Installation Manual for S&T H-Ex(2022).indd

REV.3 : JAN. 01, 2022

www.dascohex.com

Shell & Tube

Heat Exchanger

OPERATING & MAINTENANCE MANUAL

CONTENTS

1. INTRODUCTION

1.1 DASCO’S MAIN TYPE

1.2 DESIGN & MANUFACTURE APPLICATION CAPACITY

2. STORAGE & LIFTING

2.1 RUST PREVENTION for INTERNAL (for VCI)

2.2 RUST PREVENTION for INTERNAL (for DRY AIR or N2

CHARGE)

2.3 RUST PREVENTION for OUTSIDE

2.4 LIFTING

3. SITE OR SHOP INSTALLATION

4. OPERATION

4.1 START-UP OPERATION

4.2 SHUT-DOWN OPERATION

5. MAINTENANCE

5.1 CHEMICAL CLEANING

5.2 PHYSICAL CLEANING

5.3 PRECAUTIONS FOR RE-ASSEMBLY

5.4 CORRECTIVE ACTION FOR TUBE DAMAGE

APPENDIX-1 SPECIFICATION OF SILICAGEL

APPENDIX-2 INSTALLATION PROCEDURE (As per TEMA Code)

APPENDIX-3 OPERATION PROCEDURE (As per TEMA Code)

APPENDIX-4 MAINTENANCE PROCEDURE (As per TEMA Code)

APPENDIX-5 TORQUE VALUE TABLE (DASCO’S STD)

* HOW TO CONTACT US

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

1. INTRODUCTION

1.2 DASCO’S MAIN TYPE

FRONT END STATIONARY HEAD TYPES SHELL TYPE REAR END HEAD TYPES

1.1 INTRODUCTION OF H/EX.

* Flow Diagram

* Nomenclature of Heat Exchanger Components

1. Shell

2. Shell - Flange

3. Reversing Cover - Head or End Plate

4. Reversing Cover Flange or Reversing

5. Rear Tubesheet

6. Channel - Head or End Plate

7. Channel Flange

8. Front Tubesheet

9. Partition Plate

10. Saddle

11. Shell Nozzle (In/Outlet)

12. Channel Nozzle (In/Outlet)

13. Tube

14. Baffle Plate

15. Earth Lug

1. A-TYPE 1. E-TYPE 1. M-TYPE

2. W-TYPE

3. S-TYPE

4. P-TYPE

2. B-TYPE 2. EU-TYPE

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

2. STORAGE & LIFTING

2.1 RUST PREVENTION for INTERNAL (for VCI)

a) Internal : shell & channel side [VCI-SILICAGEL (Refer to Appendix-1)]

b) VCI Condition : 3 months storage at site.

c) Re-fill the VCI every 3 months during storage

2.2 RUST PREVENTION for INTERNAL (for DRY AIR or N2 CHARGE)

a) Internal : Shell & Tube side [Dry air or Nitrogen gas charge (0.3 barG ~ 0.5 barG)]

b) Check the pressure gauge every 3 months during storage.

c) Re-fill the Nitrogen gas if the pressure is decreased over 0.1 barG.

2.3 RUST PREVENTION for OUTSIDE

a) Store under cover in a heated area (indoor) with dry, low humidity atmosphere.

b) When storage outdoor, it’s necessary to do extra packing to prevent entry of blowing dust, rain or snow, etc.

* Photo of

Caution

Mark

* Photo of

N2 Charge

* Photo of P.G

for N2 Charge

* Photo of

VCI Filling

1.3 DESIGN & MANUFACTURE APPLICATION CAPACITY (by TEMA RCB-1.11)

a) Inside diameters of 100 in. (2,540mm)

b) Product of nominal diameter, in.(mm) and design pressure, psi (kPa) of 100,000(17.5 x 10

)

c) A design pressure of 3,000 psi (20684 kPa)

The intent of these parameters is to limit the maximum shell wall thickness to approximately 3 in. (76mm),

and the maximum stud diameter to approximately 4 in. (102mm). Criteria contained in these Standards may

be applied to units which exceed the above parameters.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

* Photo of Crane-lifting * Photo of Fork-lifting

3. SITE OR SHOP INSTALLATION

a) First, set the fixed side of saddle base plate, and set the sliding side of saddle base plate.

