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    Heat Exchanger Inspection PDF

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    glazetm
    The document discusses inspection of heat exchangers used by Saudi Aramco. It outlines the main types of heat exchangers including shell-and-tube, air-cooled, and plate-and-frame. It describes Saudi Aramco specifications, forms, and industry standards for heat exchanger design, fabrication, and inspection. The document provides details on TEMA classifications, materials selection, and the fabrication process through inspection and testing plans.

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    Heat Exchanger Inspection PDF

    Uploaded by

    glazetm
    535 views27 pages
    The document discusses inspection of heat exchangers used by Saudi Aramco. It outlines the main types of heat exchangers including shell-and-tube, air-cooled, and plate-and-frame. It describes Saudi Aramco specifications, forms, and industry standards for heat exchanger design, fabrication, and inspection. The document provides details on TEMA classifications, materials selection, and the fabrication process through inspection and testing plans.

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    161348128-Heat-Exchanger-Inspection.pdf

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    The document discusses inspection of heat exchangers used by Saudi Aramco. It outlines the main types of heat exchangers including shell-and-tube, air-cooled, and plate-and-frame. It describes Saudi Aramco specifications, forms, and industry standards for heat exchanger design, fabrication, and inspection. The document provides details on TEMA classifications, materials selection, and the fabrication process through inspection and testing plans.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    535 views27 pages

    Heat Exchanger Inspection PDF

    Uploaded by

    glazetm
    The document discusses inspection of heat exchangers used by Saudi Aramco. It outlines the main types of heat exchangers including shell-and-tube, air-cooled, and plate-and-frame. It describes Saudi Aramco specifications, forms, and industry standards for heat exchanger design, fabrication, and inspection. The document provides details on TEMA classifications, materials selection, and the fabrication process through inspection and testing plans.

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    The document discusses different types of heat exchangers used in Saudi Aramco, including shell-and-tube, air-cooled, double-pipe and plate-and-frame exchangers. It also covers Saudi Aramco specifications, inspection requirements, fabrication processes and more.

    The main types discussed are shell-and-tube, air-cooled, double-pipe and plate-and-frame heat exchangers.

    Standards and specifications mentioned include Saudi Aramco specifications 32-SAMSS-007, 32-SAMSS-011, 32-SAMSS-028, SAES-E-004 through SAES-E-015. Industrial forms like SA F175 are also referenced.

    Inspection of Heat Exchangers

    Saad G.AL-Dufairi
    BGP-Inspection Unit
    July4,2005

    Outline

    Objective. Types of Heat Exchangers. Saudi Aramco Specifications, F175 Forms. Industrial Standards & Codes.

    TEMA Classifications.
    Air-Cooled Heat Exchangers. Primary Process Functions of Heat Exchangers.

    Fabrication steps through ITP.

    Objective

    Identify the main types of heat exchangers and their


    primary components..

    Inspection, and testing procedures for heat exchangers.


    Saudi Aramco Specifications and F175 Forms. Industry Standards And Codes.

    Evaluate vendor fabrication drawings for suitability, using 32-SAMSS-007, 32-SAMSS-011, TEMA, and API standards. industry codes and standards to determine heat exchanger inspection and testing requirements.

    Describe the use of 32-SAMSS-007, 32-SAMSS-011, and

    Types of Heat Exchanger


    The main types of heat exchangers that are used by Saudi Aramco are as follows:

    Shell-and-tube heat exchangers Air-cooled heat exchangers Double-pipe heat exchangers Plate-and-frame heat exchangers

    Types of Heat Exchanger Shellside Flow In Tubeside Flow Out Shell

    Tube Bundle

    Shellside Flow Out Tubeside Flow In


    Shell-and-Tube Heat Exchanger

    Types of Heat Exchanger


    Tube Keeper (top) Lifting Lug Air Seal Header

    Air Seal

    Tube Nozzle

    Air Seal

    Header
    Tube spacer Side Frame
    Typical Air-Cooled Heat Exchanger

    Fins Tube Support (bottom)

    Types of Heat Exchanger


    Shell Cover Gasket Vent Shell Cover Shell External Fin Pipe

    Return Bend (welded) Drain Sliding Support Twin Flange Fixed Support Shell End Piece

