ANNEXURE VIII

ES 3201

RCF LTD, TROMBAY

SHEET 1 OF 23

ENGINEERING STANDARD
HEAT EXCHANGERS

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 2 OF 23

CONTENTS

CLAUSE
NO.

DESCRIPTION

SHEET NO.

1.0

GENERAL

2.0

RESPONSIBILITY OF SUPPLIER

3.0

MECHANICAL DESIGN

4.0

MATERIALS

5.0

SCOPE OF SUPPLY

11

6.0

FABRICATION

12

7.0

INSPECTION AND TESTING

16

8.0

CLEANING, PAINTING AND DESPATCH

18

9.0

GUARANTEE

20

10.0

DOCUMENTATION

21

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 3 OF 23

1.0

GENERAL

1.1

The specification defines the responsibility of the supplier and covers supplementary
requirements relating to design, materials, fabrication, inspection, testing,
painting, packing and dispatch etc. The specification shall be read in conjunction
with code, specification sheet and other enquiry documents. In case of conflict
between code and enquiry documents, the vendor shall contact TPI for
clarifications. As a general rule the most stringent requirement shall govern.

1.2

The offer shall include a sketch indicating thicknesses of major parts, empty
weight, operating weight and test weight. It may be noted that decrease in
offered thickness shall not be allowed.

1.3

-------------------------------------------------------------------------------------------------------------

1.4

TPI shall have the right to split the order and part orders shall be acceptable to the
supplier.

1.5

The offer must be technically and commercially complete. Incomplete offers are
liable to be rejected.

1.6

Any deviation from the clauses stipulated herein, specified codes and other enquiry
documents shall be clearly mentioned in the offer with proper references to clause
numbers. In absence of any such indication it shall be assumed that the offer
complies with all requirements and such assumption shall be strictly binding on the
supplier.

1.7

Some of the sizes and dimension marked under HOLD on enquiry drawings and
data sheets shall be removed later on and the required size/dimensions shall have to
be adopted by supplier without any commercial implication.

2.0

RESPONSIBILITY OF THE SUPPLIER

2.1

The responsibility of the supplier shall include but not be limited to the following. Any
other item/activity which is not listed here but is required for completion of the supply
as per the enquiry document shall also be the responsibility of the supplier.
a)

Complete design of the equipment as per code/equipment specification and any

other enquiry documents; supply of civil load data for foundation design.

b)

To obtain approval
specified in para 10.0.

c)

To obtain statutory
wherever applicable.

d)

Procurement of all the materials whatsoever required to meet the scope of supply.

e)

Fabrication, inspection, testing, painting, packing and dispatch of the equipment.

f)

Submission of the periodic progress report showing the status of the job.

g)

Supply of the final documents as specified in para 10.0.

of

TPI on

approval

drawings
of

and

drawings

other documents as

and

other documents

3.0

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 4 OF 23

MECHANICAL DESIGN

3.1

Strict compliance with the requirements of code / equipment specification and

any other referred document shall be fully ensured.

3.2

For high alloy steel parts/components designed as per ASME Sec.VIII DIV.1
lower allowable stresses shall be adopted, for tubesheet and flanges of
gasketed joints unless otherwise specified. After the approval of various documents
subsequent deviations shall be discouraged.

3.3

___________________________________________________________________

3.4

All equipments shall also be designed for hydrostatic test in operating position in
corroded condition considering 25% of design wind load. Allowable stress during
hydraulic testing shall be 90% of yield stress.

3.5

Unless other wise specified elsewhere in enquiry/order document, Wind loads shall
be calculated in accordance with BIS:875 (Part 3) with following consideration:
Equipment shall be considered as Important Building Class of Structure accordingly
risk coefficient (K1 Factor) shall be taken from Table 1 BIS:875.
Terrain category (K2 Factor) shall be taken conservatively as 2, Terrain Class shall
depend upon the size of equipment.
Topography (K3 Factor) shall be taken to be equal to 1.0.
Force coefficient (Cf) for the equipment (non-smooth) shall be taken from table 23
accordingly wind force calculated.
Wind forces shall be increased by 20% to cater for the effect of piping system,
platforms and ladders etc.
Vertical vessels with height/diameter ratio equal to or greater than 6 shall be
analyzed for vibration due to vortex shedding when critical wind speed does not
exceed 30 m/s.
Unless otherwise site spectra furnished by client, Seismic loads shall be calculated in
accordance with BIS : 1893. For the design values of horizontal seismic co-efficient

h Response Spectrum Method shall be computed as given in

structures BIS:1893, ( Part 4):2005

section 2 stack line

3.6

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 5 OF 23

Design of supports and anchor/foundation bolts shall be the responsibility of the

supplier. The type, numbers, location and any other information if furnished in the
specification sheets shall be strictly adhered to. However, adequacy of the same
must be checked by the supplier. In no case diameter of anchor bolts shall be less
than M24 for skirt support and M16 for others.
Self-supported vertical vessels with shell diameter greater than 2000 mm, length
(T.L.-T.L.) 3000 mm max. shall be supported on skirt. Skirts for vessels shall be
normally being cylindrical mean dia coinciding with head mean diameter. In certain
cases vessel skirts may be conical in order to provide an adequate bolt area at the
base rings and to minimize the vessel deflection. Maximum half apex angle of the
cone shall be limited to 9 max. In no case the skirt thickness shall be more than
head thickness.

3.7

All items whether internal or external which are welded directly to a shell or head
shall be of the same material category as that of the shell or head. This shall apply to
all nozzles, brackets, pads and upper portion of the skirt for vertical exchangers.

3.8

Base rings for skirt supported equipment shall be in accordance with standard as
applicable. Base ring dimensions shall be calculated to ensure that the compressive
stress on the grout under any part of the base ring does not exceed 44 Kg/cm2g.

