ATTACHMENT-I
TECHNICAL SPECIFICATION OF EXCHANGERS
NOTE: DEVIATIONS IF ANY, SHALL BE MADE ONLY WITH RESPECT TO THE FOLLOWING
SPECIFICATIONS AND SHALL CLEARLY HIGHLIGHT THE SAME BY INDICATING
APPROPRIATE CLAUSE NOS. NO OTHER CONSIDERATIONS / ELABORATIONS SHALL BE
ENTERTAINED.
1.0 BRIEF SCOPE OF SUPPLY & WORK
1.1 This specification covers the requirement for exchangers Mechanical Design, Supply of material including
internals parts, complete tube bundles, lining (wherever specified) nozzles etc. preparation & obtaining
approval of design calculations, development of fabrication drawings, fabrication, inspection, testing,
Cleaning, painting, Guarantee, packing and forwarding along with spares and Documentation, as applicable
duly complete in all respects and ready to install and use.
1.2 The intent of this specification is to supplement, amend, or limit the reference codes and standards
mentioned below.
1.3 Exceptions or variations shown in the job specifications take precedence over requirements shown herein.
1.4 No variations from the Job Specifications and this specification are permitted unless approved in writing by
HPCL.
1.5 In case of any conflict between the various specifications and codes, the matter shall be referred to HPCL
for clarifications and the clarifications provided by HPCL shall be final and binding on supplier.
1.6 Preparation for shipment, transportation of the equipment at HPCL, Mumabi Refinery. Vendor to bring
necessary lifting items like winches hoists slings for unloading the equipment at HPCL Refinery.
2.0 REFERENCES
2.1 Design codes
The following codes in their latest edition including addenda at the time of bidding shall form the basis for
design, fabrication, inspection, testing, and acceptance of equipment. Wherever code is applicable for the
enclosed exchanger data sheet same shall be considered from the following list.
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
TEMA, Standards of Tubular Exchanger Manufacturers Association,
ASTM Specifications.
ASME Boiler and Pressure Vessel Code Section VIII, Division 1, Unfired Pressure Vessels.
AWS-ASME Specifications for Welding Electrodes.
ANSI-American National Standards Institution Inc. B 16.5, Steel Pipe Flanges and Flanged Fittings
and B 16.11, Forged Steel Fittings, Socket Welding and threaded (Latest Editions Approved by
ASME).
Expansion joint manufacturers Association, (EJMA) Standards.
3.0 DESIGN
3.1 General Requirements
3.1.1 Materials are specified in the Job Specifications in general terms and enclosed attachments / drawings.
Required materials shall conform or be equal, to the ASME specifications given in TEMA. Cast iron
shall be not be used.
3.1.2 Designer of exchanger unit shall be responsible for furnishing equipment that is free of overstressing
for any loading within the specified maximum loading.
3.1.3 Supplier shall check as part of his responsibility any design information issued by the owner. Any comment
and/or reservations shall be stated at the bidding stage. Modifications and/ or variations which may prove
necessary during the order phase for ensuring the full reliability and efficiency of the equipment and/or
adjusting the design to suit the job/ equipment specification the design codes local regulations or to suit the
technical and fabrication facilities of the supplier, shall be his responsibility and liability and shall in all
cases be submitted in writing for the owner’s approval.
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3.1.4 Unless expressly stated otherwise in the job specification or in the Purchase Order, shell and tube heat
exchangers shall be designed and made in accordance with references (latest editions) as specified above.
3.1.5 a) During the design of fixed tube sheet heat exchangers, considerations must be given to the stresses
induced at operating, alternate operating, start-up, shutdown and other upset conditions. Where
necessary, expansion joints shall be provided.
b) Perforated baffles are not permitted.
3.1.6 In general, tube to tube sheet joints shall be expanded. All tube- sheet holes and the grooving in them
shall conform to TEMA and the following supplements. Grooves shall be squared edged and
concentric. When heat treatment of tube sheet is required, final tube hole sizing shall be attained by
reaming after heat treatment. Refer specification by reaming after heat treatment. Refer specification
ATTACHMENT-II for “Expanded Tube to Tube sheet Joints”.
3.1.7 The tube to tube sheet join shall be welded for following cases :
a) The design temperature is < 0 Deg C or > 350 Deg C.
b) Design pressure exceeding 50 kg/ sqcm(g) for all type of exchangers.
c) When there is cladding on the tube side face of the tube sheet ( channel side, floating head side .
d) Where the high reliability of the joint is required because of lethal substance, product quality,
hazards of inter-mixing etc.
3.1.8 Where stated, tube bundles may be designed for the differential pressure given in Job Specification.
Vendor shall provide visible warning plate adjacent to, or part of, name plate outlining test pressure
regulations, when differential design is used.
3.1.9 In case of fixed tube sheet exchangers, only thick flexible expansion joint designed as per TEMA shall
be used. These shall be suitable for 500 start-up/shut down cycles and 5000 operating cycles.
3.1.10
3.1.11
3.1.12
a)
b)
c)
3.1.13
3.1.14
3.1.15
At other places, light gauge bellow type expansion joints as per EJMA may be used. These shall be
designed for 2000 start-up/shut down cycles and 7500 operating cycles.
The minimum metal temperature shall be taken as lower of o deg C or the design temperature unless
lower MDMT is specified elsewhere. The requirement shall be comply with all the code /specification
requirement for MDMT such as impact tested, heat treatment, radiography.
Provide multipurpose ( MP ) connections for pressure gauge/temperature indicator/inline
hydrotest/chemical cleaning etc. These connections shall be 40 NB flanged with BF for nozzle size 100
NB and above. For nozzles 80 NB, the MP connection shall be 1”-6000 class socket welded with plug.
