BP DOC NUMBER - GP-26-101 REV A

Document No. GIS 26-101

Applicability Group
Date 7 April 2009

GIS 26-101

Shell and Tube Heat Exchangers (ISO

16812 or API 660)

Group Instruction for Supply

BP GROUP
ENGINEERING TECHNICAL PRACTICES
7 April 2009 GIS 26-101
Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Foreword

This issue of Engineering Technical Practice (ETP) GIS 26-101 is updated to align with the 2007
versions of ISO 16812 and API Std 660. Locations of revisions are marked by bars in the margin.

Copyright © 2009 BP International Ltd. All rights reserved.

This document and any data or information generated from its use are classified, as a
minimum, BP Internal. Distribution is intended for BP authorized recipients only. The
information contained in this document is subject to the terms and conditions of the
agreement or contract under which this document was supplied to the recipient's
organization. None of the information contained in this document shall be disclosed
outside the recipient's own organization, unless the terms of such agreement or contract
expressly allow, or unless disclosure is required by law.

In the event of a conflict between this document and a relevant law or regulation, the
relevant law or regulation shall be followed. If the document creates a higher obligation, it
shall be followed as long as this also achieves full compliance with the law or regulation.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Table of Contents
Page
Foreword ........................................................................................................................................ 2
Introduction ..................................................................................................................................... 4
1 Scope .................................................................................................................................... 5
2 Normative references............................................................................................................. 5
3 Terms and definitions............................................................................................................. 5
3.8 hydrogen service......................................................................................................... 5
4 General.................................................................................................................................. 5
5 Proposals............................................................................................................................... 6
6 Drawings and other required data .......................................................................................... 7
6.2 Information required after drawings are reviewed........................................................ 7
6.3 Reports and records ................................................................................................... 7
7 Design ................................................................................................................................... 7
7.1 Design temperature and pressure............................................................................... 7
7.2 Corrosion control and cladding.................................................................................... 8
7.3 Shell supports ............................................................................................................. 8
7.6 Tube bundle................................................................................................................ 8
7.7 Nozzles and other connections ................................................................................... 9
7.8 Flanged external girth joints ........................................................................................ 9
7.9 Expansion joints........................................................................................................ 10
7.10 Gaskets .................................................................................................................... 10
8 Materials .............................................................................................................................. 11
8.3 Tubes........................................................................................................................ 11
9. Fabrication........................................................................................................................... 11
9.1 Shells and heads ...................................................................................................... 11
9.5 Welding..................................................................................................................... 11
9.10 Tube-to-tubesheet joints ........................................................................................... 11
9.11 Assembly .................................................................................................................. 11
10 Inspection and testing .......................................................................................................... 12
10.1 Quality assurance ..................................................................................................... 12
10.4 Nameplates and stampings....................................................................................... 12
11 Preparation for shipment...................................................................................................... 12
11.1 Protection ................................................................................................................. 12
Bibliography .................................................................................................................................. 14

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Introduction

a. Requirements for shell and tube heat exchangers are based on ISO 16812, Petroleum and
natural gas industries - Shell-and-tube heat exchangers, Second edition, 2007-02-15 and
API Standard 660, Shell-and-tube Heat Exchangers, Eighth edition, August 2007.
b. Requirements of this GIS are modifications to ISO 16812 and API 660.
c. Modifications to ISO 16812 and API 660 are identified as Add, Modify to Read, or Delete.
d. Clause numbers in this specification correspond to ISO 16812 and API 660.
e. Clauses of ISO 16812 and API 660 that are not revised remain applicable.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

1 Scope

Add
This GIS provides requirements for the design, materials, fabrication, inspection, testing,
documentation, and preparation for shipment of unfired shell and tube heat exchangers based on
ISO 16812 and API 660.
This GIS may be used directly for the purchase of all new equipment. Any project
specific requirements should be incorporated in the data sheet or requisition.
Excluded from the scope of this GIS are interconnecting piping and power plant
heat exchangers (for example, steam turbine surface condensers, which are
specified in GIS 26-106).
The special requirements for double pipe/hairpin heat exchangers are given in
GIS 26-102.