3.9

Forces & moments coming on the nozzles shall be furnished, which

shall be considered in the design by the supplier, without any
commercial implication. Alternatively supplier shall indicate maximum
permissible forces & moments for review and confirmation by TPI.

3.10
3.11

Lifting lug shall be designed with a shock factor of 2.

Where fixed tube sheet construction is used suitable provision shall be made for
expansion to prevent overstressing of tubes and shell. Stress due to thermal
expansion shall be calculated to determine the necessity of using expansion joints in
clean and foul conditions.

3.12

Expansion bellows shall be designed for min. 5000 cycles, as per TEMA.

3.13

Tube and shell side components shall be designed considering mean metal
temperatures as per section UHX of ASME Sec. VIII Div.1.
Unless detailed thermal calculations prove otherwise the tube sheet design
temperature shall be considered to be the design temperature of either the tube-side
fluid or the shell-side fluid, whichever is higher.
FE Analysis shall be carried out for thin tube sheet exchanger and the same shall
be submitted for TPIs reference / record. Stresses shall be evaluated as per
ASME Sec. VIII Div.2.

3.14

Longitudinal baffle on shell side of an exchanger having two-pass system shall be

designed considering total pressure drop on shell side.

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HEAT EXCHANGERS

SHEET 6 OF 23

3.15

Longitudinal baffle in removable tube bundle exchanger shall be provided with

flexible sealing (10 numbers 0.1 mm thk. S.S strips on both sides & ends on the
edges adjacent to the shell) to prevent by-passing. The strip width shall be selected
so that during operation they are pressed, by spring action, against the shell. The
strip shall be bolted /screwed with flats along length of longitudinal baffle.

3.16

Baffles and support plates in horizontal exchangers shall be provided drain & vent
with notches at the extreme point. Whenever bypass area exists, dummy
tubes/sealing strips shall be provided.

3.17

Tubesheets in vertical exchangers shall be provided with drain and vent arrangement
with threaded plug seal welded.

3.18

Components in contact with both shell and tube side fluids shall be designed for the
most stringent pressure/temperature combination.

3.19

In no case minimum corrosion allowance for C.S and low alloy steel material shall be
less than that specified in equipment specification sheet or TEMA unless otherwise
specified.

3.20

Adequacy of tube bundle against flow induced vibration shall be checked by supplier
if called for and any modification, if required, shall be carried out in consultation
with TPI without any commercial implication. Vibration analysis shall be
submitted to TPI for review.

3.21

Impingement Baffles
Unless otherwise stated inlet nozzles on shell side shall be provided with
impingement plate in compliance with TEMA requirement.

3.21.1

The flow area around solid impingement plate shall be at least equal to the inlet
nozzle cross-section. In case of two phase flow impingement baffle shall be
perforated.

3.21.2

Impingement baffle plate shall extent at least 25 mm beyond the projection of the
nozzle bore.

3.21.3

The clear distance from the nozzle (at the inner surface) to the impingement plate
shall be at least 0.25 x nozzle diameters.

3.21.4

The nominal thickness of the impingement baffle shall be at least 6 mm.

3.22

In case of girth flange design, minimum width of gasket shall be checked to withstand
required design condition.

3.23

In case of girth flange design correction factor for flange moment shall be based on
maximum bolt spacing as 2db + t where db is bolt diameter and t is the flange
thickness.

3.24

For equipment to be designed as per I.B.R all requirements specified therein shall be
taken care of.
For parts/components, design of which is not covered in I.B.R, recommendations
of ISO R 831 or any other international code accepted by I.B.R shall be followed
and it shall be with the prior approval of TPI.

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HEAT EXCHANGERS

SHEET 7 OF 23

3.25

Baffle and support plates shall be tied together with tie rods and spacer pipes unless
otherwise specified. Tie rods and spacers should be preferably on the peripheral
open area so as to block the bypass area between outer most tubes and shell inside.

3.26

Unless otherwise stated all girth flange joints shall be confined type.

3.27

For equipment to be lined with refractory material by the supplier, calculation for
refractory thickness along with the properties of the refractory selected shall be
submitted for comments & approval in addition to other design calculations.

3.28

Bolts of size M52 and above shall be designed and spaced so as to permit tightening
with a hydraulic stud tensioner. The bolts shall have an extra threaded length at one
end of appx. 1 bolt diameter and shall be provided with threaded protection caps.
Hex nuts shall have suitable holes for manual tightening.

3.29

Kettle- type shells must be provided with rails on which the tube bundles can be
supported and guided. The baffle should be designed accordingly. Also proper tube
bundle holding arrangement shall be provided at last support baffle to avoid any
damage during handling/ transportation.

3.30

U-tube exchanger, requiring shell removal requirements shall be provided an

additional saddle at tubesheet. The saddles on shell shall have suitable spoolsaddles for shell movement/removal.

3.31

Where the operating load on the sliding saddle > 2500 kg. It shall preferably rest on
low friction pad or rollers. The drawing shall show this pad included in the saddle
height. No slotted holes are required in the saddle base. But the saddle shall be
guided and prevented from lifting. When low friction pads e.g. Teflon are used,
counterpart shall be polished SS plate and be designed so that low friction pads are
entirely covered by the SS plate under all operating conditions.
When the rollers are used, the rollers shall be prevented from running out. The roller
can, for example, be 40 mm nominal diameter CS bars linked together in parallel at
60 mm spacing. They shall extend to the outer vertical webs of the saddle, but shall
not be attached either to the saddle or to the supporting steel. The vessel drawings
also shall show that the saddle resting on the rollers is 40 mm shorter than the fix
saddle.

3.32

When deciding which saddle should be chosen as fixed, the permissible deflection of
any large bore pipe attached to the equipment shall be taken into consideration.

3.33

When design pressure is more than 400# class and/or shell thickness is 50 mm and
above, selfreinforced forged nozzle shall be provided. Nozzle size 3 NPS Shell to
SR nozzle welding shall be set-in type welding. For small sizes shell to SR nozzle
welding may be set-on type welding.

