mec-spe- air cooled heat exchangers

Transmittal No.:

"SPECIFICATION FOR AIR COOLED HEAT EXCHANGERS"

. h _/

c 10/15/12 ISSUE FOR INQUIREY )l

Rev Date Revision Title Engineer Lead Engineer Department Manager

o.

Sheet 1 of 2 Company Doc. No.:

TECHNICAL SPECIFICATION FOR AIR COOLER HEAT EXCHANGER

INDEX

1 INTRODUCTI ON................................................................................................................................41.1 Scope of Document............................................................................................................41.2 Definitions............................................................................................................................41.3 Language.................................................................................................................................... 41.4 Unit of Measurement....................................................................................................41.5 Reference Documents.........................................................................................................51.6 Acronims and abbreviations................................................................................................51.7 Supplier Responsibility........................................................................................................5

2 SCOPE OF SUPPLY..........................................................................................................................63 TECHNICAL REQUIREMENTS OF SUPPLY....................................................................................6

3.1 Basis for thermal design...............................................................................................73.2 Tube bundles.......................................................................................................................73.3 Headers...............................................................................................................................83.4 Nozzles and Flanges....................................................................................................83.5 Fans.....................................................................................................................................83.6 Power Transmission............................................................................................................93.7 Nameplates..........................................................................................................................93.8 Noise level...................................................................................................................103.9 Tubes..........................................................................................................................................103.10 Finned Tubes......................................................................................................................113.11 1 Structures...............................................................................................................113.12 Design loads...............................................................................................................11

3.12.1 Equipment weight....................................................................................................123.12.2 Wind loads........................................................................................................123.12.3 Seismic loads....................................................................................................123.12.4 Loads on nozzles..............................................................................................12

3.13 Provision for thermal expansion...................................................................................133.14 Material requirements.........................................................................................................13

3.14.1 Steel plates for fabrication.................................................................................143.14.2 Use of 13% Cr Steel..........................................................................................143.14.3 Claddings.................................................................................................................14

4 FABRICATION...............................................................................................................................154.1 Qualifications of Welding Procedures and Welders.....................................................154.2 Welding...............................................................................................................................154.3 Post-Weld heat treatment...................................................................................................164.4 Painting...............................................................................................................................164.5 Spare Parts.........................................................................................................................16

5 PREPARATION FOR SHIPMENT....................................................................................................176 INSPECTION & TESTS.............................................................................................................17

6.1 Tests on steel plates....................................................................................................186.1.1 Plates Exceeding 50 mm in Thickness..............................................................186.1.2 Clad Plates........................................................................................................186.1.3 Plates for Hydrogen-containing Equipment.......................................................18

6.2 Inspection and testing during construction...................................................................186.3 Non-Destructive Examination.............................................................................................18

6.3.1 X-ray examination....................................................................................................186.3.2 Magnetic particle inspection.....................................................................................196.3.3 Dye-penetrant inspection.........................................................................................196.3.4 Ultrasonic testing on welds................................................................................196.3.5 Pressure testing........................................................................................................19

7 PERFORMANCE GUARANTEE.......................................................................................................208 DOCUMENTATION...........................................................................................................................20


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8.1 Technical documentation.............................................................................................208.2 Inspection Documentation...........................................................................................218.3 Final Documentation....................................................................................................21


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1 INTRODUCTION

1.1 Scope of Document

This specification defines codes, design, tests and minimum requirements for the supply of Air Cooled Heat Exchangers which shall be considered in the development of the Project in object.

1.2 Definitions

The following definitions will be used in the document without the needs of any further explanation:

Company:

Project:

Job:

1 .3 Language

The official language of the project is English.All the documents, including communications between the Parties and instructions/manuals of each single part constituting the Supply shall be written in English.

1.4 Unit of Measurement

Basically the SJ units shall be used for the Project; however, being more familiar in the field, for pressure, flow rates and temperature the Imperial Units could also be adopted (reported in brackets beside the SJ value), as listed below:

Temperature: Pressure:

OFpsia/psig


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Liquid flow: Gas Flow:

bbld MMSCFD

As an exception nominal diameter of pipes will be expressed only in inches and pressure will be expressed in barg (relative pressure).

1.5 Reference Documents

Materials or equipments mentioned in this Specification shall be in accordance with all Project documents listed in the relevant MR and applicable codes, standards and regulations.

1.6 Acronims and abbreviations

Abbreviations used in this specification have the following meaning:

AISI ANSI ASME AWScsHSE MDMT MR WPS SS TEMA GRP

American Iron and Steel Institute American National Standard InstituteThe American Society of Mechanical Engineers American Welding SocietyCarbon SteelHealth Safety & Environment Minimum Design Metal Temperature Material RequisitionWelding Procedure Specification Stainless SteelTubular Exchanger Manufacturers Association Glass-reinforced plastic


1.7 Supplier Responsibility

The SUPPLIER shall be responsible for the complete mechanical design, supply of documentation, fabrication, inspection and testing of the equipment in compliance with the requirements of this specification, its attachments, all applicable codes, standards and regulations referred therein and any requirements of the certifying authority (as applicable).Air cooler shall be supplied by Supplier qualified by experience in manufacturing the units proposed. To qualify, the Supplier must have manufactured at the proposed manufacturing location, at least two air coolers having comparable characteristics. These air coolers must have been in service for at least one year and must be performing satisfactorily.

