INDEX

BANTREL CO. / SUNCOR ENERGY SERVICES, INC.

P.O. NO.: 987-PO215-E-2-1BC
ITEM NO.: 215E-301

SECTION

TITLE AND CONFORMANCE

CERTIFICATES OF CONFORMANCE
1.1 WARRANTY PAGE
1.2 MANUFACTURER S DATA REPORT
1.3 HYDROSTATIC TEST CERTIFICATE
1.4 STRESS RELIEVE CERTIFICATE W/CHARTS
1.5 PAINT REPORT
1.6 CERTIFICATE OF CONFORMANCE
1.7 WAIVER S AND NCR S NOT APPLICABLE

ENGINEERING & FABRICATION DETAILS

2.1 AS-BUILT DRAWINGS
2.2 EQUIPMENT DATA SHEET
2.3 PRICED SPARE PARTS LIST
2.4 INSTALLATION & OPERATION INSTRUCTION

FABRICATION MATERIALS
3.1 MATERIAL LOCATION MAP
3.2 MATERIAL TEST REPORTS

WELDING DOCUMENTATION
4.1 WELD / NDE LOCATION MAP
4.2 QUALITY ROUTE SHEET
4.3 WELD PROCEDURE & QUALIFICATION RECORD

NON-DESTRUCTIVE TESTING
5.1 ULTRASONIC TEST REPORT
5.2 LIQUID PENETRANT REPORT

PROCEDURES
6.1 SHIPPING & STORAGE RECOMMENDATION

PHOTOSTATIC COPIES
7.1 NAMEPLATE (s)

CANADIAN REGISTRATION

INSPECTION REPORT
9.1 SHIPPING RELEASE
9.2 QUALITY ASSURANCE TRAVELER / PLAN

IND-10662-08-1

Page 1

ADDITIONAL REQUIREMENTS SHEET

Customer
Address
Plant Location
Painting Requirements

Suncor Energy Services Inc.

Calgary, Alberta
Ft. McMurray, Alberta

YES X

S.O. No.
Item No
Date

910662-08
215E-301
4/29/2008

NO

NON-SILICA BLASTING C.S. SUPPORT BRACKET AND EXTERNAL ATTACHMENT ONLY PER SP-6 & PRIME W/ 2-3 MILS DFT OF CARBOZINC 11 GRAY (0700).

Heat Treat Requirements

YES

NO X

Special Welding Requirements

YES

NO X

Max. for each weld pass shall not exceed 3/8". FCAW process is not allowed for root pass welding. GMAW process is only allowed for root pass
welding.

Special Weld Joints Required

YES

NO X

Non-Destructive Examination
RT:
MT:
U.T.:

YES X

NO

Corner joint per UG-93.

P.T.:
HARDNESS:
Special Test Requirements

YES

NO X

Stacking Required

YES

NO X

Special Support Brackets

YES X

NO

A
A

SA-516-70N material to be used for support brackets.

Extra Nozzles / Connections Required

YES
NO X
Exchanger shellside and tubeside shall have 1.5" RFWN w/ blinds low point drain connections (bottom leg)
and high point vent connections (top leg). Flange rating shall be the same as shell and tubeside nozzles respectively.
Country Of Origin Restrictions For Materials
YES
NO X
Acceptable Manufacturers List for Matls/Parts (AML)
KHT standard AML applies.
Special Charpy Impact Tests/Values

YES X

NO

YES

NO X

Material Chemical / Physical Restrictions

YES X

NO

YES X

NO

YES X

NO

All C.S. plate and forging pressure components shall be normalized.

Spare Parts Required

Two (2) sets of spare gaskets to accompany shipment.

Lifting Lugs, Ground Lugs Required

Exchanger shall be provided with two (2) KHT standard lifting lugs welded to the support bracket, one on each bracket.
Exchanger shall be provided with two (2) grounding lugs, one on each support bracket, per Suncor dwg DD00-P-103-1, rev. 2.
Rev A 7/1408 db; Rev. B 9/04/08

Page 2

ADDITIONAL REQUIREMENTS SHEET

Customer
Address
Plant Location

Suncor Energy Services Inc.

