GENERAL SPECIFICATION Sofa ey ENGINEERS. FOR AIR COOLED HEAT GEEES@RSALAIED — FORARCOOLED! ‘STANDARD SPECIFICATION No. 6-15-0071 Reva Page 1 of22 TR ages dle vada ® ferg araree fare sr GENERAL SPECIFICATION FOR AIR COOLED HEAT EXCHANGERS 19h. ata 10 REVISED & REISSUED AS STANDARS 7 een ‘SPECIFICATION Ls Ret ary 0M NO REVISED AND REISSUEDAS 325032009 _STANDARD SPECIFICATION Ls mi an No TREVISED AND REISSUED AS 2 200080 STANDARD SPECIFICATION ae is a a 7 TSSUED AS STANDARD : 29.05.89 eee RKA BSG VKM RNS ‘Siandards Standards Commitise "Bureau Rew Prepared Checked Date urpose omvenor imam No Purpos i nt chal ‘Approved by Formato, 800.0001-F1 Rev. 0 ‘Copyright El. Alighs reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No, searebies © NIALAATED FOR AIR COOLED HEAT 6-15-0071 Rev.4 ES soca, EXCHANGERS. Pazera Abbreviations ACHE Air-cooled heat exchangers Al Authorised Inspector APL American Petroleum Institute ASME. American Society of Mechanical Engineers ASTM. American Society of Testing of Materials AWS American Welding Society BIS Bureau of Indian Standards BEN Brinell hardness number BV Bureau Veritas, CA Corrosion Allowance CAF Compressed Aramide Fibre CCOE Chief Controller OF Explosives CMRI Central Mining Research Institute cs Carbon Steel DFT Dry Film Thickness DNV Det Norske Veritas DP Dye Penetrant Test DPDT Double pole double throw EIL Engineers India Limited FM Factory Mutual FRP Fibre Reinforced Plastics HAZ Heat Affected Zone HIC Hydrogen Induced Cracking HP Horse Power HTRI Heat Transfer Research Institute IEC International Electrochemical Commission vp Current to pneumatic converter LAS Low Alloy Steet LP Liquid Penetrant Test LTcs Low temperature C MDMT Minimum design metal temperature MP lagnetic Particle Test NACE National Association of Corrosion Engineers op Outside Diameter prc Production test coupons ss Stainless steel SPDT Single pole double throw STAAD Software for structural design UL Underwriters Laboratory usT Ultrasonically Tested Static Equipment Standards Committee Convenor: Mr. A.K. Malik Members: Mr. RK. Trivedi Mr. K Anjaneyulu Mr. Tarun Kumar Mr. Chandra Kant (Inspection) Mr. [Link] (Construction) Mr. Ratan Lal (Project) Format No. &-00:0001-F1 Rev. 0 ‘Copyright EL ~All rights vesesvedGENERAL SPECIFICATION STANDARD SPECIFICATION No. SE SANE FOR AIR COOLED HEAT 6-15-0071 Rev.4 searecs CNOA EXCHANGERS Page 3of 22 CONTENTS B. SPECIFIC REQUIREMENTS. 4. GENERAL. 5. PROPOSAL DOCUMENTATION. DESIGN... 8. MATERIAL. FABRICATION. 10. _ INSPECTION, EXAMINATION AND TESTING... Il. PREPARATION FOR SHIPMENT... 12. SUPPLEMENTAL REQUIREMENT! 13, SPARES. Format No, 6:00-0001-F1 Rev. 0 ‘Copyight EL Alvighis rowedSoils GENERAL SPECIFICATION STANDARD SPECIFICATION No. ENGINEERS ge teee@NWAtieD FOR AIR COOLED HEAT 6-15-0071 Rev a febtég > NOIALMITE Benaraees earths A 4. 41 SCOPE This specification covers the general requirements for the thermal and mechanical design, materials, fabrication, workmanship, inspection, testing and supply of ACHE and is intended to supplement the minimum requirements of the applicable codes and standards. In case Purchaser furnishes thermal design, Clause-7.0 under Section-7 of this specification on thermal design is not to be considered. In case thermal and mechanical designs are done and engineering drawings furnished by Purchaser, then details given in these engineering drawings, take precedence over this specification This specification shall not be considered limiting and it shall be Vendor's responsibili comply with all requirements of Material Requisition/Purchase Requisition/Bid Documents (referred to as enquiry documents), to which this specification is attached. SPECIFIC REQUIREMENTS ‘The Standard applicable for ACHEs shall be API Standard 661, Sixth Edition February 2006 except to the extent modified hereunder. The section, paragraph and figure numbers refer to those used in API 661. "New” applies to entirely new paragraph presently not included and to be inserted in the numbering order of API-661. "Addition" applies to an addition to the original Para. "Modified" applies to modification of applicable portion of the API-661 Para. GENERAL. The pressure design code shall be ASME Section VIII Division 1, unless specified (Modified) otherwise. Hereinafter referred to as Code, 44 For ACHE to be installed in India, Vendor shall comply with all applicable local (Addition) regulations like approval from CMRI, PESO, and CCE etc. for all electrical and 5.10 (New) 6. 70 (New) 701 7.02 instrument items. PROPOSALS ‘The proposal shall include power consumed by the motor and required motor HP. DOCUMENTATION ‘Vendor shall furnish documents as per Vendor Data Requirements specified in the requisition. DESIGN ‘Thermal Design The Vendor shall do thermal rating when specified. Thermal design proposed by the Vendor will have to be in order as per either HTRI or HTFS software. This includes adequacy of heat transfer area and tube and airside pressure drops. If any modifications are required to be carried out by the Vendor in order to make the thermal design acceptable as per either HTRI or HTFS software, the same will be done without any cost and delivery implications. If an ACHE has to satisfy more than one process condition, separate "Equipment Data Sheet" shall be furnished for each condition. The relevant process condition number shall be given in the heading of