21100-4-8480-SP-0001 - 0 - Heat Exchangers (E-101)

PROJECT : S-OIL Residue Upgrading Complex Project (RUCP)
PLANT : Residue Upgrading Complex
ENGINEERING SPECIFICATION
FOR
HEAT EXCHANGERS
ES NO. E-101
Document No. 21100-4-8480-SP-0001
DOCUMENT CLASS : Z
0 September 07, 2015 Issue for Construction B.I.MOON

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A August 12, 2015 Issue for Approval B.I.MOON

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REV. DATE DESCRIPTION MADE CHECKED APPROVED REVIEW BY
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S-OIL RUC PROJECT PAGE 2 OF 41
*ES NO. E-101 REVISION HISTORY SHEET*
REV.NO. DATE DESCRIPTION

A Aug 12, 2015 Issue for Approval
0 Sep 07, 2015 Issue for Construction
THIS SPECIFICATION IS A REVISION TO S-OIL SPECIFICATION ES No. E-101

REVISION 4 5/11/08 AND HAS BEEN UPDATED FOR SPECIFIC USE ON THE S-OIL
RESIDUE UPGRADING COMPLEX PROJECT (RUCP).
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CONTENTS
PAGE
1. GENERAL
1.1 Scope 5
1.2 Codes, Standards and Regulations 5
1.3 Related Engineering Specifications 6
1.4 Units 7
1.5 Drawings and Documents 7
2. DESIGN
2.1 Design Pressure 8
2.2 Design Temperature 8
2.3 Corrosion Allowances 9
2.4 Materials 9
2.5 Loading Conditions and Strength Calculation 10
2.6 Tolerances 11
3. DETAILED DESIGN
3.1 Shells and Channels 12
3.2 Tubes and Tube Bundles 13
3.3 Nozzles 14
3.4 Opening 16
3.5 Alloy Lining 16
3.6 Bolts, Nuts and Gaskets 17
3.7 Supports 17
3.8 Miscellaneous 18
4. FABRICATION
4.1 Plate Layout 19
4.2 Forming 19
0
4.3 Welding 20
4.4 Heat Treatment 20
4.5 Hardness 21
0 4.6 Miscellaneous 22
5. INSPECTION AND TESTS
6. NAMEPLATE, PAINTING AND MARKING
6.1 Nameplate 22
6.2 Painting 22
6.3 Marking 23
7. PACKING AND SHIPPING
7.1 General 23
0 7.2 Packing and Preparation for Shipping 23
7.3 Shipping 24
8. GUARANTEE
Appendix A Basic Design Requirements 25

Appendix B Inspection Requirements 30
Appendix C Painting Requirements 36
Appendix D Special Design Code Requirements 38
Appendix E Requirements for Specific Corrosion Environment 39
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DEFINITIONS
S-OIL : S-OIL Corporation the Owner of the PROJECT.
PURCHASER : Individual or organization that issues the purchase order and

specifications to the vendor. The purchaser may be the owner
of the plant in which the equipment is to be installed or the
owner’s appointed agent
VENDOR : The Persons and Firms with whom EQUIPMENT are

purchased
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1. GENERAL
1.1 Scope
1.1.1 This Specification covers the Minimum Requirements for the Materials, Design,
Fabrication, Inspection, Testing and Supply of Shell and Tube Heat Exchangers for the
S-OIL Residue Upgrading Complex Project (RUCP) at Onsan, Korea.
1.1.2 This Specification shall also apply to Suction Tank Heaters or Auxiliary Heat
Exchangers for Turbines, Engines, Pumps, Compressors and other mechanical
equipment wherever applicable.
For such Auxiliary Heat Exchangers, the Heat Exchangers shall be designed in
accordance with the Basic Design Requirements in Appendix A.
1.2 Codes, Standards and Regulations
1.2.1 Heat Exchangers shall be Designed, Fabricated, Inspected and Tested in accordance
with the requirements of the latest edition of the following Codes, Standards and
Regulations listed below.
(1) Applicable Regulations in Republic of Korea
(2) International Codes / Standards
- TEMA Standard Tubular Exchanger Manufacturers Association
- API Standard 660 Heat Exchangers for General Refinery Service
- ASME Section II Materials
- ASME Section VIII Div. 1 Rules for Construction of Pressure Vessels.
- ASME Section VIII Div. 2 Rules for Construction of Pressure Vessels –
Alternative Rules
- ASME Section IX Welding and Brazing Qualifications.
- ASME B16.20 Metallic Gaskets for Pipe Flanges Ring-Joint,
Spiral Wound, and Jacketed – Addenda A
- ASME B16.47 Large Diameter Steel Flanges
- ASME B16.5 Pipe Flanges and Flange Fittings
- ASME B1.1 Unified Inch Screw Thread
- ASME B16.9 Factory – Made Wrought Buttwelding Fittings
- WRC Bulletin 107 Local Stresses in Spherical and Cylindrical Shell
due to External Loadings.
- WRC Bulletin 297 Local Stresses in Spherical and Cylindrical Shell
due to External Loadings – Supplement to WRC
107.
0 - NACE MR 0103 Materials Resistant to Sulfide Stress Cracking in
Corrosive Petroleum Refining Environments
- NACE TM 0284 Evaluation of Pipeline and Pressure Vessel Steels
for Resistance to Hydrogen-Induced Cracking
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- NACE TM 0177 Laboratory Testing of Metals for Resistance to

Sulfide Stress Cracking and Stress Corrosion
Cracking in H2S Environments.
- ASCE 7-05 Minimum design loads for building and structures-
0 For wind load
- UBC-97 Uniform Building Code - For Seismic load
0 1.2.2 Unless otherwise specified in TEMA Standard Class R shall be applied.
1.2.3 VENDOR shall be responsible for ensuring that all aspects of the Materials, Design,
Fabrication and Testing shall conform to the requirements of PURCHASER’s
Requisition, Data sheets, Specifications, Specified Codes, Standards and Local
Regulations.
1.2.4 Where there are conflicts between the requirements in the applicable documents for this
Project, the order of precedence shall be as follows:
(1) Local Regulations and Laws
(2) Licensor Specifications
(3) Data sheets
(4) Engineering Specifications
(5) Codes and Standards
In such a case, VENDOR shall promptly refer the conflicts to PURCHASER in writing to
obtain PURCHASER’s resolution.
1.2.5 PURCHASER reserves the right that the most stringent requirement shall be applicable
without any added cost.
1.3 Related Engineering Specifications
1.3.1 The related Engineering Specifications to supplement this Specification are as follows.
These Specifications shall form an integral part of the requirements.
D-112 (21100-4-8430-SP-0010) “Marking for Vessels & Heat Exchangers”
D-115 (21100-4-8430-SP-0011) “Platforms & Ladders”
D-121 (21100-4-8430-SP-0002) “Pressure Vessels of Low Alloy Steel”
D-202 (21100-4-8430-SP-0008) “Inspection and Tests of Vessels and Heat
Exchangers”
H-103 (21100-4-8230-SP-0005) “Piping Materials”
L-101 (21100-4-8440-SP-0010) “Thermal Insulation Design”
O-301 (21100-4-8440-SP-0006) “Painting”
O-304 (21100-4-8440-SP-0009) “Inspection of Painting”
R-453-1 (21100-4-8610-SP-0001) “Shipping Instruction”
R-453-2 (21100-4-8610-SP-0002) “Packing Instruction”
R-503 (21100-4-8440-SP-0007) “Rust Preventive Instruction”
R-505 (21100-4-8430-SP-0004) “Vessel Standard”
IN-48 (21100-4-8440-SP-0003) “General Requirements for Welded Fabrications”
IN-49 (21100-4-8440-SP-0004) “Material Fabrication of Integrally Clad Equipment”
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IN-47 (21100-4-8440-SP-0002) “Positive Material Identification at Supplier Works”

1.3.2 S-OIL Standard R-505 (21100-4-8430-SP-0004) shall be referred to for Vessel Standard
Drawings.
1.3.3 Licensor Specifications

0
Licensor Specifications shall be applicable to each Licensed process unit in additional to

this Specification.
1.4 Units
Unless otherwise specified, SI units shall be applied as the measurement system for all
0 Drawings and Documents. However, nominal sizes of Piping components shall be in
accordance with the inch system.
1.5 Drawings and Documents
1.5.1 In the event that PURCHASER provides Engineering Drawings that contains information
such as the Shape, Basic Dimensions, Estimated Thickness and Weight, Design
Conditions, Materials for Primary Parts, Nozzle Specifications and Tube Arrangement, it
is the VENDOR’s responsibility to perform a Mechanical Detail Design to confirm this
information.
1.5.2 Deleted
1.5.3 VENDOR shall submit to PURCHASER all Drawings and Documents called for in
PURCHASER’s Requisition.
1.5.4 All Drawings and Documents shall give the name of S-OIL, the number and title of
Project, Item No. and Equipment Name.
1.5.5 Vendor’s Drawings shall be prepared to scale and in third angle projection.
1.5.6 Vendor’s Drawings shall contain:

(1) Title block (Project Name, Requisition No., Item No., Equipment Name)
(2) Design Data
(3) Material List (Material Specifications and Quantities for all Parts including
Spare Parts)
(4) Nozzle List
(5) All Weld Seams, and Weld and Surface Finish Symbols
(6) Detailed Dimensions and Thicknesses
(7) MAWP and Limiting (Governing) Parts
(8) Weights of Removable Parts
1.5.7 Vendor’s Strength calculations shall cover:

(1) Code Calculations for all pressure retaining parts including reinforcements for
nozzle openings
(2) Structural Calculations for internals, lifting lugs and transportation fittings
(3) Stability check of Heat Exchanger and support for Wind/Seismic Load
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(4) Stability check of Heat Exchanger and support at Transportation, Loading &
Unloading and Erection
(5) Local Stress Analysis against External Loading on Nozzles
1.5.8 Deleted
1.5.9 For Heat Exchangers Fabricated and/or Assembled and/or Repaired at job site, the
0 Method Statement for the work shall be submitted for PURCHASER's approval.
1.5.10 PURCHASER’s approval for VENDOR’s Drawings and Documents shall not relieve the
VENDOR of his responsibility to meet all requirements of Purchase Order.
2. DESIGN
2.1 Design Pressure
2.1.1 Design pressure shall be as specified in Data Sheets.
In case of two different operation cases, they shall be separately taken into
consideration for the Design and shall be separately indicated on Drawing and
Nameplate.
For example
Operation
- Design Pressure 20 bar (g)
- Design Temperature 100 °C
Regeneration
- Design Pressure 5 bar (g)
- Design Temperature 250 °C
This only applies for cases where these operation cases occur separately. Whenever it
cannot be excluded that these Pressures and Temperatures occur in combined form,
then only that operation case with maximum stress shall be considered.
2.1.2 When Design Pressure of “F.V. (Full Vacuum)” is specified, Exchangers shall be
designed to withstand for External Pressure of 101.3 kPa.
2.1.3 Unless otherwise specified, Exchangers normally subject to Internal Pressure shall be
designed to withstand for External Pressure of 50.7 kPa at 150 ºC.
2.1.4 Unless otherwise specified, Parts in contact with both shell and tube side fluids such as
Tubes, Tubesheets and Floating Heads shall be designed for the pressure on one side
only or the combination of the pressure, whichever that requires the maximum material
thickness for the part. Use of differential Design Pressure is subject to PURCHASER’s
approval.
2.1.5 Maximum Allowable Working Pressure (MAWP) is the maximum Gauge Pressure at
each side of a completed Exchanger, which is obtained from the Calculation for every
element of the Exchanger based on the used thickness under corroded condition.
MAWP shall be calculated for each Exchanger.
2.2 Design Temperature