For nozzles 50 NB, the MP connection shall be ¾” –6000 class socket welded with plug. Provide one
connection each on one inlet and one outlet nozzle on each side of heat exchanger. In addition,
provide vent/drain connection 40NB, flanges with BF on each side of exchanger if exchanger cannot
be vented/drained through MP connections.
Integral reinforced nozzles are required if any of the following conditions is applicable :
The design pressure exceeds 50 kg/ sqcmg.
The design temperature is < o Deg C or > 350 Deg C.
Plate thickness exceeds 50mm or there is a limitation on 1st and last baffle spacing.
All connection shall be flanges unless specified otherwise. Minimum nozzle size shall be 40 NB.
Nozzles shall be designed for external loading from connected piping. For equipment where piping
analysis is not in vendor’s scope, the loading on nozzles shall be considered in design as 100 Kg-m per
inch dia of nozzle ( moment ) and 100 kg. Per inch dia of nozzle ( force ) in each of three directions.
For other special applications such as kettle re-boilers, kettle steam generators, slurry handling, HF
acid service, Hydrogen service etc., applicable special constructional features shall be indicated in the
bid.
4.0 MATERIALS : Material shall be followed as per enclosed attachments.
4.1
Tubing :
4.1.1 All tubing shall be seamless and cold drawn.
4.1.2 Tubing shall be in the fully heat treated conditions as received from the mill. Heat treatment shall be
annealed for CS & SS tube. Copper alloy tubes shall be supplied in the annealed tempered condition.
4.1.3 Product analysis of tubes shall be carried out and reported.
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4.2 Bolting and Flange Closures :
4.2.1 Bolting shall consist of continuously threaded bolts conforming to ASTM A-193-B7 with nuts in
accordance with ASTM-194-2H unless otherwise specified. Vendor of exchanger unit shall guarantee
tightness compatibility of their closure designs. This, especially, pertains to closures where designer
amalgamates components having different thermal expansion properties. Stud bolts shall be fully
threaded. Bolt length specified is the effective thread length. Rounded or chamfered end joints
shall not be included when measuring length of bolts. The test temperature for impact testing of all
L7 bolts and grade 4 nuts per ASTM A 320 shall be -120 deg F. Nuts conforming to A 194 gr. 2, gr.
2H and Gr. 4 in sizes greater than 1/2" shall not be machined from bar stock. Nuts conforming to A
194 Gr4 in sizes smaller than 1/2" shall not be machined from cold finished bar stock. Bolts
conforming to A 320 Gr. B8 shall be strain hardened.
4.2.2 For floating head flanges, low hardness bolting such as SA 193 Gr. B 7M /SA 320 Gr. L 7M etc. shall
be used.
4.3 GASKETS
4.3.1 Metal jacketed gaskets - Gaskets shall be double jacketed enclosed by two seams with graphite
or suitable filling, shall have minimum total thickness of 3 mm before compression with jacket
thickness of 0.4 mm (min).
4.3.2 Jacket material shall be same as H E material except for carbon steel vessel, jacket shall be of
SS304 material. Gasket contact face shall be provided with smooth finish.
4.3.3 Spiral wound gaskets - metallic spirals with asbestos or PTFE filled gaskets shall have minimum
total thickness of 4 mm. Each gasket shall be provided with internal compression and external guide
ring, when not available integral in flange.
4.3.4 Gaskets shall conform to the following standards
Double jacketed
API 601 for corrugated jackets
Spiral wound
API 601
4.3.5 The grade of binders for impregnates used shall be suitable for service fluid temperature.
4.3.6 The metal windings of spiral wound gaskets shall be of 18 Cr 8 Ni unless other special material
is required by the process fluid. For operating temperatures below -50 deg F, the centering
ring shall also be 18 Cr 8 Ni.
4.3.7 For ring gaskets the hardness of the ring shall be lower than that of the flange. Where it may not
be possible to obtain this feature as in the case of various alloys, the material shall be resolved
with HPCL .
4.3.8 Manufacturer shall furnish gaskets for intermediate flanges between multiple shell, direct connected
exchangers.
4.3.9 The hardness of the metal for solid or clad gasket is not to exceed the following values :
Iron, copper, brass, or other soft metals : Max. 80 Brinell.
Stainless steel, Monel, or other hard alloys, Brinell number as low as possible and to be minimum 15
Brinell lower than for the material of the flange gasket facing.
4.3.10 All gaskets shall be made in one continuous piece all around including the pass ribs and therefore
must be cut from one sheet.
4.4
PLATES :
4.4.1 The carbon content of CS boiler quality plates shall not exceed 0.25%.
4.4.2 Carbon steel plates to specification SA-515/516 shall be in the normalized condition.
4.4.3 Plates having thickness 16mm to 50mm ( both inclusive ) shall be examined ultrasonically as per
ASTM-A 435.
4.4.4 For thickness above 50mm, ultrasonic examination shall be carried out as per ASTM-A- 578 and shall
have acceptance standard of level-I. Ultrasonic examination shall be done after the specified heat
treatment of plates.
4.4.5 CS Boiler quality plates/ low alloy steel plates above 50mm in thickness shall meet the following
additional requirements :
i)
Vacuum treatment as per the supplementary requirement S1 of SA 20.
ii)
Charpy V-notch test as per the supplementary requirements S5 of SA20 Test temperature : Minus 26
Deg C or lower as specified in SA 20/ individual materials .
iii)
Acceptance criteria : As per Table A2.15 of SA 20.
Orientation of test bar : Transverse to the direction of rolling.
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For material SA-515 Gr. 60/70, values for SA-516 Gr. 60/70 shall be taken.
iv)
Bend test as per the supplementary requirement S14 of specification SA 20.