3.34

Minimum nozzle diameter shall be 1 nominal.

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HEAT EXCHANGERS

ES 3201
SHEET 8 OF 23

4.0

MATERIALS

4.1

All materials, whatsoever, required to complete the supplies shall be procured by the
supplier and all such materials shall be covered with due identifiable material test
certificates.

4.2

Materials indicated in specification sheets are recommended for the required

service conditions. Supplier however, may use better or equivalent
material with prior approval of TPI. Details of such materials must be indicated
in the offer with proper reference.

4.3

Material procured to other approved specification than stipulated in design code shall
be acceptable provided it meets all the requirements of applicable design code.

4.4

Unless otherwise specified all C.S and low alloy steel materials including forging
used for pressure parts shall be fully killed and in normalized condition.

4.5

Unless otherwise specified copper or copper alloys shall not be used. Copper content
up to 0.40% are acceptable in carbon steel and 0.6% in stainless steel.

4.6

Material used in low temperature service shall be impact tested (Charpy-V) if

required as per design code and specification. Impact test temperature and energy
value shall be in accordance with code requirement, unless specified otherwise.

4.7

For coarse grained and high tensile materials in carbon steel (UTS 52 Kg/mm2) and
low alloy steel, guaranteed impact strength shall be ensured at a temperature 15OC
below envisaged hydraulic test temperature as a precaution against brittle fracture
during hydraulic test. Similar precaution shall be taken for thicker plates > 50 mm for
equipment designed for pressure 15 Kg/cm2g.

4.8

C.S. and low alloy steel exceeding thickness of 50 mm shall be vacuum degassed
except for plate ring flanges.

4.9

All plate materials over 50 mm thickness shall be ultrasonically tested both on

surfaces and edges as per ASTM A 435.

4.10

Unless more restrictive prescription given by material specification the maximum

carbon content of carbon steel used for fabrication as shown by laddle analysis shall
be
0.23% for plates, pipes & tubes.
0.25% for forging.

4.11

Temper embrittlement
The risk of temper embrittlement (TE) must be taken into consideration for Cr-Mo low
alloy steel plates and forgings (P. Nos. 4, 5A and 5C as per ASME PV Code ) used in
pressure vessels and piping operating in the temperature range of 375C to 575C.
In order to reduce the risk of TE the following requirements shall be applied:
1 Cr- Mo (P4) Base Metal

Phosphorus (P) max 0.007 weight %.

Tin (Sn) max 0.01 weight %.

X = (10P + 5Sb + 4Sn + As) x 100 < 15

(Elements weight %)

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HEAT EXCHANGERS

SHEET 9 OF 23

2 Cr - 1 Mo / 3Cr 1 Mo (P5A and P5C) Base Metal

J = (Si + Mn)(P + Sn) x 104 < 120 for P.No. 5A

100 for P.No.5C

(Elements in weight %)

Step cooling tests shall be performed if nominal thickness exceeds 50 mm.

procedures for heat treatment, testing and evaluation as per API 934.
Weld Metal (as deposited)

X = (10P + 5Sb + 4Sn + As) x 100 < 15

(Elements weight %)

The above guidelines shall be adhered to unless, on specific jobs, codes/standards

or end user specification impose more stringent requirements.
4.12

All forgings shall be ultrasonically tested as per Sec. ASTM A 388 for thickness
greater than 100 mm with the criteria shown in ASME Sec.VIII Div.2 para AM-203-2.
In case any defect is found, no repair by welding shall be allowed. ASME flange for
equipment designed as per ASME Sec.VIII Div.1 need not be UT tested.

4.13

All forgings including nozzles flanges shall be examined for surface defects MP/DP
after machining.

4.14

For SS 316 and 316L material, ferrite content for plates, pipes, tubes & forgings shall
be maximum 2%. However, for SS316L Urea grade ferrite content shall be
maximum 0.6%.

4.15

Intergranular corrosion test shall be carried out on all SS 316L Mod (Urea grade)
materials, weld and HAZ as per ASTM A 262 practice C if specified. The corrosion
rate shall not exceed 0.025 mm / month.

4.16

Inter granular corrosion test shall be carried out on all SS 316L materials, weld &
HAZ as per ASTM A 262 practice E (Strauss test) unless otherwise specified in
specification.

4.17

For equipment designed as per IBR, materials shall strictly comply with the
requirement of the IBR code. All materials must be procured from well known steel
maker recognized by IBR (refer Appendix G of IBR).

4.18

For equipment designed as per IBR, certificate for materials in respect of yield point
at design temperature, the average stress to produce elongation of 1% in 100,000 hrs
and the minimum stress to rupture in 100,000 hrs shall be obtained from the steel
makers wherever design conditions call for use of these data.

4.19

For IS 2062 materials without mill test certificates, check test, if called for by the
inspector, shall be performed without any commercial implication. Material shall be
fully killed.

4.20

All nozzles 10 NPS shall be seamless.

4.21

Spiral- wound gasket shall be provided with S.S guide rings. Outside diameter of
gaskets shall extend up to bolting.

4.22

All pipe fittings including elbows for sizes 10 NPS shall be forged / wrought.

4.23.1

All heat exchanger tubes shall be cold drawn and seamless.

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HEAT EXCHANGERS

SHEET 10 OF 23

4.23.2

Where seam welded tubes are permitted as an alternative, the weld shall be
inspected through out the whole length by eddy current or ultrasonic method.

4.23.3

As a general rule the preferred tube size is O.D. The minimum tube wall thickness
for O.D. carbon steel tubes is 2.11 mm (B.W.G.14) and for stainless steel 1.65
mm (B.W.G.16). (Heat exchanger for steam systems, under the preview of IBR
requires, according to paragraph 338, a minimum tube wall thickness of 2.03 mm for
both carbon and stainless steel. The nearest TEMA wall thickness is B.W.G. 14 =
2.11 mm).

