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 12.21.05 (September 2016) replaces PTS 12.21.05 (May 2013).
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2.0 BASIC DESIGN REQUIREMENTS

The PCHE shall be selected for clean hydrocarbon services with proven operational track
records. The Contractor/ Manufacturer design shall include all process condition i.e. start-up,
shut-down, power failure or interruption of the process flow as indicated in the Owner’s data
sheet and assure the adequacy/ integrity of the proposed PCHE. The proven records of supply
of the PCHE for similar service condition including its operational records, feasibility of
inspection and maintenance shall be furnished by Contractor/Manufacturer for Owner’s
review/ evaluation.

2.1 THERMAL DESIGN

2.1.1 The PCHEs are proprietary in design and the Manufacturer shall be entirely responsible for its
design, mechanical integrity and performance and shall furnish the desired information and
document in compliance with requirement of this PTS and as per purchase order.

2.1.2 The Manufacturer shall carry out the thermal design of the PCHEs and provide detailed data
sheets, basis of design, input and output sheets, design and performance simulation of PCHEs
for verification of the thermal and hydraulic design by Owner.

2.2 DESIGN MARGINS

2.2.1 The design margin shall be at least ten percent (10 %) on the designed heat transfer surface
area calculated to satisfy the specified thermal duty requirements using the clean overall heat
transfer coefficient, unless any specified fouling margin already accounts for more than 10 %
of the total heat transfer resistance.

2.3 PRESSURE DROP

2.3.1 The Manufacturer shall furnish the total pressure drop in clean and fouling condition across
the exchanger including strainer and intermediate piping and the designed pressure drop shall
be limited to 90% of the allowable pressure drop. The losses occurring in nozzles, headers,
fittings, distribution and thermal sections shall be considered. The pressure drop in two phase
streams shall include frictional, static head and acceleration including momentum recovery
components.

2.4 THERMOSYPHON REBOILER

2.4.1 If the PCHE is to be used as thermosyphon reboiler, the Manufacturer shall verify the fluid
dynamics for the applicable system/ flow loops with respect to data/ requisition sheet e.g.
configuration of piping, equivalent piping length including pressure reducing valve, if any, in
reboiler inlet piping etc. In case of any conflict the Manufacturer shall inform the Owner and
optimize the design mutually.

2.4.2 The effective mean temperature difference shall consider the effect of boiling point elevation
due to the liquid static head for vaporizing streams provided by thermosyphon action,
including submerged plate-fin heat exchangers in a vessel.

NOTE: The outlet piping from reboiler to the column shall be routed vertically with only one 90° elbow and one horizontal part.
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2.5 TWO PHASE FLOW INLET DISTRIBUTOR

2.5.1 To ensure effective distribution of two-phase flow the liquid and vapour streams to be
introduced via separate flow paths into the PCHE by introducing a separator vessel at the inlet
in case of two phase flow.

2.5.2 The design of the separator vessel shall be included in the scope of the Manufacturer with a
guarantee of the performance of the distribution system at 50 % turndown from the normal
flow rates for all operating cases unless a higher turndown requirement has been specified in
purchase order.

2.5.3 The Manufacturer shall furnish the final design including layout of the separator vessel and
the liquid static head to be used for the design for Owner’s review and approval.

2.5.4 The distributor shall be designed to cater not more than 10% of misdistribution of either fluid
phase between the channels of fin exchanger over the full range of turndown.

2.6 STRAINER

2.6.1 A permanent strainer during operation as well as temporary strainer during commissioning is
required considering particulate size in process stream used. The Manufacturer shall specify
the strainer requirement for each stream during commissioning and for permanent
installation. The permanent strainer should be of a maximum size of 300 µm (48 Tyler mesh).

2.6.2 Manufacturer is to recommend the type of readily serviceable strainer e.g. Y-type, wedge
wire, duplex strainer etc. depending on fluid condition if cleaning in short interval is
anticipated. The scope of supply of the strainer shall be as per Owner’s data/ requisition sheet.

2.6.3 The pressure drop across the strainer shall be limited to 0.1 bar to 0.5 bar. The strainer
element shall be designed to sustain a minimum design pressure of 5 bar (gauge) or ten
percent (10%) of designed pressure, whichever is higher, in order to avoid collapse. The
strainer element shall be able to withstand a reverse flow condition.