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2.2.1 Design Temperature shall be as specified in Data sheets. Two kinds of Design
Temperature, one for Maximum Design Temperature (called as “Design Temperature”)
and the other for Minimum Design Temperature (called as “Minimum Design Metal
temperature” or MDMT) are specified.
2.2.2 When Operating Temperature is 15 °C and below, the Design Temperature shall be the
Minimum Anticipated Operating Temperature.
2.2.3 When Design Temperature or MDMT cannot coincide with the Maximum Pressure, the
corresponding Design Pressure shall be designated together with the Temperature.
2.2.4 Exchanger parts in contact with two fluids having different temperatures shall be
designed for both higher and lower Design Temperatures.
2.2.5 When the Exchanger inside is insulated from high temperature fluid, the Design
Temperature may be determined by Heat Transfer Calculation.
2.3 Corrosion Allowances
2.3.1 The Corrosion Allowance for the Shell and Channel Sides shall be as specified in Data
0 sheets and/or Specifications.
2.3.2 The necessity of Corrosion Allowances for various Heat Exchanger parts shall be in
accordance with applicable Codes and Standards.
2.3.3 No Corrosion Allowance is required for the parts not in contact with the inside fluid such
0 as Outside Surface of Shell, Support and so on unless otherwise specified. Corrosion
allowance of 3 mm in diameter is required for design of anchor bolts.
2.3.4 Unless otherwise required by the Governmental Regulations, no Corrosion Allowance is

added to Tubes.
2.3.5 Corrosion Allowance is not usually required for non-pressure parts such as Tie-Rods,
0 Spacers, Baffles, Support Plates, bolting, floating head backing devices and Pass
Partition Plates. (See also Paragraph 3.2.6)
2.3.6 When it is not practical to provide Corrosion Allowance by increasing the thickness of
the base metal, a Corrosion Resistant Material shall be used in either a Solid, Lining,
Cladding or Weld Overlay Construction. Any Changes to Construction Materials shall be
referred to PURCHASER for approval.
2.4 Materials
2.4.1 The Materials for Primary Parts shall be as specified in PURCHASER’s Requisition or
Data sheets.
2.4.2 Materials of the parts not specified in PURCHASER’s Requisition or Data sheets shall
be proposed by VENDOR and shall be submitted for PURCHASER’s Approval.
2.4.3 VENDOR may propose the use of alternative materials. Such alternatives shall be
clearly indicated in his proposal giving official material designation or the chemical
composition and physical properties for such materials having only a Trade or Supplier
designation, and shall be submitted for PURCHASER’s Approval.
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2.4.4 Gaskets, Bolts and Nuts for Blind Nozzles and Manholes shall be as specified in
PURCHASER’s Requisition, Drawings and/or Data sheets.
2.4.5 Carbon Steel Materials to be used in Fabrication of Pressure Retaining Parts shall be
Fully Killed Steel. The grain size shall be of coarse grain where Design Temperature
over 350°C. The use of Semi-Killed Carbon Steel and/or Rimmed Steel are subject to
PURCHASER’s approval.
2.4.6 External Bolting Material for Minimum Process Design Temperature not less than -10 °C
0 shall generally be A193GrB7 for Bolts, and A194Gr2H for Nuts. For Design
Temperature over 425 °C, the Material shall be A193GrB16 for Bolts and A194Gr4 for
Nuts.
A320-L7 and A194-4 shall be used for Minimum Process Design Temperature colder
than minus 10 °C throughout minus 100 °C. Internal Bolting shall be selected to be
suitable for process fluid.
The plant MDMT of -18°C shall not be considered for selecting bolt material.
2.4.7 Use of Stainless Steel Dual Certificate Materials is acceptable.
2.5 Loading Conditions and Strength Calculation
0 2.5.1 Any thicknesses indicated in PURCHASER’s Drawings and/or Data sheets are those
proposed by PURCHASER. VENDOR shall be responsible to check and confirm that
such thicknesses provide the proper strength under the specified conditions. Any lesser
thickness considered by VENDOR shall immediately be referred to PURCHASER. In no
case shall a thickness be decreased without PURCHASER’s prior approval, even if
there is an extra margin beyond the offered and calculated required thickness.
2.5.2 Lining, Cladding and Weld Overlay Thickness shall not be considered to contribute to
the strength of pressure parts.
2.5.3 The following Loading Conditions shall be considered in Designing Heat Exchangers
including its Support and Anchor/Setting Bolts.
(1) Operating Condition

The Loadings shall include those from:
(a) Internal or External Design Pressure
(b) Weight of Exchangers and contents at operating condition (including static
head of liquids)
(c) W eight of Insulation and Fire Proofing
(d) Weight of combined equipment, if specified
(e) Reactions from Piping Systems, if specified
(f) Cyclic or Dynamic Reactions from combined equipment, if specified
(g) Wind or Seismic Load whichever is greater
(2) Erection Condition

The Loading shall include those from:
(a) Weight of Exchangers and contents at erection
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(b) Weight of Other Attachments, if any

(c) W eight of combined equipment, if specified
(d) Wind or Seismic Load whichever is greater
(3) Testing Condition (in the installed position and corroded condition).
The Loadings shall include those from:
(a) Test Pressure
(b) Weight of Exchangers and contents at Testing Condition (including static head
of liquids)
(c) W eight of Piping and Other Attachments
(d) Weight of combined equipment, if specified
2.5.4 Wind Load shall be determined in accordance with the Requirements of ASCE 7-05 with
the following conditions.
Basic Wind Speed : 60 m/sec (three second guest speed in ASCE 7-05)
Exposure Category : C
Occupancy Category : III as per ASCE 7-05 Table 1-1
Importance Factor : 1.15 as per ASCE 7-05 Table 6-1
2.5.5 Seismic Load shall be determined in accordance with the Requirements of UBC 97 with
the following conditions.
Seismic Zone : 2A
Exposure Type : No exposure type required in UBC 97
Importance Factor : 1.25 (Category / Standard Occupancy)
Soil Profile Type : SE (Soft Soil)
2.5.6 Classification and Evaluation of stresses at various Loading Conditions shall be done in
accordance with the applicable Codes and Standards. Higher Allowable Stresses may
be used according to the Category of the Stresses for short time and local loads.
2.5.7 Allowable Tensile Stress of Foundation Bolts of A307 Gr.B shall be 100 N/mm2 for long-
term and 120 N/mm2 for short-term Loading Conditions.
Nominal Concrete Bearing Stress shall not exceed 12 N/m2 under any Condition.
2.5.8 Local Stresses at shell around attachments such as Nozzle, Exchanger Support and
Lifting Lug and so on, shall be Calculated and Evaluated when requested by
PURCHASER.
The following generally accepted Calculation Procedure, or the equivalent, may be

applied.
(a) Bulletin of Welding Research Council No.107 or 297
(b) BS 5500 Appendix G
(c) Pressure Vessel Handbook (By E.F. Megyesy)
(d) Process Equipment Design (By L.E. Brownell & E.H. Young)
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(e) Finite Element Analysis (FEA) Method may be used and subjected to
2.6 Tolerances
2.6.1 Tolerances shall be in accordance with Appendix B “Inspection Requirement” and

Inspection and Test of Vessels and Heat Exchangers, D-202 (21100-4-8430-SP-0008)
unless otherwise specified.
2.6.2 The Thickness after forming of any pressure retaining parts shall not be less than the
Design Thickness. Plates with an under tolerance of not more than the smaller value of
0.25 mm or 6% of the ordered thickness maybe used, unless requested otherwise by
the Applicable Code.
Mandatory Appendix 32 of ASME VIII Div.1 shall not be applicable.
3. DETAILED DESIGN
3.1 Shells and Channels
3.1.1 When shell diameter is 600 mm and under, pipes may be used.
3.1.2 The Minimum Nominal Shell Thickness including Corrosion Allowance shall be in
accordance with TEMA including RECOMMENDED GOOD PRACTICE.
0
3.1.3 The shape of the formed Head shall be as specified in PURCHASER’s Drawings and/or
Data sheets. 2:1 Semi-ellipsoidal or Hemispherical Heads are preferred.
3.1.4 The Nominal Thickness of 2:1 Ellipsoidal or Hemispherical Head shall be selected to
assure that the Minimum Thickness after Forming shall not be less than the Minimum
Design Thickness of Head. Also, the Nominal Thickness shall not be less than the
Minimum Design Thickness of Connecting Cylindrical Shell for 2:1 Ellipsoidal Head.
3.1.5 Except for Kettle and U-Tube Types, Exchangers with Removable Tube Bundles shall
be provided with Bolted Shell Covers.
3.1.6 The Angle of a Conical Section of Kettle Type Exchangers shall generally be 30°
3.1.7 For Fixed Tube Sheet Construction, the necessity of Expansion bellows shall be
determined in accordance with the ASME and TEMA Standards. The Metal
Temperatures of Shell and Tubes shall be as specified in Data sheets or
PURCHASER’s Requisition. Unless otherwise specified, it is necessary that Expansion
Bellow Requirement shall be evaluated for all Operating Conditions including Hydrotest
Condition.
Expansion Joint Type

- If Thick Wall (Flanged and Flued) type is chosen, the Design shall be in
accordance with TEMA RCB-8 using Finite Element Analysis (FEA) method.
Expansion Joint Material shall be of the same as shell. Construction Details
shall be submitted for PURCHASER’s approval.
- If Thin Wall type is chosen, the Design shall be in accordance with ASME
Code. Expansion Joint Material and Construction Details shall be submitted for
- Minimum Cycle Life shall be 1000 cycles
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3.1.8 Girth Flanges shall have a Confined Gasket Joint to hold the gasket in place during
assembling.
3.1.9 Gasket Contact Surface of Girth Flange shall have a finish equivalent to the following in
μm:
(1) For Non-Asbestos Sheet Gasket : Ra 3.2
(2) For Spiral Wound Gasket : from Ra 1.6 to Ra 3.2
(3) For Metal Jacket, Solid Metal Gasket : Ra 1.6 and finer
3.1.10 All Girth Flanges shall be of Welding Neck Construction. Number of Flange Bolt Holes
shall be in multiples of 4 (four) and they shall straddle Heat Exchanger normal
centerlines.
3.1.11 Vent and Drain Holes of approx. 6 mm in diameter shall be provided at the highest and
lowest points of each Pass Partition Plate.
3.1.12 Thickness of Floating Head Backing Device shall be determined from formula based on
Bending Calculation.
3.1.13 Flatness Tolerance on Peripheral Gasket Contact Surface of Girth Flanges and Tube
sheets for Exchangers in Wet H2S Service, High-Temperature Service, and High-
0 Pressure Service shall be in accordance with Table 5 of API-660.
3.2 Tubes and Tube Bundles
3.2.1 Each U-tube shall be formed from a single length, and mean radius of U-tube bend shall
not be less than 1.5 times the Tube Outside Diameter.
3.2.2 Tube-to-Tubesheet Joints shall be Strength Welded followed by Heavy Rolled