* Type of Anchor bolt

* Photo of saddle base plate

Type

2.4 LIFTING

a) Check the total weight of heat exchanger on name plate before lifting.

b) Choose to lift by Crane or Fork-lift.

First, set

the Fixed side

Second, set

the sliding side

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

4.1 START-UP OPERATION

a) Open vent valve on cold fluid side, and flow the cold fluid to heat exchanger.

b) After flowing up, close the vent valve after discharging air.

c) After closing the vent valve, increase the pressure slowly not over than 5 barG per min.

d) After flowing up the hot fluid, increase the pressure slowly not over than 5 barG per min.

e) Check any leak on all connections.

4.2 SHUT-DOWN OPERATION

a) First, shut down the hot fluid line.

b) Next, shut down the cold fluid line.

4. OPERATION

* Photo of Flange Joint type

Slip-On

Raised Face Flat Face

LappedWelding Neck V-Joint

Ring type Joint

* Photo of Flange facing

b) Connect gas side nozzle flange. Connecting method is shown as following.

c) Connect cold fluid(water) side nozzle flange.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

b) Connect the crane to lifting lug on front cover and rear cover.

* Case of TEMA “A” type for front cover, refer to following procedure.

* Front cover removal

(for TEMA “A” type)

Cleaning

Pulling Pulling

Jack Bolts

5.1 CHEMICAL CLEANING

a) Select proper chemicals considering site condition, and remove the foreign materials.

* Proper chemicals shall be selected after discussing it with specialized company.

b) After that rinse inside with pressured clean water.

5.2 PHYSICAL CLEANING

5.2.1 SHELL SIDE CLEANING

a) Front cover & rear cover removal (for TEMA “B” type) is proceeded as following procedure.

5. MAINTENANCE

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

* Case of TEMA “S” and “W” type for rear cover, refer to following procedure.

c) Dis-assemble the covers loosening Jack bolts, set them on the wooden skid.

d) Clean the inside of front cover and rear cover with pressured clean water.

e) Clean the tube inside with wire brush.

Tube O.D

Brush O.D

Φ19.05 Φ22

Φ16 (Φ15.88) Φ18

Φ12 Φ14

Φ9 Φ12

* Rear cover removal (for TEMA “S” type)

* Rear cover removal (for TEMA “W” type)

BRUSH

FIN-TUBE

TUBESHEET

* Photo of Tube Cleaning by Bursh

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Pulling

SKID SKID

5.2.2 SHELL SIDE CLEANING

a) Front cover & rear cover removal (for TEMA “B” type) is proceeded as following procedure.

b) Connect the crane to lifting lug (Dowel lug) of tubesheet, and pull the tube bundle to outside.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

5.4 CORRECTIVE ACTION FOR TUBE DAMAGE

5.4.3 Tube replacement : Contact to Maker

5.3 PRECAUTIONS FOR RE-ASSEMBLY

a) Replace gaskets as new one, and be careful in any damage on gasket surface.

b) If any damage is detected on the peak of bolt or nut, replace new one.

c) At any cost, do the leak test.

d) Any leak can happen by long terms storage, or screw loosening phenomenon due to hot fluid operation.

Then, re-fasten all bolts with nuts in accordance with Appendix-3.

e) bolts/nuts shall be fastened with 40%, 80% and 100% of torque value per each size in accordance with

Appendix-5.

f) Touch-up the painting on any damage, and re-bolting area for rust prevention.

5.4.2 Double tubing5.4.1 Plugging

Tube O.D

A x B x L

OD 12 8 x 12 x 40

OD 15.88 or 16 11 x 16 x 40

OD 19.05 14 x 19 x 40

OD 25.4 18 x 25 x 40

Wood or

Brass

TUBE

TUBESHEET

Wood or

Brass

Hammering

and/or

Welding

Hammering

and/or

Welding

TUBE

TUBESHEET

Hard

Expanding

and/or

Seal(Strength)