4.4.6 All SS plates shall be hot rolled annealed and pickled and shall have No.1 finish on both sides with
reference to SA-480.
4.4.7 Plates representative of each heat shall be intergranular corrosion tested as per ASTM A-262 practice E
for all 300 series SS materials.
4.5
4.5.1
4.5.2
4.5.3
4.5.4
FORGINGS :
Flanges shall be forged weld neck type.
All pressure forging for CS and L.A.S. shall be in normalized and tempered condition.
The carbon content of CS forging shall not exceed 0.25 %.
CS forging above 75mm, all tubesheet forging and all forging of other materials shall be 100%
ultrasonically tested as per ASTM A-388. Acceptance standards shall be a sper AM 203.2of ASME
Section VIII Div. II.
4.6
PIPES
4.6.1 All pipes shall be seamless..
4.6.2 All LAS pipes shall be procured in normalized & tempared condition.
5.0 DESIGN & DRAWING APPROVAL
5.1 DRAWING REVIEW / APPROVAL: The complete design of the equipment design calculations and
all fabrication drawings (incl. Test rings) are to be reviewed and approved by Third party Inspection.
After approval of third party inspection, vendor has to obtain the HPCL's approval for design
calculations and fabrication drawings. HPCL shall have the authority to alter the specifications even after
approval of third party’s approval. Fabricator should stand guarantee for design of the exchanger. HPCL
shall have the authority to alter the specifications even after third party’s approval. All As-built tracings
& prints shall be duly signed by Third party inspection.
5.2 In case of equipment requiring inspection by an independent authority like Lloyds, the supplier shall
obtain the necessary approval after getting the preliminary approval from HPCL
5.3 Thickness mentioned in the drawing is indicative. Vendor should recheck the thickness of the Equipment
provided in the drawing as per code. If the provided thickness is not sufficient as per code vendor has to
provide the code thickness as per calculations. Otherwise provided thickness in the drawing shall be
opted for fabrication. For new design irrespective of material using in exchangers, Allowable Material
strength shall be considered as 17100 psi for calculation purpose.
For 23-E-6 A/ B/ C, exchangers shall be fabricated identical to the drawings submitted as V-3208 (4
sheets). However, vendor to check all parts to meet Code requirement. For any improvements to meet
good engg. Practices, Code, Standards, please inform HPCL for upgradation.
Purchaser’s order number and fabricator’s shop order number, client’s name, location of plant, item
number etc.
5.4
5.5 HPCL’s review of drawings shall not relieve the Vendor of his responsibilities in any manner. The
drawings shall be submitted alongwith the design calculations.
5.6 The supplier shall not proceed with the fabrication of the equipment unless the design and drawings are
approved by HPCL/Inspection Authority.
5.7 DEVIATIONS
In general, no deviations from HPCL standards and specifications shall be permitted. This does not
preclude possible innovations or improvements on the part of the supplier based on available facilities.
Such deviations must be clearly points out as a separate paragraph entitled “DEVIATIONS” in the
supplier’s bid, so as to avoid any confusion and ambiguity and to facilitate analysis of quotation in
minimum possible time. It shall be taken for granted that except for the deviations pointed out under the
“DEVIATIONS” paragraph, all other technical requirements shall be adhered to, by the supplier No
deviations shall be incorporated, unless it has been approved in writing by HPCL. It is in supplier’s own
interest to get the written approval of HPCL for all deviations before accepting the Purchase Order. No
deviations shall be entertained or approved after the Order has been accepted by the Supplier. Delay in
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supply of the equipment, on account of such deviations being not entertained or approved by HPCL shall
be contractor’s liability.
In case there are no deviations required by the supplier, quotation under the “DEVIATIONS” paragraph
shall read as “EQUIPMENT SHALL BE SUPPLIED AS PER HPCL’S SPECIFICATIONS, CODES
ETC., IN ALL RESPECTS” It shall be presumed that supplier has understood very clearly the job
requirements and shall fully comply with them.
6.0 MATERIAL SUPPLY
6.1 All materials and accessories required for the fabrication of the heat exchangers shall be supplied by the
supplier unless otherwise stated. All materials procured from outside India shall be inspected by reputed
third party inspection agency shall be borne by vendor. Mill test certificates alone are not final.
6.2 Stainless steel name plate shall be provided by the supplier on each heat exchanger shell.
6.3 Test rings, dummy shell and test flanges shall be designed and supplied by the supplier. Drawings for
these also shall need prior approval of HPCL. Material used for fabricating these shall be of tested
quality. The number of test ring/ test flange assemblies shall be equal to the number of shells stacked.
6.4 Test ring shall be provided for all floating head exchangers with bonnet on channel side and for channel
with flat covers having test pressure on tubeside greater than shell side. Design all testing accessories for
testing the bundle outside the shell for exchangers with design pressure on tubeside greater than shell
side. Only one set of Test Ring to be provided for 3 (three) nos. of exchangers 23-E-6 A/B/C.
6.5 All necessary arrangements such as supports, blind flanges, test gaskets, bolts, nuts and other accessories
shall be provided by the supplier for testing of heat exchangers.
6.6 Supplier shall include in his quotation supply of tie bolts, leveling shims or intermediate supports for
stacked units, gaskets, nuts and bolts relating to interconnecting nozzles ( tube and shell side). All these
components shall be dispatched separately with due care having been taken regarding identification of
these for ease of installation. Supplier should also include for minor modification/additions like ladder
and insulation cleats etc. which may be required at a later stage.