Expanding with two Grooves. When all of the following conditions are applied, Tube-to-
Tubesheet Joint shall be of Heavy Rolled Expanding with two Grooves.
(1) Design Pressure does not exceed 5 000 kPa
(2) Design Temperature, both Maximum and Minimum, are from -10 °C up to
0 350 °C (The plant MDMT of -18°C shall not be considered as Minimum Design
Temperature for selecting tube-to-tubesheet joint type.)
(3) Hydrogen Partial Pressure is 600 kPa and smaller
Use of Hydraulic or Explosive Expanding is subject to PURCHASER’s Approval.
3.2.3 The Welding Procedures, Welding Methods and Inspection Methods of Strength Welded
Tube-to-Tubesheet Joints shall be submitted for PURCHASER’s approval. WPS and
PQR for Tube-to-Tubesheet Welding shall be prepared separately from other fillet
welding.
3.2.4 Thickness of Tubesheets shall be designed and provided to satisfy both TEMA and the
Construction Code. Extended Tubesheet shall be applied to Removal Type Tube
Bundle.
Where a No Tube In Window (NTIW) design is used, the Proposed Method of

Calculation of the Tubesheet Thickness shall be submitted for PURCHASER’s review
and acceptance prior to order of the Tubesheet Material. In general the Calculation
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Methods of TEMA and ASME VIII Division 1 Part UHX will be considered unacceptable
for this application.
3.2.5 Baffles and Support Plates shall be tied together with Rods and Spacers, and for
Horizontal Exchangers they shall be provided with Notches at the Lowest Point to permit
full drainage of the Shell and at Highest Point for Venting.
3.2.6 When the specified shell-side corrosion allowance exceeds 3 mm, the minimum baffle
and support plate thickness specified in the TEMA standard shall be increased by the
shell-side corrosion allowance in excess of 3 mm.
3.2.7 For Exchangers which do not require Baffles, Support Plates of 45 % vertical cut shall
generally be provided. Support Plates need not be cut for Kettle Type Exchangers. To
avoid the flow-induced vibration problem, the Maximum Unsupported Tube Span should
not be exceeded 80% of the specified value in TEMA Standard.
3.2.8 When Longitudinal Baffles are welded to the Shell, the Welding Seams shall not be
close to the Longitudinal Welded Seams of the shell.
3.2.9 Clamp Bands shall be installed for Kettle Type Exchanger with the Shell Diameter of
400 mm and over, and the Tube Length 1 500 mm and over.
3.2.10 Tubes shall be extended by 3 mm beyond the Channel Side Surface of each Tubesheet.
For Vertical Exchangers, all Tubes shall be flush on to Tubesheet Surface.
3.2.11 For Heavy Expanded Joints, Tubesheet Holes shall be provided with two Square
Grooves conforming to the TEMA Standard. For Clad Tubesheets, one Groove shall be
in the Cladding and the Cladding shall extend 3 mm beyond the Groove.
3.2.12 The tube wall thickness reduction for Heavy Rolled Expanding shall be in accordance
0 with the following,
1) Carbon steel, Low Alloy Steel (Max 9% Cr): Minimum 6% and Maximum 8%.
2) Stainless Steel and High Nickel Alloy: Minimum 4% and Maximum 6%.
3) Copper Alloy Steel: Minimum 4% and Maximum 8%.
3.2.13 The Intermediate Support Plates at the Inlet/Outlet Spacing or between the NTIW (no
tubes in windows) Baffles shall be provided to keep the flow direction without Flow-
Induced Vibration problem.
3.2.14 The Supplemental Requirements defined in API-660 Section 12 are applicable for the
following conditions
a) Shell or Channels with a Cylinder thickness greater than 50 mm
b) For Hydrogen, Hydrogen Sulphide or other Lethal Services.
3.2.15 For Exchanger in H2 Service, the Floating Head Cover Flange shall be Designed Fully
in accordance with API 660 Paragraph 7.5.4 Figs (b) or (c).
3.3 Nozzles
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3.3.1 Nozzle and Manhole size shall not be changed without PURCHASER’s approval.
However, if Nozzles, Reinforcement Pads, and Main Seams should interfere with each
other, these Dimensions may be changed upon PURCHASER’s approval.
0
3.3.2 The Type, Rating and Facing of Nozzle Flanges shall conform to those specified in
PURCHASER’s Drawings and/or Data sheets.
3.3.3 Each Blind Cover with mass over 200 N shall be supported by a Davit or Hinge. The
Details of Davit or Hinge shall be in accordance with Vessel Standard R-505 (21100-4-
8430-SP-0004).
3.3.4 Nozzle Flange Standard shall generally conform to Piping Material, H-103 (21100-4-
8230-SP-0005). Nozzle Flanges 24 inch and smaller shall be as per ASME B16.5.
Nozzle Flanges larger than 24 inch nominal shall be as per ASME B16.47 Series B or
Designed per ASME Sec. VIII Div.1 when ASME B16.47 Series B is not applicable. In
case a Non-Standard Flange is designed, the Companion Flange with Bolt, Nut and
Gasket shall be supplied with it.
Non-Standard Flanges shall be designed to Code Rules and shall take into account
External Loads, Flange Deflection, Initial Bolt Load and Hydrotest Condition.
3.3.5 The Nozzle Neck Thickness shall be selected in accordance with Vessel Standard (R-
505) for Materials, Nominal Size, Flange Rating and Corrosion Allowance. A Code
Calculation is still required to be submitted for Review to confirm Wall Thickness meets
Code Requirements. The Pipe Material for Nozzle Neck shall be Seamless, unless
otherwise approved by PURCHASER.
3.3.6 - DELETED -
3.3.7 When Male and Female (M&F) or Tongue and Groove (T&G) Type Flanges are
specified, the Nozzle Flange Facing of the Exchanger shall be of Female or Groove
Type.
3.3.8 Drain, Vent and Process Nozzles shall be Trimmed Flush with the Inside Surface of the
Exchanger. Other Nozzles may Extend Inward within the limits necessary for Welding.
3.3.9 For Nozzles that are to be connected to piping by Butt Welding, Final Weld Bevel on the
end shall be completed in shop before Pressure Testing. Pad Plate shall be furnished
on the Nozzle Neck in order for the Temporary Cap / Closure can be attached by Fillet
Welding. Detailed Drawings shall be submitted for PURCHASER’s review and approval.
3.3.10 The Highest and Lowest Points on Shell and Tube Sides, not otherwise Vented or
0 Drained, shall be provided with 1 inch nominal size Drain and Vent in the following
manner.
(1) For General Service : 1" 6000# Coupling w/plug of 150mm length
(2) For Hydrogen Service (partial H2 P ≥ 7kgf/cm2 abs.) and/or Wet H2S Service
- 600# & less : 1" Flange, SW Gasket W/Blind Flange
- 900# & higher : 1" Flange, RTJ Gasket W/Blind Flange".
Note. For heavier than VGO, Drain shall be 1-1/2” flange.

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3.3.11 The Nozzle Facing of the Intermediate Nozzles between the units which are to be
Stacked shall be Raised Face (RF) Type unless Ring Type Joint (RTJ) is specifically
specified.
3.3.12 Level Gauge Nozzles of Kettle Type Exchangers shall be supported from the shell.
3.3.13 Flanged Nozzles larger than 2 inch nominal shall be provided with one instrument
connection in the following manner.
(1) For General Service : 3/4" 6000# Coupling w/plug of 150mm length
(2) For Hydrogen Service (partial H2 P ≥ 7kgf/cm2 abs.) and/or Wet H2S Service
- 600# & less : 1" Flange, SW Gasket W/Blind Flange
- 900# & higher : 1" Flange, RTJ Gasket W/Blind Flange"
3.3.14 Weld Neck Flanges shall have the same bore as the Nozzle Neck.
3.3.15 Slip-On Flanges shall not be used.
3.3.16 Nozzle Outstands shall keep Flange Bolting or the Field Butt-Weld clear of the Vessel
Wall, Insulation, Platforms or other Obstructions.
3.3.17 Nozzles, Manways and their Reinforcement shall be attached to the Vessel with Full
Penetration Welds and the Nozzles set through the Vessel Wall.
3.3.18 Deleted
3.4 Opening
3.4.1 The Opening Reinforcement shall be so designed as not to limit the Maximum Allowable
Working Pressure of the Heat Exchanger.
3.4.2 Nozzles made of Pipe or Plate and Sized 2 inch Nominal and Larger shall generally be
provided with Reinforcement Plates. Each Reinforcement Plate shall be provided with
at least one Tell-Tale Hole of NPT 1/8 inch.
Long Weld Neck (LWN) Type Nozzle may be used without Reinforcement pad up to 3
inch Nominal.
3.4.3 The Reinforcement for the Nozzle Opening shall be of Integral Type, when required by
the Applicable Codes/Standards or where any of the following conditions are met:
(1) Design Temperature exceeds 370 °C for Carbon Steel, 427 °C for Low Alloy Steel and
538 °C for Austenitic Stainless Steel materials.
(2) Design Pressure exceeds 10,000 kPa
(3) Design Temperature exceeds 350 °C and Design Pressure exceeds 3,000 kPa
(4) Wall thickness exceeds 50 mm
(5) Size 1-1/2 inch and below
Integral Reinforced Nozzles employing Butt Welds that can be 100% Radiographed and UT
Tested shall be used for the following applications.
a) Heat Exchanger is in Cyclic or Thermal Shock Service.
b) Heat Exchanger is in a Service that demands Integral Reinforcement e.g. H2, H2S,
HF.
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3.4.4 Where Nozzles are subject to External Loads, the strength of the Nozzles and Shells
against shall be checked based on the Minimum Nozzle Loads given in Vessel Standard,
R-505 (21100-4-8430-SP-0004) and additional Reinforcement shall be provided if
required. See Paragraph 2.5.8 for Calculation Procedures.
3.4.5 Segments of split Reinforcing Pads shall be joined with Full Penetration Butt Welds.
3.5 Alloy Lining
3.5.1 Alloy Lining shall be either Integrally Clad Plate or Overlay Weld Metal. Unless
0
otherwise specified, the Minimum Thickness shall be 2 mm for Cladding and 3 mm for
Weld Deposit after machining. The Minimum Clad Thickness for Tubesheet shall be 8
mm. For Clad Tubesheet, one Groove shall be in the Cladding and Cladding shall
extend 3 mm beyond the Groove. If Seal or Strength Weld is specified, all Grooves shall
be in Base Material.
3.5.2 Nozzles attached to Alloy-Lined Shell shall be of Alloy-Lined by Integrally Cladding or