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2 SCOPE OF SUPPLY

The supply includes design, material prov1s1on, manufacture, testing, inspection, certification, technical documentation and drawings, painting, packing and preservation for shipment and all other activities required in this specification and in the documents herein listed.The following shall be included:

• pre-assembled tube bundles;• plenum system;• fans;• reduction gear (or pulleys and belts);• couplings;• protection guards for fans and belts;• electric motor and relevant support frames;• support structures;• anchoring plates;• vibration dampeners for motors;• ladders and walkways.

Foundation bolts are excluded from the scope of supply.

3 TECHNICAL REQUIREMENTS OF SUPPLY

The equipment shall comply with the requirements set out in the relevant Data Sheets and in the documentation issued for the specific project.The available services are specified in the documents issued in respect of the specific project.The Supplier shall verify the availability of any needed service, the specificconsumption and their time distribution.


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All the environmental conditions which may affect the reliability of the equipment shall be taken into account, as:

• minimum and maximum temperatures,• wind direction and speed,• sand storms• elevation on the sea level,• condensate formation,• presence of solids (sand, dust),• presence of corrosive or polluting substances,• mildew formation,• seismic events,• direct or indirect lightning,• mechanical stresses and vibrations during the normal operations,• electromagnetic influences,• explosion or fire hazard.

3.1 Basis for thermal design

Manufacturer design, including bundle arrangement, tube pitch, number of rows, fin spacing/height, tube size, and number of passes shall be suitable for the intended service, for all operating sequences, including start-up and, shut-down.Fouling resistances are indicated in the air cooler data sheets, in line with the individual plant's operating experience in similar service, where possible. In the absence of such information, the following fouling resistance can be considered as reference:

Foulin!l resistanceFluid m2 K/W ft' h 'F/BtuFuel oil 0.0009 0.005Natural qas 0.00035 0.002

Crude oil (up to 121'C and <2 ft/s)

0.0005 0.003

Crude oil (up to 121'C and >=2 fUsl

0.00035 0.002

Gasoline 0.00035 0.002Naohtha 0.0004 0.0025

Clear sea water 0.00025 0.001Dirty sea water 0.00035 0.002

Dirty Brackish water 0.00052 0.003Sour water 0.00035 0.002River water 0.0005 0.003

Steam + (sour) condensate

0.00017 0.00095

Treated boiler feed water

0.00025 0.001

Table 1 - Typical fouling resistance values

For different fiuids (not considered in the table above) fouling resistance shall be selected from the values recommended by TEMA.The airside fouling resistance shall be 0.000352 m2 'K/W (0.002 ft2 h 'F/Btu).

Design air inlet temperature shall be the maximum design value of dry bulb temperature for the particular site.

3.2 Tube bundles

Tube bundles shall be designed and constructed as to minimize vibration.Tube bundles should contain a maximum of eight rows. Designs with more than eight rows will require written Company approval.Four rows of staggered tubes shall be provided as minimum.Bundle frames shall be rigid and self-contained for handling as a complete assembly and shall be equipped with lifting lugs. Tube bundle construction shall prevent the tubes from sagging and consequent deformation of the fins.Tubes shall be expanded into the headers, if not otherwise specified in the relevant Data Sheet.Adequate solutions shall be provided in order to avoid unwished air passages at theexternal of bundles in all the possible operative conditions (considering the piping thermal expansion).

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3.3 Headers

Unless otherwise specified, plug-type headers shall be provided.For fouling fluids having fouling factors <:. 0.0007 K m2/W (0.004 ff h 'F/Blu) removable cover-plate type headers shall be used provided that the operating pressure does not exceed 40 bar (4 MPa).Plug type headers may be used with pressures exceeding 40 bar.For high pressures, manifold type headers with return bends shall be used.

The mechanical calculation for stress relieving of headers shall be in accordance with the regulations in force in the country of installation. Failing such regulations, the requirements of ASME Code, Section VIII, Division 1, latest edition, shall govern. The "U" Stamp is required.

Provisions shall be made in the design of headers lo prevent deflection and distortion.

One of the two headers shall be floating to allow for free expansion of tubes.

Plugs shall be of such lengthlo have a maximum of two threads projecting into the header.Inspection plugs shall be of hot-dip electro galvanized carbon steel ASTM A- 105, orequivalent.

3.4 Nozzles and Flanges

For diameters uplo 1O" nozzles shall be made from seamless tube. For diameters over 1O" nozzles may be made from plate. Any deviation shall be authorised by the Company.

The neck thickness of a welding-neck flange shall be the same as the thickness of the nozzle welded to ii.

Unless otherwise specified, RF type flanges shall have smooth faces with a superficial finishing of 125 AARH and waviness height of 0.05 mm accordinglo ANSI B 46.1

Bollcenters of flanges shall evenly straddle vertical axis.

The air coolers shall be supplied with one installed set of gaskets (not included in commissioning spare parts).

Vent and drain connections shall be al least NPS 1".

3.5 Fans

Due to the presence of sand storms fan blades shall be made of GRP (aluminium is not allowed).

Blades shall be even in number (4 as a minimum). Fans shall be statically and dynamically balanced.


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As an alternative, when removable blades are utilized, the hub shall be dynamically balanced and the blades balanced against a master blade.

The Supplier shall calculate the power absorbed at motor shaft with the specified air quantity and static pressure, both for minimum and maximum air temperature.When checking the power, the Supplier shall take into account the actual shape and size of fan ring (inlet and outlet ring conditions, radial clearance, etc.).Fans shall be able to handle 110% of design air quantity without stalling.

Unless otherwise specified in the Data Sheets, fans shall be manually adjustable for blade angle (pitch).