each sheet. Format No, &-00-0001-F1 Rev. 0 Copyright EIL~ All ights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No. FOR AIR COOLED HEAT 6-15-0071 Rev.4 EXCHANGERS Page 5 of 22 7.0.3 ACHE design shall take into account operation at part load. This is important for viscous materials (>=SeP) and those with high pour points. Vendor shall consider the following: The inside tube wall temperature shall be a minimum of 10 °C (18 °F) above the pour point. This condition shall be satisfied for the lowest part-load design case with the air entering at winter design temperature. The provision of counter or parallel flow piping arrangement, air re-circulation and/or heating coils may be necessary to achieve this. In cases where the process fluid may solidify or become highly viscous when flow is interrupted or for systems where there is a maximum allowable cooling rate, e.g. deposition of ammonium carbonate, steam heating & control shall be incorporated for start up & shut down. 7.0.4 The varying air temperature across the rows of a single pass condenser results in unequal performance. Employing variable fins per inch in the individual rows with the lowest in the bottom row and highest in the top row should eliminate this. 7.1 Tube Bundle Design 710 Vendor shall strictly follow the design information issued by the Purchaser. Any (New) comment and/or reservations shall be resolved with the Purchaser at the bidding stage Reservations or deviations not accepted during bidding stage shall not be reopened during job execution, TALS. ‘There shall be practically no air gaps in bolted joints (plenum to beam, in between (Addition) _~ parts of plenum etc.). However these gaps shall be limited to 0.5 mm (maximum). TALI3 ‘The bundle side frame shall have minimum 5 mm thickness for tube lengths less than (New) 6 mand bundle width up to 2 m and shall have 8 mm thickness (minimum) for greater tube lengths or bundle widths. Only one joint is permitted in the frame. The weld, if any, shall be full penetration weld, shall be ground flush from inside and DP tested. Tadad Tube to tube sheet joints (New) Tube to tube sheet joints shall be expanded type except that the tube to tube sheet {joints shall be welded for the following cases: a) Critical service requirements such as lethal, hydrogen service with hydrogen partial pressure > 7 kg/em? (g), et b) For duplex and super duplex materials where reliable expanded joints are difficult to achieve. ©) When specified in Process Licensor's requirements or datasheet. 4) Tube hardness or yield strength exceeds that of tube sheet. e) ‘When design pressure > 50 kg/cm’ (g) and design temperature is > 400°C. £) When design pressure > 70 kg/em? (g) and design temperature is > 300°C. 2) Forsourservice with 8S tubes and tube sheet. 713 Tube Bundle Design Temperature 731 ACHE MDMT shall be taken lower of 0 °C or the design temperature specified in the (Addition) equipment drawing or Design Basis. Format No, 8-00-000%-F1 Rev. 0 Copyright EL — Alights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No. Soitotarey Se ENGINEERS aE OR UMITED: FOR AIR COOLED HEAT 6-15-0071 Rev.4 at EXCHANGERS Peseaiss 7132 Extruded fins may be used for design temperature up to 288 °C (maximum). (Addition) Embedded °G” fins may be used for design temperature up to 400 °C (maximum), Beyond 400 °C, only welded fins shall be used. For ACHEs in offshore service, extruded fins shall be preferred. 71.6 Headers 71.6.0 Type of header (New) ‘The type of header as specified by Purchaser shall be adopted. In general cover plate type headers shall be used when fouling resistance is greater than 0.0004 hrm”*C/kcal. Plug headers shall be provided for services such as hydrogen, lethal, sour, amine, design pressure greater than 50 kg/cm’ (g). 7161.2 If the design temperature exceeds 180 °C, a split header shall be provided after first (Addition) tube pass of multi pass bundle. [Link].4 Header shall be designed so that the inter pass cross-sectional flow area is at least (Modified) 130% of the flow area in the previous tube pass. 7.16.16 The minimum tube sheet thickness for expanded tube to tube sheet joint shall be (Addition) 25mm for CS and LAS materials with 3mm CA and 22mm for SS material with no CA, to ensure two grooves for expansion. For higher CA, minimum thickness shall be increased by the additional CA (e.g. CA in excess of 3 mm for CS or LAS, ete.) [Link] _-Even number of passes are preferred for simplicity in piping layout. Process nozzles (New) shall be at the fixed header end to minimise thermal expansion stresses. Pass partition plates shall be provided with one 6mm diameter drain hole. 71.6.2 Removable Cover Plate and Removable Bonnet Headers [Link].2 Removable bonnet headers shall not be used. (Modified) [Link] (Addition) TAB 7181 (Modified) Bolted joints shall be designed with confined gasket only. Refer figure 4 A and B for ‘typical confined joint detail. Use stud bolts for header flange and cover plate joint. Plug Headers For strength welded tube to tube sheet joint, if clearance between the top/bottom/si partition plate and tube is less than 18mm or the plug size is less than tube OD. plus ‘9mm, then Vendor shall demonstrate his experience by giving past references and by performing mock up to prove his capability in this regard. The mock-up shall be done before the submission of design or drawings, Plugs