2.6.4 A pressure differential measuring device shall be installed across the strainer.

2.7 FOULING

2.7.1 Due to the small flow channels, fouling process streams shall be avoided.

2.7.2 The Manufacturer shall state on the PCHE data sheet the maximum size of particles that can
freely pass through the PCHE.

2.7.3 The requirement to install pressure differential measuring device across the PCHE shall be as
stated in the equipment datasheet.
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3.0 MECHANICAL DESIGN

3.1 CODES AND STANDARDS

3.1.1 The mechanical design of PCHE shall be in accordance with ASME Section VIII Division 1
Appendix 13 or ASME Sec VIII Div.2, including PTS 12.20.01 and other relevant codes &
standards. If other design codes are used, it shall be subject to approval by Owner. The
allowable material design stress shall be selected from ASME Section II based on highest
design temperature considering all operating scenario. Contractor/Manufacturer shall furnish
the basis of allowable stress in their design calculation for Owners review.

3.2 DESIGN CONDITIONS

3.2.1 The mechanical design shall be based on specified operating cases & design conditions,
considering most stringent case so that all design conditions are met with. Structural integrity
shall be verified in the design in accordance with applicable PTS, codes and standards.

3.2.2 The design pressure on the low pressure side shall be greater of either the initial design
pressure on the low pressure side or 10/13 of the design pressure on the high pressure side,
(refer to PTS 16.50.01 for limitations). However, if it is economical to maintain the initial
design pressure on the low-pressure side by installing a relief device, this may be considered.
The size of the relief device shall be determined in accordance with PTS 16.53.01.

3.2.3 The Owner shall specify the design pressure and temperature of the header and nozzle for
each stream through the heat exchanger (refer to PTS 16.50.01). The possibility of exposure
to system pressure waves, e.g. water hammer, shall be taken into account.

3.2.4 The temperature profiles and its effect through the PCHE shall be taken into account in the
design since it has a significant effect on the "mean metal temperature" as well as on the
stresses within exchanger.

3.2.5 Manufacturer shall consider additional analysis based on the operation of the equipment for
any pressure or thermal cyclic loading including start-up/ shutdown, other cycles including
blow down operations over life, etc.
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3.3 DESIGN CALCULATIONS

3.3.1 The mechanical design of all pressure and stressed parts shall be furnished for Owner’s review
but not limited to headers, nozzle compensations, nozzles local loads, manifold(s), PCHE block,
supports, lifting lugs and adequacy at hydrostatic test pressure.

3.3.2 Where it is important to minimize thermal stresses, the layer arrangements should be
optimized to give the lowest possible temperature differentials. The Manufacturer shall
furnish design calculation to ensure adequacy of the equipment for such loads including
additional analysis using Finite Element Analysis (FEA) to show that the PCHE will be able to
sustain all the loading including cycling conditions during its service life.

3.4 DESIGN ANALYSIS

3.4.1 For the design of headers, the pressure vessel code rules associated with the design of
conventional pressure vessels can be used to assess the levels of stress resulting from internal
pressure, thermal stresses (e.g. resulting from temperature gradient over the core and/or
temperature differences between streams) and external forces. The assessment shall include
the header to plate stack joints and the area around the nozzle.

3.4.2 For the block, design calculations shall consider the separating forces between plates caused
by internal pressure creating tensile stresses in the regions of metal bonding, particularly
where the metal ridges between channels are bonded to the adjacent plate. Design
calculations to take into account stresses in the other two planes. The width of the ridges can
thus be chosen to provide sufficient metal to maintain acceptable stress levels.

3.4.3 The Manufacturer shall furnish design calculation and its basis considered for assessing the
stresses in the PCHE block component to Owner. The following joint and bond factors shall be
considered in the design calculations:

Joint Type Factor

i. Diffusion bonds 0.7

ii. Non-radiographed welds 0.7

iii. Header-to-block welds, spot RT/UT 0.85

iv. Fully inspected welds RT/UT 1.00

3.4.4 The resultant membrane and bending stresses are compared with those permitted by the
pressure vessel code for the particular material grade under consideration.