3.6 Power Transmission

Power transmission shall comply with AP! 661 requirements, with a single exception; belt transmissions shall be allowed for power lower than 22 kW (30 CV).

The power of the electric motors shall be at least 20% higher than the power absorbed by the fan in design conditions.

Pulley wheels shall be cast iron or steel; aluminium is not acceptable. Belt type and pulley diameter shall be selected as to minimise the number of belts and pulleys. Pulleys shall be painted in accordance with the requirements of the Data Sheet.

Bearings and actuators shall be properly sealed to keep out dust.

Each bearing support shall be provided with remote lubrication connection, accessible from nearby walkways, to permit lubrication without shutting down the motor.Mechanical vibration switch with SPOT free voltage contact shall be provided.

3.7 Nameplates

Austenitic Stainless Steel (316L) name/rating plates shall be provided for each item of tagged equipment and for each skid mounted package. The information shall be stamped or engraved in a minimum of 0.01 inch (0.25 mm) deep. Nameplates shall be appropriately attached to machine casing or welded brackets.

Name/rating plates shall be legible, in English language, and include as a minimum:

a) Manufacturer's name and location

b) Vendor's name and reference number

c) Company's name, order number and equipment tag number

d) Serial number

e) Size/model/type

f) Principal duty parameters (e.g. Capacity, pressure, head, rpm, etc)

g) Lubricant

h) Test Conditions

i) Year of manufacture

j) Code stamp

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An arrow indicating the direction of rotation shall be permanently and distinctly marked on all machines, in a contrasting colour. Both Nameplates and rotation arrows shall stand clear of any insulation, where this is used.Fasteners for indication plates, nameplates, etc. shall not penetrate the machine casing and shall be of a material compatible with both the nameplate and the bracket or casing to which is attached.

3.8 Noise level

Unless otherwise specified in other documents, it will be necessary to observe 85 dB(A) 1 m below the fan for forced draft air coolers, or 1 m below the tube bundle for induced draft air coolers. This value is applied to the whole motor-transmission-fan complex, for each group.

3.9 Tubes

Tubes shall be a minimum of 25.4 mm outside diameter.The maximum tube length shall be 12,200 mm; designs with a greater length shall be submitted for Company approval.Tubes of low-alloy steel and non-ferrous material shall be seamless.

Unless otherwise specified, electrically joined tubes in carbon steel, stainless steel, titanium and superalloy can be used provided the following conditions exist:

• design pressures :> 5 MPa ;• design temperature :> 343 'C .• all electrical welded tubes shall be checked for their entire length using a non

destructive examination method {ultrasonic and/or eddy current) in accordance with ASTM A-450.

• carbon steel tubes shall undergo a final heat treatment (normalisation).• for non-drawn tubes, the bead shall be removed over the entire length of the

external surface, while bead removal on the internal surface shall be limited to a distance of 50 mm beyond the length required for expansion

The tubes shall protrude 3 mm (1/8 inches) beyond the surface of the tube sheet.

The tubes/tube sheet coupling shall be done by forced expansion with two grooves; different types of joining shall be defined each time in the equipment specifications.

When the material can be welded, the tubes shall be slightly expanded and strength welded to tubesheet when even one of the following conditions occurs:

• design pressure <: 15 MPa ;• design temperature <: 400 'C ;• hydrogen service;• lethal fluid.

If, for metallurgical reasons, strength welding between tubes and tube sheet is impossible (e.g. low alloy materials or compliance with NACE, etc.), as an alternative, forced expansion with three grooves shall be adopted.

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3.10 Finned Tubes

Due to the presence of sand storms aluminium as fin material is not allowed.Carbon steel fins shall be used for CS tubes, CS or SS fins shall be used for SS tubes.Taking into account his own experience for applications in similar environmental conditions the Supplier may submit different materials for Company approval.Supplier shall propose the most suitable fin bonding type considering the materials of tube and fins and the process fluid temperature.During inspection and testing, the Supplier shall certify the compliance of the materials used for fins with the proposed material by means of chemical analysis certificates.

3.11 Structures

The equipment shall be prefabricated and mounted on skids to the maximum possible extent, ready for setting on prepared foundations with the minimum of site erection.

No welding at site permitted to assemble the units.

Structural steel shall conform to ASTM A-36 or equivalent, hot galvanized.

All necessary lifting lugs shall be provided.The skid shall be of a rigid construction and fitted with lifting lugs suitably inspected to ensure soundness and integrity of attachment welds. The lifting lugs shall be located such to allow lifting slings to clear all appurtenances.

The equipment shall be arranged to provide adequate access for safe operation, maintenance or replacement of any component, including grated floating, proper pipe supports, etc..

No part of the equipment, piping, instruments etc. shall overhang the edge of the skid.

The support structures shall be independent, that is they shall not be transmitting any load to adjacent supports or structures, as for instance pipe racks.

The supply shall include walkways for access to both the headers and relevant connections, provided with hot galvanized non-skid grating.

3.12 Design loads

For all items of equipment, stability at the design pressure and hydraulic test pressure shall be checked, and the stability of equipment and its components shall be ensured taking into consideration all possible design loads combinations under operating and hydraulic test conditions (refer to project specification 11J01834-CIV SP-000-010 Civil and structural design criteria).