4.23.4

Circumferentially finned tubes are not permitted.

4.24

The mean bending radius of U - tubes shall be not less than 1.5 times the tube
outside diameter.
Thickness of two-inner most rows of U-tube bundle shall be higher by 2 gauge.

4.25

All SS tubes shall be subjected to non-destructive examination like eddy current or

ultrasonic test at mill. C.S. and low alloy steel tubes shall also be subjected to such
examination when design pressure exceeds 100 Kg/cm2g.

4.26

Unless otherwise specified tube sheets and girth flanges shall be of forged quality
and ultrasonically tested.

4.27

Tubesheet and girth flanges must be in one piece. Segmental butt-weld construction
shall not be accepted.

4.28

All tubes including U-tubes must be in one piece. Circumferential welds are not
allowed.

4.29

Where heat treatment of U-bends is required, the heat treated portion shall extend at
least 150 mm beyond the point of tangency.

4.30

Shear test according to ASTM A 264 is required for clad plates. At least 14 Kg/cm2
shear strength shall result from such test. All clad plates shall undergo ultrasonic
examination at the steel work in accordance with ASTM A 578 level S8.

4.31

Gasket for all medium except cooling water service with flange rating 600 # shall be
spiral wound graphite filled gasket with external & internal guide rings 3.2 mm thk.
For prevention of crushing of gasket. For CW service gaskets for flange rating 150 #
compressed fiber gasket type in accordance with ANSI B 16.21 shall be used.
Gaskets with flange rating 900 # shall be octagonal ring-joint gasket. Hardness of
the gasket shall be 50 BHN lesser than that of the mating flange gasket groove.

4.32

Special flat closures shall normally be furnished with gaskets of one of the following
types:
i.

Double conical - Where double conical gaskets are used, a seating membrane
of graphite tape, 0.25 mm thick, shall be inserted between the joint ring and the
conical surfaces on the vessel and the flange. The quality of the graphite tape
will be specified by the purchaser.

ii.

Welded Diaphragm - Welded diaphragm gaskets shall normally be made of

Inconel 600.

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SHEET 11 OF 23

5.0

SCOPE OF SUPPLY

5.1

Unless otherwise specified the complete main equipment and its various components
as specified in specification sheets and enquiry documents shall be included in
suppliers scope of supply.
Scope of supply shall included but not be limited to the following:

5.1.1

Cover flanges for manholes, handholes, inspection openings etc. with bolting and
gaskets.

5.1.2

Test blind flanges. (for hydrotesting)

5.1.3

Eye bolts, jack screws, dowel pins and lifting lugs.

5.1.4

Sealing strips for longitudinal baffle.

5.1.5

All external welded attachments like platforms and ladder cleats, insulation supports
and pipe support cleats etc.

5.1.6

Lifting lugs / erection lugs.

5.1.7

Impingement baffle.

5.1.8

Gland packing.

5.1.9

Test rings for removable tube bundle exchanger.

5.1.10

Cleats for earthing connections.

5.1.11

Name plate with bracket.

5.1.12

Foundation / Anchor / Holding down bolts with nuts and washers.

5.1.13

Support stool.

5.1.14

Lapping tool with transportation ring etc.

5.1.15

Welding / wire rods for weld seal gasket.

5.1.16

Special tools / tackles.

5.1.17

Expansion bellows, wherever required.

5.1.18

Internal sliding arrangement for removable tube bundle.

5.1.19

Hydraulic stud tension device. Complete with all accessories and operating manual
for bolt size M52 and above.

5.1.20

Internal sliding arrangement, guide rails, rollers and pulling Yoke for removable tube
bundle exchangers.

5.1.21

Ferrules.

5.1.22

Sight glass with protector glass.

5.1.23

Demister complete with housing and support grid.

5.1.24

Sliding plate, low frictional pads / rollers for free support.

5.1.25

Templates for skirt support of equipment.

5.1.26

Seasoned wooden blocks under support base for LT exchangers with bolting.

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5.1.27

Interconnecting piping for stacked heat exchangers.

5.1.28

Adjustable shim plates between stacked saddle and bolting.

5.1.29

Protection caps for stud ends to be tightened with hydraulic tensioner.

5.1.30

Documents according to clause 10.0.

5.1.31

Spare parts according to clause 5.2.

5.2

The following 2-Years Operation Spares shall be supplied along with the
equipment.
i)

200% gaskets for all nozzle connections with blind flange.

ii)

200% gaskets for girth flange.

iii)

200% ring joint gaskets.

iv)

200% 0 ring gaskets for lipseal gasket.

v)

200% graphoil tape / aluminum foil for double conical gasket.

vi)

10% bolts/nuts for each nozzles with blind/companion flanges (min 5 pieces).

vii)

10% bolts/nuts for each body flange joints (min 5 pieces).

viii) 10% internal bolts, nuts & clamps (min 5 pieces of each size).
ix)

200% gland packing.

x)

5% tube plugs for both ends.(Tube plug length equal to tubesheet thickness).

xi)

10% ferrules.

xii) 300% sight glasses and protector glasses.

xiii) 100% demister pad complete with top & bottom grids and fasteners.
6.0

FABRICATION

6.1

The manufacturer of the equipment shall comply in all respects with the provisions of
the applicable code/standards and specifications with respect to welding, fabrication,
forming of heads, radiography, heat treatment, inspection, testing and quality control
etc.

6.2

All welding shall be carried out by qualified welders using approved procedure in
compliance with the requirements of code & specifications and duly certified by the
inspecting authority. All welding procedure must be got approved from authorized
inspecting authority before starting any fabrication job. Welding of all parts must be
completed before heat treatment.

6.3

Plates of different thicknesses shall be made flush with the inner surfaces of
equipment unless otherwise stated.

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6.4

Top portion of skirt (Minimum 1000 mm skirt) welded with bottom head shall be of
same material as that of shell/head. Skirt to head joint shall be full penetration type.