for Tube Access Plug shall not project into the header box. In case of sour and lethal service, double plug shall be used for CS and LAS materials. Gasket Metal Jacketed (3 mm thick) gaskets shall be 13mm (minimum) wide all around, CAF (2 mm thick) gaskets shall be 19 mm (minimum) wide all round. Width of the ‘gasket at pass partition shall be equal to the pass partition plate thickness. Format No. 8-00-0001-F1 Rev. 0 Copyright EL — Alvights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No. SREES@NOALMIED —FORAIR COOLED HEAT 6-48-0071 Rev.a Smreemeros tom enim EXCHANGERS: Page 70f 22 118.8 Gaskets shall be preferably in one piece. This shall however not mean exclusion of (Modified) gaskets made by welding, provided the weld and HAZ is not harder than the parent material and has the same corrosion resistance. The pass partition ribs of metal- jacketed gaskets may be tack welded to the inside of peripheral section. 718.10 ‘The selection of gaskets in header flanges depends on the temperature, pressure and (New) corrositivity of the fluid to be sealed. For cover type header, the gasket shall be CAF ‘or metal-jacketed type with the metal compatible with cover and flange material. CAF may be used only for water, air, steam (up to 150°C) with ASME 150 Class and if permitted as per Purchaser’s specifications. CAF shall be 2mm thick only. Asbestos not to be used if not specifically permitted. For plug headers, only solid soft metal gaskets are to be used. 119 Nozzles and other connections 71.9.0 Maximum nozzle size shall be limited to 12"NB and where possible shall be (New) restricted to 8"NB by splitting large flows into multi nozzles, if necessary. Header boxes having length more than 1800mm shall have minimum two nozzles for process inlet and outlet. 71.95 lll connections shall be flanged irrespective of flange rating. (Modified) 719.7 Bolt holes shall straddle principal centrelines. (Addition) 7198 Fabricated transition pieces wherever indicated in this clause shall not be permitted. (Addition) __Swaged CS nozzles shall be normalised if the thickness exceeds 16mm or if they are not formed in the normalising range. Hot-formed SS nozzles to be solution annealed. 7.19.10 Slip-on flanges shall not be used. (Modified) [Link]/12/15/18/21 Threaded connections shall not be used. (Modified) 719.16 If specified by Purchaser, additional chemical cleaning connection shall be minimum (Modified) 2"NB. The type and location shall be as specified. 719.17 ‘Multi-purpose connections shall be as per Design Basis. (Modified) [Link] All process nozzles of 3°NB and above shall be provided with 3 no. stiffeners and (New) process nozzles of 2”NB and below shall be provided with 2 no. stiffeners. Size of stiffener shall be 50 wide x 8thk. 71.10 Maximum allowable moments and forces for nozzles and headers 71.105 Minimum nozzle load shall be twice the API 661 limit. For Air coolers of 600# nozzle (New) flange rating and above, the same shall be 3 times API 661 limit. Structural components shall be designed for these loads. Nozzle loads in excess of these loads, if specified by purchaser, shall be considered. Format No. 6-00-0001-F1 Rev. 0 Copyight EL Alvights reservedSERGE Ay ENGINEERS, GENERAL SPECIFICATION STANDARD SPECIFICATION No. Bar felies “INDIA UMITED. FOR AIR COOLED HEAT 6-15-0071 Rev.4 Se eee Asien EXCHANGERS Page 6 of 2 71M Tubes TLS For extruded fins (integral type) the minimum tube thickness applies to the inner (Addition) tube. TAALS Fins serrated on the outside edge may be used only for CS fins. (Addition) TALI L-fins shall not be used. (Addition) 71.11.14 The mechanical bond between tube and embedded fins shall be tested as follows: (New) i) Cut fin to obtain a sector with a chord of approx. 12mm at the root of the fin. ii) Pull out the fin sector by hanging weights or any other appropriate method. Acceptance criteria shall be a force of at least 3.0 kg iii) 1% of the total number of tubes per size, fin diameter, fin pitch shall be tested at two locations along the tube length. Tubes, which pass the test, may be used after stitching of fin portions across the cut. iv) In the event of any tube failing to comply with pull out test requirements, a further two tubes shall be re-tested and, ifthe results are satisfactory, the tubes can be accepted. If, however, the further test results are unsatisfactory, the entire lot of tubes shall be rejected v) The pulling test shall not be carried out within 25mm from each fin connection point. Two cross-section cutaways shall be made for inspection of tube grooving and fin bonding per each machine setting (ie. one tube for each type of tube and fin detail and minimum one test per order), 71.11.15 The number of fins shall not exceed 433 per meter (11 per inch). (New) 12 Air side Design 7242 If the control of airflow is to be achieved by use of auto variable fans or variable (Addition) speed drives at least 50% of the fans are to be made auto variable, unless specified otherwise. Auto variable fans or variable speed drives, if used, shall be located towards that end of the bundle where inlet nozzle(s) is/are located. 