Welding

Smaller

Tube

* PLUG SPEC.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

APPENDIX-1

Properties / Grade Unit SA SB

Particle Size

4 MESH RESIDUE

20 Max 2.0 - 4.0

4 - 8 MESH

80 Max G or B

8 MESH UNDER

0 -

Shape

Bead

Moisture Content

% 2.0 Max 2.0 Min

Bulk Density

g/ml 0.720 - 0.780 0.630 - 0.690

Surface Area

m²/g 500 Min 500 Min

True Specific Gravity

- 2.6

2% Suspension PH

- 2.6

Broken bead ratio

% 10 Max 10 Max

Pore Volume

ml/g 0.50

Average Pore Diameter

Broken Bead ratio in Water

% 2 Max 2 Max

Average Particle Strength

kg 10 Min 10 Min

Moisture Adsorption

Capacity

5 %

RH % 5

20 %

RH % 12.5

50 %

RH % 27.7

75 %

RH % 33.5

90 %

RH % 34.9

Remarks

Alumina SilicaGel

Brief

Silica and Alumina composite Gel (AL2O3, SiO2)

Use

Dehydration of gases (petroleum-symmetry), Remove of oil mist in compressed

of gas or air, Filtration of liquid air, Remove of F or F, Catalyst.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

APPENDIX-2

E-2 INSTALLATION OF HEAT EXCHANGERS

E-2.1 HEAT EXCHANGER SETTINGS

E-2.11

CLEARANCE FOR

DISMANTLING

For straight tube exchangers fitted with removable bundles, provide sufficient clearance at the

stationary head end to permit removal of the bundle from the shell and provide adequate space beyond

the rear head to permit removal of the shell cover and/or floating head cover.

For fixed tubesheet exchangers, provide sufficient clearance at one end to permit withdrawal and

replacement of the tubes, and enough space beyond the head at the opposite end to permit removal of

the bonnet or channel cover.

For U-tube heat exchangers, provide sufficient clearance at the stationary head end to permit

withdrawal of the tube bundle, or at the opposite end to permit removal of the shell.

E-2.12

FOUNDATIONS

Foundations must be adequate so that exchangers will not settle and impose excessive strains on the

exchanger. Foundation bolts should be set to allow for setting inaccuracies. In concrete footings, pipe

sleeves at least one size larger than bolt diameter slipped over the bolts and cast in place are best for

this purpose, as thy allow the bolt center to be adjusted after the foundation has set.

E-2.13

FOUNDATION BOLTS

Foundation bolts should be loosened at one end of the unit to allow free expansion of shells. Slotted

holes in supports are provided for this purpose.

E-2.14

LEVELING

Exchangers must be set level and square so that pipe connections may be made without forcing.

E-2.2 CLEANLINESS PROVISIONS

E-2.21

CONNECTION PROTECTORS

All exchanger openings should be inspected for foreign material. Protective plugs and covers should not

be removed until just prior to installation.

E-2.22

DIRT REMOVAL

The entire system should be clean before starting operation. Under some conditions, the use of

strainers in the piping may be required.

E-2.23

CLEANING FACILITIES

Convenient means should be provided for cleaning the unit as suggested under "Maintenance of Heat

Exchangers,"Paragraph E-4.

E-2.3 FITTINGS AND PIPING

E-2.31

BY-PASS VALVES

It may be desirable for purchaser to provide valves and by-passes in the piping system to permit

inspection and repairs.

E-2.32

TEST CONNECTIONS

When not integral with the exchanger nozzles, thermometer well and pressure gage connections

should be installed close to the exchanger in the inlet and outlet piping.

E-2.33

VENTS

Vent valves should be provided by purchaser so units can be purged to prevent vapor or gas binding.

Special consideration must be given to discharge of hazardous or toxic fluids.

E-2.34

DRAINS

Drains may discharge to atmosphere, if permissible, or into a vessel at lower pressure. They should not

be piped to a common closed manifold.

E-2.35

PULSATION AND

VIBRATION

In all installations, care should be taken to eliminate or minimize transmission of fluid pulsations and

mechanical vibrations to the heat exchangers.

E-2.36

SAFETY RELIEF

DEVICES

The ASME Code defines the requirements for safety relief devices. When specified by the purchaser,

the manufacturer will provide the necessary connections for the safety relief devices. The size and type

of the required connections will be specified by the purchaser. The purchaser will provide and install the

required relief devices.