6.7 It is deemed that supplier shall supply the equipment strictly as per the requirements of the codes,
specifications etc. As such it is presumed that unless indicated under the “DEVIATIONS” paragraph of
the quotation, the dimensions and materials for various components in a heat exchanger are as per
HPCL’s requirement. This does not preclude use of equivalent or better materials. However, these
deviations should be clearly indicated in the quotation. If an equivalent material sought by the supplier is
to a specification, other than IS or ASTM/ASME, it might be necessary for the supplier to submit the
specifications of the equivalent material ( translated in English language, if the original is not in English).
7.0
SPARES TO BE SUPPLIED BY SUPPLIER
7.1 The supplier shall supply 20% extra studs and nuts but not less than 4 studs with 8 nuts for each pair of
mating flanges, interconnecting nozzles, nozzles with blind flanges etc.
7.2 The supplier shall also supply four sets of spare gaskets other than those used or testing and/or during
transportation.
7.3 Any other spares, tools and tackles required for two years operation/ maintenance shall be supplied.
Supplier shall submit the details of such spares in the bid package.
8.0
FABRICATION
8.1 Plate Cutting .
8.1.1 Carbon and Low Alloy Steels : Carbon steel and low alloy steel plates are to be cut to size by flame
cutting and/or machining. When plate thickness does not exceed 25mm, cold shearing may be used,
provided that the sheared edge is cut back by machining or chipping for a distance of 1/4th of thickness of
plate but in no case less than 3 mm. All plate, edges after cutting shall be examined for laminations to
ensure that the sheared edges are free from cracks. Dye penetrant and ultrasonic check of edges forming
main weld seams is recommended especially for higher thickness plates when these plates are used for
low temperature or hydrogen service. For low alloy steel plates, edges of plates shall be preheated before
flame cutting
8.1.2 Austenitic Steels : Austenitic stainless steel plates should be cut by plasma cutting, however for
thickness upto 15mm cold shearing may also be adopted. In all cases the cut edges will be ground back
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8.2
by 2 to 3 mm and checked for laminations and cracks. It is recommended that cut edges forming main
weld seams of pressure containing parts be checked ultrasonically or by dye-penetrant examination
Handling of Materials : To preserve the quality and finish of the materials and to avoid any rusting, and
minimize additional cleaning etc., following preventive measures should be taken care of :
Material should be kept in original cases or wrappers until fabrication actually begins. Cases or
wrappers may have to be opened for initial inspection, but after inspection, these should again be
carefully packed. These should be stored indoors on clean racks, shelves or platforms and should be
suitably covered and kept free of shop dirt, pickling or plating fumes, particles or scale from steel
fabrication, lubricating oil etc.
Fabricating equipment should be cleaned of all residues before being employed for a new operation on
SS. Paper or other protective covering should be placed on all surfaces.
a)
b)
8.3 Rolling and Dishing of Plates
8.3.1 Rolling : Rolling of plates shall be in longitudinal direction of the plates. The direction shall be
clearly marked on the plates. Re-rolling after welding is not normally recommended. However, if for
large diameter shells, rerolling of welded shell course is required, this shall be done in the presence of
the owner’s authorized inspector. All welds on the section to be rerolled must be ground flush. After
rerolling, all the welds on the rerolled section must be checked by the dye penetrant test. Such welds
shall then be subjected to radiography as required by drawings/ codes.
8.3.2 Dishing : All dished heads shall be single piece construction and ellipsoidal in shape. Torispherical
dished heads with knuckle radius greater of 3T or 15% and crown radius 80% of OD are also
acceptable. Straight face shall be minimum 38mm or 3T whichever is more ( T being nominal
thickness of plate from which forming is done ). Straight face in any case need not exceed 50mm
unless specifically indicated otherwise. Dished heads shall be subjected to dye penetrant test on
knuckle portions ( both inside and outside ) and weld edges after heat treatment. All carbon steel and
low alloy steel heads shall be normalized if not formed in normalizing range. All SS dish heads shall
be solution annealed after forming.
8.4 Welding : All welding procedures shall be submitted to HPCL /Third party inspection agency for
approval giving all relevant details. Welding qualification records shall indicate hardness values of weld
metal, HAZ and parent metal and also results of impact tests when design temperature is 0 deg C or
lower or when specifically indicated for materials being welded. No welding shall be undertaken until
the welding procedure and welder’s qualifications have been approved by HPCL and/ or by the
authorized inspection agency. All welding procedures and welders shall be qualified for the particular
type of welding and material in accordance with the ASME Boiler and Pressure Vessel Code, Section IX.
Supplier shall be responsible for the quality of the welds performed.
8.4.1 Welded Joints and Procedures : Pressure holding butt joints shall be full penetration double side
welded butt joints. Root pass of single side welded butt joints shall be done with TIG welding and
with Argon gas purge. This procedure shall also be followed for tube-sheet to shell welds in fixed
tubesheet heat exchanger. Backing strips for single side welded butt joints is not permitted. All other
pressure holding welds, and welds of lugs etc. with pressure parts, shall be full penetration and shall be
DP/MP tested.
8.4.2
8.4.3
All internal welds on the shell, shall be ground flush from inside. All other welds may be left in the
descaled condition only. However, for LTCS materials, even these shall also be ground flush or
dressed smooth.
Staggering of Weld Seams : Longitudinal seams shall be staggered with a minimum circumferential
distance between the centers of welds of 5 times the thickness of thicker plate. Weld seams shall be so
located as to avoid connections and external attachments.
External Attachments : External attachments like lugs, supports etc. of carbon steel shall not be welded
directly to high alloy or austenitic stainless steel heat exchanger components. These attachments
should be of the same material as the heat exchanger component. If this is not so, intermediate pad
plates of the same material type as the heat exchanger component may be used. These pads shall be at
least 100mm wider and longer than the attachment and shall be at least 5 mm thick. Welding of carbon
steel to austenitic stainless steel shall be done with 25% Chrome-12% Nickel electrodes ( AWSASTM-E-309).
