Shell and Tube Heat Exchangers.pdf

Polaris 

Engineering 

Standard 

SHELL AND TUBE HEAT EXCHANGERS 

610.1 

Rev.: 10 

Page: 1 of 30 

Date: 07/08/02 

TABLE OF CONTENTS PAGE 

I. SCOPE 3 

II. REFERENCES 3 

III. GENERAL REQUIREMENTS 4 

IV. SECTION 1 - GENERAL 5 

1.2 General 5 

V. SECTION 2 - PROPOSALS 6 

VI. SECTION 3 - DRAWINGS AND OTHER REQUIRED DATA 6 

3.1 Outline Drawings 6 

3.2 Information Required After Drawings are Reviewed 6 

3.3 Final Records 8 

VII. SECTION 4 - DESIGN 9 

4.1 Design Temperature 9 

4.2 Cladding for Corrosion Allowance 9 

4.3 Shell Supports 9 

4.4 Stationary Head (Channel) 11 

4.5 Floating Head 11 

4.6 Tube Bundle 12 

4.7 Nozzles and Other Connections 16 

4.8 Flanged External Girth Joints 20 

4.10 Gaskets 21 

4.11 Handling Devices 21 

VIII. SECTION 5 - MATERIALS 22 

5.1 General 22 

5.2 Gaskets 22 

5.3 Tubes 22

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TABLE OF CONTENTS PAGE 

IX. SECTION 6 - FABRICATION 23 

6.1 Shells 23 

6.2 Pass Partition Plates 23 

6.3 Connection Junctions 23 

6.5 Welding 23 

6.6 Heat Treatment 23 

6.8 Gasket Contact Surfaces Other than Nozzle Flange Facings 24 

6.10 Assembly 24 

X. SECTION 7 - INSPECTION AND TESTING 25 

7.1 Quality Assurance 25 

7.2 Quality Control 25 

7.3 Pressure Testing 26 

7.4 Nameplates and Stamping 27 

XI. SECTION 8 - PREPARATION FOR SHIPMENT 27 

XII. SECTION 9 - SUPPLEMENTAL REQUIREMENTS 28 

APPENDIX I: SHELL & TUBE EXCHANGER ANCHOR LOCATION 29 

APPENDIX II: PREPARATION OF ROLLED JOINTS IN TUBESHEETS > 4" (thick) 30

I. SCOPE 

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Engineering 


SHELL AND TUBE HEAT EXCHANGERS 

610.1 

Rev.: 10 

Page: 3 of 30 

A. This Standard, together with applicable Industry Standards, covers the minimum 

requirements for shell and tube exchangers used in general refinery and 

petrochemical services. 

B. This Standard does not cover double pipe exchangers, tank heaters, surface 

condensers (partially covered), and standard “off-the-shelf” accessory exchangers 

normally furnished with packaged equipment, such as small lube or seal flush 

coolers on rotating equipment. 

C. Where conflicts exist between this Engineering Standard and other Polaris 

Engineering Standards and/or applicable codes or regulations, the more stringent 

requirement shall govern. All conflicts shall be brought to client’s attention for 

resolution. client shall be the sole arbiter of any conflicts. 

II. REFERENCES 

This Polaris Standard is to be used in conjunction with the latest revision of the standards 

and codes listed below, unless specifically noted. The terminology “latest revision” shall 

be interpreted as the revision in effect at the time of contract award. This Polaris 

Standard may reference specific sections of some of these codes and standards. The 

revision of the codes and standards being referenced is noted below in parenthesis. This 

information is provided to identify the subject matter being referenced. Changes or 

exceptions made to the referenced code or standard shall apply to later revisions as 

applicable. 

A. American Petroleum Institute (API) Standards 

660 Shell-and-Tube Heat Exchangers for General Refinery Services 

(6 th Edition, 2001) 

B. Standards of the Tubular Exchanger Manufacturer's Association (TEMA) (8th 

Edition, 1999) 

C. Polaris Engineering Standards 

1. 140.10 General Welding, Fabrication and Inspection 

2. 150.1 Equipment Purchases, General Engineering Requirements 

3. 170.1 Positive Material Identification (Alloy Materials)

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4. 415.1 Design Loads for Structures and Equipment 

5. 500.1 Pressure Vessels - Carbon and Low Alloy Steel 

6. 500.2 Pressure Vessels - Alloy Lined Steel 

610.1 

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Page: 4 of 30 

7. 592.2.2 Standard Nozzle Details for Clad and Lined Vessels 

8. 592.2.1 Nameplate Bracket Details 

9. 596.1.7 Grounding Lug Details 

10. 1400.1 Painting Process Equipment and Piping 

11. 1500.2 Hydraulic Stud Torquing 

D. American Society of Mechanical Engineers (ASME) Standards: 

1. B16.5 Pipe Flanges and Flanged Fittings NPS ½ through NPS 24 

(1998) 

2. B16.20 Metallic Gaskets for Pipe Flanges, Ring-Joint, Spiral- 

Wound and Jacketed (2000) 

3. B16.47 Large Diameter Steel Flanges NPS 26 through NPS 60 

(1998) 

4. B46.1 Surface Texture (1995) 

5. Section I Rules for Construction of Power Boilers (2001) 

6. Section VIII Division 1 Rules for Construction of Pressure Vessels 

(2001) 

III. GENERAL REQUIREMENTS 

A. Shell and tube heat exchangers covered by this Standard shall be designed, 

fabricated, inspected and tested in accordance with API Standard 660 except as 

modified in this Standard, the Polaris Engineering Standards and individual data 

sheets listing specific operating conditions and special requirements, and TEMA. 