72.14 Drivers, gear boxes, transmission components, instrumentation, louver actuator and (Addition) positioner ete. shall not be installed in the hot air stream, 722 Noise Control 722.1 Permissible noise level of the ACHE measured shall not exceed 85 dB (A) with all (Addition) fans running at full load. Measurement shall be taken one meter from bundle on the header access walkways and 1 m from the bay limits on the motor maintenance platform. The permissible noise levels 1 meter below the motor shall be 90 dB (A) maximum. Vendor shall demonstrate these noise level limits during run-in tests. ‘Vendor shall furnish noise datasheet after order. Format No, -00-0001-F1 Rev. 0 ‘Copyright EI — All rights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No, eae Sanh UMITED FOR AIR COOLED HEAT 6-15-0071 Rev.4 ch beet hoe EXCHANGERS. Pasa 723 Fans and Fans Hubs 723.1 ‘Two or more fans aligned in the direction of tube length shall be provided for each (Modified) bay. All fans in a bay shall be arranged for independent operation. Common fans cooling more than one process duty shall be used only on approval from Purchaser. 7235 Fans shall be designed for a noise level of maximum 80dB(A), keeping in mind the (Addition) overall limits as per [Link]. Fan tip speed shall be suitably selected. Fan manufacturer shall furnish noise level datasheet for fans. [Link](b) Pneumatic actuator shall be equipped with a positioner. Each actuator shall have an (Modified) integral positioner mechanism and mechanical maximum and minimum. stops, adjustable over the full range. Exposed actuator shafts shall be protected with canvas gaiters. Each actuator shall be provided with flexible hose(s), terminating in a 1/4” NPT screwed female connection. The actuators shall be suitable for an air supply pressure of 9.5 kg/cm? (g) design, 7 kg/cm? (g) normal and 2.5 kg/cm? (g) minimum. Purchaser will specify the exact air supply pressure. Any pressure reduction system shall be in Vendor's scope. [Link](€) Incase of loss of air pressure or control signal, the blades shall lock at maximum air (Addition) flow position unless specified otherwise. In the event that the fan fails to respond in this manner, means shall be included by the Vendor to physically lock the blades in high pitch position. Auto variable fans to be shop adjusted for variation between zero performance and max pitch required. Positioner to be supplied and set for full signal pressure range. Signal pressure for auto variable fan shall be 0.2 to 1.0 kg/em2 (g) for zero flow to design flow unless specified otherwise. HP of motor to be selected based on the airflow at design pitch. Provide one I/P converter per item, unless specified otherwise. One volume booster shall be provided for each auto-variable fan. 723.17 Fan shall be selected so thatthe design under fouled condition satisfies the following (New) requirements with reference to fan performance curves: a) The design point shall lie on the performance curve for which fan blad angle is atleast Sdegrees and preferably 10 degrees less than the largest blade angle at which fans operate satisfactorily b) The design point shall not lie on the performance curve in proximity to the stall region which the manufacturer shall indicate in the fan curves. 723.18 Approved suppliers for fans are MOORE (UK. or USA), COFIMCO (Italy) and (New) HUDSON (USA). 723.19 Fan datasheet shall be forwarded to motor supplier and frame size shall be able to take (New) all torque/ loads/ thrust imposed by fan. Vendor shall submit necessary calculation after order. Vendor shall obtain and furnish the fan details from fan supplier as per the fan specification sheet including fan GD*value, torque vs speed curves, fan rpm etc. ‘Vendor shall also furnish the drive make, motor make and frame size. Based on this data, the drive details shall be developed by vendor and submitted to ETL. Vendor shall furnish these drive details to the drive supplier and get the confirmation from him on the adequacy of the drive to transmit the required power. Vendor shall furnish to the motor supplier the requirements of GD’, torque vs speed characteristics of fan and loads on motor from the drive affecting the selection of motor bearing, rating & frame size etc. Vendor shall ensure that the motor supplier has selected suitable motor as per motor specifications and datasheets for the conditions specified. Vendor shall obtain EIL approval for drive selection before procurement of the same. Format No, -00-0001-F1 Rev. 0 ‘Copyright EL Aiights reservedGENERAL SPECIFICATION —_ STANDARD SPECIFICATION No. S&ifetreT ey ENGNEERS SCAPEER@NOATRITED FORAIR COOLED HEAT 6-16-0071 Reva zn IIe SP NOAM ey ae 126 12.6.1 (Modified) 7212 72.721 (Addition) [Link].10 (New) 728 72.82 72.821 (Modified) 72.8.24 (Addition) 728.214 (New) 7282.15 (New) Vendor shall furnish design calculation for fan shaft and motor shaft for ELL review along with fan characteristic curves & motor datasheet. EIL comments, if any shall be fully complied with, and if required shaft size to be revised as per calculations without any cost and time implications. Fan Shafts And Bearings Fans shall be provided with QD bushes (minimum 10mm thickness) for attachment to fan shaft. Fan assemblies shall be fitted with their own thrust bearing situated at the drive end and a steady bearing at the outer end. The thrust bearing shall be capable of carrying any thrust loads transmitted by the driver. The thrust bearing inner race shall be mechanically locked by means of split rings to prevent accidental downward movement of shaft Fan Guards Removable galvanised stee! fan guard shall be