3.4.5 The calculation method shall be reviewed by Owner and must demonstrate that the effects of
all design requirements including external loads have been taken into consideration. Finite
element analysis method is acceptable for stress calculation.
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3.5 DESIGN LOADS CASES

3.5.1 The mechanical design of the PCHE shall take into account the following loads acting
individually or in combination:

i. pressure loads

ii. nozzle and support loads including during start-up, shut-down and emergency

iii. depressurising conditions

iv. seismic, wind or other motion loads

v. snow, impact and blast loads

vi. loads associated with installation at site

The Manufacturer/ Contractor shall indicate to the Owner for the load cases including
pressure/ temperature cyclic loading and other loading considered in their design for any
particular PCHE for its design life.

3.5.2 The Manufacturer/Contractor shall perform fatigue analysis in accordance with the provisions
of ASME Boiler and Pressure Vessel Code VIII Div. 2 Part 5 based on agreed number of fatigue
cycles with Owner for its design life. The probable cyclic loading due to start-up, shutdown,
thermal cycles, blow-down, flushing etc. with agreed factor safety shall be considered for its
design life.

3.5.3 For thermal cycle, an inlet fluid temperature differential of 160°C maximum for steady state
service and with proper stable control of fluid flows is acceptable for at least 1,000 full start-
up/shut-down cycles. Modest load changes (± 10% in flow rate and ± 10°C in inlet
temperature) have a negligible fatigue effect.

3.6 HEADERS

3.6.1 The minimum required thickness for fluid headers inclusive of any corrosion allowance shall
be 6 mm for header diameter < 1200 mm and for higher diameter it shall be 8 mm.

3.6.2 Headers or tees should be of sufficient thickness to provide the required reinforcement for
openings and nozzle loads. Reinforcement pads or rings shall be leak tested via a ¼” NPT
tapped tell-tale hole, which shall be filled with heavy/ hard grease prior to shipment.

3.6.3 Headers shall contain no longitudinal welds other than the header-to-block joints.

3.7 NOZZLES, CONNECTIONS AND OPENINGS

3.7.1 The nozzles, connections and openings shall satisfy the requirements in accordance with
ASME Code and PTS 12.20.01.

3.7.2 If the nozzle diameter approaches that of the header, set-on nozzles may be considered.
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3.7.3 Nozzles which protrude beyond the inside contour of the header shall be self-venting or
draining by notching at their intersection with the high or low point of the cylinder. If separate
vent and drain connections are used, they shall be flush with the inside contour of the header.

3.7.4 Seam welded nozzles shall be subjected to 100 % RT.

3.7.5 The minimum nozzle size shall be DN 50, except for the venting of the sheathing or venting of
the block-to-block joints.

3.8 NOZZLE LOADS

3.8.1 The calculation method employed for stresses due to external loads on nozzles shall depend
upon the relative nozzle and header sizes, as follows:

i. Where the nozzle internal diameter is less than one-half the header internal
diameter, stresses shall be calculated according to WRC 107 and WRC 297,
employing the ASME VIII Div. 1 design stress.
ii. Where the nozzle internal diameter equals or exceeds one-half of the internal
diameter of the header, the stresses shall be calculated by a finite element
calculation.

3.8.2 Manufacturer shall indicate maximum forces and moments that can be sustained by nozzles.
These maximum values shall be subjected to Owner’s review and approval.

3.9 SUPPORTS

3.9.1 Supports brackets or saddles shall be designed to withstand applicable loads e.g. seismic,
wind, blast, transportation including loads generated on the supports due to dead weight and
external applied forces and moments.

3.9.2 Supports shall be provided with slotted holes to accommodate any change in block
dimensions or block position under operating or upset conditions and during start up and shut
down.

3.9.3 Saddles height shall provide clearance of at least 50 mm from the projection of bottom
nozzles, including the drain nozzle with blind flange, to prevent damage to flange facings
during transport, storage and maintenance.

3.10 EARTHING

3.10.1 Two earthing bosses shall be provided at the supports brackets or saddles.
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3.11 INSULATION

3.11.1 The Owner shall specify the thickness of insulation to be applied to the PCHE external surfaces,
the Manufacturer shall provide adequate insulation clips as required for attachment of the
insulation, and nozzle projection shall be increased accordingly.

3.11.2 Insulation requirement shall be in accordance to PTS 15.13.01.

3.12 BLOCK-TO-BLOCK CONNECTIONS

3.12.1 The diffusion-bonded blocks shall be welded together endplate-to-endplate separated by a

picture frame, used as backing strip to form an all welded heat exchanger core. The use of
these backing strips are allowed since these are not pressure retaining nor in contact with the
process fluids.