The order of precedence is: 

1. Data Sheet 

2. This Standard 

3. Polaris Engineering Standards 

4. API Standard 660 

5. TEMA R 

B. Paragraph numbers referenced in this standard refer to paragraph numbers

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in API Standard 660. Reference is made only to those paragraphs where 

an exception is taken, an option exercised, or supplementary information 

is added. Each paragraph is identified by the heading shown below which 

denotes what action has been taken regarding the subject matter of the 

corresponding paragraph of API Standard 660. 

HEADING ACTION 

Decision A decision has been made where required by the 

corresponding paragraph. 

Exception An exception has been made to the corresponding 

paragraph. Such exception does not invalidate the entire 

subparagraph, but only that portion of the paragraph to 

which the exception applies. 

Substitution A substitution has been made for the corresponding 

paragraph in its entirety. 

Modification An amplification, rewording, or addition has been made to 

the corresponding paragraph, but not a substitution 

invalidating the paragraph. 

New A new subparagraph, which does not appear in API 

Standard 660, which is to be inserted in numerical order in 

API Standard 660 adding supplemental requirements to the 

same main paragraph subject matter. 

Deletion A statement that is to be completely removed from the 

standard. 

IV. SECTION 1 - GENERAL 

1.2 General 

1.2.1 Modification - Exchangers shall conform to Class R requirements, of the 

TEMA Standards (latest edition and addenda). In addition ASME Section 

I of the ASME Code may be mandated in lieu of Section VIII, Division I 

when required. Where conflict occurs with regulatory and/or insurance 

agencies concerning full Section I stamping, it is incumbent on the Vendor 

to advise the Purchaser of the circumstances immediately.

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1.2. 4 Decision - All exchangers shall be ASME Code stamped and registered 

with the National Board of Boiler and Pressure Vessel Inspectors. 

V. SECTION 2 - PROPOSALS 

2.2.8. New - The vendor shall guarantee the exchanger against defective 

workmanship or materials, improper design, freedom from vibration either 

mechanical or acoustical, and failure to perform as specified at design 

conditions. The guarantee period shall be as stated in the Purchase Order 

Terms and Conditions. If the exchanger does not perform satisfactorily or 

defects occur during this period, the vendor shall make necessary repairs, 

alterations, or replacements at no cost to Polaris. If shipment or receipt of 

the completed exchanger is delayed by the purchaser or by factors outside 

the control of the vendor or purchaser, extension of the guarantee period 

shall be subject to negotiation with Polaris. 

VI. SECTION 3 - DRAWINGS AND OTHER REQUIRED DATA 

3.1 Outline Drawings 

3.1.1 Modification – Vendor shall submit drawings for approval as required by 

the purchase order. All drawings and other documentation shall be in 

English and shall be prepared using US customary units for all dimensions 

and data. Vendor shall furnish one reproducible copy of qualified welding 

procedures and other documents, required by Polaris Engineering 

Standard 140.10 for review and approval prior to start of fabrication. No 

welding shall be done prior to the client’s and/or Polaris’ written 

acceptance of the procedures. Vendor shall ensure that all sub-vendors are 

also in complete compliance with this standard. 

3.2 Information Required After Drawings Are Reviewed 

3.2.1 Modification - Vendor shall furnish certified outline drawings in 

accordance with the Purchase Order. 

3.2.3 Modification - Vendor shall furnish one reproducible copy of qualified 

welding procedures and other documents, required by Polaris Engineering 

Standard 140.10 for review and approval prior to start of fabrication. No 

welding shall be done prior to the client’s and/or Polaris’ written 

acceptance of the procedures. 

3.2.4 Modification - After receipt of Purchaser's comments on the outline 

drawings the Vendor must send calculations with detail drawings as 

described in Paragraph 3.2.5. Failure by the Vendor to include 

calculations with detail drawings can result in contract delay.

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3.2.5 Modification - Vendor shall prepare and submit, for review, one 

reproducible copy of calculations to accompany the detail approval 

drawings. They are to represent complete mechanical design. 

Calculations must have a cover sheet with the following information: 

a. Identification: Item number, purchase order number, Vendor's shop 

order number and project name and location. 

Where design calculations are computer generated, input data shall 

be included along with necessary explanatory notes for 

interpretation. Output data shall include the applicable formulas 

with the proper values shown as a part of those formulas along 

with the results. The exchanger fabricator is responsible for the 

accuracy of all computer programs used for the analysis. 

b. Design pressure and design temperature. 

c. Corrosion allowances. 

d. TEMA size and type. 

e. Number of passes 

f. Maximum allowable working pressure (hot and corroded) and 

limiting component 

g. Maximum allowable working pressure (new and cold) and limiting 

component 

Detailed calculations, for approval and record, are required for the design 

of all components and appurtenances of the exchanger. These shall 

include: 

a. Weight calculation: fabricated, operating, and full of water. 

b. Thickness of shell, head, tubesheets, etc. 

c. Compliance with Charpy test requirements per ASME code based 

on material, thickness and minimum design metal temperature 

(MDMT) 

d. Reinforcement requirements for nozzles, manways, etc. 

e. Saddle supports based on Zick analysis

3.3 Final Records 

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f. Wind and earthquake analysis 

610.1 

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g. Local stress analysis for external loads on nozzles and attachments. 

h. Lifting and tailing devices including their effects on the exchanger. 

i. Drawings of any required test rings shall be furnished. Drawings 

shall be submitted of the "code" nameplate and the supplementary 

nameplate. Information provided on the supplementary name plate 

will include the following: 

1) Exchanger Service and Item Number 

2) P.O. Number 

3) Maximum Allowable Working Pressure - MAWP (New 

and cold) and “shop test pressure”. 