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3.12.1 Equipment weight

Equipment weight is defined as follows:

a) Empty weight: it represents the weight of the equipment being erected and includes:

• tube bundle complete with winterization devices, if necessary;• dampers;• supporting structure and plenum chambers;• fans with supports, motors, transmissions, etc.;• any other accessories envisaged and assembled (air recirculation

panels, etc.);• walkways for the inspection of headers with access ladders, piping;• fireproofing, where required;• brackets and supports for any additional piping.

b) Weight during hydraulic test: it represents the weight of the equipment when the hydraulic test is undeiway on site and includes:

• empty weight (as under point a), above);• test water.

c) Weight during operation; it represents the weight of the equipment under operating conditions and includes:

• empty weight (as under point a), above)• weight of the fluid contained during operation.

3.12.2 Wind loads

The wind loads by unit of exposed area are laid down in the codes and in the applicable documentation.Hereunder is a description of the surfaces exposed to the wind for consideration inthe check of stability under operating and hydraulic test conditions.

a) The air cooler complete with bundles, steam coil, dampers, plenum chambers, motor-fan sets;

b) If included in the design: air recirculation panels, wind shields, etc.;c) Platforms and ladders, if any. Unless otheiwise specified, they include

service platforms for the headers on all of the four sides, as well as those for fan motors;

d) Steel structures and any piping supported by the structure of the air coolers

3.12.3 Seismic loads

Seismic loads shall be calculated in accordance with the applicable codes and documentation and the weight during operation shall be taken into consideration.

3.12.4 Loads on nozzles


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The loads on individual nozzles to be taken into consideration shall not be less than those shown in the table below:

NPS 2Moments

Mx - Mz 700 1200 2000 3500 7000My 1000 2000 3000 5500 9000

Forces [NJx 3500 4000 6000 7000 9000y 5000 8000 10000 12000 14000z 4000 5000 7000 9000 11000

Table 3 - Allowable loads on nozzles

For nozzles with rating 600 or higher, the loads specified in table 1 increased by 100% shall be considered.

For each header, independently of the rating of nozzles, the overall loads indicated below shall not be exceeded:

• For each header sum of Fx ,; 15 500 N• For each header sum of Fy ,; 20 000 N• For each header sum of Fz ,; 17 000 N

In any case the Vendor shall indicate in the bidding phase and submit for Company approval the maximum allowable loads on the nozzles.Thermal displacements and allowable loads of each main header nozzle shall be indicated in the equipment drawings.

3.13 Provision for thermal expansion

Air cooled heat exchangers shall be designed to absorb thermal expansions.Each tube bundle shall be sized so as to absorb safely the thermal expansion of its own components in the three directions.Unless otherwise specified, the inlet header at its midpoint shall be considered as fixed point. The opposite header shall be considered as floating.Unless otherwise specified, it will be assumed that the tube bundles belonging to thesame unit (same service) are fed with a rigid manifold. Consequently, the thermal expansion of the main line is transmitted to the tube bundles that shall absorb it without any damage.

3.14 Material requirements

Materials shall be selected to conform to the requirements of the Data Sheet and shall be subject to Company's approval.If not indicated, Supplier is responsible for the selection of appropriate materials tosuit all specified operating conditions and meet the requirements of all applicable specifications.Material of the pulleys shall be cast iron or steel, due to the presence of sand storms aluminium is not acceptable.


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3.14. 1 Steel plates for fabrication

Carbon steels plates used for pressure parts shall be accord ing to EN 10028 I ASTM A 516 or equivalent.

Unless otherwise indicated by the Company, non-pressure internal or external parts to be welded to headers shall be of the same material as the header.

3.14.2 Use of 13% Cr Steel

If 13% Cr solid alloy or clad plates are specified (AISI 405 or AISI 410 S}, 410 S or equivalent materials shall be used.

3.14.3 Claddings

If the coating type is not specified, the lined equipment can be either of clad steel type or with electro-deposition.The electro-deposition process shall be subject to Company's approval.


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4 FABRICATION

4.1 Qualifications of Welding Procedures and Welders

The welding procedures to be used shall be previously qualified by the Supplier, in compliance with the codes and standards referenced on the drawings, as well as with the regulations in force in the country where the air cooled heat exchanger shall be installed.

Welding on air-cooled heat exchangers shall be done by welders and welding operators qualified for the welding procedure, the filler material used and type of welding.

Supplier shall submit for Company approval, the welding procedures and specifications. Fabrication cannot start without the Company's approval of the welding procedures and specifications.

4.2 Welding

Only basic coated electrodes shall be used and these electrodes shall be suitably treated in accordance with the Manufacturer's instructions.

For carbon steel plates with thickness exceeding 30 mm (save for more restrictive requirements provided by the applicable codes), adequate preheating shall be carried out during the whole welding phase. This also applies to welding of nozzles, connections and miscellaneous accessories.

Temperatures shall be controlled by means of temperature-indicating crayons or equivalent methods. Preheating to at least 40° C is also required for thicknesses lower than 30 mm when welding is carried out at ambient temperatures below +5° C.

Unless otherwise indicated on the Company's drawings, for 13% Cr steel (series AISI 400 or equivalent) clad equipment, welding on the clad side shall normally be performed using AWS A-5.4 309L filler material or equivalent, or other filler materials approved by the Company.

For Cr-Ni austenitic steel (series AISI 300) clad equipment, basic electrodes AISI 309L or equivalent shall be used, in the clad area and shall also extend beyond the clad/base material interface. Subsequent welding passes shall be deposited with a consumable compatible with the base material.

Where the base material is a carbon, carbon manganese or low alloy steel, a buffer layer shall be deposited with a pure iron consumable prior to commencing with the carbon manganese or low alloy welding consumable.