- As per TEMA 2019 10th ED SECTION 4, Installation, Operation, and Maintenance -

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

APPENDIX-3

E-3 OPERATION OF HEAT EXCHANGERS

E-3.1

DESIGN AND OPERATING

CONDITIONS

Equipment must not be operated at conditions which exceed those specified on the name

plate(s).

E-3.2

OPERATING PROCEDURES

Before placing any exchanger in operation, reference should be made to the exchanger

drawings, specification sheet(s) and name plate(s) for any special instructions. Local safety

and health regulations must be considered. Improper start-up or shut-down sequences,

particularly of fixed tubesheet units, may cause leaking of tube-to-tubesheet and/or bolted

flanged joints.

E-3.21

START-UP OPERATION

Most exchangers with removable tube bundles may be placed in service by first establishing

circulation of the cold medium, followed by the gradual introduction of the hot medium. During start-

up all vent valves should be opened and left open until all passages have been purged of air and are

completely filled with fluid. For fixed tubesheet exchangers, fluids must be introduced in a manner to

minimize differential expansion between the shell and tubes.

E-3.22

SHUT-DOWN OPERATION

For exchangers with removable bundles, the units may be shut down by first gradually stopping the

flow of the hot medium and then stopping the flow of the cold medium. If it is necessary to stop the

flow of cold medium, the circulation of hot medium through the exchanger should also be stopped.

For fixed tubesheet exchangers, the unit must be shut down in a manner to minimize differential

expansion between shell and tubes. When shutting down the system, all units should be drained

completely when there is the possibility of freezing or corrosion damage. To guard against water

hammer, condensate should be drained from steam heaters and similar apparatus during start-up

or shut-down. To reduce water retention after drainage, the tube side of water cooled exchangers

should be blown out with air.

E-3.23

TEMPERATURE SHOCKS

Exchangers normally should not be subjected abrupt temperature fluctuations. Hot fluid

must not be suddenly introduced when the unit is cold, nor cold fluid suddenly introduced

when the unit is hot.

E-3.24

BOLTED JOINTS

Heat exchangers are pressure tested before leaving the manufacturer's shop in accordance

with ASME Code requirements. However, normal relaxing of the gasketed joints may occur

in the interval between testing in the manufacturer's shop and installation at the jobsite.

Therefore, all external bolted joints may require retightening after installation and, if

necessary, after the exchanger has reached operating temperature.

E-3.24.1

It is possible for the bolt stress to decrease after initial tightening, because of slow creep or

relaxation of the gasket, particularly in the case of the softer gasket materials.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

E-3.24.2

Excessive initial bolt stress can cause yielding of the bolt itself. This is especially likely with

bolts of small diameter or bolting having relatively low yield values such as stainless steels.

E-3.25 RECOMMENDED BOLT TIGHTENING PROCEDURE

E-3.25.1

All gasket joint surfaces shall be clean and free of oil or debris. If the gasket requires

assistance to be held in place for installation, grease shall not be used. Any tape applied

to a spiral wound gasket for shipping or assembly shall be removed prior to installing the

gasket. No tape, string or other object will be allowed to remain on the gasket surface once

assembly is complete.

E-3.25.2

Thoroughly clean threads, nut faces and the flange where nut face bears. If roughness, burrs

or any irregularity is present, dress it out to as smooth a surface as possible.

E-3.25.3

Thoroughly lubricate threads on studs, nuts and contacting surfaces on nuts and flange.

E-3.25.4

The joint shall ve snugged up squarely so the entire flange face bears uniformly on the

gasket.

E-3.25.5

"Tightening of the bolts shall be applied in at least three equally spaced increments using a

cross bolting pattern as illustrated in Figure E-3.25.5.

E-3.25.6

Once the cross bolting patterns are complete; a circular chase pattern shall be applied until

no nut rotation occurs.

START

- As per TEMA 2019 10th ED SECTION 4, Installation, Operation, and Maintenance -

FIGURE E-3.25.5

APPENDIX-3

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

APPENDIX-4

E-4. MAINTENANCE OF HEAT EXCHANGERS

E-4.1

INSPECTION OF UNIT

At regular intervals and as frequently as experience indicates, an examination should be made of the

interior and exterior condition of the unit. Neglect in keeping all tubes clean may result in complete

stoppage of flow through some tubes which could cause severe thermal strains, leaking tube joints,

or structural damage to other components. Sacrificial anodes, when provided, should be inspected to

determine whether they should be cleaned or replaced.