4) Field Hydrostatic Test Pressures on each side based on 

MAWP (hot and corroded) 

5) Any test or operating limits such as differential pressure. 

6) Number, size and gauge of tubes, (Birmingham Wire Gage 

- BWG specified minimum or average wall), length, and 

square feet of surface area. 

7) Minimum design metal temperatures and specified vacuum 

service and temperature. 

8) If Post Weld Heat Treatment (PWHT), a warning should 

specify that the equipment is stress relieved and welding is 

not permitted. 

Modification - The Vendor shall maintain records of the following for at least five 

(5) years: 

(a) Certified material test reports or certificates of compliance. 

(b) Temperature-Recorder charts made during PWHT. 

(c) A complete set of radiographs and records as described in UA-51 of 

Section VIII of ASME Code; except for time retention.

VII. SECTION 4 - DESIGN 

4.1 Design Temperature 

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4.1.4 New - For design temperatures of 800 o F and higher, the design details for 

nozzles, supports and other attachments to the exchanger shall be free of 

high local stress concentrations. Design details using fillet welds shall be 

avoided unless welds are ground to a smooth radius. 

4.1.5 New- Unless otherwise specified exchangers shall be designed for full 

vacuum at 300 °F on shell and tube sides. 

4.2 Cladding for Corrosion Allowance. 

4.2.1 Modification - Unless indicated otherwise on the exchanger data sheet, the 

minimum thickness of applied liners or cladding shall be the greater of 1/8 

inch or the specified corrosion allowance 

4.2.2 Modification - Unless indicated otherwise on the exchanger data sheet, the 

minimum thickness of applied liners or cladding shall be the greater of 1/8 

inch or the specified corrosion allowance 

4.2.3 New - Shellside corrosion allowance shall be applied to tube bundle 

baffles. 

4.2.4 New - The specified minimum thickness of corrosion-resistant lining or 

cladding shall be applicable to all exposed surfaces including sides and 

bottom of partition grooves and other gaskets grooves. See Polaris 

Engineering Standard 592.2.2.. 

4.2.5 New - For sleeve lining or strip lining refer to Polaris Engineering 

Standard 500.2 and Section 5 of this Standard. 

4.3 Shell Supports 

4.3.1 Modification - The fixed shell support and anchor bolt size are to be 

designed to withstand a longitudinal force twice the bundle weight. 

Minimum anchor bolt size is 1 inch diameter. Refer to Appendix I, the 

saddles with slotted holes are to be at the saddles closest to the channel 

end. 

4.3.3 Modification - The lower shells of stacked removable-bundle heat 

exchangers shall be designed to carry the superimposed load without 

suffering distortion that could cause binding of the tube bundles. The 

corrosion allowance shall be deducted before investigating such external 

loading. Differential thermal expansion between shells shall be 

considered.

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4.3.6 New - Projection distance of upper and lower intermediate supports 

between stacked exchangers shall provide a minimum of 12" clearance 

between adjacent body flanges. 

4.3.7 New - All exchangers weighing 30,000 lbs. or more (full of water) shall 

have supports designed in accordance with L.P. Zick's paper "Stresses in 

Large Horizontal Cylindrical Pressure Vessels on Two Saddle Supports". 

The calculations shall be submitted for review. 

4.3.8 New - When stacked exchangers are used, the Fabricator shall investigate 

potential thermal expansion problems of the intermediate connecting 

nozzles and supports, caused by vertical and horizontal differential 

expansion forces. 

4.3.9 New - All exchangers with an I.D. of 36 inches or greater or weighing 

more than 30,000 lbs. full of water, shall have the shell evaluated for the 

effect caused by loading on support lugs. Calculations shall be made with 

the shell cylinder in the corroded condition and the exchanger full of 

water. The calculations shall be submitted for review. 

4.3.10 New - The Fabricator shall locate all welded joints on shop drawings 

submitted for approval. Longitudinal joints in adjacent shell courses shall 

be offset. 

4.3.11 New - Wherever possible, nozzles, reinforcing pads for nozzles, and other 

attachments shall not be located over longitudinal and circumferential 

weld joints. If this is unavoidable, approval must be obtained from the 

client and/or Polaris and the welded joint shall be ground smooth and 

radiographed for its entire covered length, plus 1 inch on each side. 

4.3.12 New - The maximum shell diameter shall be 44 inches I.D. unless 

otherwise approved by the client and/or Polaris. 

4.3.13 New - Exchanger supports shall be located per Appendix I, of this 

Standard, unless otherwise noted. 

4.3.14 New – Exchangers shall be designed for the wind load and seismic loads 

specified in Polaris Engineering Standard 415.1. 

4.4 Stationary Head (Channel) 

4.4.4 New - Unless otherwise specified channel covers shall be removable 

(flanged). 

4.4.5 New - Drain holes shall not be provided in pass partition plates unless 

approved by the client and/or Polaris. 