Overlay Welding with exception in Par. 3.5.3 and Par. 3.5.4.
3.5.3 Solid Austenitic Stainless Steel Nozzles may be welded to Ferritic Shells in case of the
followings:
(1) Nozzle Size is 2 inch and smaller with Design Temperature 400° C and lower
(2) Nozzle Size is 4 inch and smaller with Design Temperature 250° C and lower
When Post Weld Heat Treatment is required, such nozzles shall be made of stabilized
Stainless Steel or Low Carbon Grade and Welded by Inconel Filler Metal.
3.5.4 Unless otherwise specified in PURCHASER’s Requisition or Data sheets, Loose Sleeve
Type Lining may be used for the Nozzles up to and include 6 inch size with Design
Temperature 400 °C and lower.
Expansion Ring shall be provided when the Design Temperature exceeds 250 °C. Each
Segment of Liner Welds shall be provided with Tell-Tale Holes with Threaded End for
Plugging.
When Postweld Heat Treatment is required, such Sleeve Liner shall be made of
stabilized Stainless Steel and Welded by Inconel Filler Metal. One end of Loose Sleeve
Liner shall be welded after Postweld Heat Treatment.
3.6 Bolts, Nuts and Gaskets
3.6.1 Unless otherwise specified, all Bolting Threads to be used for Heat Exchangers shall be
ANSI Unified System. When Bolt Size is U1-1/8 and over, Unified Screw Threads of 8
threads per inch shall be used. When bolt size is U1 and less, Unified Coarse Screw
Threads shall be used. Girth Flange Boltings shall be of Stud Bolt Type, Threaded Full
Length, and at least U 5/8 for Flange of 600 mm and smaller inside diameter and at
least U7/8 for over 600 mm Inside Diameter Flange.
3.6.2 The Hardness of Metal Gaskets shall not exceed the values in the following table.
Hardness of the Gasket shall be lower than that of the Gasket Contact Surface.
Gasket Materials Brinell Hardness
Soft Iron, Low Carbon Steel and Nickel 120
5 % Cr - 1/2 % Mo Steel 130
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Austenitic Stainless 160

410SS (13Cr) 170
The use of Asbestos Gasket is not permitted. Non-Asbestos Gasket may be used
provided that it is suitable for the service.
3.6.3 Threads of Bolts and Nuts shall be coated before Installation with Anti-Galling Agent.
0 3.6.4 All Bolt 1½” and larger Non Standard Body Flanges shall be fitted with Washers.
3.6.5 All Bolts 1½” and larger on Flanges shall require Hydraulic Bolt Tensioners. Bolt lengths
shall be specified one Nut thickness longer to accommodate the use of the Hydraulic
Bolt Tensioning Tool. The Design of the Flange shall provide enough clearance
between Bolt Holes to allow fitting of the Tensioning Tool. Use of other methods shall be
subject to PURCHASER’s approval.
3.6.6 All Bolts 1⅜” and smaller on Flanges shall require tightening by Torque Wrench. Use of
other methods shall be subject to PURCHASER’s approval.
3.7 Supports
3.7.1 Saddles or Lugs for Exchangers shall be as per the Tables in Vessel Standard, R-505
(21100-4-8430-SP-0004). For Exchangers which meet all the conditions stipulated in
the Tables such as Maximum Weight or Saddle Height, Strength Calculations are still
required to be submitted for PURCHASER’s review / approval.
3.7.2 Units which are to be Stacked shall be provided with the Required Additional
Intermediate Supports and Liners for elevation adjustment.
3.7.3 Supports for Low Temperature Horizontal Exchangers with the Operating Temperatures
-20 °C or below shall be provided with Wooden Pillows according to Vessel Standard,
R-505 (21100-4-8430-SP-0004).
3.7.4 1.5 time of Load at Bundle Extraction shall be considered in Design of Saddle and
Anchor Bolts in accordance with API-660. Loading Data at Bundle Extraction shall also
be submitted.
3.7.5 Units which are to be Stacked shall be designed so as to withstand the Load at Stacked
condition. For Nozzles Connected each other and Intermediate Saddles, Thermal
Expansion shall also be considered in design.
3.8 Miscellaneous
3.8.1 To facilitate breaking Gasketed Joint of Main Girth Flanges, Jack Screws or at the
periphery of the Male Flange a cutback of 5 mm to a depth of approximately 30 mm and
width of 30 mm shall be provided.
3.8.2 Guide Rails shall be provided for Kettle Type Exchangers and the Horizontal
Exchangers with the Removable Bundle weighing 100 kN and over.
3.8.3 Each Channel, Channel Cover and Shell Cover shall be provided with Plate Type
Welded-On Lifting Lug with 25 mm Diameter Hole.
3.8.4 Pulling Lugs or Tapped Holes for insertion of Eyebolts shall be provided on the Outer
Face or Tubeside Face respectively of Tubesheets for Pulling Bundles. Tapped Holes
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shall be Plugged for protection. Clad Tubesheets shall be the subject of special
consideration and details shall be reviewed and accepted by PURCHASER.
3.8.5 Alignment marks shall be provided to prevent mis-assembly of Channel Covers,

Channel Flanges, Shell Flanges, Shell Cover Flanges and Floating Heads.
3.8.6 The Strength of the Heat Exchangers during Transportation and Field Erection shall be
0 checked, and any necessary Reinforcements shall be provided prior to Shipment. A
shock factor of 1.25, as minimum, shall be considered in these designs. Strength
Calculations shall be submitted for PURCHASER’s approval.
3.8.7 For Vertical Heat Exchangers, Plate Type Lifting Lugs shall be provided in general.
Trunnion Type Lifting Device needs PURCHASER’s prior Written Approval. Lifting lugs
shall be Designed taking account of Heat Exchanger Weight and Lifting method, etc.
The shock factor of 1.25, as minimum, shall be considered in the Design of Lugs and
Shell.
3.8.8 In General, Exchangers shall be provided with two Earth Lugs. Location of the lug shall
0
be referred to Vessel Standard R-505 (21100-4-8430-SP-0004)
3. 8.9 For U-Tube or Floating Head Type with a Bonnet Channel, Stationary Tubesheet shall
be of extended construction. In this case, a Test Ring for the Stationary Tubesheet is
not required.
When required for Floating Head Side Testing, one set of Test Gear shall be supplied
for each Exchanger. When Exchangers are coupled Nozzle to Nozzle, the number of
sets of Test Gear must be equal to the number of Exchangers so coupled. For example
an Exchanger item consisting of Four Shells Stacked in two pairs shall be provided with
two sets of Test Gear.
4. FABRICATION
4.1 Plate Layout
4.1.1 Shell plates shall be laid out so that there will be a Minimum of Welded Seams.
4.1.2 Longitudinal and Circumferential welded seams shall not interfere with Openings and /
or cover any Internal / External Attachments. They shall be arranged as far as possible
to avoid any interference. If the seams are covered with reinforcement plates or saddle
pads under PURCHASER’s approval, the welds shall be ground flush with the Shell
surface and Radiographically examined in the full length of the interference area plus
100mm.
4.1.3 Longitudinal Welded Seams on Adjacent Shell Segments shall be separated by at least
5 times the Wall Thickness of the thicker Plate but not less than 100 mm.
4.1.4 Longitudinal and Circumferential Welded Seams shall be kept out of the Internal Welds
insofar as practical, and shall be so located that they can be easily inspected with
Internals in place.
4.2. Forming
4.2.1 Selection of Hot or Cold Forming of Materials may be made by VENDOR, but Heat
Treatment after Forming shall conform to the Requirements of Applicable Code.
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4.2.2 Despite of Par. 4.2.1, Low Alloy Steel of 50mm and over in thickness shall be subjected
to Hot Forming. Cold Forming shall not be employed unless otherwise approved by
PURCHASER.
4.2.3 Despite of Par. 4.2.1, Austenitic Stainless Steel including Clad Plate shall generally be
subjected to Cold Forming. Hot Forming shall not be employed unless otherwise
approved by PURCHASER.
4.2.4 A Formed Head shall generally be made of Single Plate.
4.2.5 When Temporary Attachments are required during the forming work, they shall be
welded to the Shell Plate using the same Welding Procedures as for the Main Seams.
After removing these attachments, the Surface shall be Ground Flush and Examined by
Magnetic Particle Method. In case of High Alloy Steel or Non-Ferrous Materials, Liquid
Penetrant Method can be substituted.
4.2.6 When Forming of Clad steel is required, the Procedure shall be submitted for
PURCHASER’s approval prior to operation.
4.3 Welding
4.3.1 As a rule, Pressure Retaining Parts of Pressure Vessels shall be welded by the Fusion
Arc process but Flux Cored Arc Welding process for Pressure Retaining Parts is
0 prohibited. Exceptional applications shall be as per 21100-4-8440-SP-0003 (IN-48),
General Requirements for Weld Fabrication. The Electroslag welding for Overlay Welds
may be applied with PURCHASER’s prior approval.
4.3.2 Welding Procedures and Welders shall be qualified in accordance with the Specified
Code or Standard.
4.3.3 Pressure Holding Seams shall normally be Full-Penetration Double-Welded Butt Joints.
Single-Welded Butt Joints which ensure Full-Penetration may be used, where Double-
Welded Butt Joints are impractical. Butt Joint with Permanent Backing Strip needs to
obtain PURCHASER’s prior written approval.
4.3.4 Welding Electrodes and Wires shall have Chemical Compositions and Mechanical
Properties equal to or of higher grade than the Base Material.
4.3.5 Welding Procedures shall be selected to minimize the Residual Stresses insofar as
practical.
4.3.6 Preheating shall be carried out for Carbon and Low Alloy Steel Welding where required.
Preheating Temperature shall be kept uniform from the start to the end of welding.
4.3.7 Welding Procedure for any dissimilar Metal Welds of Stainless Steel to Carbon Steel or
Low Alloy Steel shall be presented in full detail to PURCHASER for approval.
4.3.8 Dissimilar Metal Welding of Stainless Steel to Carbon Steel or Low Alloy Steel in
pressure retaining Butt Weld shall be carried out in the following manner.
(1) Filler metal of Inconel 182 : For joints where PWHT is required or Design
Temperature is over 350 ºC.
(2) Filler metals of E309, E309L : For first layer of joints where no PWHT is
309Mo, 309MoL required and Design Temperature is less
than 350 ºC.
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Note: The Welding Method and Welding Parameters of the Dissimilar Weld Overlay shall
be carefully selected to control the dilution and micro-structure of Weld Deposit to
avoid any cracks. 20,000 J/cm is Allowable Maximum Heat input for the First Layer
of Pressure retaining Dissimilar Butt Weld.
4.3.9 The Minimum Bead Length for Low Alloy and High Alloy Steel shall be 80 mm.
4.3.10 Where joining Alloy-Clad Plate, the Alloy layer shall be stripped back for a minimum
distance of 8 mm from the bevel to assure a sound weld joint of Base Materials. For any
other procedure, the details of it to assure the sound weld joint of the Base Material
shall be referred to PURCHASER for approval. The thinning of Base Metal due to this
Clad stripping is not necessary to consider in the Shell thickness calculation if the
thinning is within the smaller of 1.0 mm or 10 % of the Base Metal nominal thickness.
4.4 Heat Treatment
4.4.1 Heat Treatment after Bending of U-tubes shall be carried out prior to Bundle Assembling
for the following conditions:
(1) Carbon Steel U-tubes in Wet H2S Service, HIC Service, Caustic Service or
Amine Service
(2) Austenitic Stainless Steel U-tubes when Stress Corrosion Cracking may be
expected
(3) Al-Killed Steel U-tubes of which mean Bending Radius is less than or equal to
5 times the Tube Outside Diameter in low temperature service.
(4) Cr-Mo Steel U-tubes in all Services
4.4.2 Unless otherwise specified, Post weld Heat Treatment shall be carried out in
accordance with the Applicable Codes or Standards.
Use of ASME VIII Div.1 table UCS-56.1 or ASME VIII Div.2 table 6.16 is not acceptable.
4.4.3 No Welding shall be performed on Heat Exchangers after the final Postweld Heat
Treatment without PURCHASER’s approval.
4.4.4 When Clad Steel or Dissimilar Metal Welded Parts are Heat Treated, the Heat
Treatment Procedure shall be submitted for PURCHASER’s approval prior to
commencing of the Heat Treatment.
4.4.5 The Gasket Faces of Shell and Channel Girth Flanges shall be machined after final
Heat Treatment.
4.4.6 When Fixed Tubesheet Exchanger Bundles are Heat Treated, the Heat Treatment
Procedure shall be submitted for PURCHASER’s approval.
4.4.7 When Post Weld Heat Treatment is specified on Tubeside due to process reason, all
parts exposed to Tubeside fluid shall be Heat Treated. Tube-to-Tubesheet Welds shall
also be Heat Treated where the Tubes and Tubesheets are made of Carbon Steel or
Low Alloy Steel.
4.4.8 Nozzle Flange Faces shall be protected properly to prevent oxidation.
4.5 Hardness
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Hardness of Base Metal, Weld Metal and Heat Affected Zone (HAZ) shall not exceed
the limits given below.
Material (P-Number) Brinell Hardness
Carbon Steel (P-1) 225
Low Alloy Steel (P-3, 4) 225
Low Alloy Steel (P-5, 6, 7, 9) 235
4.6 Miscellaneous
Materials for Heat Exchangers shall be carefully stored at shop not to be heavily rusted
or damaged. Stainless Steel shall be stored under roof and protected from the
contamination of any harmful substances such as Chloride and Zinc.
Chloride free pens shall always be used for the Marking of Stainless Steel.
5. INSPECTION AND TESTS
5.1 All Heat Exchangers shall be Inspected and Tested in accordance with the applicable
Local Regulations, Applied Code, Appendix B “Inspection Requirements” and Inspection
and Test of Vessels and Heat Exchangers, D-202 (21100-4-8430-SP-0008) unless
otherwise specified.
5.2 A Detailed Procedure of Inspection and Test shall be submitted for PURCHASER’s
approval.
0 5.3 PURCHASER and PURCHASER’s representative shall have the right to Witness
Inspection and Test to be performed at VENDOR’s shop.
5.4 Units which are to be Stacked, shall be examined by Hydrostatic Test in the Stacked
Condition to check Leakage from the Connected Nozzle Flange. Pneumatic Test may
be acceptable subject to PURCHASER’s approval.
6. NAMEPLATE, PAINTING AND MARKING
6.1 Nameplate
A Nameplate as shown in the Vessel Standard, R-505 (21100-4-8430-SP-0004) shall be