provided on each fan for forced as well as induced draft units. A hinged door shall be provided on the fan guard of fan diameter greater than 2m, to attend to problems without removing entire fan guard. Electric Motor Drivers All electrical equipment shall be selected to suit the specified hazardous area classification, and the environment in which these have to operate. Area classification shall be as specified in the enquiry documents. Vendor shall provide plate guards made from galvanized steel plates on the motor assemblies to avoid ingress of rainwater and capable of withstanding washing down by water hose. Details of the guards shall be developed by the vendor and submitted for information. Start and stop switches shall be provided for ACHE motors. Emergency stop switch shall also be provided at the grade. Supply of switches shall be as per requisition/ bid document, Couplings and Power Transmissions Belt Drives Belt drives shall be high torque type, positive drive belts and shall be either HTD of Gates or Fenner; PG-GT of Gates; or TORQUE DRIVE PLUS of Fenner unless specified otherwise by the Purchaser. Belt drive tensioning means shall be adjustable without the need to remove the guard and without losing the alignment of the pulleys. Pulley wheel shall be of cast iron or steel. lll pulleys shall be dynamically balanced. Pulleys shall be thoroughly cleaned of rust, grease, and dirt and shall be shop coated. Belt drive pulleys shall be supplied by Vendors approved by belt supplier indicated in Para [Link].1 and shall be certified accordingly. Belts shall be heavy duty, oil resistant, antistatic, fire resistant and have neutral twist and shall be selected to suit the specified hazardous area classification. Belt drives shall not be used for offshore applications where only gear box shall be used. Format No. 6-00-0001-F1 Rev. 0 Copyight EI —Alvights reservedGENERAL SPECIFICATION STANDARD SPECIFICATION No. GRIT BS ENGINEERS, eaten ORR UMITED FOR AIR COOLED HEAT 6-18-0071 Rev.4 anes noree EXCHANGERS Page 11 of 22 729 (Modified) 72.10 72.10.15 (Addition) 72.10.17 (Modified) Vibration Cut-out Switches Vibration switch shall be inertia sensitive type with the vibration range suitable for the offered fan. Set point shall be adjustable throughout the range i.e. 0 to 100%, and shall be adjustable extemally without opening the switch housing. Switch shall have local as well as remote reset facility. Unless specified otherwise, switch shall provide two independent contacts i.e. either by one DPDT or two SPDT type each rated for 240V AC, SA and 110V DC, 0.5A. Switch enclosure shall be weatherproof to IP65. Unless otherwise specified, the housing shall also be certified flameproof and explosion proof suitable for specified area classification (IEC Zone I, gas group-IIC). In addition to the certification from authorised agencies like CMRI, FM, UL etc., the switch shall have the valid approval from statutory authorities of place of installation, which is CCOE in case of Indian installations. ‘The switch assembly shall have two cable entries as a minimum, each of 1/2" NPT size. In case vendor standard model does not support two entries, the switch housing shall be supplied with integrally mounted 3-way junction box. The junetion box shall be certified flameprooffexplosion proof meeting above requirements, Vibration switch shall be located at motor suspension beams as close to the motor as possible. Switches shall be readily accessible for re-setting from maintenance platform without any interference. Vibration cut-out switches shall be supplied from manufacturer of repute like Metrix or equivalent. In addition shall have proven references of operating satisfactorily for a period of minimum 4000 hours, in the similar type of application. Switches of prototype design or not having proven references shall not be supplied. Louvers Requirements for each pneumatic actuator: - (@) The positioner shall have mechanical pneumatic louver position feedback. For electrical or electronic control signals, a /P converter located at grade or local platform shall be used (b) Each change in signal shall give a proportional change in louver angle from fully closed to fully open repeatable to within S degrees for the same instrument air pressure signal, increasing or decreasing (©) There shall be a minimum of one actuator per bay, a minimum of one actuator per unit and minimum of one actuator per 15 m’ of louver surface area. (@ The actuators shall be suitable for an air supply pressure of 9.5 kg/em? (g) design, 7 kg/m? (g) normal and 2.5 kg/cm* (g) minimum. Purchaser will specify the exact air supply pressure. Any pressure reduction system on the supply air shall be in Vendor's scope. (©) The signal to actuator shall be 0.2 to 1.0 kg/em? (g) for fully closed to fully open position unless specified otherwise Where a single controller operates more than one actuator, isolation valves or other means shall be provided by Vendor to allow maintenance. Format No. 6:00-000-F1 Rev. 0 ‘Copyright EIL— AI ights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No, SGifetzTeT i ENGNEERS, eaten SRK UMITED FOR AIR COOLED HEAT 6-15-0071 Rev.4 SEIS SO noes ‘EXCHANGERS Parise 72.10.19 With loss of control air pressure the louver shall lock in at ‘fully open position’ unless (Modified) specified otherwise. [Link] Provision shall be kept for manual operation of all louvers. (Addition) 72.10.21 Provide legible indicator that indicates "angles of louver blade" and "open" or (Addition) "closed" position. [Link] Approved suppliers for louvers are CHITTOM (Calgary, Alberta, Canada), AIRCO (New) FIN (Holland) and GEI Hamon Industries (India). 