6.5

All conical heads unless otherwise stated shall be of toriconical type.

6.6

Minimum skirt height of dished head shall be 50 mm unless otherwise stated.

6.7

CS / Alloy steel dished end/toriconical head including cone if cold formed or hot
formed below normalizing temperature shall be subsequently normalized. In case
of austenitic SS materials solution annealing shall be carried out if hot worked.
Formed ends of vessels with diameters less than 1600 mm shall preferably be
made in one piece. Larger heads which can not be formed in one piece shall
be fabricated as follows with prior approval from TPI :a.

In two pieces, with the welding seam included in the middle third and
preferably on the centre line.

b.

In petal construction, with meridianal seams and a central cap of diameter

not larger than 0.75 times the vessel outside diameter.

Formed heads when fabricated in pieces shall be normalized and weld seams
radiographed after forming.
6.8

Impact test when required as per code & specifications shall be carried out on parent
metal, weld and HAZ.

6.9

In case of CS and low alloy steel expansion bellows, all joints shall be fully
radiographed and bellow shall be stress relieved.

6.10

Production control coupons, when required as per code & specifications shall be
subjected to impact test, corrosion test etc. in addition to mechanical tests as
required. In case of heat treated equipment test coupons shall be given similar heat
treatment as for the equipment.

6.11

Each shell section having diameter equal for less than 2 meters to the extent
possible, shall be rolled out of a single plate with one longitudinal seam.

6.12

Orientation of longitudinal seams and position of circumferential seams shall be

clearly marked in the fabrication drawings. Nozzles, support and other attachments
shall be located clear of weld joints.

6.13

The centers of the welded longitudinal joints of adjacent courses shall be staggered
or separated by a distance of five times the thickness of the thicker plate or 100 mm
whichever is greater.

6.14

All parts involving welding construction including internals and stiffener ring shall
have continuous welds unless otherwise stated.

6.15

In case of SS welds, procedure must be qualified to ensure that the weld meets the
minimum requirements of C, Cr, Ni and Mo as that of the parent metal. In addition to
various tests required as per code, weld procedure shall be qualified for intergranular
corrosion test, as per ASTM A 262 practice C/E, if specified. Carbide contamination
shall be avoided during welding.

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6.16

In case of equipment fabricated of materials SS 316L/ SS 316 for urea service, low
ferrite filler material shall be so selected that ferrite content in two subsequent weld
pass in contact with process fluid shall be maximum 2% & for equipment fabricated of
materials SS 316L urea grade the limitation of ferrite content shall be 1%. The
welding not in contact with process fluid may have ferrite content limited to 6%.

6.17

All welds shall be full penetration welds with back chipping and rewelding from the
second side. For those joints which are inaccessible for back chipping the root run
shall be carried out with TIG process. Single side welding with backing strip is not
permitted.

6.18

Due provisions must be kept for venting out entrapped gases during welding of pads,
flanges and liner plates etc.

6.19

All nozzle reinforcing pads shall be tested pneumatically at 0.5 Kg/cm2g pressure
with soap solution on attachment welds. Vent holes shall be plugged with non
hardening mastic to prevent ingress of water.

6.20

Pads for supports and external cleats etc. shall be of same material as that of shell.

6.21

All sharp corners shall be rounded off with smooth radius. Inside edge of manhole
and hand hole at the internal surface shall be rounded to min. radius 5 mm.

6.22

Unless otherwise stated all nozzle flanges shall be weld neck type. For nozzle flange
size 24 dimensions shall conform to ASME ANSI B16.5 and nozzle flange
size >24 NPS dimensions shall conform to ASME ANSI B16.47 (Series - B).
All welding neck flanges shall be bored to suit nozzle I.D. Flange facings shall have
suitable serrations for gasket seating in case of plain, male/female and raised.

6.23

Unless otherwise stated all girth flange joins shall be confined type. Minimum depth
of gasket facing for girth flanges shall be 5 mm for compressed fiber gaskets and 6
mm for spiral wound / metal jacketed gaskets.

6.24

All internals fabricated in pieces shall be shop assembled and properly match
marked for easy assembly at site.

6.25

Each partition plate shall be welded to channel for their full length with full penetration
welds.

6.26

Each partition plate shall be provided with 3 mm dia drainage hole located as far
from the tubesheet as possible

6.27

Procedure shall be qualified for tube to tubesheet joint. Mock-up test shall be carried
out to establish all the requirements to the satisfaction of inspector.

6.28

In case of equipment to be assembled at site trial assembly in shop shall be carried

out and match marked for proper assembly at site.

6.29

Equipment shall be provided with suitable bracings/stiffeners to avoid any damage

during transportation and erection at site.

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 15 OF 23

6.30

In case of equipment involving site assembly/fabrication, the entire site job including
fabrication, radiography, heat treatment, inspection, testing and transportation to site
shall be in suppliers scope of works at his cost.

6.31

All flange bolts & skirt-bolts shall straddle centre line unless otherwise stated.

6.32

Flange gasket contact surface shall not exceed 125 in roughness. In case of
metallic gasket the side wall surface of the gasket groove shall not exceed
63microns.

6.33

All nozzles less than or equal to NPS 65 shall be stiffened with three equispaced
plate ribs of the same material as that of shell.

6.34

External bolting for gasketed flanges shall always be stud bolts and nuts. Bolt
threads shall be in accordance with ANSI B1.1 (UNC for dia. 1, 8 UN for dia.> 1).
Threads of bolts and nuts shall be coated before installation with lubricant to prevent
galling of the threads.

6.35

Tubes holes in tube sheets of high alloy steel exchanger shall be finished to the
diameter and tolerances as special close fit specified in TEMA.

6.36

Tubes shall be flush with or extend by 3 mm beyond the face of each tube sheet,
except that tubes shall be flush with the top tube sheet in vertical exchangers unless
otherwise specified.

6.37

Bent portion of C-Mo, Cr-Mo U-tubes shall be heat treated after bending. Non ferrous
tubes shall be annealed.