mounted on each Exchanger. Mounting on removable Parts is prohibited.
6.1.1 Fixed Tubesheet Heat Exchangers shall be equipped with Supplemental Nameplate in
accordance with UHX-19 of ASME VIII Div.1.
6.1.2 Warning Plates are required for Differential Pressure or Temperature Designs, Low
Temperature Operations, Hydrogen Service and any other special cases.
6.2 Painting
6.2.1 All exterior surfaces of Heat Exchangers shall be painted in accordance with Painting
Requirements in Appendix C and Painting Specification,O-301 (21100-4-8440-SP-0006).
Gasket Surface faces do not require Painting.
6.2.2 All Flange Faces and other Machined Surfaces shall be coated with a readily removable
rust preventive paint.
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6.2.3 Weld Bevels on the ends of Carbon Steel and Low Alloy Steel Nozzles which are to be
welded at site shall be coated on the inside and outside for a distance of 75 mm from
the end of the nozzle with Deoxyaluminite, Taseto Silver or equivalent.
6.2.4 A Detailed Procedure of Applicable Painting System (Painting Specification) shall be

submitted for PURCHASER’s approval.
6.3 Marking
Each Heat Exchanger and its parts shall be marked in accordance with VS-55-0 of
Vessel Standard, R-505 (21100-4-8430-SP-0004) and Marking for Vessels and Heat
Exchangers, D-112 (21100-4-8430-SP-0010).
7. PACKING AND SHIPPING
7.1 General
Shipping and Packing shall be in accordance with Shipping Instruction, R-453-1 (21100-
4-8610-SP-0001), Packing Instruction, R-453-2 (21100-4-8610-SP-0002), Rust
Preventive Instruction, R-503 (21100-4-8440-SP-0007) and the following additional
requirements.
7.2 Packing and Preparation for Shipping
7.2.1 All Exchangers shall be dried up by Draining and Air Blowing, thoroughly cleaned inside
and outside and free of all dirt and loose foreign materials before shipping.
7.2.2 All Flanged Openings shall be provided with Bolted Steel Cover of minimum 4.5 mm
thickness with Gaskets. Number of Bolting is one fourth of the Service Bolt but not less
than 4 sets.
For Ocean Shipment, Flanged Openings shall be covered with securely taped Heavy
Plastic Sheet.
7.2.3 All Bevelled Openings shall be Covered or Capped to protect the inside from Rust and
Moisture. The Welded Cover or Cap shall be so designed to protect the Weld Bevel and
to be removed easily at site.
7.2.4 Nitrogen Filling or Volatile Corrosion Inhibitor such as DICHAN* shall be applied for
Carbon or Low Alloy Steel Heat Exchangers.
* Dicyclohexylammonium Nitrite
0 7.2.5 Spare Parts including test ring(if required) and its auxiliary parts shall be Packed
Separately from the Exchangers.
7.2.6 Tell-Tale Holes on the outside of Exchangers shall be Greased Up. Plugging of holes is
prohibited.
7.2.7 Demisters shall be free of wire pieces in so far as possible.
7.2.8 Unless otherwise specified, Girth Flanges shall not be loosed after final Hydrostatic Test
and Shipped as it is, Provided Service Gasket is used for the Hydrostatic Test.
The test gasket used for nozzles with permanent blind flanges shall be replaced by service
gasket after the hydrostatic test and with proper tightening ready for the operation.
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7.2.9 All Exchangers shall be suitably protected against salt water for Ocean Transport. All
Loose Items shall be suitably Packaged and Marked with Identification. All Exchanger
Appurtenances susceptible to damage shall be suitably protected.
7.3 Shipping
7.3.1 Templates and Foundation Bolting shall be shipped separately from the Exchangers
according to PURCHASER’s Instruction.
7.3.2 No Exchangers shall be released for Shipment from VENDOR’s Shop until it has been
approved by PURCHASER’s Inspector.
0
7.3.3 Units which are to be Stacked may be Shipped in the combined condition, if Approved
by PURCHASER.
7.3.4 Vertical Exchangers shall be delivered with 2 Shipping Steel Saddles, unless otherwise
agreed with PURCHASER.
8. GUARANTEE
8.1 A Guarantee shall be provided for the Mechanical design, Material and Workmanship of
Heat Exchangers.
8.2 Unless otherwise specified, a Thermal Performance and Vibration guarantees shall be
0 provided for Heat Exchangers.
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Appendix A Basic Design Requirements
This Appendix describes the Basic Requirements of the Design of the Shell and Tube
Heat Exchangers. For Shell and Heat Exchanger in Package Units, the Requirements
of this Appendix shall be followed in addition to the body of this Specification.
A.1 Type Selection
A.2 Basic Dimensions
A.3 Design Temperature (Minimum)
A.4 Corrosion Allowance
A.5 Material Selection
A.6 Gasket Selection
A.7 Minimum Shell Thickness
A.8 Pipe Shell
A.9 Minimum Nozzle Size
A.10 Nozzle Flange Design
A.11 Nozzle Protrusion
A.12 Girth Flange Design
A.13 Support Design of Vertical Heat Exchangers
A.14 Fire Proofing
A.15 Extent of Radiographic Examination
A.1 Type Selection
A.1.1 TEMA Standard type S hell and Tube H eat E xchangers shall be used except for
H igh Pressure & Temperature or other Special Services.
A.1.2 Normally, Heat Exchangers shall be designed with Corrosive or Fouling Fluid in the
Tube Side. Cooling Water shall be serviced in the Tube Side to prevent C.W Corrosion.
If Cooling Water should be serviced in Shell Side, Approval of PURCHASER is needed.
A.1.3 Fixed Tubesheet Exchangers shall be used for Little-Fouling Service on the S hell Side,
or when Chemical Cleaning Device is provided. Special considerations must be given to
Fixed Tubesheet Exchangers that are in Dry-Out or Steam-Out conditions.
A.1.4 U-tube Exchangers shall be used for Little-Fouling Service (Fouling Factor is
less than 0.00034 m2·°C/W) on the Tube Side, or when Fixed Tubesheet or Floating
Head Exchangers are not practicable.
A.1.5 In case of Cooling Water or Fouling Fluid (Fouling Factor is equal and larger than
0.00034 m2·°C/W) on the Tube Side, Removable Flat Covers (TEMA Type A) shall be
provided on the Channel.
A.1.6 "S" type of TEMA shall be limited to Design Pressure on Tubeside of 100 - (0.055 x
Shell Diameter (mm)) bar g, unless otherwise agreed with PURCHASER.
A.2 Basic Dimensions

