Exploration & Production

GENERAL SPECIFICATION

PIPING VALVES VESSELS

GS EP PVV 411

Shell and tube heat exchangers

05 01/2011 General review

04 10/2009 Update of reference documents - Modification of § 6.1
03 10/2007 Revision crossed references and § 7.11
02 10/2005 Addition of “EP” root to GS identification
00 02/2002 First issue
Rev. Date Notes

Owner: EP/TDO/TEC Managing entity: EP/TDO/TEC/PVV

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Contents

1. Scope ....................................................................................................................... 4

2. Reference documents ............................................................................................. 4

3. Manufacturer's responsibility ................................................................................ 6

4. General requirements ............................................................................................. 7

4.1 Construction category ........................................................................................................7

5. Design ...................................................................................................................... 7
5.1 Pressure ............................................................................................................................7
5.2 Temperature ......................................................................................................................8
5.3 Corrosion allowance ..........................................................................................................8
5.4 Clad steel ...........................................................................................................................8
5.5 External loads ....................................................................................................................8
5.6 Local loads.........................................................................................................................8
5.7 Horizontal heat exchangers ...............................................................................................8
5.8 Cyclic loading.....................................................................................................................9
5.9 Additional design requirements .........................................................................................9
5.10 Fixed tube sheet calculation ............................................................................................10

6. Material................................................................................................................... 10
6.1 Tubesheets ......................................................................................................................10
6.2 Bolting ..............................................................................................................................11
6.3 Clad steel .........................................................................................................................11

7. Rules of construction ........................................................................................... 11

7.1 Shells and channels.........................................................................................................11
7.2 Shell flange ......................................................................................................................12
7.3 Tubesheet ........................................................................................................................12
7.4 Tubes and tube bundles ..................................................................................................12
7.5 Tube and tubesheet assembly.........................................................................................13
7.6 Expanded tube-to-tube sheet joints .................................................................................13
7.7 Welded tube-to-tube sheet joints .....................................................................................14
7.8 Stiffeners..........................................................................................................................14

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 2/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

7.9 Connections .....................................................................................................................14

7.10 Inspection and access openings for kettle .......................................................................15
7.11 Reinforcement of openings ..............................................................................................15
7.12 Support and lifting devices...............................................................................................16
7.13 Shell expansion bellows ..................................................................................................16
7.14 Girth joints gaskets ..........................................................................................................17
7.15 Other gaskets ..................................................................................................................17
7.16 Bolting ..............................................................................................................................17
7.17 Shell attachments ............................................................................................................17
7.18 Nameplates......................................................................................................................18
7.19 Thermal insulation ...........................................................................................................18
7.20 Protection of personnel ....................................................................................................18

8. Fabrication requirements ..................................................................................... 18

8.1 General ............................................................................................................................18
8.2 Tolerances .......................................................................................................................18
8.3 Cutting .............................................................................................................................18
8.4 Forming............................................................................................................................18
8.5 Welding ............................................................................................................................18
8.6 Heat treatment .................................................................................................................19

9. Quality control ....................................................................................................... 19

9.1 Inspection and testing ......................................................................................................19
9.2 Stamping..........................................................................................................................21

10. Preparation for shipment...................................................................................... 22

10.1 General ............................................................................................................................22
10.2 Particular requirements....................................................................................................22
10.3 Packing ............................................................................................................................23

11. Documentation ...................................................................................................... 23

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 3/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

1. Scope
This General Specification covers the Company practices and minimum requirements for the
design, materials, fabrication, inspection and testing of Shell and Tube Heat Exchangers subject
to internal and/or external pressure and conforming in definition to TEMA Standards.
Such equipment may contain liquid or gaseous petroleum or chemical products, air, water or
steam. However, this specification does not cover steam condensers, double pipe, multi-tube
heat exchangers, plate heat exchangers, cryogenic heat exchangers and air cooled heat
exchangers.
Shell and tube heat exchangers shall be considered to be pressure vessels.
Unless otherwise specified, the Pressure Vessel Code shall be ASME Section VIII div. 1 or
ASME Section VIII div. 2 as amended/supplemented by GS EP PVV 211 or BSI PD 5500 as
amended/supplemented by GS EP PVV 212.

2. Reference documents
The reference documents listed below form an integral part of this General Specification. Unless
otherwise stipulated, the applicable version of these documents, including relevant appendices
and supplements, is the latest revision published at the EFFECTIVE DATE of the CONTRACT.
Shell and Tube Heat Exchangers covered by this specification shall be designed, engineered,
and built in accordance with the latest revisions issued at the date of the call for tender of the
documents listed hereafter.
Any divergence between any of the Contractual Reference Documents, or between this
specification and any other Contractual Reference Document, shall be reported to the Company
for decision. In such a case, and unless otherwise agreed or decided by the Company, it is
understood that the more stringent requirement shall apply.
Exceptions to, or deviations from this specification are not permitted unless previously accepted
in writing by the Company. For this purpose, Manufacturer’s requests for substitution or change
of any kind shall be complete with all pertinent information required for the Company
assessment. In case of approval, such approval shall be valid only for a specific case and shall
not be construed as having general validity for other applications
Standards