4.4.6 New - When using TEMA the maximum allowable flat channel cover

4.5 Floating Head 

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610.1 

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deflection for all diameters shall be 0.03125 inches. The thickness used 

for the channel cover will be the greater of the ASME Sect. VIII 

calculation or TEMA R. 

4.5.6 New - Floating head flanges and bolting shall be designed for the most 

severe design temperature (Internal and External). Metal temperatures 

may be used only if calculations for metal temperatures are submitted to 

the client and/or Polaris for review. 

4.5.7 New - Gasket seating area of pass ribs shall be considered in the design of 

floating head flanges. 

4.5.8 New - For internal flange bolting, when the shell material is higher alloy 

than carbon steel, the bolts and nuts shall be equal to or better than the 

shell material with regard to chemical and mechanical properties. 

4.5.9 New - Where a single pass floating head design is required and approved 

by the client and/or Polaris, a bellows type internal expansion joint shall 

be used for the floating head nozzle connection. 

4.5.9.1 New - The expansion joint shall be designed for full internal and 

external design pressure applied independently, and jointly. 

4.5.9.2 New - The expansion joint shall be designed to accommodate the 

maximum design temperature, including steam-out conditions. 

4.5.9.3 New - There shall be an internal sleeve welded to the upstream 

end. 

4.5.9.4 New - The expansion joint shall be "cold set" during assembly 

for the design movement so that it will be in the neutral position 

when at the normal operating temperature. 

4.5.9.5 New - Provide permanent external stiffening stays to prevent 

damage to the expansion joint during maintenance. 

4.5.9.6 New - Minimum design cycle life shall be 5000 cycles. 

4.5.10 New - The Vendor is expected to expose the floating tubesheet tube-joints 

during the testing process for verification of leakers or seepers. If the 

client has not ordered a test head, the Vendor shall use a head from 

inventory suitable for a low pressure test of at least 50 PSI. If the client 

has ordered a test head, a full test pressure is expected. Care should be 

taken by the Vendor to avoid work-hardening tube ends at this joint. The 

painting system on the test head shall be per Polaris Engineering Standard 

1400.1, system I.A. on all surfaces (internal and external). The gasket

4.6 Tube Bundle 

4.6.1 Tubes 

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surfaces shall be coated with a rust inhibitive. 

610.1 

Rev.: 10 


4.6.1.1 Substitution - The minimum tube outside diameter shall be 3/4 

inches. 

4.6.1.2 Substitution - 3/4 inch O.D. tubes and 1 inch O.D. tubes shall be 

used and if 12 BWG minimum wall or thicker is required due to 

frequent cleaning, such as residual oil service, then 1 inch O.D. is 

required. The required minimum values of tube diameter and 

wall thickness are as follows: 

Material 

Copper and 

Copper Alloys 

Carbon Steel, Aluminum 

and Aluminum Alloys 

Stainless Steel and Other 

Alloys 

Tube B.W.G. B.W.G. 

O.D. (Min. Wall) (Avg. Wall) Thickness 

3/4” 16 NA 0.065” 

1” 14 NA 0.083” 

3/4” NA 12 0.109” 

1” NA 10 0.134” 

3/4” NA 14 0.083” 

1” NA 14 0.083” 

Notes: 

a) Average wall tubes of one BWG thicker may be used in place of 

the specified minimum wall tubes. 

b) Tubes specified from Copper & Copper Alloys shall be 

minimum wall tubes. Tubes from all other materials shall be 

average wall tubes. 

c) Carbon Steel tubes must be seamless. Stainless Steel tubes may 

be seamless or autogenous fusion welded, with client’s approval. 

All other alloy tubes shall be seamless unless approved by client. 

4.6.1.5 New - Unless otherwise specified on the individual data sheet 

and approved by client, U-Bends in U-Tube bundles shall be in a 

vertical plane. 

4.6.1.6 New - The nominal length of tubes for removable bundles shall 

be a maximum of 20 feet. 

4.6.1.7. New - Where yield strengths of tubes used in an Exchanger shell 

exceed 10% variation due to heat or mill differences, the Vendor 

will advise the client and/or Polaris immediately and also provide 

an "as-built" tubesheet drawing locating the groups of tubes to 

assist the client in future re-rollings when confronted with such

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variation. In such instances, data requested on Appendix II will 

be completed by the Vendor and furnished to the client. 

4.6.1.8 New – Square pitch shall be used on exchangers in high fouling 

services with a shell side fouling factor over 0.002 Hr Ft 2 ºF/Btu. 

4.6.1.9 New – A minimum in-tube velocity based on liquid normal flow 

rate with a fouling factor of: 

4.6.2 Tube Sheets 

0.002 Hr Ft 2 ºF /Btu shall be minimum 3.3 fps 

0.003 Hr Ft 2 ºF /Btu shall be minimum 4 fps 

0.004 Hr Ft 2 ºF /Btu shall be minimum 4.5 fps 

4.6.2.4 Exception - The Fabricator is expected to calculate a full 

diameter tubesheet using formulae from ASME Section VIII, 

Division I, Paragraph UG-34, and TEMA 1999, Paragraph 

RCB7.134, and use the thicker tubesheet. Both calculations are 

to be shown on Vendor submittal. 