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A.2.1 Nominal Shell Inside Diameters shall be selected on every 50 mm, and limited, except
for Kettle Type Exchangers, to the maximum of 1800 mm, as a rule.
A.2.2 Tube lengths will be selected from 3 000, 5 000 and 6 000 mm.
A.2.3 Standard Tube Outside Diameters and Tube Pitches shall be as follows:
Unit: mm
Tube Outside Diameter Pitch
19.05 25.40
25.40 31.75
A.2.4 Standard Tube Patterns shall be of Triangular and Square. Square Pattern shall be
applied in case of Boiling Service in Shell Side or Fouling Fluid (Fouling Factor is equal
and larger than 0.00034 m2·°C/W) on the Shell Side.
A.2.5 Standard Tube Thickness shall be as follows:
Unit: mm
Tube Thickness
Tube Outside C.S. & Low Copper &
High Alloys
Diameter Alloys Copper Alloys
(Minimum thickness) (Minimum thickness) (Minimum thickness)
19.05 2.11 1.65 1.65
25.40 2.77 2.11 2.11
Note:
a. 25.40 mm Diameter Tube shall be applied when Fouling Factor on Tube Side is
equal and larger than 0.00034 m2 °C/W.
b. For Al brass, and Ti tubes, 19.05 mm Diameter Tubes with 1.65 mm average
thickness may be used.
A.2.6 The Effective Heat Transfer Surface shall be defined as the Outside Surface of the
Tubes between the Inner F aces of T ubesheets. Bent Portions may be considered as
the H eat Transfer S urfaces in U-Tube Exchangers.
A.2.7 Maximum Un-Supported Length shall be 0.8 times of TEMA specified values.
A.3 Design Pressure and Temperature
A.3.1 Internal Design Pressure shall be whichever greater from the following.
Calculation formula In case
a) Pmax.op. + 0.15 MPa Pmax.op. < 1.500

b) Pmax.op. x 1.1 1.5 ≤ Pmax.op. ≤ 10.000
c) Pmax.op. + 1.0 MPa Pmax.op. > 10.000
d) 0.350 MPaG as minimum design pressure
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Note: Pmax.op. (MPaG) is maximum pressure of normal operation
A.3.2 The Design Temperature (Maximum) shall be Tmax.op. + 15°C, with Minimum 80°C.
But Tmax. Op. + 25 ̊C for Feed/Effluent Exchanger of Reactor Section.
Note: Tmax.op. (°C) is Maximum Temperature of Normal Operation.
A.3.3 Design T emperature M inimum for O perating T emperatures below 0 ° C , shall be

M inimum Operating Temperature minus 5 °C or Minimum Ambient Temperature (-
18 °C), whichever is lower.
A.4 Corrosion Allowance
A.4.1 The necessity and the values of Corrosion Allowances shall be determined
depending on the Material, Inside Fluid Characteristics, Operating Conditions and
Applicable Codes and Standards.
A.4.2 Minimum Corrosion Allowances for Pressure Parts shall be as follows.

(1) Carbon Steel : 3.0 mm
(2) Carbon Steel under Wet H2S Service : 6.0 mm
(3) Low Alloy Steel (up to 2.25% Cr included) : 3.0 mm
(4) Low Alloy Steel (above 2.25% Cr and up to 9% Cr included) : 1.5 mm (*)
(5) Stainless Steel (11% Cr and above) : 0.75 mm
(6) High Alloy and Non Ferrous Metals : 0.0 mm
(*) maybe extended, in accordance with S-OIL, to 3 mm for Critical Heat Exchanger.
.5 Material Selection
A.5.1 Materials shall be selected from those listed in the ASTM / ASME Standards
considering the Inside Fluid Characteristics, Design Conditions and applicable Codes
and Standards. Equivalent materials with Country of Origin acceptable within
PURCHSER’s Requisition may be selected with PURCHASER’s prior approval.
A.5.2 Unless otherwise specified, Girth Flanges and Flat Covers shall be Forged Steel. Plate
construction shall be subject to PURCHASER’s approval.
A.5.3 Materials for the Low Temperature Service shall be selected considering the Impact
Properties of the material and MDMT specified for the Heat Exchanger. The
requirements of the Impact Test shall be as specified in UCS-66 of ASME Boiler and
Pressure Vessel Code Section VIII, Div.1.
A.5.4 A283 Gr. C shall not be used for pressure retaining parts.
A.5.5 Seamless Tubes shall be used.
A.6 Gasket Selection
A.6.1 Gaskets for G irth F lange shall be determined depending on the I nside F luid
Characteristics, D esign Conditions and Applicable Codes and Standards.
ES NO. E-101
FOR REV 0
HEAT EXCHANGERS
As a rule, Spiral Wound with Inner Ring shall be selected except that Non-Asbestos
Sheet Gasket may be used when all of the following conditions apply.
(1) Flange Inside Diameter does not exceed 1200 mm
(2) Design Pressure does not exceed 1000 kPa
(3) Design Temperature, both Maximum and Minimum is from 0°C up to 180°C.
(4) Flange Rating is 150# and below
(5) Utility Service such as Cooling Water, Steam, Steam Condensate, Air, N2, etc.
A.6.2 Spiral Wound Gaskets with an Inner Ring shall be used for Confined Type Joint Flanges
and an Outer Ring shall be used for Raised Face Flanges.
A.7 Minimum Shell Thickness
A.7.1 The M inimum N ominal S hell T hickness including C orrosion A llowance shall be in
accordance with TEMA including RECOMMENDED GOOD PRACTICE.
A.8 Pipe Shell
A.8.1 When Shell Diameter is 600 mm and under, Pipes may be used.
A.9 Minimum Nozzle Size
A.9.1 In general, Nozzles shall be Flanged and Minimum 1-1/2 inch Nominal Size.
A.10 Nozzle Flange Design
A.10.1 Nozzle Flange shall be of Welding Neck Type.
A.11 Nozzle Protrusion
A.11.1 Nozzle P rotrusion shall be decided considering the M inimum Clearance of 50 mm

between the Bottom of Bolt to the Surface of the Shell or Surface of the Insulation
Cover. S-OIL’s Vessel Standard, R-505 (21100-4-8430-SP-0004) shall be referred.
A.11.2 For the Nozzles to be connected to Piping, the Distance of the Flange Face to the
center of the Heat Exchanger shall be Rounded Up to each 10 mm by adjusting the
Nozzle Protrusion.
A.12 Girth Flange Design
A.12.1 All Girth Flanges shall be of Welding Neck Construction.
A.1 3 Support Design of Vertical Heat Exchangers
A.13.1 Vertical Heat Exchangers shall generally be supported by Lugs unless otherwise
specified.
A.1 4 Fire Proofing
A.14.1 Fire P roofing shall be provided for the H eat E xchangers installed in the F ire
Hazardous A rea in the following manner. Application of Fire Proofing to Heat
Exchangers installed on Elevated Structure shall be decided for each case.
ES NO. E-101
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HEAT EXCHANGERS
For Lug Type Support, Fire Proofing shall not be provided.
For Saddle Type Support, Fire Proofing shall be provided for Saddles of the Non-
Insulated Lowest Height is greater than 300 mm.
A.15 Extent of Radiographic Examination
A.15.1 The E xtent of Radiographic E xamination of the S hell, H e a d , S hell C over and
C hannel S eams shall be S pot Examination, as Minimum.
A.16 For “E” Type of TEMA
A.16.1 The Shell Side Inlet Nozzle should be Positioned at the Floating Head End, U-Bend End,
or near the return Channel End. The Fluid Flows on either side generally follow the
principle of 'Heating Up" and "Cooling Down".
ES NO. E-101
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HEAT EXCHANGERS
Appendix B Inspection Requirements
B.1 Material
B.1.1 Ultrasonic Examination with 100% Grid shall be done on Base Metal in accordance with
the following criteria.
(1) Plate Material and Thickness over 50 mm ASTM A435
(2) Forging Material, Plate-like one such as Tubesheet, Forging Shell, ASTM A578
and Thickness over 100 mm Level B
(3) Forging Material, not included in (2) above, and Thickness over 100 mm ASTM A508
Par. 7.3
(4) Cladding Material, any thickness ASTM A578
Level S6
B.1.2 Charpy I mpact T est shall be done in accordance with the Code, based on MDMT
specified on PURCHSER’s Requisition or Data sheets. For Carbon Steel and Low Alloy
Steel, when the Nominal Thickness of Plate or Forging exceeds 100 mm, Charpy
Impact Test as specified in Table B-1 is mandatory.
Table B-1
Item CRITERIA
Sampling - Min. 1 set from each heat
- Min. 3 specimen in 1 set
- Sampling from 1/4T (Thickness) depth
Test Temperature 0 °C or MDMT whichever is lower
Absorbed Energy ASME Div.1, Fig. UG-84.1
B.1.3 Integrally Cladding Material shall conform to ASTM A263, A264 or A265 whichever
Applicable, and Shear Test is mandatory.
B.2 Welds
B.2.1 Welding Edge shall be inspected by MT or PT when any of the following conditions met.
(1) Carbon Steel and Thickness of Base Metal is 75 mm and over.
(2) Low Alloy Steel (Cr-Mo) and Thickness of Base Metal is 50 mm and over.
(3) Low Alloy Steel (Ni) and Thickness is 38 mm and over.
(4) Dissimilar Welding, any Material and any Thickness
B.2.2 Welding Backchip Surface shall be inspected by MT or PT when any of the following
condition met.
(1) Carbon Steel and Thickness of Base Metal is 50 mm and over.
(2) Carbon Steel and MDMT ≤ -10 °C and Thickness of Base Metal is 25 mm and over.
(4) Low Alloy Steel (Ni), any Thickness
(5) Austenitic Stainless Steel and Thickness is 25 mm and over.
ES NO. E-101
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HEAT EXCHANGERS
B.2.3 All Butt Weld Joint shall be Inspected by UT after PWHT in the following cases.
B.2.3.1 Spot UT (Min. 10% in length) is required for Carbon Steel of 38 mm and over
0 in thickness. PURCHASER’s inspector will specify location to be examined with UT
B.2.3.2 Full UT is required when any of the following conditions is met.