Reference Title
Not applicable

Professional Documents

Reference Title
Not applicable

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 4/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Regulations

Reference Title
Not applicable

Codes

Reference Title
API STD 660 Shell-and-Tube Heat exchanger for general refinery service
ASME B1.1 Unified inch screw threads
ASME B16.5 Steel pipe flanges and flanged fittings
ASME B16.11 Forged steel fittings, socket welding and threaded
ASME B16.20 Ring joint jackets and grooves for steel pipe flanges
ASME B16.21 Non-metallic gaskets for pipe flanges
ASME B16.25 Butt-welding ends
ASME B16.47 Large Diameter Steel Flanges
ASME B46.1 Surface texture
ASME Section II Boiler and Pressure Vessel Code - Materials specification
ASME Section V Boiler and Pressure Vessel Code - Non-destructive examination
ASME Section VIII div. 1 Boiler and Pressure Vessel Code
ASME Section VIII div. 2 Boiler and Pressure Vessel Code
ASME Section IX Boiler and Pressure Vessel Code - Welding and brazing
qualifications
ASTM A 193 Standard Specification for Alloy-Steel and Stainless Steel Bolting
Materials for High Temperature or High Pressure Service and
Other Special Purpose Applications
ASTM A 194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts
for High Pressure or High Temperature Service, or Both
ASTM A 435 Straight-Beam Ultrasonic Examination of Steel Plates
ASTM A 578 Straight-Beam Ultrasonic Examination of Plain and Clad Steel
Plates for Special Applications
BSI PD 5500 Specification for unfired fusion welded pressure vessels
OCMA TEW-1 Recommendations for tube and welding
TEMA Standards of the Tubular Exchanger Manufacturers Association
WRC 107 Welding Research Council: Bulletin 107 (*)
WRC 297 Welding Research Council: Bulletin 297 (*)
(*)
Published by the “Welding Research Council” (New-York)

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 5/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Other documents

Reference Title
Not applicable

Total General Specifications

Reference Title
GS EP COR 350 External protection of offshore and coastal structures and
equipment by painting
GS EP COR 352 Internal protection of equipment by painting
GS EP COR 354 External protection of onshore structures and equipment by
painting
GS EP COR 356 Corrosion Protection of Fasteners for Subsea and Topside
applications
GS EP COR 560 Physical and chemical treatment of hydrostatic test water
GS EP PVV 107 Piping Stress Analysis
GS EP PVV 146 Bolting for piping
GS EP PVV 211 Design and fabrication of pressure vessels according to
ASME VIII
GS EP PVV 212 Design and fabrication of pressure vessels according to
BSI PD 5500
GS EP PVV 441 Procedure for shop hydraulic tests of shell and tube heat
exchangers
GS EP PVV 611 Welding of pressure containing piping and equipment
GS EP PVV 771 Thermal insulation (hot service)
GS EP PVV 772 Thermal insulation (cold service)
GS EP PVV 773 Thermal insulation (cyclic service)

3. Manufacturer's responsibility
This specification together with the particular specifications shall not be construed as releasing
the Manufacturer from his responsibility, fulfilment of his duties, guarantee and/or liabilities, nor
does the Company, by any acceptance or approval, assume any responsibility for the
conformance of the vessels to the requirements of the Code and/or of the Governing Authority.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 6/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

4. General requirements
4.1 Construction category
The selection of the construction category shall be done as follow:
• Full radiographic examination (as per ASME Section VIII) or Category 1 (as per
BSI PD 5500) shall be selected in any case:
- For heat exchangers which contain lethal substances
- For heat exchangers to operate at low temperature1
- For heat exchangers in vacuum service (when vacuum occurs during start-up or in
other conditions than normal service, it is not considered as "vacuum service")
- For heat exchangers which are to be heat treated for any reason
- For heat exchangers in cyclic service
- For heat exchangers made in Titanium.
• Spot radiographic examination (as per ASME Section VIII) or Category 2 (as per
BSI PD 5500) may be selected for other heat exchangers not related for category 1.
• No radiographic examination option (as per ASME Section VIII) or Category 3 (as per
BSI PD 5500) shall not be selected.

4.1.1 Selection of TEMA class

Selection of the TEMA class (R, C or B) shall be made as per section RCB 1.1 of TEMA.
Class R shall apply for hydrocarbon and gas services. Class R shall also apply for lethal, toxic
or inflammable fluids.
Class C may be used for utility services only.

5. Design
Service, duty and other design parameters as well as proposed type, position, arrangement and
materials, are specified on the Heat Exchanger data sheets.
The design calculations shall take into account the various mechanical and thermal loadings
(and their combination) to which the exchanger may be submitted.

5.1 Pressure
The design pressure is indicated in the data sheet.
Any part or element of the exchanger submitted to the stresses exerted by both fluids shall be
capable to withstand the maximum pressure of each side. It shall not be designed for the
differential pressure between both sides.
The minimum hydrostatic test pressure shall be established in accordance with the code.