13 Structural Design 73.11 For ACHE to be installed in India, the Codes for structural design shall be Indian (Addition) Standard unless specified otherwise. 73.15 For induced draft units, tube bundles shall be removable without requiring removal (Modified) of the platforms. For forced draft units, the bundles shall be removable without separately supporting or dismantling of the fan, plenum, or platforms and without requiring disturbance of the structure or adjacent bays. 7317 The structural design shall be done on a reputed software package based on stiffness (New) method of analysis e.g. STAAD PRO. Spliced joint is not permitted in columns and bracings. Beams of length 6 m and below shall not have a splice joint, however for length above 6 m one splice joint may be permitted subject to the following: i) Itisnot located at the point of maximum bending moment or shear. ii) It shall be full penetration weld duly DP tested. iii) Suitable size of connecting plate shall be welded on both sides of the web and preferably inside of flange. 73.18 In order to meet the vibration requirements it is preferred that the drive assembly (New) shall not be suspended from plenum but supported on the main column. 73.19 The structural assembly shall be done by bolting only so that the same can be casily (New) dismantled. However, structural modules like platforms and brackets may be pre- welded and bolted to columns at site. Steel structure shall be shop assembled (where possible) and match marked before despatch. 73.1.10 Piping support loads on structure, if specified by Purchaser, during detailed (New) engineering shall be considered by Vendor. 73.2 Vibration Testing 73.22 Vibration check shall be made on each motor (both driving and non-driving ends). (Addition) Motor base plate, fan or motor supporting beams, main structure columns with all machines running individually and also with all machines running together at their full load. Motor and bearing blocks shall also be checked for any abnormal heating by running all the machines for sufficient time. Vendor shall arrange necessary instrumentation for carrying out the vibration check; and shall carry out modifications, if required. 733 Structural Design Loads and Forces 1335 Thermal force reaction shall be based upon an effective coefficient of friction equal (Addition) to 0.3. Format No. 6:00-0007-F1 Rev. 0 Copyright EL ~All ights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No, sitet Sy ENGINEERS. eae SRN UMITED FOR AIR COOLED HEAT 6-15-0071 Rev.4 EGE tam eum EXCHANGERS Page 13.0122 733.7 For ACHE to be installed in India, Wind load shall be in accordance with IS-875 (Modified) unless stated otherwise. 1338 For ACHE to be installed in India, Earthquake forces shall be in accordance with (Modified) 15-1893 unless stated otherwise. 734 Plenums 73.4.6 Minimum thickness of steel sheet material used in construction of plenums shall be (Modified) be 2.8 mm (12 gauge) minimum, if the construction is transition type or straight box type. If it is inclined panel type as in case of induced draft then the minimum thickness shall be 3 mm for fan diameter up to 1.2 m (ie. 4 feet) and 4 mm for larger size of fans. 135 ‘Mechanical Access Facilities 13.51 ‘Access platform shall be provided on all four sides of a continuous bank of bundles, (Modified) Stair shall be provided on one side and ladder on the other side. 135.2 Maintenance platform shall be provided, unless specified otherwise, beneath each (Modified) drive assembly to provide access for removal and replacement of all drive components. An unobstructed platform area extending at least 900 mm in any plan dimension on all sides of the driver and drive components shall be provided. However such platforms shall not extend beyond the bay plan limits. Ladders shall be provided for access to induced fan for maintenance. Fan and motor assemblies shall be designed for remote lubrication from maintenance platform without shutting down the equipment, Suitable SS tubing ('4"diameter) shall be provided outside the fan and motor guards to permit lubrication of fan shaft bearing, and motor shaft bearing without shutting down the fans and/or motors. These connections shall be accessible from maintenance platform and terminated at one point. Vendor to develop detailed drawing, 1353 Platform for header access shall have minimum clear width of 900 mm. (Addition) 1354 Grating shall be provided. These shall be anti-skid type, removable with maximum (Addition) length of 1.5 m. 1359 Headroom clearance of 2200mm below motor suspension shalll be maintained. (New) 136 Lifting Devices 736.1 Positioning of lifting lugs shall be such that horizontal balance of bundles is obtained. (Addition) 14 Roofing (New) Roofing shall be provided if specified by Purchaser and covering shall be of asbestos sheet unless specified otherwise 8. MATERIALS 811 Al materials shall be new. Material of construction may be specified in the (Addition) requisition or data sheets in the general terms. Materials shall conform to relevant ASME specifications, or equivalent thereof. Format No, 6-00-0001-F1 Rev. 0 ‘Copyright EIL Al rights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No, SGifetezey GS ENGINEERS eaten SAN UMITED: FOR AIR COOLED HEAT 6-15-0071 Rev.4 cere EXCHANGERS age 14 of 22 812 Cast iron including nodular ductile iron shall not be used for pressure components, (Modified) in any service. 