E-4.11

INDICATIONS OF

FOULING

Exchangers subject to fouling or scaling should be cleaned periodically. A light sludge or scale coating

on the tube greatly reduces its efficiency. A marked increase in pressure drop and/or reduction in

performance usually indicates cleaning is necessary. The unit should first be checked for air or vapor

binding to confirm that this is not the cause for the reduction in performance. Since the difficulty of

cleaning increases rapidly as the scale thickness or deposit increases, the intervals between cleanings

should not be excessive.

E-4.12

DISASSEMBLY FOR

INSPECTION OR

CLEANING

Before disassembly, the user must assure himself that the unit has been depressurized, vented and

drained, neutralized and/or purged of hazardous material.

To inspect the inside of the tubes and also make them accessible for cleaning, the following procedures

should be used:

(1) Stationary Head End

(a) Type A, C, D & N, remove cover only

(b) Type B, remove bonnet

(2) Rear Head End

(a) Type L, N & P, remove cover only

(b) Type M, remove bonnet

(d) Type W, remove channel cover or bonnet

E-4.13

LOCATING TUBE LEAKS

The following procedures may be used to locate perforated or split tubes and leaking joints between

tubes and tubesheets. In most cases, the entire front face of each tubesheet will be accessible for

inspection. The point where water escapes indicates a defective tube or tube-to-tubesheet joint.

(1) Units with removable channel cover: Remove channel cover and apply hydraulic pressure in the

shell.

(2) Units with bonnet type head: For fixed tubesheet units where tubesheets are an integral part of

the shell, remove bonnet and apply hydraulic pressure in the shell. For fixed tubesheet units where

tubesheets are not an integral part of the shell and for units with removable bundles, remove

bonnet, re-bolt tubesheet to shell or install test flange or gland, whichever is applicable, and apply

hydraulic pressure in the shell. See Figure E-4.13-1 for typical test flange and test gland.

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

E-4.13

LOCATING TUBE LEAKS

(3) Units with Type S or T floating head: Remove channel cover or bonnet, shell cover and floating head

cover. Install test ring and bolt in place with gasket and packing. Apply hydraulic pressure in the shell. A

typical test ring is shown in Figure E-4.13-2. When a test ring is not available it is possible to locate leaks

in the floating head end by removing the shell cover and applying hydraulic pressure in the tubes. Leaking

tube joints may then be located by sighting through the tube lanes. Care must be exercised when testing

partially assembled exchangers to prevent over extension of expansion joints or overloading of tubes

and/or tube-to-tubesheet joints.

(4) Hydrostatic test should be performed so that the temperature of the metal is over 60 F

(16 C) unless the materials of construction have a lower nil-ductility transition temperature.

E-4.2

TUBE BUNDLE

REMOVAL AND

HANDLING

To avoid possible damage during removal of a tube bundle from a shell, a pulling device should be

attached to eyebolts screwed into the tubesheet. If the tubesheet does not have tapped holes for

eyebolts, steel rods or cables inserted throught tubes and attached to bearing plates may be used.

The bundle should be supported on the tube baffles, supports or tubesheets to prevent damage to the

tubes.

E-4.3 CLEANING TUBE BUNDLES

E-4.31

CLEANING METHODS

The heat transfer surfaces of heat exchangers should be kept reasonably clean to assure satisfactory

performance. Convenient means for cleaning should be made available.

Heat exchangers may be cleaned by either chemical or mechanical methods. The method selected

must be the choice of the operator of the plant and will depend on the type of deposit and the facilities

available in the plant. Following are several cleaning procedures that may be considered:

(1) Circulating hot wash oil or light distillate through tubes or shell at high velocity may effectively remove

sludge or similar soft deposits.

(2) Some salt deposits may be washed out by circulating hot fresh water.

(3) Commercial cleaning compounds are available for removing sludge or scale provided hot wash oil or

water is not available or does not give satisfactory results.

(4) High pressure water jet cleaning.

(5) Scrapers, rotating wire brushes, and other mechanical means for removing hard scale, coke, or other

deposits.