1
An exchanger is considered as “low temperature service” when the design temperature in operation is equal or lower than -
30°C, or for a exchanger with a design temperature in operation greater than -30°C when the impact tests are required at -30°C
and lower.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 7/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

The term "test pressure" shall apply to the pressure measured at the highest point of the vessel
in its test position.

5.2 Temperature
The design temperature is specified in the data sheet.
The depressurisation conditions (if any) are specified in the data sheet.

5.3 Corrosion allowance

The minimum corrosion allowance shall be specified in the data sheet.
The corrosion allowance shall be added to the calculated thickness of shells, heads and the
necks of connections.
The corrosion allowance shall be applicable to all medium exposed surfaces of pressure parts
except:
• Tubes of the bundle
• Elements made of (or clad with) corrosion resistant alloy.

5.4 Clad steel

The thickness of the material used for cladding shall not be included in the computation of the
wall thickness.

5.5 External loads

External loads due to wind and/or earthquake shall be determined in accordance with the
procedures given in the paragraph UG 22/UG 23 of ASME Section VIII div. 1.
Hull movements shall be taken into account for vessels on floating facilities (accelerations and
hull distortion).

5.6 Local loads

Local stresses shall be evaluated using one of the following methods:
• BSI PD 5500, Appendix G
• WRC 107, local stresses in spherical and cylindrical shells due to external loading
• WRC 297, local stresses in cylindrical shell due to external loadings on nozzles -
Supplement to WRC bulletin no. 107.
The basic stress intensity is limited to Appendix 4 of ASME Section VIII div. 2.

5.7 Horizontal heat exchangers

The stresses in the shell due to supporting on saddles shall be calculated in accordance with
the L.P. Zick method, BSI PD 5500 assuming vessel fully corroded:
a) Operating condition - Heat exchanger at design pressure or vacuum and temperature,
complete with its attachments and liquid at maximum levels.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 8/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

b) Same as a), but without pressure.

c) Test condition - Heat exchanger at test pressure, ambient temperature and full of water
complete with its attachments.

5.8 Cyclic loading

The cyclic loading if any shall be specified in the data sheet.
When the vessel is intended for a service with highly fluctuating pressure or temperature cycles,
or in generally for cyclic service, the equipment shall be designed and constructed in
accordance with Appendix 5 of ASME Section VIII div. 2 and particularly Paragraph AD 160.

5.9 Additional design requirements

Stresses generated during lifting shall be determined based on the lifting method proposed
assuming uncorroded vessel thickness.
For large, thin wall equipment, a design check shall be made and, if necessary, additional
stiffening shall be provided to prevent shell distortion during fabrication, heat treatment, hydro-
testing, shipment or erection.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 9/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

5.10 Fixed tube sheet calculation

The various combinations shall be studied in each of the following situations:
Metal temperatures stated on
Thickness Pressure loads
eng. drawings
Fixed tube sheet Component
Design cases Shell and allowable stresses
Shell Tube
tube side Shell Tubes Tubesheet
side 1 side 2
tubesheets
S
at design
θ D1 temperature for
a) Design conditions Corroded PD 1 PD 2 θD 1 θD 2 maxi tubesheet, at
θ D2 service temperature
for other
components
θ Op1
b) Operating conditions Corroded POp 1 POp 2 θOp1 θOp2 maxi
θ Op2
S
c) Other cases: at operating
θ case 1 temperature for all
- start-up
Corroded P1 P2 θ case 1 θ case 2 maxi components
- shutdown θ case 2
- steam out
d) Shell side hydrotest Uncorroded PT1 0 20°C 20°C 20°C S at 90%
yield strength for all
e) Tube side hydrotest Uncorroded 0 PT2 20°C 20°C 20°C components
PD = Design Pressure θD = Design temperature
POp = Operating pressure θOp = Operating temperature
PT = Hydrotest pressure θcase = Special case temperature
Pcase = Special case pressure

6. Material
All materials used in the fabrication of heat exchangers shall be new and have the minimum
grade as specified in the data sheet and shall be in accordance with related code/material
specifications and standards.
Substitution of materials shall comply with the standards or quality required by the code and by
this specification and shall be subject to the Company written approval prior to start fabrication.
The selection of materials used in construction of vessels shall be in accordance with
GS EP PVV 211 or GS EP PVV 212.

6.1 Tubesheets
Tubesheets shall preferably be made of forged steel.
If the tubesheet forms a flange or is directly welded to the shell it shall be a forging and not a
plate material.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 10/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Tubesheets for brass or aluminum brass tubes shall be made of cast or forged copper
aluminum, the grade of which shall be approved by the Company.

6.2 Bolting
Unless otherwise specified in the job specification:
• The minimum diameter shall not be less than 16 mm (5/8")
• The minimum quality shall not be less than ASTM A 193 Gr.B7 for stud bolts and
ASTM A 194 class 2H for nuts.
The bolting of floating heads shall be suitable for the fluid temperature and aggressiveness
conditions and the relevant specifications shall be submitted to the Company for approval.
The bolting of internals shall be locked or tack-welded.