    Double-Pipe Heat Exchanger

    Types of Heat Exchanger


    Separating Sheet

    Bin

    Aout

    Nozzle Header

    Cin

    Corrugated Sheet

    Effective Width

    Heat Transfer Section Effective

    Side Bar Distributor

    Length

    Cout

    Distribution Section

    Ain

    Bout

    Plate-and-Frame Heat Exchanger2

    SA Specifications
    32-SAMSS-007 32-SAMSS-011 32-SAMSS-028
    Exchangers SAES-E-004 Manufacture Of Shell And Tube Heat Exchangers Manufacture Of Air-Cooled Heat Exchangers Inspection Manufacture of Double Pipe Heat Design Criteria Of Shell And Tube Heat Exchangers Design Criteria of Double Pipe Heat Exchangers Design Criteria Of Air-Cooled Heat Exchangers Design Criteria Of Plate And Frame Heat Exchangers Design Criteria Of Electric Heat Exchangers

    SAES-E-006
    SAES-E-007 SAES-E-014 SAES-E-015

    Saudi Aramco Inspection Requirements Forms SA F 175

    Form 175-323100 Form 175-323500 Form 175-323600 Form 175-323300

    Manufacture of Shell And Tube Heat Exchangers Floating Heads or Tube Bundles Manufacture of Air-Cooled Heat Exchangers Manufacture of Plate & Frame

    Industrial Standards

    ASME SEC VIII


    D1/D2

    Rules for Construction of Pressure Vessels Standards of the Tubular Exchanger Manufacturer's Association

    TEMA

    API 660
    API 661

    Shell and Tube Heat Exchangers for General Refinery Services


    Air-Cooled Heat Exchangers for General Refinery Service

    TEMA Classifications
    TEMA Class Application Example
    __________________________________________________________________________________________________________________________________________

    R
    C

    Severe environments
    Moderate service

    Refineries
    Building services, commercial, and general process industries

    Chemical process

    Chemical manufacturing

    TEMA Classifications
    Design Item Corrosion Allowance (carbon steel) Minimum Thickness of Shell Minimum Tie-Rod Diameter Gasket Contact-Surface Tolerance Class/Service R/Refinery 1/8 in. See Table R3.13 3/8 in. 1/32 in., max. in. C/General 1/16 in. See Table CB-3.13 in. None in. B/Chemical 1/16 in. See Table CB-3.13 in. None 5/8 in.

    Minimum Bolt Size

    TEMA Size and Type Normally Written: 23192 AES

    23 Shell I.D.

    Straight Tube Length 192 (16 0)

    Type A Channel

    Type E Shell Single-Pass

    Type S Split-Ring Floating Head

    TEMA Designation System Example

    TEMA Types

    Acceptable Exchanger Components Materials for Carbon and Alloy Steels


    Design Temperature
    Exchanger Component
    (Note: The numbers in ( ) refer to the specific notes at the end of the table)

    -100C - 47C (-150F - 51F) SA-203 Grades D or E

    -46C - 0C (-50F - 32F) SA-516 Grade 70N, or SA-537 Class 1

    1C - 425C (33F - 800F) SA-516 Grade 70 or SA-537 Class 1 or SA-285 Grade C (1)

    351C - 645C (651F 1200F) SA-387 Grade 11

    Shells, Channels, Dished Heads, Tube sheets, Rolled Nozzle Necks, Covers, and Reinforcing Pads Pips, Nozzle Necks

    SA-333 Grade 3 SA-333 Grade 6 SA-106 Grade B SA-53 Grade B (1)

    SA-335 P11, 12 or 22

    Shell and Tube Heat Exchangers

    Air-Cooled Heat Exchangers


    Forced-draft
    Air forced across tube bundle by fan located in air plenum

    below bundle.

    Induced-Draft
    Fan located above hood covering tube bundle. Air pulled across tube bundle and exhausted through hood.

    Humidified Forced-Draft
    Air humidified before forced across tubes. Evaporation draws heat from air and cools air below

    temperature of process fluid.