8.1.3/5 For painting and hot dip galvanizing refer clause 11.2 (Modified) 8.1.7 Pressure part plates having thickness 16 mm to $0 mm (both inclusive) shall be UST (New) as per ASTM A-435, Pressure part plates having thickness above 50 mm and all plates to be used for tube sheet and plug sheet shall be UST as per ASTM A-578 Level B. No laminations or inclusions shall be permitted. 818 Tubes (New) i. All the tubes shall be seamless and cold drawn. ii. Product analysis of tubes shall be carried out and reported. iii, CS tubes shall be in annealed condition. iv, SS tubes shall be in solution-annealed condition. v, Actual yield strength and maximum hardness of tubes should be checked at the time of procurement and it should be ensured that these are lower than those of tube sheet, in order to achieve a sound expanded tube-to-tube sheet joint. vi. Tubes shall be eddy current tested in addition to hydro test at the mill. For eddy current testing entire metal column of the tube shall be used. vii, Hydro test pressure shall be higher of actual exchanger pressure or as required as per ASME Section Il 819 All pipes shall be seamless and hot finished. dimensions and tolerances shall be in (New) accordance with ASME 36.10 or 36.19 as applicable per material specification. 8.1.10 CS or LTCS MATERIALS (Pressure Parts or Non-pressure parts welded to (New) pressure parts or parts wetted by the fluid in tube side) a) Carbon content shall not exceed 0.23%. b) Plates shall be in normalised condition. Pipes shall be SA 106 Gr. B or higher grade. LTCS pipes shall be SA 336 Gr. 1 or higher grade. ©) Use of SA 515 is not permitted. 4) CS plates above 50 mm thickness shall also meet the following additional requirements of SA-20: i) Vacuum treatment as per the supplementary requirement SI. If vacuum degassing is not reported in the test certificates then through thickness test as per SA 770 shall be conducted and minimum reduction in area of 35 % shall be ensured. ii) Charpy V-notch test as per supplementary requirement SS of specification SA-20, Material meant to be used for design temperatures warmer than 0°C, Format No. &:00-0007-F1 Rev. 0 Copyright EL ~All rights reservedGENERAL SPECIFICATION _ STANDARD SPECIFICATION No. SAAB foam coop near 6180071 Reva ROA LMT EXCHANGERS Eee 8.1.11 (New) 8.1.12 (ew) impact test shall be carried out at 0°C or MDMT whichever is lower and acceptance criteria for energy absorption shall be as per Table A2.15 of SA~ 20. Incase acceptance criteria is not available in SA-20, then applicable design code shall be referred unless otherwise specified in requisition. Orientation of test bar shall be transverse to rolling direction. ©) Unless specified otherwise in requisition or bid document, all CS materials specified as HIC tested shall meet the requirements of specification: 6-79-0012 or 6-79-0013 (as applicable). £) MDMT shall be taken as 0°C or the design temperature specified in drawing or datasheet whichever is lower, unless specified otherwise in design basis or datasheets or drawings. For low temperature service (0°C and colder), all CS and LTCS materials for pressure parts and attachments to pressure parts shall be charpy V-notch impact tested. Impact test temperature shall be lowest of ‘minimum ambient temperature, design temperature and MDMT. LAS MATERIALS (Pressure Parts or Non-pressure parts welded to pressure parts or parts wetted by the fluid in tube side) a) All LAS plates, pipes and forgings except C-Mo materials shall be in normalised and tempered conditions. b) For 14Cr- %4Mo materials the maximum room temperature tensile strength of all pressure containing components, materials and welds shall be 100000 psi. c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside of the tubes as per ASTM A-450. 4) For LAS plates above 50 mm thickness, following supplementary requirements of SA-20 shall also apply. i) Vacuum treatment as per supplementary requirement S1. If vacuum degassing is not reported in the test certificates then through thickness test as per SA 770 shall be conducted and minimum reduction in area of 35 % shall be ensured. ii) Charpy V-notch impact test as per supplementary requirement SS with: Test temperature: Minus 18 °C or MDMT. For SCr-'/;Mo ‘materials, test temperature shall be 0 °C. Acceptance Criteri As per Code Orientation of test bar: Transverse to the direction of rolling. ii) Bend test as per supplementary requirement S 14. SS MATERIALS (Pressure Parts or Non-pressure parts welded to pressure parts or parts wetted by the fluid in tube side) a) All SS material (300 series) shall be in the solution annealed and pickled condition, All stabilised grades of SS (i.e. SS 321, SS 347 etc.) shall be given stabilisation treatment in addition to solution annealing. For all stabilized grades of stainless steel materials soaking temperatures for stabilization heat treatment shall be 915°C + 10°C and soaking period shall be minimum of 4 hours (2 hours for thickness < 3.5mm). Format No, 8-00-0001-F1 Rev. 0 ‘Copyright EI — Alvights