6.3 Clad steel

In case of weld overlay the metal deposit shall have the required chemical composition on a
depth of 3 mm.
Clad tubesheets:
Tubesheets with non-ferrous or alloy cladding for corrosion protection shall meet the following
requirements:
• The cladding shall be integrally and continuously bonded to the base material
• All surfaces exposed to the corrosive medium, including gasket seating surfaces, shall
have at least a 10 mm thickness of cladding if tubes are only expanded (to allow a groove
within the cladding thickness) and at least a 3 mm thickness for a strength-welded
connection
• Brazing shall not be used to bond the cladding to the tubesheet
• Integrally clad tubesheets and tubesheets with cladding applied by overlay welding shall
be ultrasonically tested to check the integrity of the bonding in accordance with
ASTM A 578, with an acceptance level of S7.

7. Rules of construction
7.1 Shells and channels
Shells shall be of one piece construction whenever practical and shall be fabricated from pipe or
rolled plate.
Thickness specified on drawings and documents for pressure containing parts must be
considered as minimum design thicknesses. Rolling tolerances, forming of different parts, etc.
shall be considered for defining the minimum plate thickness.
Shell head shall be of true semi-ellipsoidal shape, ratio 2:1 or hemispherical. Torispherical head
should not be used.
Shell and channel girth flanges shall be designed for through bolt joint construction.
Partition plates shall be seal welded full length, in place, either from both sides, or with full
penetration welds.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 11/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

A 6 mm diameter drain hole shall be provided in all partitions.

Whenever channels are welded onto the tubesheet the pass partitions shall be mounted in slide
channels and shall compress a flexible gasket against the tubesheet ("U"-shaped gasket or
inset in the tubesheet).

7.2 Shell flange

Shell flange shall be of the welding neck type for TEMA class R exchangers and class B or C
with design pressure above 21 bars.
Flat flanges may be used for dished covers of floating heads; they should be forged but may be
cut from plates of "boiler and pressure vessel" quality subject to the Company approval.
To facilitate breaking the gasketed joint of girth flanges, jack screws shall be provided on one of
each pair of main girth flanges.

7.3 Tubesheet
When tubesheet is tightened between flanges by gaskets inserted on each side of the
tubesheet, the tightening and assembling system shall be such that each gasket may be
removed independently from the other.

7.4 Tubes and tube bundles

The ratio outer diameter to length of removable tube bundles shall be limited so that bundle is
sufficiently stiff for maintenance and hoisting.
Unless otherwise specified in the data sheets or drawings, dimensions of tubes used shall be in
accordance with those specified in the TEMA standard:
• Tube wall thickness shall be specified as BWG (Birmingham Wire Gauge) as defined by
TEMA RCB 2-21.

Material Diameter BWG

CS, LTCS and 3.5 Ni ¾" 14 minimum
1" 12 minimum
Stainless steel ¾" 16 average
1" 14 average
Titanium ¾" 20 average
1" 18 average
Titanium HPT ¾" 0.71 mm minimum
Type 305 028

• Unless otherwise specified, tubes shall be seamless type for U-tube bundles
• Tubes shall be delivered in one piece without extension weld.
Each U-tube shall be formed from a single length (without circumferential welds) and the length
specified shall be the straight length, measured from end to return bend tangent. The mean
radius of U-bends shall not be less than 1 ½ times the nominal outside diameter of the tube and

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 12/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

shall be such that wall thinning in the bend shall nether be more than 10% of the thickness of
straight part.
Sliding strips shall be provided to facilitate pulling the removable tube bundles. Sliding strips
shall be properly seated in the baffles, secured with a complete seal weld (both sides) and
attached to the stationary tube sheet with a full penetration weld. The sliding strips shall
protrude 2 mm beyond the periphery of the baffles.
Baffles shall be tied together with rods and spacers and provided when necessary with 90° top
and bottom notches 12 mm wide for venting and draining. Tie rods and spacers shall be evenly
distributed around the circumference of the baffles.
Longitudinal baffle subject to large differential pressure due to high shell fluid pressure drop
shall be provided with a device ensuring tightness with the shell.
If necessary impingement protection shall be provided by a square plate baffle, a distributing
belt or by an enlarged inlet nozzle with an internal distribution plate.
Heat exchangers with steam as heating medium on the shell side shall always have
impingement protection.
Impingement plate baffle edges shall extend at least 25 mm beyond the projection of the nozzle
bore.
The unrestricted bundle entrance flow area at the impingement plate baffle shall not be less
than the flow area of the inlet nozzle.
For non-corrosive, non-abrasive, single-phase fluids, instead of using impingement protection
the nozzle diameter may be increased to reduce the fluid velocities at the shell entrance.