(6) Employ services of a qualified organization that provides cleaning services. These organizations will

check the nature of the deposits to be removed, furnish proper solvents and/or acid solutions containing

inhibitors, and provide equipment and personnel for a complete cleaning job.

APPENDIX-4

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

E-4.32

CLEANING

PRECAUTIONS

(1) Tubes should not be cleaned by blowing through individual tubes since this heats the tube and may

result in severe expansion strain, deformation of the tube, or loosening of the tube-to-tubesheet joint.

(2) When mechanically cleaning a tube bundle, care should be exercised to avoid damaging the tubes.

(3) Cleaning compounds must be compatible with the metallurgy of the exchanger.

E-4.4

TUBE EXPANDING

A suitable tube expander should be used to tighten a leaking tube joint. Care should be taken to ensure

that tubes are not over expanded.

E-4.5

GASKET REPLACEMENT

Gaskets and gasket surfaces should be thoroughly cleaned and should be free of scratches and other

defects. Gaskets should be properly positioned before attempting to retighten bolts. It is recommended

that when a heat exchanger is dismantled for any cause, it be reassembled with new gaskets. This will

tend to prevent future leaks and/or damage to the gasket seating surfaces of the heat exchanger.

Composition gaskets become dried out and brittle so that they do not always provide an effective seal

when reused. Metal or metal jacketed gaskets, when compressed initially, flow to match their contact

surfaces. In so doing they are work hardened and, if reused, may provide an imperfect seal or result in

deformation and damage to the gasket contact surfaces of the exchanger.

Bolted joints and flanges are designed for use with the particular type of gasket specified. Substitution of

a gasket of different construction or improper dimensions may result in leakage and damage to gasket

surfaces. Therefore, any gasket substitutions should be of compatible design. Any leakage at a gasketed

joint should be rectified and not permitted to persist as it may result in damage to the gasket surfaces.

Metal Jacketed type gaskets are widely used. When these are used with a tongue and groove joint

without a nubbin, the gasket should be installed so that the tongue bears on the seamless side of the

gasket jacket. When a nubbin is used, the nubbin should bear on the seamless side.

E-4.6

DIAPHRAGM

INSTALLATION

PROCEDURE

(1) Position diaphragm and tighten to remove all voids between diaphragm and component to which it

will be welded. This may be accomplished by bolting the cover in place, by a series of clamps or any other

means that guarantees that the diaphragm will not move during final bolt-up and crack the weld.

(2) Make the diaphragm to component weld and liquid penetrant inspect.

(3) Install cover and tighten studs to required torque or tension.

(4) Liquid penetrant inspect weld again after tightening studs.

E-4.7

SPARE AND

REPLACEMENT PARTS

The procurement of spare or replacement parts from the manufacturer will be facilitated if the correct

name for the part, as shown in Section 1, Table N-2, of these Standards is given, together with the serial

number, type, size, and other information from the name plate. Replacement parts should be purchased

from the original manufacturer.

E-4.8

PLUGGING OF TUBES

In U-tube heat exchangers, and other exchanger of special design, it may not be feasible to remove

and replace defective tubes. Defective tube may be plugged using commercially available tapered plugs

with ferrules or tapered only plugs which may or may not be seal welded. Excessive tube plugging may

result in reduced thermal performance, higher pressure drop, and/or mechanical damage. It is the user's

responsibility to remove plugs and neutralize the bundle prior to sending it to a shop for repairs.

- As per TEMA 2019 10th ED SECTION 4, Installation, Operation, and Maintenance -

APPENDIX-4

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Nut type

Hex. Nuts

(ANSI B 18.2.4.2M)

Heavy Hex. Nuts

(ANSI B 18.2.4.6M)

Thread Designation

(Metric coarse)

Joints without

washers

Joints with

washers

Joints without

washers

Joints with

washers

min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm)