reservedPEs GENERAL SPECIFICATION _ STANDARD SPECIFICATION No. eae SAR hi FOR AIR COOLED HEAT 6-15-0071 Rev.4 TAOS noes gnmtornrt EXCHANGERS. Page 180122 8.1.13 (New) 8114 (New) 83 832 (Addition) 833 (Modified) 84 84.1 (Addition) 84.2 (Modified) 8.46 (Modified) b) All SS (300 series) plates shall be hot finished with No. 1 finish on both sides. Cold rolled plates, if permitted by requisition, shall have No.2B finish. ©) SS (300 series) materials shall be procured with the IGC test as per ASTM-A 262 (test shall be carried out, after the specified heat treatment and sensitisation per specification) with acceptable corrosion rate and practices as under: i) All services except nitric acid service - Practice E Specimen after exposure shall be bent as per mentioned in A 262 Practice E and shall be examined at a magnification of 200 X. The bent specimen shall be free of any cracks or grain droppings. The microscopic examination result shall be submitted to AI for approval ii) Nitric acid service- Practice C corrosion rate <635 micro-m per annum. d) All Duplex Stainless stee! materials shall meet the requirements of 6-81-0015. All forgings except nozzle flanges less than 10"NB shall be 100% UST as per ASTM. ‘A-388. Acceptance standard shall be as per AM 203.2 of ASME Sec VIII Div. 2. Al steel sections, plates and other miscellaneous structural steel materials shall be free from loose mill scales, rust as well as oil, mud, paint or other coatings. ‘The materials, construction specifications such as dimer , shape, weight, tolerances, testing etc. forall structural materials shall conform to IS 2062 Grade A or equivalent, unless specified otherwise. Louvers Louver bearings shalll be guaranteed for life and shall never require lubrication, Louver blades shall be made of corrosion-resistant material like aluminium. Louver frame shall be made of aluminium or steel. Steel louver frames shall be hot dip galvanized. Other Components Aluminium fin material shall not be less than 99.5% pure (SB 209 Alloy 1060) For offshore applications fin shall be to SB 209 Alloy 3003 Temper O. Fan blade material Fan blades shall be of aluminium alloy. Aluminium alloys for fan blades shall be selected to be resistant to stress corrosion cracking. Fan hub and blade material shall be non-sparking type. Copper content in aluminium blade should not exceed 0.4%. If specifically indicated by Purchaser, FRP blades may be used. FRP blades shall be used only for forced draft units. FRP blade fans shall meet all the requirements of EIL specification 6-15-0072. Solid metal gaskets for shoulder plugs shall be dead soft annealed. It is recommended that Soft Iron and Soft SS gaskets for plugs shall have hardness of minimum 15 BHN Jess than the material of plug and plug sheet. Hardness of Soft Iron gaskets shall not Format No, 8-00-0001-F'1 Rev. 0 ‘Copyright EL — Allights reservedSTANDARD SPECIFICATION No, SAGA ENGINEERS, GENERAL SPECIFICATION seats @ NIA TRATED FOR AIR COOLED HEAT 6-15-0071 Rev.s 8.4.7 (New) 84.8 (New) 9. 91d (Addition) 9.113 (Addition) OLS (New) [Link] (New) 912 9121 (Modified) 913 9133 (New) 93 93.3 93.3.0 (New) 93.4 93.4.0 (New) Peer nao EXCHANGERS Page 17 of 22 exceed 90 BHN and that of Soft SS gaskets shall not exceed 140 BHN. This shall be a hold point for Al Fan shaft shall be to either SA 105 or EN 24 (hardened and tempered and UST). CS pipes may be used for shaft housing. Bearing housing shall be to SA 105, Material for instrumentation valves and tubing shall be SS. All instrumentation shall be suitable for the hazardous area classification for electrical safety. FABRICATION All welding procedures shall be submitted to AI for approval. All welding shall be done with electrodes, fillers and fluxes of reputed make with proven reproducibility of results, Brand names shall be specifically approved by Al. Only low hydrogen electrodes shall be used for all CS pressure parts welds. Backing strips shall not be used. Repairs to base material and welds shall not be made without the approval of the Purchaser or AL Non-pressure attachments, such as lugs or structural steel supports, shall be attached to the pressure parts with a continuous weld. All double fillet welds in contact with hydrogen stream shall be vented. All LAS weld attachment to pressure retaining component shall be full penetration weld and ground to a smooth concave contour. Plug Headers Partition plates and stiffening plates to plugsheet and tubesheet welding shall be full penetration welds. Removable Cover Plate and Removable Bonnet Headers Stiffener plates 6 mm thickness shall be provided to stiffen the flanges of all flanged headers at a spacing of approximately 250 mm. These shall be spaced as not to interfere with the bolts and nozzles. Post Weld Heat Treatment For hydrogen, sour, amine and caustic service, minimum stress relieving temperature for CS or LAS materials shall be 620 °C. For PS materials, the temperature shall be as per Code. ‘Tube-to-tube sheet Joints Expanded tube-to-tube sheet joints Expanded tube-to-tube sheet joints shall be in accordance with EIL. specification no. 6-15-0004. Welded tube-to-tube sheet joints ‘Welded tube-to-tube sheet joints shall be in accordance with EIL specification no. 6-15-0003 for ferritic and austenitic materials. Seal welded joints are not acceptable. Format No. 6-00-000-F1 Rev. 0 ‘Copyright EIL— Al rights reserved