    Air-Cooled Heat Exchangers


    Inlet Nozzles Tube Bundle Return Header(s) Inlet Headers Outlet Headers Outlet Nozzles

    Supports

    Fan Drive Assembly

    Plenum Fan Ring

    Typical Forced-Draft Air-Cooled Heat Exchanger

    Air-Cooled Heat Exchangers


    Hood or Plenum Fan Ring Fan Inlet Nozzles Return Headers

    Inlet Headers

    Outlet Headers

    Outlet Nozzles

    Tube Bundle Drive Assembly

    Supports Horizontal Tube, Induced-Draft Air-Cooled Heat Exchanger

    Air-Cooled Heat Exchangers


    Hot Air Tube Bundle Process Nozzle Partition Plate Header
    Fine Water Mist

    Header

    Plenum Chamber

    Process Nozzle Water Header Nozzles (above fan Typical)

    Forced Draft Fan

    Water Header Nozzles (below fan Sometimes)

    Humidified Forced-Draft Heat Exchanger

    Acceptable Materials for Fin fan cooler


    Design Metal Temperature Exchanger |Component Header Plates, Pass Partition Plates and Stiffener Plates
    (Note: The numbers in ( ) refer to the specific notes at the end of the table)

    -46C to 0C (-50F to 32F)


    SA-516 Grade 70N or SA-573 Class 1

    1C to 425C (33F to 800F)


    SA-516 Grade 70, or SA-537 Class 1 or SA-205 Grade C (1) SA-106 Grade B SA-53 Grade B (1) SA-179 or SA-214 SA-105N

    351C to 645C (651F to 1200F)


    SA-387 Grades 11, 12 or 22

    Nozzle Necks Tubes (inner) (2) Forged Flanges, Forged Fittings, and Plugs Wrought Fittings

    SA-333 Grade 6 SA-334 or SA-249 Type 304 SA-350 LF2

    SA-335 P11, 12 or 22 SA-179 or SA-214 or SA-213 Type 304 SA-182 F11, 12, or 22 SA-234 F11. 12. pr 22

    SA-420 WPL6

    SA-234 WPB

    Studs/Nuts for Pressure Connections

    SA-320 L7 w/ SA-194 Grade 2H

    SA-193 B7/ SA-194 Grade 2H

    SA-193 B5, or B16/SA-194 2H, or 3

    Primary Process Functions of Heat Exchangers

    Change temperature of a fluid


    Change phase of a fluid.

    Fabrication steps through ITP

    Fabrication drawing should be issued for constriction. Welding Procedure Specification (WPS) & Procedure
    Qualification Record (PQR) shell be approved by CSD.

    Material certificates to be 3.1B for pressure parts plus


    NACE TM0284 for HIC service.

    Certificate should include material chemical analysis &


    mechanical test.

    Verification of heat number between certificate and


    actual material.

    Material traceability. (hard punching prior to cutting)

    Fabrication steps through ITP (2)

    Layout marking for cutting of shell and header box. Rolling & edge preparation of long seam & circ seams. Re-rolling after long seam. Fit-up of long seams then circ seams. Layout marking of all nozzles pipe. Fit-up of flange to neck pipe. Marking of all nozzles on shell & channels.

    Bevel edge preparation of nozzle opening.


    Fit-up of nozzles to shell & Channels.

    Fabrication steps through ITP (3)

    Layout & drilling of baffle plate & tube sheet . Tube bundle preparation & assembling of tubes, tierods, spacers etc, to tube sheet.

    Tube expansion to be between 5.0% to 10%. Post Weld Heat Treatments (PWHT) if required. NDE (RT, UT, MT & PT) and Hardness test. Final visual & dimensional test. Pneumatic test of all reinforcements pads at 30 KPA. Hydrotest of shell side, tube side then channels side.

    Fabrication steps through ITP (4)

    Draining the whole equipment. Verification of U stamp and name plate. Surface preparations, blasting then coating. Fin-fan coolers shall be completely drained with dry air to an exit dew point of less than -1C. as CORTEC VCI-309, VCI-307 or 5 PSIG of nitrogen blanket.

    Internal surface protection by corrosion inhibitor such Shipment release.

    Thank you

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