2 Normative references

Add

BP
GIS 06-601 Painting of Metal Surfaces.
GIS 18-014 Heat Exchanger Tube End Fixing.
GIS 46-010 Pressure Vessels.

American Society of Mechanical Engineers (ASME)

ASME Boiler and Pressure Vessel Code (ASME Code).

British Standards Institute (BSI)

BS EN 13445-3 Unfired pressure vessels - Part 3: Design.

International Organization for Standardization (ISO)

ISO 9001 Quality management systems - Requirements.

U.S. Military Specifications

Mil Spec A-18001 Anodes, Sacrificial Zinc Alloy.

3 Terms and definitions

3.8 hydrogen service

Modify to Read
…350 kPa (3,5 bar) (50 psi) absolute.

4 General

4.1
ASME VIII Division 1 contains Part UHX, Rules for Shell-and-Tube Heat
Exchangers design and Division 2 has Clause 4.18. These are both very similar and

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

resemble the rules in BS EN 13445-3 Clause 13. The tubesheet design rules are
based on elastic analysis and significant calculation may be required.
BS EN 13445-3, Annex J contains a novel method for tubesheet design, based on
limit analysis. It may have cost benefits, particularly for the design of fixed
tubesheet heat exchangers.
PD 5500 and TEMA provide rules for tubesheet design. TEMA also contains
requirements for the design and fabrication of other heat exchanger components
and continues to be a widely used standard.
Guidance on the other aspects of code selection is given in GP 46-01.
4.3 Add
Heat exchangers shall comply with GIS 46-010, unless otherwise agreed with BP.
4.6
Simply providing inlet and outlet properties for two phase streams may be
inadequate, particularly if there is a phase change e.g. de-superheating followed by
sub-cooling. It may also be inadequate for single phase streams which have a large
variation in viscosity.
Since most process simulation programs can produce the required physical
properties, the presentation of physical properties and heat release information in a
format similar to that shown in the Specification sheet in Annex C of ISO 16812 and
API 660 is required.

Add
4.8 Thermal design shall be performed using Heat Transfer and Fluid Flow Services (HTFS) or
Heat Transfer Research, Inc. (HTRI) methods and software. If other methods and software are
used and a dispute regarding design of the unit arises, a crosscheck using HTFS/HTRI software
shall be required.
4.9 In case of conflict between documents, order of priority (highest to lowest) shall be:
a. Inquiry or purchase order.
b. Data sheet.
c. This standard.
d. TEMA standards.
e. Pressure design code.
4.10 In the event of any conflict between requirements of this standard and the data sheet, said
conflict shall be referred to BP for clarification before proceeding with the manufacture of
affected items.
4.11 Resolution of conflicts between the proposal and purchase order shall be subject to BP approval.
Work affected by such conflict shall not proceed until approved by BP.

5 Proposals

5.7 Modify First Sentence to Read

Vendor shall provide the following items:

Add
5.8 Minimum required thickness (retirement thickness) calculations shall be provided for exchanger
shell, channel, tubesheet, shell and channel covers, and each inlet and outlet process nozzle.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Minimum required thicknesses are thicknesses required for the design condition calculated in
accordance with the pressure design code and TEMA standards.
5.9 Thermal and hydraulic performance and vibration calculations shall be performed; thermal and
hydraulic performance and freedom from vibration damage shall be guaranteed. Input data and
results of thermal design and vibration calculations shall be submitted in the form of an HTRI or
HTFS computer file and shall be subject to BP approval.
5.10 Fabrication, inspection, and testing shall not be subcontracted without prior written approval
from BP. Quotation shall clearly indicate intentions to subcontract any part of the work and the
name and location of subcontractor.