Calgary, Alberta
Ft. McMurray, Alberta

S.O. No.
Item No
Date

Exact Tube Length Required

YES

NO X

Special Packaging

YES

NO X

Special Bolting Materials

YES

NO X

Torque / Tensioning

YES

NO X

Shell Thickness Specified

YES X

NO

Third Party Requirements

YES X

NO

Fabricated Bonnets

YES

NO X

Additional Nameplates

YES

NO X

Other Mechanical Limitations

YES

NO X

Special Document Requirements

YES

NO X

Tubesheet O.D./Thickness Specified

YES

NO X

Nozzle Loads Required

YES X

NO

910662-08
215E-301
4/29/2008

CRN (Alberta) required.

Perform nozzle load analysis/calculations and provide maximum allowable values on GA-dwg.

Wind, Seismic, Motion Loads Required

YES

NO X

Any Limitations for Construction

YES

NO X

Special Construction Notes

1) One piece U-tubes.
2) Calculate MAP and MAWP, limiting component to be identified on the drawing. When nozzle rating limit MAWP or MAP, any excess material shall
be converted to corrosion allowance. The nozzle to shell attachment shall not limit MAWP.
3) Shop hydrotest pressure shall be 1.3XMAP and field hydrotest pressure shall be 1.3XMAWP.
4) Support brackets and external attachments shall be designed for -49 deg F.
5) Shell nozzle projection measure from shell external surface shall not be less than 12" plus 1.5" insulation (by others).
6) The MDMT shall be calculated for non-proprietary pressure component and the controlling component shall be indicated on the drawing.
7) Tubeside outlet nozzle to be eccentric for proper condensate drainage during operation.

Rev A 7/1408 db; Rev. B 9/04/08

B
B

Bulletin 1200/5
(Revised 8/07)

Installation, Operation and Maintenance

Hairpin Heat Exchangers
W
/External Split Flange Design

INNOVATORS IN HEAT TRANSFER

Brown Fintube Hairpin Heat Exchangers w/External Locking

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I.

II.