3.13 SHEATHING

3.13.1 The exposed areas of hot austenitic stainless steel shall be sheathed with at least 1.5 mm thick
duplex stainless steel sheet, or other material as approved by Owner, where protection
against the external saliferous atmosphere is required.

3.13.2 The sheathing shall be welded and the welds shall be examined using the PT method. A DN 15
vent pipe incorporating a spring loaded pressure relief device with an opening pressure of
0.3 bar g shall be provided as sheath-vent. Alternatively, the vent nozzle could be combined
with the vent nozzle for the venting the block-to-block cavities.

3.14 VENTING OF BLOCK-TO-BLOCK JOINTS

3.14.1 All the cavities enclosed by the block-to-block joints shall be connected to a single vent to
ascertain no pressure between the blocks. The vent nozzle shall be a DN 15 vent pipe
incorporating a spring-loaded pressure relief device with an opening pressure of 0.3 bar g.

3.15 VENTS AND DRAINS

3.15.1 The vent and drain sizes of at least DN 40 x DN 25 (reducer) shall be provided for all high and
low points of a PCHE, if not otherwise vented or drained by specific vent and drain nozzles.

3.15.2 All vent and drain connections shall be flanged and provided with a blind flange unless
otherwise specified.

3.16 THREADED CONNECTIONS

3.16.1 Threaded connections shall not be used.

3.17 CLEANING CONNECTIONS

3.17.1 Flanged nozzle connections of at least DN 80 size shall be provided if in-service cleaning with
hot water, steam, solvents or other chemical methods is specified.

3.17.2 Nozzle connections shall be located on the connecting piping and not on exchanger nozzles.
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3.18 INSTRUMENT CONNECTIONS

3.18.1 The requirement of temperature indicator and pressure gauge shall be specified by Owner.
There shall be no temperature instrument or pressure gauge connections in printed circuit
heat exchanger nozzles, and the connections shall be made on the inlet and outlet piping.

3.19 RELIEF SCENARIOS

3.19.1 In case a relief device would be required, the relief rate shall be based on the requirements as
specified in PTS 16.53.01.

3.20 SAFETY/RELIEF VALVE NOZZLE CONNECTIONS

3.20.1 Flanges for safety/relief valve nozzles shall have a minimum rating of ASME Class 300#.

3.21 LIFTING LUGS

3.21.1 The lifting devices shall be located above the centre of gravity of the parts to which they are
welded or cast.

3.21.2 Welded plate type lugs shall be welded with full penetration employing either double welding
or by single welding with a GTAW root pass.

3.21.3 Welding procedures specifications, welding procedure qualification records, repair welding
procedures, welder qualifications, NDT procedures and ND Operators shall be approved by
Owner. Completed welds shall be examined by 100% UT.

3.21.4 The lugs hole diameter shall minimum 28 mm.

3.21.5 The lugs shall be designed for a static force of at least twice the weight of the unit(s).

3.22 DIMENSION AND TOLERANCES

3.22.1 In addition to tolerances as required by the Code, tolerances for all PCHE shall be in
accordance with PTS 12.20.01.

3.23 DATA AND DOCUMENTS FURNISHED BY OWNER

3.23.1 The Owner shall specify the design pressure and temperature for each stream through the
heat exchanger separately (refer to PTS 16.50.01). The possibility of exposure to system
pressure waves, similar to e.g. water hammer, shall be taken into account.

3.23.2 The Owner shall specify maximum design temperature and minimum metal temperature for
each individual stream, heat transfer duty, allowable pressure drop, flow rates, compositions
and physical properties of the fluids passing through the heat exchanger including various
design & operating cases and fluid conditions for designing of exchanger by the Manufacturer.

3.23.3 The Owner shall specify which streams would be subject to cyclic or frequently repeated
temperature fluctuations. The ability of a PCHE to withstand pressure cycling, at a constant
operating temperature, can be proven by accelerated cycle testing of a representative
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exchanger, e.g. a full cross section with full-size headers or by finite element calculations. The
design life shall be determined in accordance with ASME VIII Division 2 Part 5.

3.24 DATA AND DOCUMENTS FURNISHED BY MANUFACTURER

3.24.1 The Manufacturer shall complete all information and submit the documentation as required
by Equipment design requisition sheet, this PTS, and Purchase order requirement.