7.5 Tube and tubesheet assembly

Tube hole tolerances and machining in tubesheets for carbon steel and 3.5 Ni steel tubes shall
be standard fit.
Tube hole tolerances and machining in tubesheets for stainless steel and titanium shall be
special close fit.
Sequence of tube expanding or welding in tubesheets shall be designed so that distortion is
reduced to a minimum.
If post weld heat treatment is required for tubesheet, final hole machining shall be made after
heat treatment.
The inside edges of tubes holes in tubesheets shall be free of burrs to prevent cutting of the
tubes. Internal surfaces shall be given a workmanship like finish.
For vertical exchangers, the tubes shall be flush with the tube side face of the top tube sheet, to
allow complete drainage.

7.6 Expanded tube-to-tube sheet joints

All tubes holes for expanded joints shall be machined with at least one groove.
For tubesheets constructed of integrally clad plate or with applied corrosion-resistant facings,
one groove shall be in the centre of the cladding/facing material layer.
The tube expansion shall extend over a depth corresponding to 9/10th of the tubesheet
thickness but with a maximum depth of 60 mm.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 13/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

After expansion, the tube ends shall protrude by 3 mm (+0, -1.5) from the tube sheet surface
unless otherwise specified (vertical exchanger, etc.).
After expansion, the tubesheet shall exhibit a flat surface to within ±0.8 mm.

7.7 Welded tube-to-tube sheet joints

The tubes shall be strength welded (2 passes) after the tubes have been slightly fit-up
expanded in their housing at least in the following cases:
• When required on the data sheet
• When stainless austenitic steel tubes and carbon steel tubes sheets are used and when
metal temperature of the joint will be more than 250°C.
• When the differential design pressure exceeds 70 bars
• When leaks between tube side and shell cannot be tolerated
• When exchanger contains lethal substance
• When titanium tubes are used.
Method of preparation for welding and welding procedure shall be submitted to the Company for
approval before application. All seal or strength welds of alloy tubes in tubesheets, or any
repairs shall be submitted to dye penetrant examination.

7.8 Stiffeners
Stiffeners required by the design code for vacuum vessels shall be continuous and preferably
external.
Stiffeners shall be continuously welded to the shell.

7.9 Connections
Unless otherwise specified, minimum nozzle diameter shall be 2".
All nozzles shall be flange ended. Use of hub connectors is prohibited.
The minimum thickness of nozzle neck shall be as specified in the data sheet and in any case
not less than the code requirements.
The dimensional specification and pressure temperature rating of nozzles and manhole flanges
up to and including 24" in the range of pressure ratings of 150, 300, 600 lbs shall be in
accordance with ASME B16.5.
Bolted flanges larger than 24" shall be specified to ASME B16.47 series A. A calculation of
these flanges according to the code shall be made, including rigidity for shell flanges.
All special size/designed flanges shall be designed:
• In accordance with the code. Design shall be based on the design pressure and
temperature of the vessel when in the fully corroded condition, or upon the hydrostatic test
pressure calculated for the vessel in the new condition less corrosion allowance at
atmospheric temperature, whichever governs

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 14/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

• Using the Manufacturers minimum gasket seating stress or the code value, whichever is
greater
• To account for external loads imposed by piping reactions.
Flanged connections may be constructed as integrally forged nozzles or may be built up from
seamless pipe or rolled plate welded to forged steel flanges.
Slip-on flanges shall not be used.
In addition to the requirements of TEMA Section 5, Para. RCB. 10-31, vent and drain
connection shall be provided on the top and bottom of the shell cover.
There shall be no pressure gauge connections nor temperature instrument connections in heat
exchanger nozzles, except for direct interconnection nozzles of stacked exchangers.
The vent, and drain, connections shall be 2” flanged.
The pressure and thermometer connections shall be 1” flanged.
Bolting in flanges of mating connections between stacked exchangers shall be removable
without moving the exchangers.
Nozzle projection shall be measured from the outer surface of the shell to the flange face.
Unless internal projections are specified in the data sheet, nozzles are to be cut off flush all
along the inside contour of the shell or head and the inside sharp edge shall be ground.
Welding neck flanges shall be bored to same dimensions as inside diameter of nozzle neck.
Bolt holes shall straddle the north/south and/or vertical vessel axis, unless specifically noted
otherwise.

7.9.1 Flange facing

Flange facing and gasket contact face shall comply with the corresponding piping class or as
specified in the data sheet.

7.9.2 Butt welding connections

When required in the data sheet, the butt welded nozzles shall be supplied with over-length and
a cap for shop hydrostatic testing.

7.10 Inspection and access openings for kettle

Manholes may be used for bundle diameter above 18" or if bundle weight is greater than 10 MT.
The minimum nominal size of manhole shall be 18" diameter.
Blind flanges shall be hinged or provided with a davit.