INSTALLATION OF HEAT EXCHANGERS

A. HEAT EXCHANGER SETTINGS
1) CLEARANCE FOR DISMANTLING
Provide sufficient clearance at return bend cover end to permit withdrawal of the tube element.
2) FOUNDATIONS
Foundations must be adequate so that exchangers will not settle and cause the piping to transmit excessive strains to the nozzles of the
exchanger. Foundation bolts should be set to allow for setting inaccuracies. In concrete footings, pipe sleeves, at least one size larger than
bolt diameter slipped over the bolt and cast in place are best for this purpose, as they allow the bolt center to be adjusted after the foundation
has set.
3) LEVELING
Exchangers must be set level and square so that pipe connections may be made without forcing.
B. CLEANLINESS PROVISIONS
1) CONNECTION PROTECTORS
All exchanger openings should be inspected for foreign material. Protective plugs and covers should not be removed until just prior to
installation.
2) DIRT REMOVAL
The entire system should be clean before starting operation. Under some conditions, the use of strainers in the piping may be required.
3) CLEANING FACILITIES
Convenient means should be provided for cleaning the unit as suggested under Maintenance.
C. INSTALLATION PROCEDURE
1) Mount the sections as shown in the recommended arrangement on the certified drawings. Be sure the shell nozzle gaskets are in
place, but do not tighten the shell nozzle bolts or the shell support bracket bolts. Note the oblong holes in the brackets for
alignment.
2) Unless ANSI flanged tubeside connections are supplied on the exchanger, the tube end flanges on tubeside are bolted on a factory but
tube gasket is not seated. The tube end flange should remain on equipment for fit-up of adjacent piping but removed for welding and
then re-assembled using supplied gaskets.
ASSEMBLY OF TUBE CLOSURE
a. Slip the tube back-up flanges over the projection of the tube assembly, place the tubeside split rings in the grooves provided in
the tubesheet or fintube fitting and move the flange forward to hold the split ring in position.
b. Place the tube gaskets in position in the inlet and outlet tube end flanges, or center on tubesheet sealing surface and assemble
using the proper tubeside bolting. If the sections are arranged in parallel, the stub end flanges will be attached to the manifolds, if
manifolds are provided with equipment.
3) Any required tubeside return bend connectors are normally shipped fully assembled on the equipment. If return bend connectors are
not assembled at the factory, assemble any tubeside return bend connectors. Be sure that the tube gaskets are in place and the joint
is centered so as to bear on the gasket.
4) Tighten all tubeside bolting evenly (Refer Para II B.4)
5) Tighten shell nozzle bolting and bracket bolts. The bracket and shell nozzle bolts are left loose initially to provide the section with a
little give, in case there is difficulty in connecting tubeside bend connectors if necessary. Once these connections have been bolted in
place, all other bolting may be tightened.
D. FITTINGS AND PIPING
1) BY-PASS VALVES
It may be desirable to provide valves and by-passes in the piping system to permit inspection and repairs.
2) TEST CONNECTIONS
Thermometer well and pressure gauge connections should be installed close to the exchanger in the inlet and outlet piping.
3) VENTS
Vent cocks should be provided so units can be purged to prevent or relieve vapor or gas binding.
4) SURGE DRUMS
In all installations, care should be taken to eliminate or minimize transmissions of fluid pulsations and mechanical vibrations to the heat
exchangers.
OPERATION OF HEAT EXCHANGERS
A. DESIGN AND OPERATING CONDITIONS
Equipment must not be operated at conditions which exceed those specified on the nameplate.
B. OPERATING PROCEDURES
Before placing any exchanger in operation, reference should be made to the exchanger
drawings, specification sheet, and name plate for any special instructions. Improper starting
up or shutting down sequences may cause leaking of tube-to-tubesheet and/or bolted
flanged joints.
1) STARTING-UP OPERATION
Exchangers should be placed in service by first establishing circulation of the cold medium,
followed by the gradual introduction of the hot medium. During start-up all vent valves should
be opened and left open until all passages have been purged of air and are filled with fluid.
2) SHUTTING-DOWN OPERATION
The units should be shut down by first gradually stopping the flow of the hot medium and then
stopping the flow of the cold medium. If it is necessary to stop the flow of cold medium, the
circulation of hot medium through the exchanger should also be stopped.
3) TEMPERATURE SHOCKS
Operation must be started gradually. Hot fluid must not be suddenly introduced when the unit is
cold, nor cold fluid suddenly introduced when the unit is hot.

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4)