Vendor to provide Insulation Cleats. Insulation will be carried out by HPCL.
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8.4.4
Tube - Tube Sheet Welding : Tube-to-tube sheet welding, if specified in the heat exchanger drawing
shall be carried out as per procedure approved by HPCL / third party inspection agency. No distortion
whatsoever shall be permitted on the gasket seating surfaces due to tube to tube sheet welding. If
distorted, the same shall be machined suitably.
8.4.5 Partition Plate Welding : For CS and 300 series SS, except for low temperature service all partition
plates shall be welded to channels etc. by minimum 6mm continuous fillet welds on both sides. For all
other materials and low temperature services, all partition plate to channel welds shall be full
penetration. Partition plates thicker than 10mm shall be tapered to 10mm at partition groove, except
when mentioned otherwise on drawings. One No. 6 dia weephole shall be provided at the center of
each horizontal pass partition plate and a 5mm radius notch on top/bottom point of each vertical pass
partition plate for all multipass exchangers for effective venting and draining.
8.4.6 Welding Consumables : All welding shall be done with electrodes, fillers and fluxes of reputed make,
with reproducibility of results. Electrode shall be used only ADVANI ORLICKON/ ESSAB/D&H. For
CS pressure parts, the electrodes shall be of low hydrogen type.
8.4.7 The cladding shall be cut back at all seams to permit back welding of the basemetal. Weld metal shall
be ground flush and fully covered with the applicable weld deposit. The weld deposit shall be at least
as thick as the lining.
8.4.8 The cladding shall be 100% ultrasonically examined for lack of bond after forming and, if necessary,
repaired by weld overlay of the same or similar analysis. Nozzles may also be clad by explosion
bonding with the same examination as for clad heads, or tubular liners may be used which shall be
welded to the alloy facing at the flange end and to the inside flush with the exchanger vessel.
8.4.9 All weld overlay, whether manual or automatic procedure, shall be liquid dye penetrant examined in
accordance with the methods described in ASTM-E165. When the overlay involves two passes (
Layers ) and the procedure uses an intermediate heat treatment with cooling to room temperature prior
to applying the second layer, each layer shall be examined. Where overlay is to be machined, such as
in nozzles and flange facing machined surface shall be examined. If 100% of overlay is examined
prior to the final post weld heat treatment, the overlay shall be spot examined ( no less than 10% of the
surface ) after heat treatment. Spot examinations hall be conducted after shop hydrostatic testing.
8.5 Tube sheet and Baffle-drilling etc. : Tube holes in tube sheets shall be drilled so as to allows not less than
0.8mm in diameter of metal for reaming. These shall then be reamed to final size. Before the final
reaming operation is done, supplier should check the actual OD of the tubes for the respective heat
exchanger. This is of major importance in case of austenitic stainless steel tubes. Tube hole grooving in
tube sheets shall be carried out. Tube holes in baffles and tube sheets shall be deburred and cleaned
before assembly. The interior surface of the tube holes in tube sheets shall have a smooth finish and be
free from spiral scratches and scores.
8.6 Cleaning of Tube Holes : After the reaming operation, suitable precautions shall be taken to ensure that the
interior surfaces of the tube holes are maintained free of rust, until tubes are inserted. Before insertion of
tubes, tube holes and tube ends must be free from oil, grease, dirt and protective coatings ( on tubes as
received from mill ) and other foreign matter. For this purpose the tube ends must be thoroughly cleaned
for a distance of at least one tube sheet thickness plus 30mm. Cleaning solution should be chlorides free
( especially for stainless steels ) and should not lead to fire hazards. This solution may be sprayed by an
air-pressured spray gun.
8.7 Nozzle Flanges, Nozzles and Reinforcing Padss
8.7.1 Flanges : Unless otherwise indicated, dimensions, drilling, facing and tolerances for nozzles flanges (
and blind covers if required ) up to 24” NB shall be as per ANSI B 16.5 for the respective class.
Flanges above 24” NB shall be as per API 605, unless indicated otherwise. Bolt holes on these nozzles
flanges shall straddle principal vertical and horizontal centerlines of equipment. If the component to
which nozzles are attached is subsequently stress relieved, it shall be supplier’s responsibility to
maintain true gasket faces by machining or otherwise. If distortion expected is considerable, final
machining operation should be done after stress relieving, sufficient matching allowance for this
purpose should be available. Nozzle flange facings, gaskets, and bolting details for nozzles with the
piping specification and class shall be indicated on the drawing.
8.7.2 Nozzle Pipes : Nozzle pipes shall be attached to the heat exchanger components by full penetration
welds. Attachment welds using only inner and outer fillet welds are not permitted. Unless otherwise
shown on the drawings, necks of all nozzles shall be flush with the inside of the heat exchanger
component. Inside corners of nozzle pipes of shell/ channel ID shall be rounded off to 3mm radius. All
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nozzles 2” and below shall have two stiffeners 30 wide x 6 thk at right angles. Pipes shall be to ANSI
B 36.30 or 36.19 as applicable.
8.7.3 Reinforcing Pads and Testing : Reinforcing pads whenever required as per codes shall be of the same
material or equivalent as the heat exchanger component to which it is welded. All reinforcing pads
shall be provided with two 1/8” ( 3mm ) NPT tapped holes located 180 Deg apart for air-soap solution
test. This test shall also be required to be carried out for slip on flanges. Pressure of 1.25 kg/ sqcmg is
suggested for these tests. Higher test pressure are not recommended because of accompanying risks
and also because the soap bubbles have a chance to blow off. Tell-tale holes in the reinforcing pads
shall be plugged with heavy grease unless otherwise indicated.