6.38

Tubes in exchangers having design pressure less than 60 Kg/cm2g shall be rolled in
grooved holes in tube sheets and seal welded. Weld shall be DP checked. Tubes in
exchangers having design pressure equal to or more than 60
Kg/cm2g shall be expanded in plain holes in tube sheets and strength welded in
minimum 2 runs. Each pass DP checked.
All welding of tube to tubesheet joint shall be done using TIG method.

6.39

In case of overlayed tubesheet three grooves shall be made out of which one groove
shall be in overlayed thickness.

6.40

In case of lip seal gasket, lip shall be welded after successful hydraulic test. Lip seals
shall preferably be of hollow type and shall be furnished with O ring groove to
facilitate hydrotesting at work. O ring shall be removed after hydrotesting.

6.41

Unless otherwise specified minimum thickness of undiluted weld overlay on

tubesheet shall be 10 mm and flange face 5 mm.

6.42

In case of nozzle with butt-end construction, extra length shall be provided to

facilitate hydraulic testing and subsequently cutting and edge preparation as per
ANSI B 16.25 to suit piping welding at site.

6.43

All nozzle necks, nozzle flanges and blind flanges shall be of weld deposit
construction for clad equipment. Loose liners are not permitted.

7.0
7.1

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 16 OF 23

INSPECTION AND TESTING

All raw materials shall be inspected at source by authorized inspection agency and
test certificates with due identification shall be submitted.
In case of equipment under TPI inspection, imported raw materials will be procured
under third party inspection, unless otherwise specified.

7.2

All equipment shall be inspected during various stages of manufacture starting from
identification of raw materials to completion. The equipment shall be considered
acceptable for dispatch only after final certification for acceptance is issued by the
inspector.

7.3

Bought out items or items sub-contracted to other sub-suppliers shall

also be inspected at the sub-suppliers works. However, standard items
like bolts, nuts, ordinary gaskets etc. may be exempted from the inspection
with specific approval from TPI.

7.4

Inspection by third party, if specified, shall be arranged by the supplier. It shall be the
responsibility of the supplier to make available to the inspector all the new/revised
drawings, calculations and other enquiry documents.

7.5

Inspection order on third party shall also include specific instructions for
marking copies of all correspondence from inspecting authorities to TPI
and reporting monthly progress of the order to TPI. Complete responsibility of
getting approval of drawings/calculations and documents from inspecting authority
shall be that of the supplier.

7.6

For equipment coming under IBR preview, the items shall be inspected during
various stages of fabrication and testing by an inspecting authority acceptable to IBR.
For list of inspection authorities recognized under IBR, reference shall be made to
appendix C of IBR. It is the responsibility of the supplier to get the fabrication
drawings and design calculations approved by IBR authority in India before the start
of fabrication.

7.7

For equipment coming under the purview of IBR, the inspection by local IBR
authorities shall have to be arranged by the supplier and all cost borne by the
supplier.

7.8

In case of site fabricated/assembled equipment same inspection agency shall be

responsible for inspection, testing at site.

7.9

In case of castable refractory, 3 Nos. slab of each size shall be cast at site before
application and tested to meet the refractory specification in the presence of the
inspector.

7.10

Unless otherwise stated gaskets used during testing shall be same as specified for
operating conditions. After testing, gaskets used during testing shall be replaced by
new gaskets.

7.11

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 17 OF 23

The following NDT requirements are mandatory in addition to the requirements of

code/specifications :
a)

Ultrasonic Examinations
i.

Butt weld in thickness 50 mm as supplement to radiography.

ii.

Full penetration welds of nozzle attachments on equipment shell/head

of thickness 50 mm as substitute for radiography.

iii. Weld overlay on tube sheet.

iv. All forgings
b)

Magnetic particle / Liquid penetrant examination

i.

All edges of plates and openings in shell of C.S. having thickness 40 mm

and low alloy steel / S.S. having thickness > 25 mm and alloy steel of all
thickness.

ii.

Root-run and final layer of all butt welds.

iii. All welds having thk. > 50 mm, all welds of low alloy steels and all
materials with UTS 52 Kg/mm2.
iv. Fillet welds of 3% nickel and SS.
v.

Each layer of weld deposit in case of SS / inconnel weld overlay, cladding

& lining.

vi. Each passes of tube to tubesheet joint.

vii. Knuckle surface of dished ends / toriconical sections, pipe bends and
expansion bellow.
viii. Bent portion of all U-tubes.
ix. Skirt to head joint.
x.

All welds of SS and non ferrous materials and welds for vessels with
design temp. (-) 45OC and below after hydrotesting.

xi. All weld surfaces after PWHT.

xii. All welds of SS over thk. after hydrotesting.
xiii. All forgings after machining.
c) Radiography
i.

Radiography when called for shell is applicable to all pressure welds i.e.
longitudinal & circumferential.

ii.

In case heads are formed of welded plates / petal construction, all the weld
seams prior to forming and after forming.

iii.

Circumferential joint of shell to dished head.

iv.

All T-weld joints.

v.

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 18 OF 23

Radiography examination of welds in C-1/2 Mo and Cr-Mo steel shall

preferably be carried out after heat treatment. If radiography is carried out
Prior to heat treatment the welding and adjacent areas of base metal shall be
examined by MPT/LPT after heat treatment.

d) Hardness
i.

Weld and Heat Affected zone (HAZ) of all pressure bearing welds in
Cr-Mo steel vessels shall be tested after final heat treatment using a
portable hardness tester.
Hardness value shall not exceed 215 HB for steel having Cr < 2% and
240 HB for steel having Cr 2%.

ii.

Four opposite points of U-tube bent portion.

7.12

All completed equipment shall be tested hydraulically as per the requirements of

specification/codes in presence of the inspecting authority. Pneumatic test of
completed equipment shall be carried out only when specially mentioned in the
specification sheets. Chloride content in water used for testing shall not exceed 30
ppm for SS equipment and 40 ppm for CS and low alloy steel equipment. Duration of
test shall be 1 hour minimum.