M8 x 1.25P

14 20 16 23 - - - -

M10 x 1.50P

28 40 32 46 - - - -

M12 x 1.75P

47 66 54 76 49 69 56 79

M16 x 2.00P

111 156 128 179 116 163 133 187

M20 x 2.50P

215 301 247 346 226 316 260 363

M22 x 2.50P

297 415 342 477 300 420 345 483

M24 x 3.00P

370 518 426 596 389 545 447 627

M27 x 3.00P

538 753 619 866 563 788 647 906

M30 x 3.00P

750 1049 863 1206 775 1085 891 1248

M36 x 3.00P

1317 1843 1515 2119 1364 1910 1569 2197

M42 x 3.00P

- - - - 2194 3071 2523 3532

M48 x 3.00P

- - - - 3304 4626 3800 5320

M56 x 3.00P

- - - - 5209 7293 5990 8387

M64 x 3.00P

- - - - 7729 10821 8888 12444

M72 x 3.00P

- - - - 10950 15330 12593 17630

APPENDIX-5

1. TIGHTENING TORQUE (for SA193-B7 / Metric Coarse)

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Nut type

Hex. Nuts

(ANSI B 18.2.4.2M)

Heavy Hex. Nuts

(ANSI B 18.2.4.6M)

Thread Designation

(Metric coarse)

Joints without

washers

Joints with

washers

Joints without

washers

Joints with

washers

min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm)

M8 x 1.25P

14 19 16 22 - - - -

M10 x 1.50P

27 38 31 44 - - - -

M12 x 1.75P

45 63 52 72 47 65 54 75

M16 x 2.00P

106 148 122 170 111 155 128 178

M20 x 2.50P

164 229 189 263 172 240 198 276

M22 x 2.50P

225 315 259 362 228 319 262 367

M24 x 3.00P

281 393 323 452 295 413 339 475

M27 x 3.00P

334 467 384 537 350 489 403 562

M30 x 3.00P

466 652 536 750 481 674 553 775

M36 x 3.00P

627 877 721 1009 650 909 748 1045

M42 x 3.00P

- - - - - - - -

M48 x 3.00P

- - - - - - - -

M56 x 3.00P

- - - - - - - -

M64 x 3.00P

- - - - - - - -

M72 x 3.00P

- - - - - - - -

APPENDIX-5

2. TIGHTENING TORQUE (for SA193-B8-2 / Metric Coarse)

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Nut type

Hex. Nuts

(ANSI B 18.2.4.2M)

Heavy Hex. Nuts

(ANSI B 18.2.4.6M)

Thread Designation

(Metric coarse)

Joints without

washers

Joints with

washers

Joints without

washers

Joints with

washers

min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm)

M8 x 1.25P

13 18 15 18 - - - -

M10 x 1.50P

26 36 30 41 - - - -

M12 x 1.75P

43 60 49 69 44 62 56 79

M16 x 2.00P

101 141 116 162 105 147 133 187

M20 x 2.50P

164 229 189 263 172 240 260 363

M22 x 2.50P

225 315 259 362 228 319 345 483

M24 x 3.00P

281 393 323 452 295 413 447 627

M27 x 3.00P

334 467 384 537 350 489 647 906

M30 x 3.00P

466 652 536 750 481 674 891 1248

M36 x 3.00P

627 877 940 1316 650 909 1569 2197

M42 x 3.00P

- - - - - - - -

M48 x 3.00P

- - - - - - - -

M56 x 3.00P

- - - - - - - -

M64 x 3.00P

- - - - - - - -

M72 x 3.00P

- - - - - - - -

3. TIGHTENING TORQUE (for SA193-B8M-2 / Metric Coarse)

APPENDIX-5

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Nut type

Hex. Nuts

(ANSI B 18.2.2.2)

Heavy Hex. Nuts

(ANSI B 18.2.2.2)

Thread Designation

(Unified coarse)

Joints without

washers

Joints with

washers

Joints without

washers

Joints with

washers

min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm)

1/2 x 13UNC

54 76 62 87 57 80 66 92

5/8 x 11UNC

106 148 122 170 111 155 128 178

3/4 x 10UNC

185 259 213 298 192 269 221 309

7/8 x 9UNC

294 412 338 474 305 426 351 490

1 x 8UNC

438 613 504 705 452 632 520 727

1 1/8 x 8UNC

635 889 730 1022 653 914 751 1051

1 1/4 x 8UNC

883 1236 1015 1421 905 1267 1041 1457

1 3/8 x 8UNC

1185 1659 1363 1908 1213 1698 1395 1953

1 1/2 x 8UNC

1549 2168 1781 2493 1583 2215 1820 2547

1 5/8 x 8UNC

- - - - 2024 2834 2328 3259

1 3/4 x 8UNC

- - - - 2540 3556 2921 4089

1 7/8 x 8UNC

- - - - 3132 4385 3602 5043

2 x 8UNC

- - - - 3809 5333 4380 6133

2 1/4 x 8UNC

- - - - 5456 7638 6274 8784

2 1/2 x 8UNC

- - - - 7501 10501 8626 12076

APPENDIX-5

4. TIGHTENING TORQUE (for SA193-B7 / Unified Coarse)

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Nut type

Hex. Nuts

(ANSI B 18.2.2.2)