III

BOLTED JOINTS
a) Heat exchangers are hydrostatically tested before leaving the manufacturers shop in accordance with ASME Code requirements.
However, normal yielding of gaskets will occur in the interval between hydrostatic testing in the manufacturers shop and
installation at the jobsite. Therefore, all external bolted joints should be properly re-tightened after installation and, if necessary,
after the exchanger has reached operating temperature.
b) RECOMMENDED BOLT TIGHTENING PROCEDURE
It is important that all bolted joints be tightened uniformly and in a diametrically staggered pattern as illustrated.
5) DRAINING THE UNIT
When shutting down the system, all units should be drained completely to minimize the possibility of freezing and corrosion damage.
To guard against water hammer, condensate should be drained from steam heaters and similar apparatus when starting up or when
shutting down. To reduce water retention after drainage, the tube side of water-cooled exchangers should be blown out with air.
MAINTENANCE AND HEAT EXCHANGERS
A. INSPECTION OF UNIT
At regular intervals and as frequently as experience indicates, an examination should be made of the interior and exterior condition of all
tubes. Neglect in keeping all tubes clean may result in complete stoppage of flow through some tubes, which could cause severe thermal
strains and/or leaking tube joints.
1) Exchangers subject to fouling or scaling should be cleaned periodically. A light sludge or scale coating on the tube greatly reduces its
efficiency. A marked increase in pressure drop and/or reduction in performance usually indicates cleaning is necessary. The unit
should first be checked for air or vapor binding to confirm that this is not the cause for the reduction in performance. Since the difficulty
of cleaning increases rapidly as the scale thickness or deposit increases, the intervals between cleaning should not be excessive.
2) ACCESS TO TUBES
a. Removal of return bonnet permits complete inspection of outside of internal return bends.
b. To inspect the inside of the tubes and the tube inserts (where used) and also make them accessible for cleaning, remove the
tubeside flanges. Flange bolts should not be loosened until the unit has been completely depressurized, vented and drained.
Tube inserts can be removed by removing wire retainer, or breaking tack welds and sliding inserts out of tubes. If tube inserts are
firmly corroded in place or held by accumulation of product or fouling, do not exert excess force to remove inserts as damage to
tubes or inserts may result.
3) LOCATING LEAKS IN TUBES
The following procedures may be used to locate perforated or split tubes and leaking joints between tubes and tubesheets in Multitube
units.
a) Remove tubeside flanges of any tube return bend connectors.
b) Apply hydraulic pressure in the shell.
In most cases, the entire front face of each tubesheet will be accessible for inspection. The point where water escapes indicates a
defective tube or tube-to-tubesheet joint.
4) Water for test should be at ambient temperature. Cold water may cause erroneous indications in humid atmospheres because of
condensation on the cold metal surfaces.
B. TUBE BUNDLE REMOVAL
1) Remove return bonnet bolting and return bonnet.
2) Remove tubeside bolting and tube split rings. Also remove any tube return bend connectors.
3) Remove shell closure bolting, and shell split flanges.
4) Move compression flange and sealing ring toward the end of the tubesheet.
5) Push the hairpin element toward the return bonnet and remove the compression flange, seal ring and tube back-up flange.
6) Pull the element back through the shell using canvas sling or belt wrapped around u-bends.
7) Care should be exercised when removing a multi-tube element from the shell, otherwise the element and/or the shell may be
damaged. The tube elements should always be supported on the baffles, tube support rings or tubesheets. Never support the
element on the tubes.
8) Tube element should not handled with hooks or other devices which might damage the tubes. Elements should be supported on
cradles or skids. Horizontal tube elements should be lifted by means of suitable slings. Baffles can be bent and damaged by dragging
an element over a rough surface. All gaskets surfaces should be protected from accidental damage, since these areas are generally
difficult to repair.
C. CLEANING TUBE BUNDLES
1) CLEANING METHODS
The heat transfer surfaces of heat exchangers should be kept reasonably clean to assure satisfactory performance. Convenient
means for cleaning should be made available. Heat exchangers may be cleaned by either chemical or mechanical methods. The
method selected must be the choice of the operator of the plant, and will depend on the type of deposit and the facilities available in
the plant. Following are several cleaning procedures that may be considered:
Circulating hot wash oil or light distillate through tubes or shell at high velocity will effectively remove sludge or similar soft deposits.
Some salt deposits may be washed out by circulating hot fresh water.
Commercial cleaning compounds are available for removing sludge or scale, provided hot wash oil or water is not available or does not
give satisfactory results. Contact compound manufacturer for advice.
High pressure water jet cleaning.
Scrapers, rotating wire brushes, and other mechanical means for removing hard scale, coke or other deposits.
Employ services of a qualified organization that provides cleaning services. These organizations will check the nature of the deposits
to be removed, furnish proper solvent and/or acid solutions containing inhibitors, and provide equipment and personnel for a complete
cleaning job.
2) CLEANING PRECAUTIONS
a) Tubes should not be cleaned by blowing steam through tubes, since this overheats the tube and results in severe expansion
strain.