7.13

When required as per

shall be carried out on
results shall be plotted
procedure to such strain

7.14

Tube to tube sheet joints shall be leak tested with air and soap solution at a pressure
of 2.0 Kg/cm2g. When specified leak testing with Halogen shall be carried out.

7.15

Stacked exchangers shall be hydraulically tested as a combined unit.

7.16

After bending of U-tubes, each tube shall be tested hydraulically at 70 bars.

8.0

CLEANING, PAINTING AND DESPATCH

8.1

After hydraulic testing, the equipment shall be dried, thoroughly cleaned from inside
and outside and shall be free from all shop dirt, loose scale, grease etc.

8.2

All external surfaces of CS including internal surface of skirt to be painted shall be

degreased and all rust and mill scale removed.

8.3

specification / code, strain gauge measurements

outside circumference during hydrostatic testing. The
both during pressurizing and depressurizing and
measurements shall have prior approval of TPI.

i)

Austenitic stainless steels and non-ferrous materials shall not be painted.

ii)

The equipment shall be shot/grit blasted (min SA 2.5 ISO 8501-1) before the
primer coat is applied on external surfaces. Primer shall be compatible to
succeeding painting.

iii) In general, uninsulated equipment working below 94C, alkyd high build primer
of thickness 50 microns DFT shall be applied.
iv) For Uninsulated equipment above 94C to 204C working temperature,
aluminum paint of 30 microns DFT shall be applied.
v)

For uninsulated equipment upto 420C working temp. inorganic zinc silicate of
50 microns zinc silicate shall be applied.

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 19 OF 23

vi) For insulated equipment up to 94C, primer painting shall be of alkyd high build
epoxy primer of 50 microns DFT shall be applied.
vii) For insulated equipment temperature exceeding 94C, primer shall be aluminum
paint of 30 microns DFT.
viii) Thermo-indicative paint (three colour phases) shall be applied on refractory lined
equipment to give warning of insulation/refractory failure. Paint manufacturers
recommendation shall be followed.
ix) All flange faces, bolting and other machined surfaces shall be painted with an
easily removable rust-preventive coating.
All machined surfaces, boltings and flange faces shall be properly protected from rust
and mechanical injury during transit and storage.
8.4

Nozzles shall be sealed suitably. Threaded connections and beveled openings shall
be suitably protected.

8.5

Name and code number of equipment shall be painted on each equipment at a

conspicuous place in letters 150 mm high.

8.6

After hydraulic testing, all SS parts of equipment shall be pickled and passivated as
per the following procedure :
a)

Cleaning
Clean surface and remove all extraneous matter with a hard fiber brush or SS
wire brush. M.S. wire brush shall not be used. All organic materials shall be
removed with any paint remover like light solvent naphtha or benzene or
equivalent. Motor petrol shall not be used.

b)

Pickling
Aqueous pickling solution shall be as follows:
Nitric acid (Tech. grade) 10 to 25% plus Hydrofluoric acid 1 to 8% (to be used
only for stabilized SS grades). Temperature 50 to 60C for 10% Nitric acid and
20C for 25% Nitric acid. When size and shape of product permit, total
immersion in the pickling solution is preferred. Where immersion is impractical,
pickling may be accomplished by wetting the surface by:1) Swabbing or spraying.
2) By partial filling the item with pickling solution and rotating or rocking so that
all the surface receive the required chemical treatment.
The maximum period for which the pickling solution shall be allowed to remain
on the surface is 30 minute. During pickling removal of oxides may be hastened
by brushing with a hard fiber or SS wire brush. Over pickling shall be avoided.
The pickling agent shall be washed off with plenty of water so as to leave no
trace behind.

c)

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 20 OF 23

Passivation
After pickling and water rinsing, an aqueous caustic permanganate solution
containing NaOH 10 weight % and KMnO4 4 weight % shall be used for
neutralizing pickling solution. This shall be followed by thorough water rinsing.
Water used for pickling and washing shall not have chloride contents exceeding
30 ppm.

8.7

Equipment intended for transportation by ship shall be kept in hatch of the ship.
Suitable seaworthy packing/painting shall be applied to avoid any damage during
transshipment.

8.8

The responsibility of transport, packing and forwarding of the equipment shall be of

the supplier. In case of inland transportation equipment shall be properly lashed, fixed
on to the wagon/trailer to avoid any damage due to shocks in transport. In case of
ODC movement, ODC sanctions for movement either by rail/road shall be arranged
by the supplier from appropriate authorities in advance to meet the scheduled
delivery. Supplier shall have to arrange the chasers.

8.9

All spares shall be properly packed, marked and sent separately along with
equipment.

8.10

When specified equipment shall be dispatched with N2 filling. In case of equipment

assembled and welded at site, it shall be filled with N2 after testing at site. Dry
Nitrogen shall be filled at a pressure of 0.5 Kg/cm2g and equipment shall be fitted
with a pressure gauge and valve.

9.0

GUARANTEE

9.1

The supplier shall guarantee equipment and their components against faulty design
with regard to mechanical adequacy, improper material of construction and poor
workmanship for the specified period.

9.2

Approval of detailed shop drawings by TPI, will not in any way absolve
supplier
from his responsibilities to supply the
equipment in accordance with order specification.

9.3

Should any repair or replacement be necessary owing to any type of failure on

account of design, material or workmanship of the equipment, the supplier shall by
dint of this guarantee, be bound to replace the same either in part or in entirety,
without additional cost, at site. Repaired or replaced parts shall be covered by same
guarantee as in case or main supply.