8.8 Bolts, Studs etc. & Tapped Holes : All inch bolting and threading shall conform to ANSI B 1.1 except
for size 1” and above where it shall be 8 threads per inch. Metric bolting/ threading shall conform to
ISO-261 ( coarse ), tolerance medium, except for size M 24 and above, where it shall have 3mm pitch.
Studs shall extend beyond the nut by about 10mm, and shall be threaded full length. Threads on external
bolting, plugs etc. shall be lubricated with graphite grease for working temperatures upto 200 Deg C and
with molybdenum disulphide for higher temperature. All nut seating faces shall be machined or spot
faces. Tapped holes drilled on the channel side face of clad tube sheets for removable bundles shall be
fitted with plugs of a material similar to channel side material. Eye bolts for these shall be provided
loose and unless otherwise indicated, shall be of carbon steel forged. Flanged joints shall be provided
with jack screws and necessary lugs as per HPCL Standard. For extended tube sheets, tapped holes shall
be provided for girth bolting. Studs for these shall have square ends. Nut height shall be equal to bolt
diameter.
8.9 Assembly and Handling : Suitable method of alignment like dowels etc. shall be provided to prevent
misassembly of channel, channels covers, stationary tube sheet etc.
8.9.1
Heat Exchangers, which are stacked in service, shall be assembled in the workshop for a trial fit.
Special care shall be exercised in truing up connecting nozzle flanges. Complete assembly shall be
given a hydraulic test as a single unit except when the test pressures for individual heat exchangers are
different.
8.9.2 In case of removable bundles :
a)
Stationery tube sheets shall be drilled and tapped at vertical ( 0 deg C ) position for attaching eye bolts,
or a lifting lug of adequate thickness shall be welded with 25 dia hole ( min. )
b)
Drilling and tapping as above may be carried out on floating tube sheet.
c)
Last support plate shall be drilled ( 25 dia ) for lifting. Local stiffening may be necessary to adequately
support the bundle.
d)
The tube bundle pulling force shall be taken as 100% of the tube bundle weight.
8.9.3 Adequate lifting and handling lugs etc. shall be provided by the fabricator to ease handling, lifting,
erection etc. of the complete equipment.
8.9.4 Pulling eye bolts shall be provided for all removable bundles.
8.9.5 Davits shall be provided for removal of channel, channel cover, shell cover and floating head
assembly.
8.10 Descaling, Pickling etc.
Descaling, pickling and passivation shall be done for all stainless steel surfaces or parts which are
subjected to high temperature ( 500 deg C and above ) during forming ( like U-bending of tubes or
dishing ) or welding. The supplier shall supply details of the procedure for approval.
8.11 Fabrication Tolerances & Finish
8.11.1 The dimensional tolerances shall be within the limits indicated in standards. Where tolerances are not
specified, these shall be in accordance with the requirements of TEMA ( Latest Edition (.
8.11.2 All edges and corners shall be deburred ( or radiused if shown ).
8.11.3 Finish of all machined components shall be minimum 12 microns ( 500 RMS ) unless otherwise
indicated parts subjected to ultrasonic examination shall have minimum finish of 6 microns.
8.11.4 Tube sheet faces shall be flat within +/- 1.5mm ( camber ).
8.12 For non- ferrous heat exchangers, paragraph NF 7 and NF 14 of appendix NF in part UNF of section
VIII Div. I of ASME Code are mandatory. This applies to non-ferrous cladding or applied lining also.
9
RADIOGRAPHY AND OTHER NDT REQUIREMENTS
9.1 General
9.1.1 The minimum extent of radiography shall be spot.
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9.1.2 Supplier shall allow for full radiography in case of heat exchangers, which fall under the following
categories :
a) For exchangers under IBR
b) Where the relevant design code/ specification does not permit a lower class of construction.
9.1.3 All pressure retaining welds which are not subjected to be radiographic shall be subjected to either
magnetic particle or dye penetrant check or both at the discretion of the inspector after root pass
welding, final welding and back chipping.
9.1.4 Radiographic and other requirement for low alloy steel welds shall be in the heat treated and final
condition.
8.1.5 If radiography is being substituted by UST for the final closing seam as permitted by code, magnetic
particle inspection shall be carried out in addition to UST.
9.2 Spot Radiography. : When spot radiography is asked for, it shall mean that at least 10% of the total
welded length must be radiographed. Length of each radiograph shall be atleast 250mm. Further, all ‘-‘
joints must be radiographed and at least one shot must e taken on each longitudinal and circumferential
seam. The owner’s authorized inspector shall mark the areas to be radiographed. This requirement
shall supplement the ones specified in ASME Section VIII Div-I.
9.3 Acceptance Standards or Radiography.
Acceptance standards for radiography shall be as per ASME SECTION VIII DIV .1.
10
HEAT TREATMENT
10.1Post Weld Heat Treatment ( PWHT ) shall be done when required by relevant fabrication specification,
codes, service conditions etc. No welding or heating is permitted after PWHT Operation.
10.1.1. In addition to code requirements CS and LAS shall be PWHT including tube to tubesheet joint if
welded, if :a) Low temperature below 0 Deg C. ( Tube to tubesheet joint excluded for temperatures warmer than
b) Under IBR.
c) Other services where stipulation of hardness of welds are applicable.
d) Other services where stipulation of impact tests of welds are applicable.
10.2 All machining operations shall be carried out after heat treatment. It shall be the responsibility of the
supplier to leave sufficient allowance for this purpose.
10.3 Supplier shall submit the procedure for PWHT alongwith the fabrication drawings for HPCL’s approval.
10.4 Contact expansion in case of welded tube to tube sheet joint shall be done after PWHT.
11 INSPECTION & TESTING
11.1General
The inspection shall be carried out by the owner’s authorized representative, here-in-after referred to as
the authorized inspector.