7.11 Reinforcement of openings

Openings shall be reinforced to withstand the loads to which they will be exposed during
normal, upset and test conditions, including loads imposed by the connecting piping.
The reinforcements of process nozzles shall be designed for loads values stated in
GS EP PVV 107.
Openings may either be reinforced by pads as allowed by code or Self Reinforcing (SR) forged
nozzles.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 15/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Pad shall not be used when the vessel wall thickness is greater than 40 mm (carbon steel) or
25 mm (alloys), for low temperature service as defined in § 5.1 or when the temperature of the
vessel exceeds 300°C.
Reinforcing pads, if provided, shall be of the same material as the base metal and shall be
provided with two tell tale holes located at 180° apart and tapped for 1/4".
The tell tale hole shall be in the lowest area of the pad when the exchanger is in its normal
operation position.

7.12 Support and lifting devices

One saddle support for horizontal units shall be provided with slotted holes to allow for
expansion.
Each heat exchanger shall be provided with two earthing bosses as specified on the Exchanger
Data Sheet.
Lifting lugs shall be of plate type with a 30 mm diameter hole, welded on with full penetration
weld.
Each channel cover shall be provided with a lifting lug, located on top centreline, wherever
possible.
Lifting lugs shall be provided on floating heat covers, shell covers, channel barrel and bonnet
type channel covers.
Pulling lugs or tapped holes for insertion of eye bolts shall be provided on the outer face of the
stationary tube sheets of removable bundles to facilitate removal of bundles from shells.
Where clad tube sheets are used, pulling lugs or lapped holes shall be located on the outside
edge not in the cladding.

7.13 Shell expansion bellows

Where fixed tube sheet construction is used, suitable provision shall be made for expansion to
prevent over-stressing of the tubes or shell.
Stresses due to thermal expansion shall be analysed by investigating the normal operation in
the clean and fouled conditions to determine the necessity of using expansion bellows as per
Appendix 26 of ASME Section VIII div. 1 code.
Other conditions such as start-up, shutdown, steam out, etc., when specified, shall also be
investigated.
The types and material of construction of expansion bellows shall require the Company
approval.
Expansion bellows should preferably be made of the same material as the shell on which they
are to be fitted. The installation of a thin bellows of a different material shall be subject to the
Company approval.
The bellows shall be assembled cold pre-stressed.
Effective protection (e.g. annular sheet) shall be provided whenever justified by the bellows
thickness. Such protection shall not hinder the bellows' freedom to expand in service.
Expansion bellows are prohibited on exchangers where the risk of solid deposit is possible.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 16/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Expansion bellows shall be protected against mechanical damage during shipment and
assembly.

7.14 Girth joints gaskets

Gaskets shall be selected to meet operating conditions, design temperature and design
pressure.
Graphite containing gasket associated with corrosion resistant alloy (CRA) flanges shall be
avoided in case of chloride containing fluid.
Type of gasket selected shall be submitted to the Company for approval.
Elastomer O-rings are strictly forbidden as sealing barrier to the atmosphere whatever the
pressure class and service class.

7.15 Other gaskets

Gaskets for nozzles shall comply with the requirements of the corresponding piping class or as
specified in data sheet.

7.16 Bolting

7.16.1 Internal bolting

Non pressure bolting shall consist of hexagon headed bolts, with one nut. The minimum
allowable bolt size is M 12.

7.16.2 External bolting

Pressure bolting shall comply with GS EP PVV 146.
Length of bolts and studs shall be such that they extend beyond the nut by at least two threads.

7.16.3 Bolt tensioning equipment

Bolt tensioning equipment shall be used for bolt size > 1"1/2. If the application of bolt-tensioning
equipment is anticipated in the design stage, due attention shall be given to the clearance
required to accommodate the tensioning tools and to the bolt extra-length.

7.17 Shell attachments

All heat exchangers attachments such as insulation supports, fireproofing supports, lifting lugs,
piping clips, ladder clips and platform clips shall be provided in accordance with the appropriate
standards and drawings.
These attachments, except as otherwise indicated in the data sheet, must be made of the same
grades with the same impact tests requirements of material at the wall to which they are welded.
Reinforcing pads for internal or external structural attachments shall be provided with a 6 mm
diameter vent hole in lower position of pad.
The internal vent hole shall be plug welded after completion of all pad attachment welds.
When insulation support rings clash with nozzles, clips or other attachments, the support rings
shall be cut to stop short either side of the attachment by 30 mm minimum.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 17/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

7.18 Nameplates
Each heat exchanger shall be provided with an austenitic stainless steel nameplate,
permanently attached to the exchanger, indicating Vendor's name and design data as shown on
the applicable standard drawing.
Nameplates shall be permanently visible, whether the exchanger is insulated or not.
When cold temperature insulation is specified for the exchanger an additional nameplate
mounted on a wooden block or on insulation jacket shall be provided.

7.19 Thermal insulation

Thermal insulation must be provided either required by the process studies or for personnel
protection (although protection by metal mesh shall be preferred whenever possible). Any
required thermal insulation shall comply with the following Company specifications, as
appropriate: GS EP PVV 771, GS EP PVV 772 and GS EP PVV 773. Surfaces shall be
appropriately protected in accordance with GS EP COR 350 before installation of thermal
insulation.