3.24.2 The Manufacturer shall provide operating, inspection and maintenance manual and
precautions be taken during operation. The Manufacturer shall indicate thermal cycling
behaviour of a PCHE at required increment of temperature. The Manufacturer shall indicate
the limitations, if any, in the operation manual for Start-up and shutdown scenario e.g. in and
out phase transients among multiple stream; Pressure, temperature and flow transient
including the maximum and allowable combination of these values.

3.24.3 In addition to the design operating condition(s), the Manufacturer shall investigate on all
operating conditions that could impose significant stresses on the PCHE. This shall consider
any alternative operating cases, start-up and shutdown, turndown operation, upset cases
(with particular attention to cases where a stream’s flowing condition might change or cease
abruptly), and the process control philosophy being applied to the PCHE. If a number of design
cases and conditions are specified, the Manufacturer shall select the most stringent case so
that all design cases and conditions are met.

3.24.4 The Manufacturer shall notify the Owner if insufficient information is available to design the
plate-fin heat exchanger. The Manufacturer shall provide completed data/requisition sheets
and outline drawings, thermal and hydraulic performance, compliance of various operating
conditions scenarios, study report showing optimization of exchanger geometry considering
list of deviation/ limitation if any for Owner’s review.

3.24.5 The Manufacturer shall supply the required documents as stated in purchase order e.g. data
sheets, detailed dimensional drawings, design calculations, Piping isometric, QA/QC
documents, painting and insulation procedures, Inspection and maintenance procedure,
Operation and maintenance manual for Owner’s review.
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4.0 MATERIALS OF CONSTRUCTION

4.1 GENERAL

4.1.1 Material used shall be compatible to the process stream and external environment to avoid
any corrosion and erosion issues.

4.1.2 Stainless steel materials, other than the diffusion-bonded core, shall be delivered in the
"white" pickled and passivated condition.

4.1.3 Cast iron parts shall not be used.

4.1.4 Materials that are supplied in accordance to NACE MR0175 or NACE MR0103 shall be solution
annealed if hardness limits are exceeded after forming.

4.1.5 The materials of construction shall be supplied with chemical and mechanical properties. The
material shall be inspected in accordance with ISO 10474 type 3.1. All materials and welding
consumables shall be traceable to their test certificates.

4.1.6 The Manufacturer shall furnish material traceability records and positive material
identification (PMI). Wherever it is not practical to transfer markings from the parent material
to component parts, an alternative quality assurance procedure to maintain traceability shall
be developed for Owner’s review. All attachments such as supports, lifting points or
reinforcements shall be of a similar material specification as the material to which they are
attached.

4.1.7 Corrosion allowance shall be zero unless specifically requested by the Owner. Corrosion
allowance shall be indicated in the project datasheet. Corrosion allowance may be nil for high
alloy steel unless otherwise stated in project specification.

4.1.8 The stainless steel material shall be tested for intergranular corrosion test as per ASTM
A262Practice E or ISO 3651-2, Method A.

4.1.9 The use of dissimilar materials shall not be used to avoid galvanic corrosion.

4.2 PRESSURE PARTS SPECIFICATIONS

4.2.1 Materials of construction for vessel parts subject to internal or external pressure shall comply
with the selected pressure vessel code.

4.2.2 The thickness of metal plate of PCHE block shall be between 1.5 mm to 3 mm.

4.2.3 The flow channels are typically semi-circular in shape with 2 mm wide and 1 mm deep,
separated by ridges of 0.3 mm to 1.0 mm wide.

4.3 NON-PRESSURE PARTS

4.3.1 All attachments welded directly on the equipment shall be of similar material to which they
are attached.
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5.0 FABRICATION

5.1 DIFFUSION BONDING

5.1.1 Diffusion bonding procedures shall be qualified by transverse tensile testing of a diffusion-
bonded stack of un-etched plates. The transverse tensile test specimen shall contain not less
than 10 diffusion-bonded joints.

5.1.2 The acceptance criteria for procedure test of diffusion bonded joints shall exceed the value of
parent metal specification for Ultimate tensile strength, yield strength and elongation.

5.1.3 Where full parent material properties are not achievable for diffusion bonded joints in a
particular material, the microstructure/ metallographic samples evaluation shall be done to
show the crystal growth through the bond plane and the Manufacturer shall obtain written
agreement from the Owner and the Certifying Authority for acceptable joint efficiency to
apply to the diffusion bonded joints for mechanical design purposes.