6 Drawings and other required data

6.2 Information required after drawings are reviewed

6.2.2 Modify to Read
Qualified welding procedure specifications and procedure qualification records as required by
the pressure design code shall be submitted for review.
6.2.3 f) Add
including length of bellows and preset dimensions.
6.2.4 Modify First Sentence to Read
The following documentation shall be submitted to BP for review and shall be subject to BP
approval prior to start of fabrication:
6.2.4.b) Modify to Read
Design calculations based on seismic, wind, transportation and/or piping loads, if these loads are
provided by BP and in accordance with applicable building codes;
6.2.4 Add
e) Quality and inspection plan.
f) All postweld heat treatment procedures.

6.3 Reports and records

Add
n) copy of the thermal, hydraulic, and vibration calculations and an electronic copy of the
HTRI or HTFS computer file based on the “as built” heat exchanger for the base case and
all alternate cases. Computer files shall be suitably labelled.

7 Design

Modify 7.1 Title to Read

7.1 Design temperature and pressure

Add
7.1.4 If the exchanger requires vacuum design, exchanger shall be designed for full vacuum.
7.1.5 Heat exchanger shall be rated to highest maximum allowable working pressure (MAWP)
allowed by the actual as built equipment.
The design pressure needs to be increased to match the MAWP.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Modify 7.2 Title to Read

7.2 Corrosion control and cladding

Add
7.2.3 Alloy linings (other than clad or weld overlay) shall not be used, unless approved by BP.
7.2.4 Sacrificial anodes, if specified for cooling water service corrosion control, shall be located in the
channel. Type of anode shall be as specified on the data sheet. Sacrificial anode materials shall
be either zinc in accordance with U.S. Mil Spec 18001 or equivalent or aluminium zinc indium,
as follows:
a) Zinc should not be used above 50°C (120°F).
Zinc has a marked tendency to passivate at elevated temperatures.
b) Aluminium zinc indium alloys should not be used above 80°C (176°F).
Aluminium zinc indium alloys show a marked reduction in electrochemical capacity
at elevated temperatures.
c) Magnesium anodes should not be used in shell and tube heat exchangers.
Magnesium has a high self corrosion rate and limited life in saline water.
Magnesium also has a high driving potential that can result in damage to protective
coatings.

7.3 Shell supports

Add
7.3.6 Stacking three or more exchangers shall be subject to BP approval. Stress calculations for shell
supports shall comply with GIS 46-010, subclause 7.10.2.a.
Support design and maintenance on bundles stacked more than two high is difficult
and expensive.

7.6 Tube bundle

7.6.1 Tubes

Add
7.6.1.4 Maximum unsupported tube length shall be 80% of TEMA maximum span.
Experience has shown that using this maximum unsupported length reduces the
potential for vibration.
7.6.1.5 If required to maintain minimum tube wall thickness, the inner two rows of U tubes shall have a
wall thickness one gage thicker than the remaining tubes.
Tube wall thinning due to the bending process may indicate that the tube wall is not
sufficient to meet the minimum wall thickness for the required tube gage specified on
the data sheet.
7.6.1.6 Maximum ρV² at shell or bundle entrance and exit area shall not exceed 80% of TEMA:
3200 lb/ft-sec² (4762 kg/m-sec²).

7.6.3 Baffles and support plates

Add
7.6.3.4 Tube holes shall be chamfered with a radius if 1,6 mm (1/16 in) and deburred.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

7.6.3.5 Tie rods and spacers: The inside diameter (ID) of spacers shall not be greater than the tie rod
outside diameter (OD) plus 3 mm (0,125 in), e.g., 12,7 mm (0,5 in ) OD tie rod requires
19,05 mm (0,75 in) OD spacer with 16 BWG (1,65 mm [0,065 in]) wall thickness.

7.6.4 Impingement protection

7.6.4.1 Modify to Read
Tube impingement protection shall be provided for all shell and tube heat exchangers by rods or
a distributor belt.
a) Impingement plates shall not be used.
An impingement plate may cause excessive velocities around its edge and, hence,
tube vibration. The tubes under the plate may also be less effective for heat transfer,
leading to a loss of performance.
b) Impingement rods shall have the same diameter and pitch as the tubes.
1. Rods shall extend from the tubesheet to the first baffle and across the full cord length.
2. Staggered layouts shall require a minimum of two (2) rows of rods.
3. Square layouts shall require a minimum of one (1) row of rods.