7.20 Protection of personnel

Protection of the personnel by metal mesh must be provided on uninsulated equipment when
the service temperature thereof is over 70°C. This protection shall also apply to cold equipment,
which might be a danger to the operators.

8. Fabrication requirements
The heat exchangers shall be fabricated and controlled in accordance with the code
requirements of the specified construction category.

8.1 General
• Fabrication shall not commence without written authorisation from the Company
• Mechanical faces and edges shall be protected against damage during fabrication and
against oxidisation during heat treatment.

8.2 Tolerances
Tolerances shall be in accordance with the Figure 3 of the TEMA standard and code unless
otherwise specified in the data sheet.

8.3 Cutting
Shear cutting shall not be utilised for pressure retaining plate material.

8.4 Forming
Plate forming shall be in accordance with GS EP PVV 211 or GS EP PVV 212.

8.5 Welding
Welding shall comply with GS EP PVV 611 and GS EP PVV 211 or GS EP PVV 212.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 18/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

8.6 Heat treatment

Cold formed heads shall be heat treated, prior to welding, as required by the Code.
Heat Exchangers shall be post weld heat treated, when required by the code, or when specified.
Welded Exchangers or parts of Heat Exchangers requiring additional heat treatment to enhance
corrosion resistance or mechanical properties, shall receive these additional heat treatments
when specified in the data sheet, or when required by the material Manufacturer.
Manufacturer shall submit to the Company as part of the fabrication procedure, an outline of the
additional heating operations required during fabrication (e.g. for forming).
Manufacturer shall notify the Company of any exchanger of unusual configuration or component
design such that high stresses may be developed in welds because of restraint. The Company
approval to waive stress relieving shall be obtained.
Flanges facings shall be protected against oxidation during heat treatment.
All U-tubes bends (U-tube + 300 mm of straight portion) made from carbon and low alloy steels
shall be heat treated.
U-tubes in stainless steel material shall be heat treated for their total length after forming
(solution annealing) when bending radius is lower than 5D.
Post weld heat treatment of fabricated carbon steel channels and bonnets is required for the
following:
• Channels and bonnets with 4 or more tube passes excepted cladded heat exchangers
• Channels and bonnets whose cylinder to nozzle diameter ratio is 2.0 or less.

9. Quality control
9.1 Inspection and testing

9.1.1 General
Heat exchangers and their materials shall be inspected per the requirements of the
specification. However, the acceptance of any work and/or release of the heat exchangers shall
in no way relieve the Manufacturer of any responsibility for carrying out all the provisions of the
code and of the specifications.
Heat exchangers shall be submitted, once completed, to a series of shop tests to be witnessed
by the Manufacturer.

9.1.2 Quality plan

Manufacturer shall submit an inspection plan for the Company approval.
This Inspection Plan shall be in accordance with the provisions of the code and project
inspection requirements.

9.1.3 Material inspection

Unless otherwise stated in the data sheet, testing shall conform to the requirements of the
applicable standards.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 19/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

Ultrasonic examination of plate material shall be carried out for:

• Plate thickness greater or equal to 40 mm, examined in accordance with ASME Section V,
and ASTM A 435 (periphery and grid pattern)
• Integrally bonded clad plate for lack of bonding in accordance with the requirements of
ASTM A 578, acceptance level S6. This also applies when cladding has been restored at
welds in clad plate. Then a band of 50 mm wide, each side of the weld shall be examined.
Other suitable supplementary testing or examination are specified in the vessel data sheet.

9.1.3.1 Material test reports

For all pressure parts (plates, heads, tube sheets, nozzles, flanges, etc.) as well as for supports
(skirt, saddles, legs), the material test reports shall be provided showing the results of the
required tests and inspection, including supplementary requirements if any.

9.1.3.2 Material identification sketch

For each heat exchanger, a material identification sketch shall be prepared showing the
marking on every piece and referencing the related material test report or certificate.

9.1.3.3 Transfers of markings

Transfers of markings shall be made prior to cutting and shall be witnessed by Manufacturer's
inspectors.

9.1.4 Welding inspection

Visual and non-destructive examinations of weld preparation and welded joints shall be conform
to the requirements of the Code and GS EP PVV 611.
Ultrasonic examination, shall not be considered as a substitute to the mandatory radiographic
examination but shall be regarded as a complementary examination for the detection of planar
internal flaws except for joints of category D which are not readily radiographiable to code
standard.
UT examination shall be required for all joints of category A and B and D before and after
PWHT.
For ASME Section VIII div. 1 Exchangers, spot radiography shall include all butt-weld
intersections and not less than ten percent (10%) of each longitudinal and circumferential joint
length in the shell and heads.
Non destructive examination procedure shall be submitted to the Company for approval before
fabrication starts.

9.1.5 Dimensional check

The final dimensional check and visual inspection shall be performed after the hydrostatic test.
Tolerances shall be as per paragraph 8.2 above.