4.6.2.5 New - In the case of TEMA Type "B" stationary heads only; the 

stationary tubesheets on removable bundles shall be of "full 

diameter" design, with shoulder studs to retain the tube sheet to 

shell joint when bonnet is removed. Tubesheet extension shall 

be strong enough to allow hydrotesting of bundle on both sides 

when bolted separately to channel or shell. Allowable strength 

for this purpose only may be three-fourths of yield. 

4.6.2.5.1 Where solid stainless steel tube sheets are used with 

a design pressure over 600 psig, the requirement of 

4.6.2.5 may be modified with client’s approval to a 

design the tubesheet for a 300-450#+ differential 

pressure with a warning plate. This is typical for 

HDS combined feed service. 

4.6.2.6 New - Tubesheets for fixed tube sheet exchangers shall be 

designed per the requirements of TEMA with the following 

exception: The stress value of the tube sheet shall be based on 

the maximum design temperature of the shell side or tube side 

design temperature, whichever is greater. The modulus of 

elasticity and the mean coefficient of thermal expansion for the 

shell cylinder, tubes and tube sheet are to be based on calculated 

metal temperatures. 

4.6.2.7 New - Tubes in expanded joints shall be expanded for the full 

thickness of the tubesheet less 1/8 inch on the shellside face up to 

the tubesheet thickness of four tube diameters. If the tubesheet is

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thicker than four tube diameters, rolling shall cover a width of 

three tube diameters from the tubeside face and one tube 

diameter from the shellside face to within 1/8 inch of the 

shellside face. For thick tubesheets involving the latter 

procedure, the Fabricator will provide data to the client described 

in Appendix II. 

4.6.3 Transverse Baffles and Support Plates 

4.6.3.1 Modification - The shell side corrosion allowance shall be 

applied to the bundle baffles and support plates. TEMA Table 

RCB-4.41 (1999 Edition) thicknesses will be increased 

accordingly. 

4.6.3.3 New - Baffle material shall be the same pressure vessel quality 

plate as the shell. If the shell is clad or weld overlaid, the baffles 

will be the same material as the overlay. 

4.6.3.4 New - Baffle cuts of single-segmental baffles for sensible heat 

transfer service on the shell side shall be between 15% and 30% 

of the shell diameter. The first baffle shall be located as close to 

the tube sheets as possible, consistent with the specified baffle 

spacing. In this regard, the floating head support shall be as 

close to the floating tube sheet as possible. Baffles shall not be 

located between the inlet and outlet nozzle and the respective 

tube sheet unless a deflector baffle is provided to direct flow 

across the tube sheet. 

4.6.3.5 New - When maximum baffle cuts are required with U-tube 

construction having horizontal bends, consideration must be 

given to the addition of extra tie-rods on the vertical centerline to 

give added rigidity to the two bundle halves. 

4.6.3.6 New - Special consideration shall be given to ensure adequate 

support of tubes in inlet and outlet flow zones and of U-bends to 

prevent vibration. 

4.6.4 Impingement Protection 

4.6.4.1 Substitution - Where impingement protection of the tube bundle 

is required per TEMA RCB-4.61, a solid plate shall be used. 

Slotted or perforated plates shall not be used without the 

approval of client. Swaged inlet nozzles where the impingement 

plate is located in the nozzle shall not be used. Vapor belts may 

be used at the Manufacturer's option. 

4.6.4.2 Substitution – The diameter of impingement plates shall be equal 

to the nozzle I.D. plus 2 inches (minimum). It shall be attached

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to the tube bundle and may be any shape. There shall be at least 

1/16 inch clearance between the bottom of the plate and the top 

of the tubes. 

4.6.4.4 Substitution - The impingement plate shall not be less than 1/4 

inch nominal thickness for carbon or 3/16 inch nominal thickness 

for non-ferrous or high alloy materials. 

4.6.4.5 Modification - Impingement baffle plates shall be attached in a 

manner providing at least two parallel edges for support. 

4.6.5 Bypass Sealing Devices 

4.6.5.1 Substitution - Bypass sealing devices are required in peripheral 

bypass lanes when the radial distance from the outermost tube of 

the tube bundle and the shell inside diameter exceeds one inch. 

Internal bypass sealing devices are required in the bypass lane 

between the innermost tube row of U-tube bundles when the pass 

partition lane is not parallel to the baffle cut. The number of 

seals in each bypass lane shall be determined as follows: (Refer 

to API 660 Figure 1) 

1. A minimum of two pair of seals shall be located in the 

peripheral bypass lane with one pair at the top and one pair 

at the bottom of the tube bundle. 

2. A minimum of one pair of seals shall be located in the 

internal bypass lane. If the requirement for the minimum 

pairs cannot be physically met, single seals shall be located 

at the centerline of the tube bundle. 

3. Outermost seal plates in peripheral or internal bypass lanes 

shall be located between one and three inches from the 

edge of baffle cuts. 

4.6.5.4 Modification - Continuous tube lanes shall be maintained for all 

square and rotated square pitch arrays. 

4.6.5.8 New - Baffle window areas which are void of tubes shall be 

sealed with baffle "ears," except where "no-tubes-in window" 

designs are intentional. 

4.6.6 Bundle Skid Bars 

4.6.6.1 Modification - Bundles shall be provided with skid bars when 

bundle weight exceeds 12,000 lbs. As a minimum two bars, 1inch 

high by 2 inches wide, mounted 15 degrees each side of the 

bottom centerline shall be provided. The bars shall be adequate

4.7 Nozzles and Other Connections 

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to permit handling the bundle with a cable sling without 

damaging the tubes or baffles. Weld bars to intersecting baffles. 