Where automatic welding processes are used it is permissible to complete the entire weld with the AWS A-5.4 E 309L type consumable.

All internal welds shall be sized as to leave an adequate margin for corrosion (based on the required corrosion allowance).

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4.3 Post-Weld heat treatment

The final heat treatment shall be carried out once all the welding operations (connections and accessories inclusive) and the necessary repairs are over, with the exception of the tube-to-tube sheet welding.

Final heat treatment after welding shall be carried out at a temperature of not less than 680'C for Cr-Mo steels.In any case the temperature, duration and other conditions of final and intermediate heat treatment shall be agreed upon between the Supplier and plate and forgings supplier.

Any difference between the recorded temperature and the actual temperature in the different parts shall be taken into consideration (the use of thermocouples in contact with the piece and/or experimental surveys is recommended).

The trend of temperature above 300 'C shall be dete cted by an adequate number of thermocouples firmly anchored to the equipment and recorded as a function of time by a "multipoint" type recorder even during intermediate treatments, if any.The diagrams so prepared shall bear the name of the equipment and the date of the treatment and shall be preserved by the supplier.

After the final heat treatment, all the welds under pressure in Cr-Mo low-alloy steel headers shall undergo hardness tests with the aid of portable equipment.Such tests, that shall be carried out in an adequate number both in the weld metal and in the heat affected zone, are aimed at ascertaining that, unless otherwise specified, the following values are not exceeded:

- 215 HB for steels with Cr lower than 2%;- 240 HB for steels with Cr higher than or equal to 2%.

In each homogeneous area examined, the average of several readings will be allowed. Each area shall be suitably levelled off.Where the above values are exceeded, the heat treatment shall be repeated.

4.4 Painting

Unless otherwise required in the order technical documentation, the air plenum chambers, the supporting structural steelwork, the bundle frame together with crosspieces and wind bracing, the ladders and walkways shall be hot galvanized in accordance with ASTM A-123, A143, A-153, A-384, A-385 specifications.

Unless otherwise specified, the carbon steel headers shall be painted in accordance with Project Painting Specification ().

The accessory parts such as pulleys, bearing block, etc. shall be painted in compliance with the supplier's standard

4.5 Spare Parts

Spare Parts for start-up shall be provided. Spare parts lists (only) shall be provided for two years operation.

TECHNICAL SPECIFICATION FOR AIR COOLER HEAT EXCHANGERContractor doc. no.: I Rev.: I co I DO I I I I J Company doc. no.:


5 PREPARATION FOR SHIPMENT

All air-cooled heat exchangers and their components shall be cleaned, drained and properly packed for the transportation and storage during field construction.Protection and packaging shall be in compliance with the requirements of APl-661 and with the following clarifications and additional requirements:

• tube bundles shall be packed in cases. A suitable quantity of moisture absorbing salts shall be placed inside all major nozzles and openings. The salt quantity shall be sufficient for 18 months storage. The salt bags (or similar) shall be fastened to the discs used for sealing the openings;

• all mechanical parts (motors, reduction gears, shafts, positioners, servo controls, etc.) shall be packed in wood cases with tar paper. Moistureabsorbing salt bags sufficient for 18 months storage shall be placed inside the cases;

• Other machinery parts(hubs, fans, blades, belts, bearings, etc.) shall be carefully packed to avoid damage during shipment.

Flanges shall be protected against any damage during transportation and assembly.

The preferred protection of the flanges is as follows: the finished surface shall be protected by a removable protective coating and with easily removable antirust grease.

The whole flange surface, from the gasket side, shall be protected by a bolted steel plate cover (blind flange).

All cases or boxes containing part of the Plant are to be marked on two sides and at the top. The marking shall be made in indelible paint in English.

6 INSPECTION & TESTS

Required tests shall be in compliance with API 661 and project documents.

The Company reserves the right to have the Company's Inspectors witness the inspection and tests.

Witnessed tests are indicated on the Project Air Cooler Data Sheets.

Supplier shall supply his Inspection and Test Plan (ITP) for Company's approval, with a description of equipment available in the Manufacturer's workshop.

Inspection and tests are required in order to ensure that the equipment is in compliance with the Data Sheets, standards and codes indicated in the Project documents, as well as with the regulations in force in the country of installation.

The fact that the tests are witnessed by the Company's personnel during fabrication shall not release the Supplier from his responsibility.


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Inspections and tests are normally performed by the Supplier. The examinations, checks and tests prescribed in the codes and documents are intended to be the minimum required. If required, the Supplier may carry out additional tests and checks. The Company shall be advised on the requirements for any additional tests and the results shall be made available to the Company.

The Company reserves the right to send representatives to the Supplier and his Sub-Supplier at any time during fabrication, to check compliance with the applicable specifications and codes.

6.1 Tests on steel plates

6.1.1 Plates Exceeding 50 mm in Thickness

Plates exceeding 50 mm in thickness shall be ultrasonic examined at the mill, both on surface and on edges, in accordance with ASTM A-435.

6.1.2 2 Clad Plates

Plates exceeding 50 mm in thickness shall be ultrasonic examined at the mill in accordance with ASTM A-578 for acceptance level S.6.

Unless otherwise indicated on the Company's drawings, shear testing at the mill is required for all clad plates, in accordance with the material specification referenced in the Data Sheets. The results of this test shall not be less than 140 MPa.

6.1.3 Plates for Hydrogen-containing Equipment

Plates used for pressure parts in contact with hydrogen shall be ultrasonic examined at the mill in accordance with ASTM A-435.