9.4

In case process design is also in suppliers scope, guarantee shall include process
guarantee also in addition to above. All special instruments required to verify the
guarantee, fixtures as outlined in the equipment specification shall have to be brought
by the supplier on draw-back basis.

the

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 21 OF 23

10.0

DOCUMENTATION

10.1

Detailed fabrication drawings shall be prepared by supplier clearly indicating all

design data, nozzle data, details of all parts with tolerances, all welding joints details
and detailed bill of materials etc. Location of weld seams, construction notes, welding
processes, detailed specification of electrodes including NDT tests etc. as
applicable shall be clearly indicated in the drawing. Drawing submitted for
approval must be complete in all respects and thoroughly checked and
approved by suppliers competent authority before submitting to TPI. Drawings
without such information are likely to be rejected and any delay on this account shall
be attributable to the supplier.
Before starting any fabrication, drawings must be got approved from TPI.
Any comments marked on fabrication drawings shall have to be incorporated and
decision of TPI in this regard shall be considered as final.

10.2

10.3

In case of vessels under the purview of IBR, complete responsibility of getting

approval of drawings and design calculations etc. from concerned IBR authorities of
state of manufacture and state of installation shall be with the supplier at his cost.

10.4

For equipment requiring statutory approval from Inspector of Explosives, it will be the
responsibility of the supplier to get the fabrication drawings of equipment approved at
his cost, wherever required.

10.5

All drawings shall be drawn in CAD to scale. Subsequent revisions/incorporation of

comments shall also be made in CAD. Manual drawing shall not be accepted.

10.6

It will be preferable, if the soft copy along with 4 prints is brought to TPIs
design office for getting approval. Supplier shall depute the concerned
engineers & draftsmen with prior intimation and agreed date for deciding and
incorporating the various agreed comments during their stay. Same procedure shall
be followed for the approval of subsequent revisions, if any. Revisions shall also be
entered in CAD file. Manual revision in drawing shall not be accepted.

10.7

After approval one set of drawings / documents shall be given to the inspector by the
supplier.

10.8

Approval / comments on various documents shall be given by TPI within 3 weeks of

the receipt of the same, mailing time excluded.
Turn around time for submission of revised drawings / documents based on TPIs
comments shall be two weeks. Any delay in approval on account of
delay in submission of revised drawings / documents shall be attributable to the
supplier.
Payment against submission/approval of drawing if applicable shall be made after
approval of drawing under Code 1.

10.9

10.10
10.11

All documents / drawings shall be in English language and in Metric system.

10.12

All documents required as per IBR code for approval must be supplied on IBR
Performa.

10.13

All final documents indicated against Sl.No.8 to 31 shall be properly arranged,

indexed and bound in one folder. The document as marked (**) are to be approved
by authorized inspecting agency.

10.14

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 22 OF 23

The number of copies of documents and required delivery time in weeks from date of
letter of intent / order for each document is given below.

Sl.

Description

No.
1

2
Out line sketch showing thickness of main parts, weight &
1.
anchorage details (Refer Clause 10)

Reqd.
with bid
Copies
3

Required after
purchas
Copies Days
4
5

--

--

--

--

--

--

Based on delivery stipulations a time bar chart indicating

4 time required for material procurement, fabrication, testing,
transportation and site assembly as required

--

--

5 Billing Schedule

--

--

2 List of items likely to be subcontracted with probable

vendors
Details of demister (i.e. make and model no. free volume,
3 wire dia, surface area, density of material and separation
efficiency)

Reference list of similar equipment, supplied indicating

various parameters & material of construction.

--

--

Description of present shop load and spare load available

for this job and annual turn over.

--

--

List of drawings

--

Final civil load data including details of foundation/anchor

bolts
Design calculations
shop drawings/Detail fabrication drawing
Spare parts list

--

30

--

6
8
6

30
30
30

13 Welding procedure and performance records approved by

inspecting authority ( ** )

--

30

14 Procedure for hydraulic test and heat treatment ( ** )

--

60

15 Procedure for tube to tubesheet joint (**)

16 Procedure for site jobs like assembly, heat treatment,
testing etc.

---

6
6

60

--

30

10
11
12

17

Detailed manufacturing schedule CPM/PERT & progress

report to be submitted every month ( ** )

---

60

ENGINEERING STANDARD

ES 3201

HEAT EXCHANGERS

SHEET 23 OF 23

Sl.

Description

No.
1

Reqd.
Required after purchase order
with bid
Copies

Copies

Days from L/I

18

Procedure for removal & reassembly of weld seal

gasket. Procedure of repair of damaged tubes.

--

12+ 2 RTF

After dispatch
of equipment

19

Operating/maintenance manual wherever

required

--

12

180

20

Records of NDT tests e.g. radiography, UT,

MP/PT, hardness etc. ( ** )

--

12

After dispatch
of equipment

21

Materials test certificates duly stamped by

inspecting authority ( ** )

--

-do-

After dispatch
of equipment

22 PWHT Charts ( ** )

--

-do-

After dispatch
of equipment

23 Test on production test coupons ( ** )

--

-do-

After dispatch
of equipment

Corrosion test reports including C, Cr, Ni, Mo and

24 ferrite contents report of raw materials,
weldments, HAZ etc. ( ** )

--

-do-

After dispatch
of equipment

25 Hydraulic / pneumatic test reports ( ** )

--

-do-

After dispatch
of equipment

26 Strain gauge measurement ( ** )

--

-do-

After dispatch
of equipment

27 Inspectors final certificate ( ** )

--

-do-

After dispatch
of equipment

28 Suppliers guarantee certificate

--

12 + 2 RTF

After dispatch
of equipment

Transportation
drawing
showing
overall
29 dimension, C.G. weight and handling instructions
duly approved by appropriate authority.

--

120

All final as built shop drgs & calculations duly

certified by inspecting authority( ** )

--

12 +RTF + 2CD
ROM containing
editable soft files

After dispatch
of equipment

For equipment coming under IBR purview all

certificates required as per IBR code in IBR
31
Performa and CIB approved and stamped copy of
drawings.

--

12

After approval
of CIB

30