7.6.5 Bypass sealing devices

Bypass seals may be of considerable importance in obtaining the required
performance from a unit.
7.6.5.5 Modify to Read
The nominal thickness of seal strips shall be the nominal thickness of the transverse baffles or
6 mm (1/4 in), whichever is less, or twice the shellside corrosion allowance, whichever is
greater.

7.6.7 Tube-to-tubesheet joint

Add
Tube-to-tubesheet joints shall comply with GIS 18-014.

7.7 Nozzles and other connections

7.7.3 Modify Last Sentence to Read
Threaded connections shall not be used.

Add
7.7.10 Stresses on interconnecting nozzles resulting from different thermal growth rates of stacked
exchangers shall be included as superimposed loads in designing the nozzles.
7.7.11 Unless specified otherwise, instrument connections shall not be provided in the exchanger
nozzles.
Instrument connections are normally located in the attached piping adjacent to the
nozzles. Duplicate connections in nozzles required by TEMA need not be provided.

7.8 Flanged external girth joints

Add
7.8.10 For the following conditions, the vendor shall provide stiffness/leakage calculations for BP
review and approval before ordering flanges. Flange flexibility (to check for the likelihood of

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

leakage) shall be performed as shown in ASME Section VIII Division 1, Appendix 2,

Paragraph 2-14, or BS EN 13445-3 Annex G, or approved equal on:
• Flanges of diameter greater than 1 500 mm (59 in).
• Flanges where the design pressure – temperature combination exceeds the Class 900 rating
per ASME B16.5 for material of the flange.
• A combination of dissimilar materials or elevated or low temperatures.
• Flanges with through bolting at temperatures above 400°C (750°F) or below -50°C
(-58°F).
• Flange assemblies subject to cyclic temperature conditions.
Code calculations are concerned primarily with ensuring adequate flange strength
rather than negligible leakage.
The likelihood of leakage increases with diameter but not necessarily pressure (i.e.,
flanges for low pressure may be vulnerable to leakage). It also depends on the type
of gasket and the method of tightening. Stress relaxation or over-stressing of the
bolts due to temperature effects may be significant.
See GP 46-01, Annex Q requirements for bolt tightening.

7.9 Expansion joints

7.9.1 Modify to Read
a) Expansion joints shall preferably be single convolution thick walled type (flanged only or
flanged and flued) rated for at least 1 500 cycles at full design movement. Design code
used shall be agreed between BP and vendor (examples are AD Merkblatter or TEMA).
b) If thick wall bellows cannot be used, thin wall multiconvoluted bellows may be used,
subject to BP approval. Design code used shall be agreed between BP and vendor
(examples are EJMA and ASME Boiler and Pressure Vessel Code Section VIII,
Division 1, App 26).
Thin walled bellows need to be made in a material that is corrosion resistant to both
the process conditions and the external environment. As stresses in bellows
convolutions are high, stress corrosion cracking is a mechanism that should be
considered. Thin walled bellows provide greater flexibility than flanged and flued
expansion joints but are not as robust.
Shell bellows are needed if the differential thermal expansion cannot be
accommodated by suitable design of the tubes and tubesheet. Shell bellows are not
required for U tube or floating head type rear heads.

Add
7.9.2.h) Expansion joint design and a quality plan for manufacture of the bellows shall be prepared for
BP approval.