The materials, fabrication, and testing of exchangers shall be open to inspection by the authorized
inspector in addition to any inspection required by the specified code or by local authorities having
jurisdiction over the installation.
a)
b)
c)
d)
e)
f)
g)
h)
i)
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Inspection shall be carried out both during fabrication and before delivery and also for sub ordered
materials, in any. In addition to final inspection and certification by inspector; during the course of
manufacture, authorized inspector’s written approval shall be obtained by the supplier at all stages of
fabrication including .
Raw material identification.
Edge preparation for welding, including visual check for laminations.
Alignment of longitudinal and circumferential seams.
Rolling tolerances on individual section.
Alignment of sections and components.
Root pass clearance before welding and cleaning.
Thinning of dished ends and toriconical pieces after forming.
Checking of tube sheet after drilling, including visual check for laminations.
Tubesheet to shell set up for fixed tubesheet exchangers, prior to welding operation.
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The presence of the authorized inspectors shall not modify or reduce the obligation of the supplier to
carry out his own tests and control. Should any material and/or equipment be found not in compliance
with the requirements specified, the authorized inspectors or their delegates shall be entitled to
irrevocably reject them, even if such non compliance has not been evidenced in the course of inspection
and/or tests.
The authorized inspector will, at the time of his initial visit, set up with supplier actual details of
inspection stages to be witnessed or carried out ; the schedule of further visits and subsequent inspection
notices can be arranged between the inspector and the supplier.
The supplier shall notify the authorized inspector sufficiently in advance of any fabricating operations to
permit him to arrive at the vendor’s shop in time to witness the operations.
Prior to final inspection, all slag, weld spatter, loose scale, dirt, grit, paint, grease, oil and other foreign
matters shall be removed in order to facilitate inspection. All reinforcing pads and slip on type flange
welds shall be pressure tested with air and soap solution before and after heat treatment ( if any ) and
before final hydrostatic test.
A dimensional checking of equipment shall be carried out taking into account the tolerances shown on
HPCL standards, design specifications, or applicable codes. The more stringent values shall govern.
Dimensional checks are to be taken of the internal measurements of equipment together with external
ones and these are to be recorded on a copy of the drawings as being the “as made” dimensions.
11.2Hydrostatic and other tests
11.2.1 These tests shall be witnessed by the authorized inspector. When hydrostatic tests are performed the
indicating gauge shall be connected to the upper most part of the equipment. Testing water shall be salt
free. For stainless steel equipment and exchangers with SS bellows, use demineralised water or
condensate. Final hydrostatic tests shall be carried out using service gaskets and the equipment shall be
dispatched in as tested condition. Minimum metal temperature during hydrostatic tests shall be 20 deg
C. Test pressures shall be maintained for at least one hour.
Shell and tube sides shall be tested separately, unless otherwise mentioned on the drawings. For
tubesheet designed for differential- pressure, special care shall be taken during testing. Equipment
drawings shall clearly indicate by a note, if tube sheets have been designed for differential pressure.
11.2.2 All vertical exchangers shall be tested in vertical position. Alternatively test pressure may be modified
with prior HPCL approval.
11.2.3 Stacked exchangers, with nozzles interconnected shall by hydrotested in the stacked condition.
11.2.4 The third party inspection agencies will be either of the following
A) LLOYDS
B) BUREAU VERITAS. C) CEIL D) DNV E0 BAX COUNSEL
11.2.4 Irrespective of third party inspection, HPCL will have the right to visit vendor's premises to
ascertain quality and progress of the jobs. All third party inspection charges will be reimburse after
submission of authentic documents to HPCL
11.2.5 All materials to be approved by third party inspection Sample to be provided free of cost for
owner's test.
12.0 STAMPING AND NAME PLATES
12.1
NAME PLATE
Each exchanger will be fitted with a name plate as per standard.
12.2
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Item Number Stamping
The following exchanger parts shall bear owner’s exchanger item number :
Shell girth flanges, shell cover flanges, channel girth flanges, flat channel cover, stationery and floating
tubesheets, floating heat cover flange, floating head backing ring, connecting pieces, test rings, test
flanges and other main removable parts.
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These parts shall be stamped except for heat exchangers in low temperature service, where the item
number shall be marked with non-removable ink.
13.
DATA FOLDER
13.1 Supplier shall supply five (5) bound copies of data folders containing the following
information :
a) All drawings shall be developed on AutoCAD rel 14
b) Manufacturer’s data report ( code certificate)
c) Exchanger outline drawing and part drawings corrected to show the actual dimensions “as built” on A1 /
K size a sheet .
d) Certified material test report, showing location, heat numbers, chemical analysis, and physical properties
of all materials used in the fabrication of the exchangers.
e) Reports of tests made on welded test plates, if any such tests are made.
f) Photostat copy of the temperature recording chart obtained during heat treatment. The cycle of heating,
soaking and cooling shall be shown.
g) Copies of hydrostatic and other test reports.
h) Copy ( rubbing ) of name plate.
i)
Records of radiographic examination.
j)
Photostat copy of approving agency’s certificate if any.
k) Method of packaging proposed with sketch showing anchorage.
l)
Any other documentation as required.
m) Guarantee Certificate for the material supplied by the vendor as per Guarantee clause given above.
n) One no. As-Built transparencies (non tearable Technova) plus soft copy in latest AUTOCAD
version.
Vendor shall submit following documents at different stages as described below :
P = Prints
R = Reproducible
Documents
For Approval
Final
_____________
_______________
_______
Design Calculations
3P
5P *
Fabrication drawings
4P
5 P+1R *
Stage Inspection Reports * 4 p
5P
Final Inspection Reports * 4 P
5P
Material Test Certificate * 4 P
5P
NDT Records *
4P
5P
Guarantee Certificate
-
5P
NOTE :
1) Documents Marked * thus shall be submitted duly signed & approved by Inspection -inCharge.