4.7.1 Substitution - All nozzles must be flanged, raised face. The inlet and 

outlet stream connections shall be faced and drilled to the rating specified 

on the data sheets. 

a. Minimum nozzle size shall be 1 1/2” inch for exchanger design 

temperatures up to 750 ºF. 

b. Minimum nozzle size shall be 2 inches for exchanger design 

temperatures exceeding 750 ºF. 

c. With the exception of hill side or long projection nozzles, nozzle 

sizes 2 inches and under shall be long welding necks. 

d. The minimum exchanger nozzle rating for sizes 2 inches and less 

shall be 300 lbs. 

4.7.2 Substitution - Welded connections shall not be used. 

4.7.3 Substitution – Nonflanged or threaded connections shall not be used. All 

connections shall be flanged per paragraph 4.7.1. 

4.7.4.c. Deletion 

4.7.5 Substitution - Slip-on flanges and couplings are not allowed. N.P.T. 

connections are not allowed. 

4.7.6 Modification - Flanges 24 inches nominal size and smaller shall be in 

accordance with the dimensions and ratings of ASME B16.5. Unless 

approved by the client and/or Polaris, flange nominal sizes 26” to 60” 

inclusive, shall be in accordance with the dimensions and ratings of 

ASME B16.47 Series B(formerly API 605). Contractor shall verify that 

ASME B16.47 Series B flanges are suitable for the intended application. 

Other sizes shall be calculated in accordance with the applicable code and 

shall be approved by the client and/or Polaris. Lap-joint flanges require 

the client and/or Polaris approval. If allowed, the stub end shall be 

equipped with stops to prevent falling when bolting is loosened. 

4.7.9 Decision – Clearance shall be provided for stud tensioning in accordance 

with Polaris Engineering Standard 1500.2. 

4.7.11 New - The inner edge of all nozzles shall be rounded to 1/8 inch radius. 

All nozzles shall be flush with the inside surface of the exchanger unless 

noted otherwise.

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4.7.12 New - Nozzle necks larger than 10 inches may be made of built-up 

construction using formed plate necks and welding neck flanges when 

seamless pipe is not readily available and such construction is approved by 

the client and/or Polaris. Nozzle necks 10 inches and smaller shall be 

made with seamless pipe and welding neck flanges. In any sizes, long 

welding necks are preferred. 

4.7.13 New - The corrosion allowance for nozzles and manways shall be at least 

equal to the corrosion allowance specified for the exchanger side in which 

they are located. 

4.7.14 New - Each nozzle shall be adequately reinforced for new and cold as well 

as corroded condition in accordance with code requirements. Nozzle 

reinforcement shall not limit maximum new and cold maximum allowable 

working pressure. Reinforcement for 2 inch nozzles shall be checked for 

corroded condition. 

Each reinforcing pad or section thereof shall have at least one test hole 

tapped 1/4 inch NPT. The weld of each pad shall be given an air and soap 

solution test (5 psig minimum), in the presence of the client's Inspector 

before post weld heat treatment. After the test, the hole shall be filled with 

corrosion inhibiting grease. The hole shall not be welded or plugged. If 

the pad is fabricated in two parts the weld shall be oriented in the 

circumferential direction. All rectangular and square reinforcing pads 

shall have rounded corners with 3 inches minimum radius. 

4.7.15 New – Nozzle flange facings shall be machine finished as noted below for 

spiral-wound gaskets, and a fine serrated finish for smooth metal gaskets. 

The exchanger fabricator shall specify the type of finish to be furnished. 

Welding neck flanges shall have the same bore as the nozzle necks to 

which they are attached. 

4.7.16 New – All RF flanges shall have a flange surface finish range of 125 Ra 

minimum to 250 Ra maximum. Finishes shall be judged by visual 

comparison with AARH Standards, ASME B46.1. 

4.7.17 New - External nozzle bolting shall be supplied by the exchanger 

fabricator and shall be a minimum of ASTM A-193 Gr. B7 stud-bolts, 

complete with two ASTM A-194 Gr. 2H semi-finished oil-quenched 

heavy hex nuts each. For bolt metal temperatures over 800 °F, bolting 

shall conform to ASTM A-193 Gr. B16 stud-bolts with ASTM A-194 Gr. 

4 nuts. 

4.7.18 New - Gaskets shall be furnished as specified on the data sheets. 

Dimensions of raised face gaskets shall be in accordance with ASME 

B16.5. Flexitallic type "CG" (type "CGIU" for flanges over 24 inches 

diameter) or equal shall be used for all hydrocarbon services. All

Polaris 

Engineering 


610.1 

Rev.: 10 


gasketing and packing, including test gaskets, shall be commercial quality 

fabricated from asbestos-free material suitable for the process 

environment. The Fabricator shall ship additional gaskets, shipped 

separately with proper protection and identification, as follows: 

a. For nozzles sizes up to and including 24 inches diameter, ship one 

gasket new and unused for each nozzle having a cover. 

b. For nozzle sizes larger than 24 inches diameter, ship two gaskets, 

new and unused, for each nozzle having a cover. 

4.7.19 New - Kettles: Level control, level glass, alarm and shutdown device 

connections may be individual 1-1/2 inches (2 inches for over 750 °F 

design temperature) nozzles or on a bridle arrangement with 2 inch 

nozzles (the bridle arrangement is preferred); however, alarm and 

shutdown device connections shall not be combined on the same bridle 

with level and gauge glasses. 