6.2 Inspection and testing during construction

Inspection and testing during construction shall confonn to APl-661.

6.3 Non-Destructive Examination

NDE procedures shall be provided for Company approval.

6.3.1 X-ray examination

The X-ray examination on the welds shall be carried out in compliance with the codes and regulations specified in the Company's documents.The films shall be fine grain and high contrast type.

All radiographs shall show appropriate image quality indicators (penetrometers ), in compliance with ASME codes.However the sensitivity shall not be lower than 2% of the thickness or 1.5% in the case of MDMT lower than O'C.


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In addition to the contents of the applicable regulations and documentation, it will be necessary to consider a total X-ray examination for the welds of equipment in lethal service and for the equipment in hydrogen service.In these cases, the welds that cannot be radiographed shall be checked by ultrasounds.The supplier shall prepare a sketch showing the positioning of the radiographs made and a report summing up his judgement on the radiographs.

6.3.2 Magnetic particle inspection

The magnetic-particle inspection is required when the steel has an ultimate tensile stress of <: 510 N/mm2 or a thickness of 350 mm, and in the case of low-alloy steel (0.5 % Mo, and Cr-Mo).This check shall always be made after the heat treatment, when requested.

6.3.3 Dye-penetrant inspection

The air coolers with a design temperature or MDMT ,; -45 'C shall require, after the hydraulic test, a dye-penetrant inspection of the welds of the pressure elements.

The dye-penetrant inspection shall be carried out in compliance with ASME codes, Sect. VIII, Div. 1, Appendix 8 and with ASME Sect. V - Article 6.

6.3.4 Ultrasonic testing on welds

The headers having a thickness > 50 mm shall be tested after the hydraulic test by ultrasounds on all pressure-resistant full penetration welds, whether they are butt welds or fillet welds.

Ultrasonic testing on welds may be carried out where the results of the other tests can hardly be interpreted.

Such tests shall be carried out in compliance with ASME codes, Sect. VIII, Div. 1, Appendix 12 and the relevant reports shall be prepared following the instructions given in par. 12-4 of the said Appendix.

6.3.5 Pressure testing

The hydraulic test on stainless steel tube bundles (whether austenitic or not) shall be carried out using water with a chloride content of less than 50 ppm (mg/kg).Once the hydraulic test is over , accurate emptying and drainage shall be carried out and all the parts where water is likely to stagnate shall be dried.

As concerns water temperature during the hydraulic test, precautions shall be taken with regard to the thickness and type of steel in order to avoid the risk of brittle fracture.This applies in particular to Cr-Mo steels.


Conlractor doc. no.: I Rev.: I co I DO I I I I Company doc. no,:


Until the equipment contains water, it is strictly forbidden to carry out welding on the equipment itself or on parts which are electrically in contact with it (e.g. piping or structures).

The gaskets used for the pressure testing at the workshop shall be of the same type as those used during operation and shall not be re-used.

In special cases, the Company reserves to ask for the hydraulic test pressure to be recorded on a diagram.

Al the time of shipment, blind flanges shall be equipped with definitive gaskets and shall be clamped by means of definitive tie rods.

7 PERFORMANCE GUARANTEE

A heat transfer guarantee shall be included in the scope of supply. This shall warrant the equipment to perform satisfactorily under all specified performance cases and conditions of operation, as defined in the Data Sheet.

8 DOCUMENTATION

8.1 Technical documentation

The Supplier shall deliver to the Company all the documentation needed for the execution of the project and for the installation of all the components.

Documentation shall include the following information as a minimum:

• Data Sheets for each equipment, complete in all their parts;• Formal review of the parameters identified in the documents

issued within the specific project (construction type, execution, nominal data, performances, etc.);

• technical characteristics of equipment;• specific consumption.

• Plants, elevations and sections, able to provide the following information:

• overall dimensions and spaces necessary for maintenance and operations;

• static weights and reactions on foundations;• position and size of termination connections;• position and size of holes for baseplate bolls;• details, number and type of bolts necessary to connect at

support structure;• materials lists;

• spare parts list for two years operations;• list of necessary services (if any)

TECHNICAL SPECIFICATION FOR AIR COOLER HEAT EXCHANGERContractor doc. no.: I Rev.: I CO I DO I I I I I Company doc. no.:


8.2 Inspection Documentation

The documentation to be provided shall contain at least the following information:

• material certificates;• examinations, inspections and tests laid down in the

contract documents and/or required by the applicable codes;• description of the utilised instruments;• construction drawing;• rubbing of name plate and/or marking.

8.3 Final Documentation

The final documentation shall include at least the following information:

• project documentation;

• installation procedures;

• documentation issued for approval and approved by the Company;

• lubricants forms (recommended lubricants, physical and chemical characteristics, first fill quantity, expected annual consumption);

• spare parts list for two years operations;

• operative manual of the plant and of each equipment;

• maintenance manual (procedures for the preventive maintenance, periodic inspection schedule);

• Safety manual.

1.0 ATTACHMENT 1 - VENDOR DATA REQUIREMENTS

LEGEND:*ITEMS PRECEDED BY A'l! ASTERISK MUST BE SUBMITTED FOR REVIEW AND "APPROVED" OR "APPROVED AS NOTED" PRIOR TO FABRICATION. THE REMAINING ITEMS ARE REQUIRED FOR INFORMATION ONLY.