13.2Equipment shall be dispatched only after the completion of the data folders.
14.0
PROTECTION AND DISPATCH
14.1General After completion of all testing and inspection, the inside of complete equipment shall be
thoroughly drained and dried out. Equipment shall be completed dried by passing hot air for sufficient time
until no further increase in relative humidity of outgoing air is observed. Dry-out shall be done
simultaneously on both shell and tube sides. Flange faces shall be covered by a suitable rust preventing
easily removable oil and protected by temporary steel covers. Opening shall on no account be fitted with
tapered wooden plugs for this purpose. All threaded holes shall be suitably protected with steel bar plugs.
The exchangers shall be filled with Nitrogen at 0.25 kg/sqcm pressure, and a non return valve provided.
Write a note in bold capital letters. “ Equipment filled with Nitrogen “Exchanger shall be shipped
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alongwith complete “Packing and Shipping Instruction”. For imported exchangers, the packing shall be
seaworthy.
14.2 Shop Painting
Painting shall be carried out as per specification given below.
14.2.1 Shot Blasting : It shall be as per Sa 2 1/2
14.2.2 WASHING WITH FRESH WATER: All bare lines/ vessels/ equipment shall be fully cleaned by fresh
water before cleaning / shot blasting to remove all possibilities of salt deposits. The subject surface shall
be also cleaned before application of next coat if area is subject to salt-water sprays.
14.2.3 PAINTING AFTER CLEANING: The primer coat shall be applied within 4 hours of cleaning.
However, if rust spots appear even during this interval, the same shall be re-cleaned and re offered for
inspection before applying the paint.
14.2.4 RECOMMENDED VENDORS : The quotations should be invited only from the following vendors on
apply and supply basis.:
Asian Paints, Berger Paints, Bombay Paints, International Paints, J & N, Shalimar Paints
a) BARE VESSELS/ EXCHANGERS / (Maximum Surface Temp = 100 deg C):
Specification
No of Coats
Application
Method
Thickness
(DFT in
microns)
Surface Preparation : Shot Blast to Sa 2 ½
Primer
- Inorganic Zinc Silicate
ONE
Airless spray
1 X 60 = 60
b) ALL OTHER BARE EQUIPMENT & SURFACES For WHICH Surface Temperature is between :
above 100 to 300 Deg C
Specification
No of Coats
Application
Thickness
Method
(DFT in
microns)
Surface Preparation : Shot Blast to Sa 2 ½
Primer
Finish
- Heat Resistant Al-Silicone Paint
- Heat Resistant Al-Silicone Paint
ONE
ONE
Brush
1 X 20 = 20
Brush
1 X 20 = 20
TOTAL DFT = 40 microns
Note: No temperature curing is allowed for the Heat Resistant paint of this system.
14.3 No equipment shall be released for shipment until the authorized inspector approves it.
14.4 Equipment to be delivered to HP Fuels Refinery
and to be unloaded with the help of
owner's crane. Transit insurance to be arranged by the vendor.
Carbon Steel external surfaces other than flanged faces and other machined surfaces shall be given one
shop coat of primer paint. Surfaces to be painted shall be prepared for painting by removing loose mill
scale, rust, oil, grease and other films or substance harmful to the adhesion of paint. Shop coat shall be
zinc chromate.
14.5 Identification : The equipment item number, P.O. number and owner’s name and address shall be painted
in bold white paint letters written with stencil, on the heat exchanger.
14.6 Dispatch of Equipment : No heat exchanger shall be released for shipment until it has been approved by
the authorized inspector. Heat exchangers shall be dispatched after operations as required by above
clauses have been carried out and shall be dispatched in as tested condition.
Heat exchangers shall be securely anchored for dispatch in order to prevent any shifting and damage
during transportation. Expansion joints and bellows, wherever encountered shall be suitably protected
against any possible damage. Packaging shall be suitable for rail or road transport, and also sea worthy if
required. Spare gaskets and other loose spares shall be dispatched separately in a box and marked with
P.O. number, equipment item number and owner’s name and address.
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15.0 GUARANTEE
15.1 The supplier shall guarantee that the equipment furnished is free from fault in design, workmanship, and
material and is of proper size and capacity and is of proper material to fulfil satisfactorily the conditions
specified. Should any defect in design, material or workmanship develop before or during the guarantee
period, the supplier agrees to make all necessary or desirable alterations, repairs, and replacements of
defective equipment free of charge and shall pay transportation costs involved to and from the user’s
plant. No allowance will be made for alterations or repairs made by others without written consent or
approval of supplier. If the defect or failure to function cannot be corrected, the supplier agrees to replace
promptly, free of charge, said equipment or to remove the equipment and refund the full purchase price. In
no case will the supplier be responsible for contingent liability.
15.2 The guarantee period unless otherwise indicated in the tender documents shall be 12 months from the date
of commissioning or 18 months from the date of dispatch whichever is earlier.
16.0 PATENT INFRINGEMENT
16.1 Supplier shall defend any and all infringement suits in which the owner and or HPCL is made a defendant,
alleging patent infringement on equipment purchased from supplier. Supplier shall pay all costs and
expense incident to any such litigation. It being further agreed and understood, however, that HPCL shall
have the right to be represented therein by counsel, of their own, selection and paid by them. Supplier
shall pay all damages, profits and/or cost which may be awarded to the plaintiff in any such litigation;
and, in general, shall defend purchaser and/or HPCL against all claim or demand of every kind to which
they may be subjected under the patent laws, in connection with equipment purchased under this
specification.
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