5.2 WELDING

5.2.1 Header tanks, nozzles and supports shall be attached by welding to the PCHE blocks.

5.2.2 The requirement for material test certificates, welding procedure specification, welding
procedure qualifications records, welder qualification (including weld details) shall be in
accordance with relevant pressure vessel code. The Owner has the right to witness the
fabrication and inspection at the Manufacturer’s premises as per agreed Inspection and Test
Plan.

5.2.3 Structural welding shall be in accordance with AWS D1.1.

5.2.4 The use of overlapping and close welds is acceptable for PCHE. The joining of multiple welds
is replicated by using a single groove with multiple passes using identical welding parameters
and materials. Partially completed weld might need to be left overnight to cool down to room
temperature for inspection and NDT before completing the weld.
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6.0 INSPECTION AND TESTING

6.1 GENERAL

6.1.1 Materials, welding inspection, NDT and other stages of fabrication shall be subjected to
inspection by any of the following parties:

i. Owners’ Nominated Representative/ authority

ii. Certified Inspection Authority

6.1.2 Prior to the cutting of sheet, plate or other material, the Owner may inspect the materials and
material certification to ensure that it meets the requirements of the requisition. All pressure
retaining parts shall be subjected to 100 % PMI as per PTS 15.02.01.

6.1.3 The Manufacturer shall inspect the plates following etching to confirm that the etched
channel geometry is consistent with the thermal and mechanical design calculations.

6.1.4 The Manufacturer shall ensure that all plates are subjected to full visual inspection prior to
stacking. Plates shall be clean of etching agent and mask, free of gross etching defects, within
dimensional tolerances and correctly oriented.

6.1.5 Stacked PCHE shall be assembled and trial-fit in the Manufacturer’s workshop to verify that
all intermediate nozzles will bolt together.

6.2 NON-DESTRUCTIVE TESTING

6.2.1 The non-destructive testing (NDT) shall be carried out in accordance with relevant pressure
vessel code. Hardness testing and NDT shall also observe the requirement of PTS 15.12.01 and
PTS 12.20.01.

6.2.2 Test procedures shall be submitted to the Certifying Authority for approval prior to the
commencement of fabrication. The Owner reserves the right to review the applicable NDT
documentation at the Manufacturer’s premises.

6.2.3 UT shall be performed on header apertures for set-on nozzles to verify the absence of plate
laminations.

6.2.4 The Manufacturer shall perform maximum practical amount of RT based on accessibility of
joints for inspection.

6.2.5 The use of UT in austenitic stainless steel is not feasible as an alternative to RT because it is
not possible to obtain a meaningful signal through welded joints on PCHE.

6.2.6 PT shall be applied to the followings as a minimum:

i. All GTAW root runs and adjacent diffusion-bonded material

ii. The capping run of all weld runs and adjacent diffusion-bonded material.
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6.3 LEAK TESTING

6.3.1 A helium leak test shall be carried out on the completed equipment prior to pressure testing.

6.3.2 No detectable leak shall be permitted in the completed equipment between:

i. The various fluid circuits in the exchanger

ii. Any of the fluid circuits in the exchanger and the surroundings.

6.3.3 Unless otherwise agreed between the Owner and Manufacturer, the following allowable
leakage rate may be acceptable:

i. for an external leakage: 1x10–4 kPa m3/s (at a pressure difference of 100 kPa)

ii. for an internal leakage: 1x10–3 kPa m3/s (at a pressure difference equal to the
design pressure) or 1x10–4 kPa m3/s (at a pressure difference of 100 kPa).

6.4 PRESSURE TESTING

6.4.1 Pressure testing shall be carried out after the leak testing.

6.4.2 All PCHE shall be tested by a hydrostatic pressure test in accordance with the relevant
pressure vessel code.

6.4.3 Pneumatic testing shall be applied for PCHE in a cryogenic service, unless otherwise agreed by
Owner.

6.4.4 Each individual process stream shall be tested to the pressure stipulated by the design code.
The test shall be carried out with atmospheric pressure in the adjacent stream passages.