NR NOT REQUIREDNC AS COMPLETEDX ARC X WEEKS AFTER RECEIPT OF COi'v!lv!lTMENT

Letter And Iten1

Number

DESCRIPTION

AIR COOLED HEAT EXCHANGER

ProposalDesi n And

Cons ruction

Date Promised

by Vendor

Return to Re'tuisi.tionin g ngmeer

No. ofCopies

RetJuiredate

No. of Copies

(AAJProvalma!)

A. Drawings & Drawing Details

I Outline dra\ving Required 1

2 Preliminary process data sheets Required 1

* 3 General arrangements, plans, elevations & details. NR 3 ARC III

Projections of all connections 1nust be detailed.

* 4 Table of all customer connections, listing size, type NR 3 ARC 1/1

and rating. This maybe separate or part of the GA

dra\ving.

* 5 Anchor bolt layout and foundation loading diagram NR 3 ARC III

6 Gear box, belt drive and sheave details NR 3 ARC Il l

7 Fan details NR 3 ARC 1/1

8 Dimensional outlines for each 1notor, switch and NR 3 ARC 1/1

conduit box

9 lvlotor data sheets Required I 3 ARC Ill

10 Vibration S\Vitch data sheets NR 3 ARC Ill

11 Electrical \Viring diagrams NR 3 ARC Ill

12 Bill of materials sho\ving AST.NI numbers NR 3 ARC III

13 Set of final certified Asbuilt dra\vings NR AC I

14 List of deviations/exceptions Required 1

B. Calculations & Data Reports

* I Thermal design calculations including computer NR 3 ARC Ill

output

2 Completed process data sheets, data book NR 3 ARC 1/1

3 Fan performance curves with noise data NR 3 ARC 1/1

4 \Veight and center of gravity calculations for the NR 3 ARC 1/1

follo\ving cases clearly identifying all components

\veights for each calculation

a. Empty weight

b. Empty weight with shipping braces

c. Weight full of water

5 Reinforcement calculations NR 3 ARC 1/1

* 6 Structural support calculations NR 3 ARC Ill

* 7 Header, cover plate & tube thickness calculations NR 3 ARC 1/1

8 Code data reports and U-lf\ forms NR NC 111

• 9 Copy of mechanical design computer progra1n used NR 3 ARC Il l

(Disasu, etc.) with all inputs and outputs clearly

labeled. The final "As-builr' computer run shall

have all components and subprograms run at the

san1e time and so dated.

10 Bi-weekly detailed production schedule NR 3 NC I/I

11 Clearly legible nameplate rubbings or nmneplate NR NC 111

photographs

c. Proced ures, Instr uctions and Operation lanuals

I Installation, operation and maintenance manuals NR 8 ARC 011

2 NDE procedures NR !ARC 1/1

3 Inspection plan, including procedures for correcting NR !ARC 1/1

NCR's (Non Co1npliance Reports). Vendor is

responsible for supplying inspection plans for all

sub-vendors.

4 Erection Procedures NR 8 ARC 1/1

D. ' Velding Related Information

I Welding Procedures ·WPS NR !ARC 1/1

2 Process Qualification Records PQR's NR !ARC Iii

3 \Yelder Qualifications NR !ARC 1/1

4 Tentative Weld Maps Showing WPS per Joint NR 3 ARC Iii

5 As-Built Weld Maps NR NC 0/1

6 Post Weld Heat Treating (PWHT) Charts and NR NC 0/1

Records. These shall clearly sho'v the parts being

heat treated, item tag number, start time and date,

finish time and date, furnace start ten1perature, rate

of temperature increase, hold time and ten1perature,

and rate of temperature decrease.

E. i\'lanufacturing Tests & I\ilaterial Test Reports

I NDE Results Including: NR NC 1/1

a. Radiographic

b. Ultrasonic

c. Dye Penetrant

d. Brinell Hardness

2 Material Test Records (MTR's) or Material NR NC 011

Certifications (Certs). Each MTR and Cert shall

clearly reflect the applicable heat number used to

manut'hcture the referenced part. The tag number of

the referenced part and a description of part made

from the heat number shall be marked on the :N1TR

or Cert. All certificates of compliance should

indicate what standard (ASTM, AP!, A.i !SI, etc.) the

items arc being 1nanufactured to. Stating that the

items are n1anufactured to the tenns of the purchaseorder is not acceptable.3Hydrostatic test certificate \Vith charts

NR AJC 011

F.

1234

Other Inforn1ation RequiredPriced list of 2-year spare partsPriced list for recommended start-up spares List of all greases and lubricantsDetailed packing list sho\ving all items, individually described. A staten1ent such as "A Box of ivliscellaneous Pipe and Fittings" is not acceptable. The unit shall not be shipped without prior approval In writing by purchasing. Inspectors cannot release for ship1nent.Vendor QA/QC and safety 1nanuals

RequiredRequired NR NR

11

4 ARC4 ARC8 ARCAJC

OilOil Oil Il l

4 NR 2 ARC 1/1

2.0 ATTACHMENT 2 - UNIT SPECIFICATION SHEET

PHYSICAL QUANTITY UNITS PHYSICAL QUANTITY UNITS

ivlass kg (lb) Fouling Resistance m2·°C·hr/kcal (ft"'F·hr/Btu)

Molar Flow Rate kg·mol/hr (lb·mol/hr) Acceleration m/s2 (ft/s2)

Molar Quantity kg·mol (lb·mol)

Area m' (fi')

PO\VCr kcal/s (Btu/s)

Heat Flow Rate kcal/hr (Btu/hr)Calorific Value (ivfass Basis)

kcal/kg (Btu/lb)