4.7.20 New - On vertical exchangers: level glass, level control, alarm and 

shutdown device connections shall have their own individual connections. 

4.7.21 New - All level instrument connections shall be jig set. 

4.7.22 New - For alloy nozzles or alloy lined nozzles (the client and/or Polaris 

approval required prior to use) refer to Polaris Engineering Standard 

500.2, Pressure Vessels, Alloy-lined steel. 

4.7.23 New - All process nozzles of heat exchangers shall be provided with 

pressure and temperature connections as prescribed in TEMA R, B-10.32 

and RB-10.33. For stacked exchangers the instrument connections may be 

omitted from one of the two mating connections as per TEMA R, B-10.4. 

The connections shall have one (1) 1-inch and one (1) 1½ inch long weld 

neck flanged connection with blind flange, Flexitallic type stainless steel 

gasket and appropriate bolting provided. Pressure rating of these 

connections is to be consistent with the design of the heat exchanger, but 

in no event less than 300 lb. The projection of these nozzles shall be long 

enough to clear the insulation to allow for installation and removal of 

bolts. 

4.7.24 New - Process nozzles in the corroded condition shall be capable of 

withstanding the moments and forces in Table 1 below. The forces act as 

shown in TEMA Figure RGP-RCB-10.6 (1999 Edition). 

TABLE 1 - MAXIMUM ALLOWABLE NOZZLE LOADS

NOZZLE 

SIZE- 

INCHES 

Polaris 

Engineering 


FORCE 

POUNDS 

610.1 

Rev.: 10 


MOMENTS 

POUND-FEET 

P Vl Vc Mr Ml Mc 

3 600 600 600 600 600 600 

4 1000 1000 1000 1200 1000 1000 

6 1800 1500 1500 3000 2700 2700 

8 3000 2400 2400 6000 4500 4500 

10 4000 3000 3000 6000 5500 5000 

12 4500 4000 4000 6000 7000 6000 

14 5000 5000 5000 7000 8000 7000 

16 5800 5800 5800 7500 9000 8500 

18 6500 6500 6500 8300 9800 9300 

20 7000 7000 7000 9200 10500 10200 

24 7700 7700 7700 10500 12500 11900 

None of individual stresses (circumferential, longitudinal shear and 

combined stresses) may exceed 2.5 x Sa at nozzle pipe OD for nozzle 

without pads, or 1.0 x Sa at nozzle OD for nozzle with pad. 

4.7.25 Vents and drains are to be 1” RF LWN blinded conditions with a 300# 

minimum flange rating. For heavy oil services, fouling factor of 0.004 Hr 

Ft 2 ºF/Btu or higher, 1 1/2” drains shall be provided. 

4.8 Flanged External Girth Joints 

4.8.2 Substitution - Shell and channel girth flanges are to be of forged steel, 

weld neck type or hub type, faced for confined gaskets and have 150 lb. 

rating, or higher, and thru-bolt joint construction. Slip-on welding flanges 

shall not be used. 

4.8.7 Decision – Clearance shall be provided for stud tensioning in accordance 

with Polaris Engineering Standard 1500.2. 

4.8.8 New - All fabricated flanges shall conform to the requirements of 

Appendix 2 of the ASME Boiler and Pressure Vessel Code Section VIII, 

Division I. 

4.8.9 New - All pressure boundary forgings, except standard ASME flanges 

shall be ultrasonically examined in accordance with the ASME code,

4.10 Gaskets 

Section II, SA-388. 

Polaris 

Engineering 


610.1 

Rev.: 10 


4.10.1 Substitution - Gaskets shall be furnished as specified on the purchase 

requisition. Dimensions of raised face gaskets shall be in accordance with 

ASME B16.5, Appendix E. Flexitallic type ("CG" (type) "CGI" for 

nozzle flanges over 24 inches diameter) or equal packing, including test 

gaskets, shall be commercial quality fabricated from asbestos-free material 

suitable for the process environment. 

4.10.3 New - Internal floating head gaskets will be of double jacketed nonasbestos 

gaskets 

4.10.4 New - All solid metal gaskets and inner and outer compression -limiting 

rings of spiral-wound gaskets shall be made from a single piece of metal 

with no more than one weld. The thickness tolerances specified for the 

gasket shall also apply to the weld. 

4.10.5 New - Where spiral wound gaskets (flexitallic or equivalent) are used, and 

pass partitions are required, the gasket for the pass partition shall be a 

metal jacketed grafoil-filled strip of the same thickness as the girth gasket. 

The ends of the strip shall be pinched together and each end shall be 

welded to the spiral-wound gasket 

4.10.6 New - All carbon steel or low alloy gaskets containing welds must have 

the welds heat treated to remove hard spots. 

4.11 Handling Devices 

4.11.1 Modification - All lugs shall be completely seal welded to prevent 

corrosion behind lugs. Lifting lugs shall be provided on all channels, 

removable channel covers, floating head covers and removable shell 

covers. 

4.11.2 Modification - Attachment welds for lifting lugs that are an abutment, butt 

welded to the exchanger, shall be full penetration welds. 

4.11.5 New - Jack screws shall be provided to aid in loosening all heads, 

channels and channel covers. 