(1) Carbon Steel and Thickness of Base Metal is 50 mm and over
(3) Low Alloy Steel (Ni) and Thickness is 38 mm and over.
(4) Dissimilar Welding
B.2.4 Welding Surface shall be inspected by MT or PT after Hydrostatic Test, when any of the
following conditions met. Inspection shall be done on all accessible Interior and Exterior
Surface.
(1) Carbon Steel and Thickness of Base Metal is 38 mm and over, or Full RT(100 %)
is specified.
(2) Low Alloy Steel (Cr-Mo),any Thickness include Attachment Welds
(3) Low Alloy Steel (Ni), any Thickness include Attachment Welds
(4) High Alloy Steel, any Thickness
(5) Welds in Lining or Cladding Metal and Weld Overlay Surfaces, include
Attachment Welds
(6) Welds of Tube to Tubesheet
(8) Fillet Welds of Intermediate Heads
B.2.5 All areas where Temporary Attachment was welded and is removed shall be examined
by MT or PT.
B.2.6 When “Full RT (100 %)” is specified on PURCHASER’s Drawings and/or Data sheets,
the complete length of a butt weld joint, including Category B seam, shall be RT. When
“Full RT” without a description of “(100%)” is specified, RT shall be done in accordance
with UW-11 of ASME VIII Div.1.
B.2.7 When Spot RT is specified, each intersection of Longitudinal and Circumferential

welding seams in the Shell and Heads, or alternative location specified by
PURCHASER’s inspector, shall be radiographed.
Acceptance Standards for Spot Radiography are in accordance with UW-51 of ASME
Div.1.
B.2.8 RT shall be done before final PWHT.
B.2.9 Acceptance criteria of MT, PT and UT is;

(1) MT Appendix 6 of ASME Div.1
(2) PT Appendix 8 of ASME Div.1
(3) UT Appendix 12 of ASME Div.1
ES NO. E-101
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HEAT EXCHANGERS
B.3 Hardness Test
B.3.1 Hardness of Base Metal, Weld Metal and Heat Affected Zone (HAZ) shall be checked
as follows.
(1) For Non-PWHT Vessel : One Point per one Vessel
(2) For PWHT vessel : Two Points per one of Circumferential Welds, and
One Point per one of Longitudinal Welds, and
One Point per each Nozzle Weld
Guidelines in API 582 may be considered for the Hardness Test.
B.4 Dimensional Inspection
B.4.1 Preliminary Dimension Inspection of Heat Exchangers shall be carried out prior to
PWHT, and final Dimension Inspection shall be carried out after PWHT. Unless
otherwise specified, Tolerances for Heat Exchangers shall be in accordance with Fig. B-
1, B-2.
B.4.2 Thickness of Pressure Retaining Parts shall be checked after Forming, at least one
point of every 1 m2.
B.4.3 Heat Exchangers to be Field Assembled shall be Pre-Assembled at Shop, and any
miss-alignment, which shall be less than those specified in UW-33, shall be reported.
B.4.4 The G ap between I nterconnecting N ozzles of S tacked T ype Heat Exchangers shall
be C hecked and Reported to the PURCHASER. Tolerance of the Gap shall be ±0.8
mm.
B.4.5 100% Tube Wall Thickness Reduction check shall be performed and reported.
B.5 Hydrostatic Test
B.5.1 Hydrostatic Test shall be done prior to Painting at Weld and/or Coating.
0 B.5.2 Hydrostatic Test shall be done by Water and at the Temperature of at least 17 °C above
MDMT.
B.5.3 The Hydrostatic Test Pressure shall be held at least 30 minutes.
B.5.4 When Carbon and Low Alloy Steel Materials are exposed to Test Water, Chloride
content in the water shall be less than 100 ppm. Corrosion inhibitor such as 500 ppm
NaNo2 shall be dosed to the Test Water.
B.5.5 When Austenitic Stainless Steel Materials is exposed to Test Water, Chloride content
of water shall be less than 30 ppm.
B.5.6 Exchangers shall be drained immediately after the Testing. The Exchangers shall then
be dried by Blowing Air for controlled and limited period. For Stainless Steel Materials,
the Air Temperature shall be less than 50 °C.
B.5.7 The Gaskets applied to Hydrostatic Test shall be same as Service Gaskets.
B.6 Leak Test

ES NO. E-101
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HEAT EXCHANGERS
B.6.1 Reinforcing Pads shall be Leak Tested at least 10 kPa with Air before Hydrostatic Test.
B.6.2 Sleeve Type Nozzle shall be Leak Tested at least 10 kPa with Air before Hydrostatic
Test.
B.6.3 Tube-to-Tubesheet Joint by Welding shall be subject to Helium Leak Test prior to
Expanding. Tube-to-Tubesheet Joint by only Expanding shall be subject to Air Leak
Test after Expanding and prior to Hydrostatic test. Air Leak Test shall be Shell Side
Design Pressure or 6 kg/cm2, whichever is lesser.
B.6.4 Stacked T ype Heat E xchangers having I nterconnecting N ozzles shall be L eak
T ested in the S tacked Condition.
B.7 Inspection and Test Records
B.7.1 Inspection and Test Records for each Heat Exchanger shall be supplied..
B.7.2 Inspection and Test Records shall include (where applicable);

(1) Manufacturer’s Data Report
(2) As-built Sketch or Tabulation for Identification of the Materials showing the
location
(3) Certified Material Test Report, including Data of Impact Tests and
Records/Certificates of Non-Destructive Examination required for the
Materials
(4) Records of Production Weld Tests
(5) Time-Temperature charts of Post Weld Heat Treatment, and Records of other
Heat Treatments
(6) Records/Certificates of Non-Destructive Examination, such as Radiographic,
Ultrasonic, Magnetic-Particle and Liquid-Penetrant Examination
(7) Data/Results of Dimensional Inspection
(8) Certificates of Hydrostatic Test (including Certificate of the Test Water),
Certificates of Pneumatic Test or other Pressure Tests
(9) Rubbing of Nameplates
ES NO. E-101
FOR REV 0
HEAT EXCHANGERS
Fig. B TOLERANCES FOR HEAT EXCHANGERS

[EXTERNAL DIMENSIONS, NOZZLE AND SUPPORT LOCATIONS]
Standard Tolerances for the External Dimensions of Heat Exchangers and for Nozzle and Support locations are shown in Fig. B-1. All
Dimensions to Flange Faces are to the Gasket Surface.
0 Nominal Nozzle Size, (in.) G Max.

2 - 4 Inclusive 1.5
6 - 12 Inclusive 2.5
14 - 36 Inclusive 5
Over 36 Inclusive 6
Note: This table applies to nozzles
connecting to external piping only.
CONNECTION NOZZLE ALIGNMENT AND

SUPPORT TOLERANCES
ROTATIONAL TOLERANCE
ON NOZZLE FACES
NOTES TO Fig. B-1:

1. Tolerances given in parenthesis ( ) shall apply only to 4. For any pair of nozzles for liquid level gauge, additional
heat exchangers with inside diameters exceeding 1 500 tolerances shall be applied as follows:
mm.
a Difference in nozzle length : Max. 1
2. For heat exchangers with inside diameters not exceeding
b Distance between nozzles : ±2
1 500 mm, this figure gives the same tolerances as TEMA
Standards (Six Edition). c Difference in location from reference centerline :
3. Tolerances of the inside diameters shall be as follows: Max. 2
(1) Pipe Shells: d Alignment of flange face : ±1/4°
d
The inside diameter of pipe shells shall be in
accordance with the applicable pipe specifications.
(2) Plate Shells: c a
The inside diameter of any plate shell shall not exceed b
the design inside diameter by more than 3 mm (4 mm:
See Note 1) as determined by circumferential
measurement.
ES NO. E-101
FOR REV 0
HEAT EXCHANGERS
[TUBESHEETS, PARTITIONS, COVERS AND FLANGES]

The Standard Clearances and Tolerances applying to Tubesheets, Partitions, Covers and Flanges are shown in Fig. B-2.
STANDARD CONFINED JOINT CONSTRUCTION
t t t t t t t t t
R3 R4 R3
t
A D1
D1 D1 A
W3 A
t D3 A
t
A D2
D=I.D. DESIGN
STANDARD UNCONFINED PLAIN FACE JOINT CONSTRUCTION
t t t DIMENSIONS TOLERANCES 1. This figure is not intended to

R2 R2
A +6, -3
prohibit unmachined
R1
R1 tubesheet faces and flat cover
D1, D2, D3, D4, D5, ±0.8 faces. Therefore no plus
D6
tolerance is shown on “R4”.
D1 W1 t ±1.5
2. Negative tolerances shall not
W2=(W1+3) D4=(D1+3) (R1=5) +0, -0.8 be construed to mean that
(R2=6, R3=1.5) +0.8, -0 final dimensions can be less
than that required by design
(R4=5) -0.8 (Note 1)
ALTERNATE TONGUE AND calculations.
GROOVE JOINT W1, W2, W3 ±0.8
3. For peripheral gaskets,
“Confined” means “Confined
on the O.D.”.
4. Details are typical and do not
preclude the use of other
details which are functionally
equivalent
NOTES TO Fig. B-2:
NOTES:
1. Unless otherwise stated, all dimensions and tolerances are given in (mm).
2. Tolerances are not cumulative.
3. Tolerances indicated on Vessel Drawing shall govern.
4. This appendix shall be used in conjunction with TEMA Standards.
ES NO. E-101
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HEAT EXCHANGERS
Appendix C Painting Requirements
C.1 Painting System shall be selected from Table C-1. However, this shall be read in
conjunction with O-301 specification.
C.2 Corresponding Designation of SSPC, NACE and SIS Standards and Specifications are as
follows;
SSPC NACE SIS

SP-6 TM-01-70, No.3 05 59 00, Gr. Sa, Degree 2
SP-10 TM-01-70, No.2 05 59 00, Gr. Sa, Degree 2-1/2
C.3 Total Dry Film Thickness shall be Inspected and Recorded as follows;
Number of Points to be inspected; 1 point/ 10 m2, Min. 2 points
Acceptance Criteria; over 90 % of Specified Thickness in average

over 70 % of Specified Thickness in Minimum.
C.4 Painting Work shall be done in accordance Paint Material Manufacture’s