Heavy Hex. Nuts

(ANSI B 18.2.2.2)

Thread Designation

(Unified coarse)

Joints without

washers

Joints with

washers

Joints without

washers

Joints with

washers

min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm)

1/2 x 13UNC

52 72 60 83 55 76 63 87

5/8 x 11UNC

101 141 116 162 106 148 122 170

3/4 x 10UNC

176 247 202 284 183 256 210 294

7/8 x 9UNC

223 313 256 360 231 324 266 373

1 x 8UNC

333 465 383 535 343 480 394 552

1 1/8 x 8UNC

395 552 454 635 405 567 466 652

1 1/4 x 8UNC

548 767 630 882 562 787 646 905

1 3/8 x 8UNC

564 790 649 909 577 808 664 929

1 1/2 x 8UNC

737 1032 848 1187 753 1054 866 1212

1 5/8 x 8UNC

- - - - - - - -

1 3/4 x 8UNC

- - - - - - - -

1 7/8 x 8UNC

- - - - - - - -

2 x 8UNC

- - - - - - - -

2 1/4 x 8UNC

- - - - - - - -

2 1/2 x 8UNC

- - - - - - - -

5. TIGHTENING TORQUE (for SA193-B8-2 / Unified Coarse)

APPENDIX-5

OPERATING & MAINTENANCE MANUAL _ Shell & Tube Heat Exchanger

Nut type

Hex. Nuts

(ANSI B 18.2.2.2)

Heavy Hex. Nuts

(ANSI B 18.2.2.2)

Thread Designation

(Unified coarse)

Joints without

washers

Joints with

washers

Joints without

washers

Joints with

washers

min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm) min.(Nm) max.(Nm)

1/2 x 13UNC

49 68 56 78 52 72 60 83

5/8 x 11UNC

96 134 110 154 100 140 115 161

3/4 x 10UNC

167 234 192 269 174 243 200 279

7/8 x 9UNC

223 313 256 360 231 324 266 373

1 x 8UNC

333 465 383 535 343 480 394 552

1 1/8 x 8UNC

395 552 454 635 405 567 466 652

1 1/4 x 8UNC

548 767 630 882 562 787 646 905

1 3/8 x 8UNC

564 790 649 909 577 808 664 929

1 1/2 x 8UNC

737 1032 917 1187 753 1054 866 1212

1 5/8 x 8UNC

- - - - - - - -

1 3/4 x 8UNC

- - - - - - - -

1 7/8 x 8UNC

- - - - - - - -

2 x 8UNC

- - - - - - - -

2 1/4 x 8UNC

- - - - - - - -

2 1/2 x 8UNC

- - - - - - - -

APPENDIX-5

6. TIGHTENING TORQUE (for SA193-B8M-2 / Unified Coarse)

600

105

104

600

102

Noksansandan

Sasang-gu

Gimhae-si

Docheon-myeon

Changnyeong-gun

Gangseo-gu

Gimhae

International

Airpport

DASCO 1 Factory DASCO 2 Factory

GYEONGSANGNAM-DO

2F1F

BUSAN

DYNAMIC & SPECIAL COMPANY

Head ofce 33, Noksansandan 17-ro 78beon-gil, Gangseo-gu, Busan, Korea

and factory T. 82.51.973.4895 E-mail: [email protected] http://www.dascohex.com

Factory 2 124, Noksansandan 27-ro, Gangseo-gu, Busan, Korea

Hi Air Korea BLDG 1F, 10, Sasang-ro 181 beon-gil, Sasang-gu, Busan, Korea

T. 82.51.715.9981 E-mail: hs@heatsolution.co.kr