6.4.5 Water used for hydrostatic testing shall contain no more than 30 mg/kg chlorides.

6.4.6 Stacked PCHE shall be pressure tested in the stacked position.

6.4.7 Service bolts and gaskets furnished by the Manufacturer shall not be used in testing or
shipping of the PCHE.

6.4.8 Immediately following the hydrostatic-test, the PCHE shall be thoroughly cleaned and dried
prior to final inspection, preservation and shipment.
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7.0 PREPARATION FOR SHIPMENT

7.1 CLEANING AND PACKING

7.1.1 Exchangers shall be thoroughly cleaned both internally and externally of all foreign material,
such as grinding dust, weld flux and weld spatter. Water or other liquids used for cleaning or
hydrostatic testing shall be drained and the equipment thoroughly dried.

7.1.2 The PCHE shall be dried to a dew point less than minus (-) 25 °C, in case it is to operate in
cryogenic services.

7.1.3 The PCHE shall be properly packed and protected from damage during shipment by road, rail
and containerised sea transport.

7.1.4 All exposed parts, such as machined surfaces etc. shall be protected with rust and damages in
accordance with PTS 15.20.16.

7.2 MARKING

7.2.1 Each crate or package shall be clearly identified in accordance with the Owner’s specification.
As a minimum the package shall be marked with Purchase Order number, item number,
shipping mass and delivery address.

7.3 PROTECTION OF OPENINGS

7.3.1 The PCHE shall be shipped with nozzles hermetically sealed and all pressure chambers
pressurised with dry, oil-free nitrogen or air to between 0.2 bar g and 1.2 barg if these units
will be operating in cryogenic service in order to avoid ingress of any moisture or dust during
transport. In addition all connections must carry warning labels stating that the heat
exchanger is under pressure.

7.3.2 Flanged process connections shall be protected and fitted with steel cover plates, bolted in
place with at least four bolts then sealed with heavy-duty tape.

7.4 SPARE AND REPLACEMENT PARTS

7.4.1 Spares and replacement parts shall be in accordance with PTS 12.00.04.

7.5 WEIGHING

7.5.1 All PCHE shall be weighed on completion. The Manufacturer shall submit a weight certificate
and Centre of Gravity data completed with calculated and weighed data for dry, operating and
lift conditions.

7.6 NAMEPLATE

7.6.1 The PCHE shall be equipped with stainless steel name plates indicating all the information as
per PTS drawing D 12.92.024 as well as other information as required by Owner.
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7.6.2 If the PCHE is to be installed in a permanent enclosure, (e.g. a cold box), a second identical
(duplicate) nameplate shall be supplied loose by the Manufacturer, for attachment onto the
enclosure by others.

7.6.3 In the case where the PCHE contains more than two independent pressure chambers, it is
required to specify data for the several streams. Alternatively, different nameplates can be
used for each stream.
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8.0 BIBLIOGRAPHY

In this PTS, reference is made to the following other Standards/Publication. Unless specifically
designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide.
Symbols and identification system - Mechanical PTS 12.00.02
Spare Parts Management PTS 12.00.04
Pressure vessels PTS 12.20.01
Piping Classes – Oil Refineries, Chemical And Gas Plants PTS 12.31.01
Piping Classes - Exploration and Production (Offshore) PTS 12.31.02
Welding for Chemical, Oil, and Gas Industries (Amendments / PTS 15.12.01
Supplements to API RP 582)
Stainless Steel Weldments Oxidation PTS 15.12.03
Preservation of Upstream Production and Process Facilities PTS 15.20.16
Positive Materials Identification (PMI) PTS 15.02.01
Radiographic Testing PTS 15.30.01
Ultrasonic Examinations PTS 15.30.02
Design Conditions: Temperature, Pressure & Toxicity PTS 16.50.01

AMERICAN and ISO STANDARDS

Pressure-relieving and Depressurization Systems API RP 521
Issued by: American Petroleum Institute,, USA

ASME Boiler and Pressure Vessel Code – Rules for construction of ASME Section VIII
pressure vessels Div. 1 & 2
Pipe flanges and flanged fittings NPS 1/2 through NPS 24 ASME B16.5
Large diameter steel flanges NPS 26 Through NPS 60 ASME B16.47
Issued by: American Society of Mechanical Engineers,USA

Petroleum and natural gas industries—Materials for use in H2S- ISO 15156/
containing environments in oil and gas production.
NACE MR0175
Petroleum, petrochemical and natural gas industries -- Metallic
ISO 17945/
materials resistant to sulfide stress cracking in Corrosive
Petroleum Refining Environments NACE MR0103