Recommendation.
At least, the following information shall be included in the Painting Procedure.
A. Lowest and Highest Temperature
B. Highest Humidity
C. Cleanness of Atmosphere
Table C-1 Painting System for Heat Exchanger and its Attachments
Exposed Operating Surface Paint Nos. of Thickness
Type Condition Preparation Material Coat
Temp. (°C) (µm/Coat)
V1 T≤93 SP-10 Primer: Polyamine Cured Epoxy 2 50
Finish: Acrylic Urethane 2 40
V2 (1) Not Insulated 94°C to 240°C SP-10 Primer: Silicon Acrylic 2 25
Finish: Silicon Acrylic 2 25
V2 (2) 240°C to 540°C SP-10 Primer: Silicon Aluminium 1 25
Finish: Silicon Aluminium 1 25
V3 T≤93 SP-10 Primer: Polyamine Cured Epoxy 2 50
Finish: N/A
V4 (1) Insulated (HOT) 94°C to 240°C SP-10 Primer: Silicon Acrylic 2 25
or P/P Finish: N/A
V4 (2) 240°C to 540°C SP-10 Primer: Silicon Aluminium 1 25
Finish: N/A
V5 27.2°C to minus SP-10 Primer: Polyamine Cured Coal Tar 2 200
10°C Epoxy
Insulated (Cold) Finish: N/A
V6 Colder than SP-6 Primer: Alkyd Resin 2 35
minus 10° C Finish: N/A
ES NO. E-101
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HEAT EXCHANGERS
V7 Support (skirt, saddle, SP-10 Primer: Polyamine Cured Epoxy 2 50

lugs & legs) not -- Finish: Acrylic Urethane 2 40
require fire proofing
V8 Support (skirt, saddle, -- SP-10 Primer: Polyamine Cured Epoxy 2 50
lugs & legs) require Finish: N/A
fire proofing
V9 Davit and other -- SP-10 Primer: Polyamine Cured Epoxy 2 50
attachment, Platform / Finish: Acrylic Urethane 2 40
Ladder
V10 Grating - - Galvanising - -
V11 Insulated Stainless T≤150 SP-2 Primer: Silicon 2 50
steel Finish: N/A
V12 Non-insulated - - Not require painting - -
Stainless steel
V13 Non-insulated FCC - SP-10 Primer: Inorganic Zinc Silicate 1 75
Vessels, Standpipe Finish: Silicone Acrylic 1 40
and Associate
Equipment with
Internal Refractory
V14 Insulated FCC - SP-10 Primer: Heat Resistant 1 100
Vessels, Standpipe Inorganic Copolymer or equivalent
and Associate Finish: Heat Resistant 1 100
Equipment with Inorganic Copolymer or equivalent
Internal Refractory
V15 Insulated / Non- 540°C to 650°C SP-10 Primer: Heat Resistant 1 100
insulated Inorganic Copolymer or equivalent
Finish: Heat Resistant 1 100
Inorganic Copolymer or equivalent
ES NO. E-101
FOR REV 0
HEAT EXCHANGERS
Appendix D Special Design Code Requirements
D.1 Application of ASME Boiler and Pressure Vessel Code Section VIII, Div.2 or AD
Merkablatt or BS 5500 shall be considered for Construction of Pressure Vessel
when any of the following conditions are met;
(1) Design Pressure exceeds 10 000 kPa
(2) Plate Thickness exceeds 38 mm
D.2 When a Vessel unit consists of more than one Independent Pressure Chamber, different
Code may be applied to each Chamber. In such a case, only the combination of
ASME Boiler and Pressure Vessel Code Section VIII, Div.1 and Div.2 is acceptable.
D.3 When the equipment is fabricated to the ASME Boiler and Pressure Vessel Code Section
VIII, Div.2, the VENDOR shall have a current U2 accreditation although Code Stamping is
not required for the Equipment.
D.4 When the design code is not ASME Boiler and Pressure Vessel Code Section VIII, Div.1
or Div.2, VENDOR shall check the consistency of the code requirement and the
requirement of the Pressure Vessels, D-101 (21100-4-8430-SP-0001) and Heat
Exchangers, E-101 (21100-4-8480-SP-0001), specifications and shall inform any
inconsistency to PURCHASER.
ES NO. E-101
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HEAT EXCHANGERS
Appendix E Requirements for Specific Corrosive Environment
E.1 General
This Appendix covers the Minimum Requirements required for Materials, Fabrication
and Testing of Heat Exchangers in the specific environments listed below.
(1) Wet Hydrogen Sulfide
(2) Caustic
(3) Amine
(4) Polythionic Acid
(5) Elevated Temperature
E.2 Requirements
E.2.1 General
E.2.1.1 Material shall be Fully-Killed Steel.
E.2.1.2 Stabilized Austenitic Stainless Steel, such as Type 321, 347, shall be solution Annealed
before Fabrication. Maximum Temperature of Solution Annealing shall be 1060 °C.
E.2.1.3 Plates shall be through-thickness tested in accordance with ASTM A770. Three test
specimens, subjected to anticipated heat treatment cycle, are taken through the
thickness. Minimum average reduction (“Z” parameter) of area on the three specimens
shall not be less than 35% of the initial cross section.
E.2.2 Wet Hydrogen Sulphide
E.2.2.1 H2S resistant steel shall satisfy the following requirements.

(1) Materials shall conform to the requirements of NACE MR 0103.
0
(2) PWHT (post weld heat treatment) is mandatory.
(3) The maximum hardness of base material shall be 22 HRC.
(4) The maximum hardness of the weld after PWHT shall be 200 HB.
(5) The maximum hardness on WPQT shall be as follows.
- Weld root: 250 HV10 or 5
- Weld cap: 275 HV10 or 5
(including HAZ)
(6) Pressure holding parts used in the sour environment shall have a minimum of 6 mm
corrosion allowance, unless otherwise specified.
ES NO. E-101
FOR REV 0
HEAT EXCHANGERS
(7) Materials shall satisfy the following restriction on chemical composition.

-C 0.20 % max. for plate only
- Ni less than 1% for plate, pipe and forged material
E.2.2.2 HIC resistant steel shall satisfy the following requirements.

(1) Materials shall conform to the requirements stipulated in the above paragraph E.2.2.1.
(2) Plate, pipe and tube (Note 1) materials shall be tested in accordance with NACE standard
TM0284-2003 by using NACE Standard TM0177 solution A.
- CLR shall not exceed 15.0 %.
- CTR shall not exceed 5.0 %.
- CSR shall not exceed 2.0 %.
Note 1: If HIC test could not be performed for heat exchanger tubes or air fin cooler tubes
due to small size (test coupon could not be obtained), the tube materials shall be in full
compliance with the following chemical composition requirements.
S 0.003 wt% max.
P 0.010 wt% max.
(3) Materials shall satisfy the following restriction on chemical composition.
P 0.025 wt% max. for plate only
S 0.003 wt% max. for plate
S 0.01 wt% max. for seamless pipe
S 0.025 wt% max. for forged material
E.2.3 Caustic
E.2.3.1 PWHT shall be performed when required by the Caustic S oda Service graph in
“Corrosion Data Survey” of NACE. The Temperature shown in the graph shall be
Operating Temperature of Equipment except that it shall be Metal Temperature for
Tubes of Heat Exchanger.
E.2.4 Amine
E.2.4.1 PWHT shall be Mandatory.
E.2.4.2 PWHT shall be performed at Temperature from 595 °C up to 650 °C for 1 hour per 25
mm of thickness with a minimum of 1 hour.
E.2.4.3 The maximum hardness after PWHT shall be 200 BHN.
E.2.5 Polythionic Acid

ES NO. E-101
FOR REV 0
HEAT EXCHANGERS
When Austenitic Stainless Steel is selected in Polythionic Acid Class Equipment, the
following restrictions are Mandatory.
E.2.5.1 Stabilized Type Stainless Steel shall be used. If Maximum Metal Temperature is less
than 350 °C, Low Carbon Type Austenitic Stainless Steel may be approved.
E.2.5.2 For Plate, Pipe, Tube and Forged Material, the following restriction on Chemical
Composition shall be satisfied.
(1) For Type 321 Steel: Ti/C ≥ 7
(2) For Type 347 Steel: Nb/C ≥ 10
E.2.5.3 U-Tubes after bending shall be Solution Heat Treated. The Maximum Temperature of
Solution Treatment shall be 1050 °C.
E.2.6 Elevated Temperature
When Type 304H Stainless Steel is used at Elevated Temperature above 450 °C, Ferrite
Content at weld shall be from 3% up to 8%.

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PROJECT : S-OIL Residue Upgrading Complex Project (RUCP)

PLANT : Residue Upgrading Complex

Document No. 21100-4-8480-SP-0001

0 September 07, 2015 Issue for Construction B.I.MOON

A August 12, 2015 Issue for Approval B.I.MOON

*ES NO. E-101 REVISION HISTORY SHEET*

REV.NO. DATE DESCRIPTION

THIS SPECIFICATION IS A REVISION TO S-OIL SPECIFICATION ES No. E-101

Appendix A Basic Design Requirements 25

S-OIL : S-OIL Corporation the Owner of the PROJECT.

PURCHASER : Individual or organization that issues the purchase order and

VENDOR : The Persons and Firms with whom EQUIPMENT are

1.2 Codes, Standards and Regulations

- NACE TM 0177 Laboratory Testing of Metals for Resistance to

0 1.2.2 Unless otherwise specified in TEMA Standard Class R shall be applied.

IN-47 (21100-4-8440-SP-0002) “Positive Material Identification at Supplier Works”

1.3.3 Licensor Specifications

Licensor Specifications shall be applicable to each Licensed process unit in additional to

1.5 Drawings and Documents

1.5.6 Vendor’s Drawings shall contain:

1.5.7 Vendor’s Strength calculations shall cover:

2.1 Design Pressure

2.1.1 Design pressure shall be as specified in Data Sheets.

2.2 Design Temperature

2.3 Corrosion Allowances

2.3.4 Unless otherwise required by the Governmental Regulations, no Corrosion Allowance is

2.4.7 Use of Stainless Steel Dual Certificate Materials is acceptable.

2.5 Loading Conditions and Strength Calculation

(1) Operating Condition

(2) Erection Condition

(b) Weight of Other Attachments, if any

The following generally accepted Calculation Procedure, or the equivalent, may be

2.6.1 Tolerances shall be in accordance with Appendix B “Inspection Requirement” and

Mandatory Appendix 32 of ASME VIII Div.1 shall not be applicable.

3.1 Shells and Channels

Expansion Joint Type

3.2 Tubes and Tube Bundles

3.2.2 Tube-to-Tubesheet Joints shall be Strength Welded followed by Heavy Rolled

Use of Hydraulic or Explosive Expanding is subject to PURCHASER’s Approval.

Where a No Tube In Window (NTIW) design is used, the Proposed Method of

Note. For heavier than VGO, Drain shall be 1-1/2” flange.

3.3.15 Slip-On Flanges shall not be used.

3.5 Alloy Lining

3.5.2 Nozzles attached to Alloy-Lined Shell shall be of Alloy-Lined by Integrally Cladding or

3.6 Bolts, Nuts and Gaskets

Austenitic Stainless 160

3.8.5 Alignment marks shall be provided to prevent mis-assembly of Channel Covers,

4.1 Plate Layout

4.2.4 A Formed Head shall generally be made of Single Plate.

4.4 Heat Treatment

4.4.8 Nozzle Flange Faces shall be protected properly to prevent oxidation.

5. INSPECTION AND TESTS

6. NAMEPLATE, PAINTING AND MARKING

A Nameplate as shown in the Vessel Standard, R-505 (21100-4-8430-SP-0004) shall be

6.2.4 A Detailed Procedure of Applicable Painting System (Painting Specification) shall be

7. PACKING AND SHIPPING

7.2 Packing and Preparation for Shipping

7.2.7 Demisters shall be free of wire pieces in so far as possible.

Appendix A Basic Design Requirements

A.1 Type Selection

A.2 Basic Dimensions

A.2.5 Standard Tube Thickness shall be as follows:

A.3 Design Pressure and Temperature

ES NO. E-101 REVISION HISTORY SHEET