Calorific Value (Volun1eBasis)

kcal/m 3 (Btu/ft3

)

Pressure kg/cm2 (lb/in2)

ConcentrationIMass/Volumel kg/m3 (lb/ft3

)

Specific Entropy kcal/kg·'C (Btu/lb·'F) Density kg/m3 (lb/ft3)

Specific Heat Capacity kcal/kg·'C (Btu/lb·'F) Energy kcal (Btu)

Enthalpy kcal/kg (Btu/lb)

Stress kgf/cm2 (lb/in2)

Flo\v Rate (ivfass Basis) kg/lir (lb/hr)

Structural Loading BearingCapacity kgf/cm 2 (lb/in2

) Flo\\' Rate (Volume Basis) m3/lir (ft3/hr)

Ten1perature, Customary 'C ('F) Force kgf (Lbf)

Thcnnal Conductance kcallm"'C-hr (Btu!ft"'F·hr) Frequency HzHeat Transfer Coefficient kcallm"'C·hr (Btufft2.°F-hr)

Heat Flow Intensity kcalim"hr (Btu!ft"hr)

Thermal Conductivity kcal/m·' C·hr (Btu/ft·'F·hr) Heat Flux Density kcal/m2·hr (Btu/ft2·hr)

Heat Transmissivity from Surface kcal/m2·hr (Btu/ft2·hr)

Torque, Force N1oment kgt'm (lbf·ft)

Leugth (Note) m (ft)

Dynamic Viscosity cP (lb/ft·s) mm (in)

Kinematic Viscosity est (ft2/s)

Linear Velocity mis (ft/s)

Volume m3 (ft3) Speed mis (ft/s)

Notes :

Nominal pipe size shall be expressed in inches. Tube \Vall thickness may be expressed in BWG.

3.0 ATTACHMENT 3 -TECHNICAL QUALIFICATION TABLE

DESCRIPTION VENDOR

Reference Quote

I.Applicable Code

Pressure Vessel Code

AP! Standard 661

Wind Design

Seismic Design

ASlv!E Stamp

2. Process Design Conditions

Type

Unit Quantity

Item l

ltem 2

Item 3

Heat Exchanged kJ/hr (Btu/hr)

Item I

Item 2

Item 3

Design Pressure kg/cm2 (psig)

Item I

Item 2

Item 3

Design Ten1perature 'C ('F)

Item 1

ltem 2

lten13

Pressure Drop kg/cm2 (psig) Allowable Calculated

Ite1n I

Item 2

ltem 3

Flange Rating #

Item l

Iten1 2

Item 3

Corrosion Allo\vance mm (in)

Item l

lte1n 2

Item 3

MDMT °C ('F)

Test Pressure kg/cm2 (psig)

Radiography

NDE

PIVHT

3. I-leader and Nozzle Construction

Header Type

Item 1

lte1n 2

lte1n 3

Header i\ilaterial

Item l

Item 2

Item 3

Plug Material

Item 1

Item 2

Item 3

Gasket ivlaterial

lte1n 1

Ite1n 2

Item 3

Nozzle/Flange ivlaterial

ltem 2

Item 3

Flange Facing

4. Tube Bundle Construction

Tube Bundle Size Length Width

Item l

Item 2

Item 3

Ntunber of Bays

Iten1 l

Ite1n 2

Item 3

Tube Nfaterial

Item 1

Ite1n 2

lte1n 3

Tube Type

Item I

Item 2

Item 3

Fin Nfaterial

Item I

Item 2

Item 3

Fin Type

Ite1n l

Item 2

Item 3

Number of Fins I Inch

Item I

Item 2

Item 3

Tube Pattern

Item I

Tube OD

Item 2

Item 3

Item l

Item 2

Item 3

Tube Thickness

Item l

Item 2

Item 3

Item I

Item 2

Item 3

Nuntber of Tube RO\VS

Item I

Ite1n 2

Item 3

Number of Passes

Item I

Iten12

Item

3

5. lvlotor I Driver

Service Factor

RPM

Enclosure

Explosion Proof

Voltage / Phase I Cycles

Duty I Area Classification

Insulation Class

Temperature Rise Type

Frame

HP / Driver HP

Item I

Item 2

Item 3

Vibration S\vitch

6. Fan Specification

fanufacturer

Number of Fans I Bay

Item 1

Item 2

Item 3

Blade I Hub Niaterial

Pitch Type

Louver Controlled

HP / Fan HP

Item I

Item 2

Item 3

7. Speed Reducer

Type

Support

8. Stn1cture Design

Mounting Type

Wind Speed

Seisn1ic Zone

9. Painting

Surface Preparation Header Structure I Fraine

Item I

Item 2

Item 3

Primer Header Stn1cture I Fraine

Item I

Item 2

Item 3

Finish/Final Coat Header Structure I Frame

Item I

Item 2

Item 3

I 0. Documentation

After P.O. Documents

As-Built Documents

11. Spare Parts

Constn1ction/Pre-commissioning

Gaskets

Bolts

2 Years Operation

Gaskets

Bolts

12. Delivery Schedule

Delivery Style

Dra\vings Submission

Delivery Date

FOB Location

13. Price and Weight Price ($) Weight (lb)

Base Price

Item l

ltem 2

Item 3

Sub-Total

Additional Cost

Item l

ltem 2

Item 3

Sub-Total

Total

mec-spe- air cooled heat exchangers

Documents

project documents

iiiii company

f company

steel plates18plates

gas flow

flow rates

barg relative pressure

sj units