9.1.6 Hydrostatic testing

Heat exchangers shall be hydrostatically tested to the shop test pressure as per the code.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 20/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

9.1.6.1 Quality of the test water

Hydrostatic testing shall be carried out using clean water free from suspended solids and other
foreign matter.
Minimum test water temperature for carbon and low alloy steel exchangers, shall be 15°C. In
addition, the metal temperature during hydrostatic test shall be maintained at least 17°C above
the minimum design metal temperature to minimise the risk of brittle fracture.
Water used for testing shall conform to GS EP COR 560.

9.1.6.2 Testing procedure

The exchangers shall be tested before being painted.
Test procedure shall conform to GS EP PVV 441.
A detailed test procedure shall be submitted to the Company for approval.
• Exchangers which are to be shop hydrostatic tested in the horizontal position shall be
supported adequately to prevent deformation of the shell.
• Manometer and vent shall be located on top longitudinal line.
• To determine orientation on cradles, welded internals shall be taken into account in order
to prevent creating air pocket, or vents shall be provided on internals.
• The test pressure shall be maintained for the period specified by the code, but not less
than one hour.
• Nozzle reinforcing pad welds shall be tested with maximum 0.5 barg air and soap suds
solution.
• Body flange joints, blind flanges, and piping components, shall be bolted up and
hydrotested together with the exchanger.
• For nozzle connections test gaskets shall be the same type as the service gasket, but do
not need to be of the same material if the seating characteristics are similar. Use of a
sheet test gasket in lieu of a spiral wound, metal jacketed or similar gasket is permitted in
limited cases, with the prior approval of the Company. Ring type joints shall be tested,
using a metallic ring of similar cross section and hardness.
• Test rings required for testing floating head exchangers shall be furnished with the
exchanger. Test flanges shall be provided for exchangers with a bonnet-type head,
removable bundle and stationary tube sheet of diameter, smaller than the outside
diameter of the connecting shell flange.
• For girth flanges test gaskets shall be of the same type and material as the service
gaskets.
• Gaskets for girth flanges shall not be changed after successful pressure testing.
• When a heat exchanger is dismantled for any cause, it shall be reassembled with new
gaskets of the same type and material.

9.2 Stamping
The following exchanger parts shall be U stamped with Manufacturer's exchanger serial
number: shell cover, channel, channel cover, fixed tube sheet, test ring and test flange.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 21/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

10. Preparation for shipment

10.1 General
Cleaning, packing, shipping and storage requirements shall be subject to the Company
approval.
No vessel or vessel section shall be released for shipment without the Company prior written
authorisation.

10.2 Particular requirements

After completion of fabrication and testing, the exchangers shall be thoroughly drained of water
and dried.
After drying out, the vessels or sections shall be cleaned externally and internally of weld
spatter, weld slag, flux deposits, burrs and splinters, loose mill scale and all other foreign matter.
Internal surfaces of stainless steel exchangers shall be pickled and passivated.
External surfaces of exchangers shall be blasted and painted as prescribed in GS EP COR 350
and in the requisition.
Internal surfaces of carbon steel exchangers shall be painted as prescribed in GS EP COR 352
when required in the requisition.
Bolts shall be protected as stated in GS EP COR 356.
All machined surfaces shall be cleaned with a suitable solvent and immediately be protected
with an easily removable rust preventive coating or plastic film.
Prefabricated sections shall be protected with provisional stiffeners at each unsupported end.
Steel plates or section edges to be welded shall also be protected.
All machined surfaces shall be cleaned with a suitable solvent and immediately be protected
with an easily removable rust preventive coating or plastic film.
Test gaskets may be left in place.
Each joint bolted prior to shipment from the shop, shall be provided with a firmly attached tag,
giving the type of gasket installed.
Solid metal gaskets, reassembled for shipment shall be coated with grease or varnish, as well
as corresponding parts.
Permanent blind flanges or covers shall be bolted with service stud bolts and nuts.
Internals installed prior to shipment, shall be properly secured and protected.
All nozzle gasket faces shall be protected by gaskets and metal blanks, unless otherwise
specified.
Should it be necessary to separate a unit into several parts for transport purposes all these
parts shall be carefully marked to prevent any assembly errors.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 22/23
 Exploration & Production

General Specification Date: 01/2011

GS EP PVV 411 Rev: 05

10.3 Packing
The package and protection of equipment shall be suitable for inland and/or sea transportation
and for a storage period as defined in the project specification. Supply shall include complete
export boxing packing in compliance with this requirement.
All equipment and piping likely to vibrate during transportation shall be properly braced to
prevent damage.
Dessicant bags shall be located in all capacities to prevent built-up of condensation and warning
notices shall be attached.

10.3.1 Spare parts

10% spare bolting with a minimum of two bolts of each size and type shall be supplied.
Two spare gaskets for each girth flanges and blinded nozzle in addition to the service gasket
shall be supplied.

10.3.2 Loading
Manufacturer shall ensure that equipment is properly loaded and secured to the carrier, and to
ensure that clearance requirements are met and to prevent any damage from improper
shipment, such as from cradles or hold-down devices.

11. Documentation
Documents shall comply with the Project Specifications requirements.

This document is the property of Total. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.

Page 23/23