Brown Fintube Hairpin Heat Exchangers w/External Locking

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b)
c)

D.

E.

When mechanically cleaning a tube bundle, care should be exercised to avoid damaging the tubes.
Removal of the tube inserts (if present) should be accomplished before beginning mechanical cleaning process. Sec III (A) (2)
ACCESS TO TUBES.
d) Cleaning compounds should be compatible with metallurgy of the equipment.
TUBE ROLLING
A suitable roller type tube expander should be used to tighten a leaking roller expanded tube-to-tubesheet joint. When a welded to
tubesheet joint is present, repair of leaking tube to tubesheet joint should be performed with an acceptable welding process. A light contact
tube expansion should then be performed taking care to maintain an appropriate distance from weld. Care should be taken to insure that
tubes are not over-rolled.
GASKET REPLACEMENT
Gaskets and gasket surfaces should be thoroughly cleaned and should be free of scratches and other defects. Gaskets should be properly
positioned before attempting to retighten bolts. It is recommended that when a heat exchanger is dismantled for any cause, it is
reassembled with new gaskets. This will tend to prevent further leaks and/or damage to the gasket seating surfaces of the heat exchanger.
Composition gaskets become dried out and brittle so that they do not always provide an effective seal when reused. Metal, or metal
jacketed gaskets, when compressed initially, flow to match their contact surfaces. In so doing they are work hardened and, if reused, may
provide an imperfect
seal or result in deformation and damage to the gasket contact surfaces of the exchanger. Any leakage at a gasketed joint should be
rectified as soon as possible, and not allowed to persist as it may resultl in damage to the gasket surfaces.
SPARE AND REPLACEMENT PARTS
For procurement of spare or replacement parts please refer to spare parts list and detail drawing, which have been previously furnished, or
to the following typical parts list drawing.

Brown Fintube Hairpin Heat Exchangers w/External Locking

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Parts List: Hairpin Heat Exchangers
When ordering parts, furnish serial number as shown on the nameplate and designate parts required by number and name as shown in the following
table.

LOW/INTERMEDIATE PRESSURE
DOUBLE PIPE HEAD ASSEMBLY

1.) Shell Assembly

2.) Tube Assembly
3.) Return Bonnet
4.) Compression Flange
5.) Sealing Ring
6.) Split Flange
7.) Split Rings (Tube)
8.) Tube Back-up Flange

HIGH PRESSURE TAPER-LOK

DOUBLE PIPE HEAD ASSEMBLY

9.) Tube End Flange

10.) Tube Return Bend Connector
11.) Return Bonnet
12.) Shell Closure Bolts
13.) Tube Closure Bolts
14.) Shell Nozzle Flange Bolts
15.) Bracket Bolts
16.) Bonnet Gasket (Optional)

LOW.INTERMEDIATE PRESSURE
MULTITUBE HEAD ASSEMBLY

HIGH PRESSURE TAPER-LOK

MULTITUBE HEAD ASSEMBLY

17.) Tube Gasket

18.) Shell Nozzle Gasket
19.) Stub End

Recommended Spare Parts Inventory Per Section

Two bonnet gaskets (16)
Four tube gaskets (17)
Four sealing rings (5)
Two split rings (tube) (7)

The preceding Installation, Operation and Maintenance instructions are as outlined in Standards of Tubular Exchanger Manufacturers Association,
seventh edition 1988, except where they have been modified to specifically relate to Brown Fintube Multitube Hairpin Heat Exchangers.
KOCH HEAT TRANSFER COMPANY, LP
12602 FM 529 Houston, Texas 77041
P.O. Box 40082 Houston, Texas 77240-0082
Tel 713-466-3535 Fax 713-466-3701/3625
Email: www.kochheattransfer.com

A KOCH Chemical Technology company