7.10 Gaskets

Add
7.10.10 Design conditions and hydrostatic test pressures shall not be limited by gasketing. Gasketing
shall be verified at hydraulic test condition.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Add

7.13 Drainage
a) Channel and floating head pass partitions shall be arranged such that tube side of each
exchanger is self draining through tubes. Pass partition plates may require weep holes.
b) If possible, free drainage shall be provided through the bottom nozzles.
c) Segmented baffles, skid bars, sealing strips, and support plates that trap liquid shall be
notched for free drainage.
d) Vents and drains for the shellside of vertical fixed tubesheet exchangers shall be provided
by drilling and tapping the tubesheet (NPT 1/2 minimum). In case tubesheet thickness is
not sufficient, a smaller diameter is allowed.

8 Materials

8.3 Tubes

Add
8.3.3 Seamless tubes shall be used for onerous service (e.g., sour water, wet H2S, hydrogen, amine,
caustic, cyanide, hydrofluoric acid, nitrate, sulphur dioxide, wet CO2, or polythionic acid), in
which corrosive attack on the weld can occur.

9. Fabrication

Modify 9.1 Title to Read

9.1 Shells and heads

Add
9.1.4 Marking materials that contain bromide, chloride, or sulphur shall not be used on stainless or
nickel based alloys.

9.5 Welding

Add
9.5.11 Welding, including attachments to pressure containing parts, shall be completed before
postweld heat treatment.

9.10 Tube-to-tubesheet joints

Modify to Read
Tube-to-tubesheet joints shall comply with GIS 18-014.

9.11 Assembly
Add
Matchmarks shall be made by a 1,5 mm (1/16 in) deep scribed line at the 12 o’clock and
3 o’clock positions on the outer face of components.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

10 Inspection and testing

10.1 Quality assurance

Add
A quality system that complies with the design code and this GIS shall be operated. The quality
system shall comply with the relevant part of ISO 9001 or equivalent. Technical and QA
requirements specified in the inquiry and purchase documents shall apply to all materials,
equipment, and services provided by subcontractors.
The quality system should ensure that the technical and QA requirements specified
in the inquiry and purchase documents are applied to all materials, equipment, and
services provided by subcontractors and to any free issue materials.

10.4 Nameplates and stampings

Add
10.4.4 Nameplate shall indicate:

a. Items listed in of GIS 46-010, clause 7.11.3.

b. MAWP hot and corroded.
c. Bundle mass empty (if removable).
and shall apply for both shell and tube sides of a heat exchanger, as appropriate.

11 Preparation for shipment

Heat exchangers are usually shipped with service gaskets in place. Any gaskets for
shipping only need to be identified to avoid their being used for service.

11.1 Protection
11.1.7 Add
Treatment of external surfaces shall comply with GIS 06-601. Carbon steel exchanger shells
that will not be insulated shall be blast cleaned and given a prime coat of manufacturer standard
paint. Other exchangers should preferably be delivered without paint, except that exchangers
operating at temperatures below 93°C (200°F) shall receive a prime coat.

Add
11.1.10 a) Equipment or materials that contain or are coated with any regulated substances, such as
the following, shall be prominently tagged at openings to indicate nature of contents and
precautions for shipping, storage, and handling:
1. Insulating oils.
2. Corrosion inhibitors.
3. Antifreeze solutions.
4. Desiccants.
5. Chemical substances.
6. Hydrocarbon substances.
b) Regulated substances shall have a Material Safety Data Sheet (MSDS).

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

c) MSDSs shall fully comply with regulations for MSDS preparation specified by entity that
has jurisdiction and shall include a statement that the substance is considered hazardous by
regulation.
d) If any substance is exempt from regulation, a statement to that effect shall be included.
e) Before shipment, MSDSs shall be forwarded to receiving facility.
f) At shipment, MSDSs in protective envelopes shall be affixed to the outside of the
shipment.

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Shell and Tube Heat Exchangers (ISO 16812 or API 660)

Bibliography

Add
[8] EJMA Standard of Expansion Joint Manufacturers Association.
[9] AD Merkblatter.
[10] BSI PD 5500, Specification for unfired fusion welded pressure vessels.
[11] GP 46-01, New Pressure Vessels.
[12] GIS 26-102, Double Pipe Heat Exchangers.
[13] GIS 26-106, Steam Surface Condensers.

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