VIII. SECTION 5 - MATERIALS 

5.1 General 

5.1 Modification - Bolting - Minimum quality bolting for channel and girth flanges 

shall consist of continuously threaded bolts conforming to ASTM A193-B7 with 

nuts in accordance with ASTM A194-2H. Material for bolting in units with

Polaris 

Engineering 


610.1 

Rev.: 10 


design temperatures below -20 °F shall be selected from a suitable grade of 

ASTM A-320. 

5.1.5 New - Materials which are to be used for a pressure part, or are to be 

welded to a pressure part shall be selected from ASME Code section II 

part D when not noted on the data sheet. All materials that are to be used 

for a non-pressure part and are not welded to a pressure part shall meet the 

chemistry and mechanical properties of an equivalent ASME Section II 

part D material. The selected materials shall be clearly identified on the 

Vendor Drawings and MTR’s submitted. 

5.1.6 New - Use of any foreign materials requires prior approval of the client 

and/or Polaris. The Vendor's proposal shall clearly state if any foreign 

material is quoted and indicate names of foreign manufacturers. 

5.1.7 New - Welded non-pressure attachments to pressure parts shall be of the 

same material as the base material. For example, pass partition plates, 

lifting lugs, saddle pads. 

5.1.8 New - When killed carbon steel is specified in H2S service, then only 

killed carbon steel that does not contain aluminum shall be used. 

Aluminum killed steel is not acceptable. However traces of aluminum in 

the KCS is acceptable. Silicon killed (C.S.-SI killed) shall be specified 

and sulfur content limited to 0.008 per cent maximum. 

5.2 Gaskets 

5.3 Tubes 

5.3.3 New - Carbon Steel tubes must be seamless. Stainless Steel tubes may be 

seamless or autogenous fusion welded, with the client and/or Polaris 

approval. All other alloy tubes shall be seamless unless approved by the 

client and/or Polaris. 

IX. SECTION 6 - FABRICATION 

6.1 Shells 

6.1.3 Decision - Transverse Baffle-to-Shell clearances greater than indicated in 

TEMA Table RCB-4-.3 shall not be used. Any reduction in thickness of 

clad or overlay surfaces in order to meet TEMA tolerance is not permitted 

without written approval of the client and/or Polaris. 

6.1.4 New - When a difference in thickness exists between shell plates or plates 

and heads, the inside diameter shall be held. 

6.1.5 New - all bundles and other components are to be trial fit in the shop and 

hydrotested in the shell. Should this for any reason not be practical, a

6.2 Pass Partition Plates 

Polaris 

Engineering 


610.1 

Rev.: 10 


deviation must be obtained in writing from the client and/or Polaris. 

Substitution - Pass Partition Plates for forged or welded channels and floating 

heads shall be welded full length with full penetration welds. 

6.3 Connection Junctions 

Modification - Couplings are not permitted. Refer to paragraph 4.7.1 

6.5 Welding 

6.5.1 Substitution - Welds and welding procedures will conform to Polaris 

Engineering Standard 140.10. 

6.5.5 Deletion - Backing strips are not permitted. 

6.5.11 New - Fabrication involving welding shall not be sublet to others without 

prior approval of the client and/or Polaris. 

6.6 Heat Treatment 

6.6.2 Modification - Stress relieving the bend portion of U tubes is required for 

carbon steel, low-alloy steel and copper alloy. If specified, austenitic Ubends 

will be stress relieved in accordance with SA-688 Paragraph 7.2. 

6.6.3 Modification - The heat treated portion will extend 12 inches beyond the 

point of tangency. 

6.6.4 Modification - All carbon steel channels, bonnets and floating heads will 

be post-weld heat treated. 

6.6.5 Modification - PWHT procedures for clad or weld overlaid components, 

including temperatures, ramp and holding time shall be submitted for 

approval to the client and/or Polaris. 

6.6.7 Decision – PWHT is required when specified in Polaris Engineering 

Standard 140.10 or on the data sheet. Minimum and maximum PWHT 

temperatures and minimum holding time shall be as specified in Polaris 

Engineering Standard 140.10. 

6.6.8 New - All welding, including non-pressure attachments, must be 

completed prior to final heat treatment. 

6.6.9 New - Materials subject to post weld heat treatment (PWHT) shall be 

purchased with mill test reports indicating time necessary to allow at least 

one full PWHT cycle in addition to all planned PWHT.

Polaris 

Engineering 


6.8 Gasket Contact Surfaces Other than Nozzle Flange Facings 

6.8.2 Deletion 

6.8.3 Substitution 

6.10 Assembly 

610.1 

Rev.: 10 


All gasket surfaces will conform to the following flatness tolerances: 

a. Peripheral gasket surfaces: plus or minus 0.0025 inches (.064 mm). 

b. Cumulative flatness tolerance for two mating gasket surfaces: plus 

or minus .004 inches (0.10 mm). 

c. For exchangers without internal pass partition covers, the flatness 

tolerance on individual pass partition grooves shall be plus or 

minus .016 inches (0.40 mm). 

6.10.3 New - Fabricator is to stamp on all removable components using a metal 

punch, the item number, including the shell identifier letter, i.e., E-7001 D, 

to assist on re-assembly at turnaround. 

6.10.4 New - Tubes will project 1/8 inch (plus or minus 1/16") beyond the face of 

the tubesheet on horizontal exchangers. The 1999 TEMA Edition 

Paragraph RB-7.513 is to be followed only for vertical exchangers. 

6.10.5 New - In sulfur service the tube to tubesheet joint shall be strength welded 

in addition to a complete and fully retained rolled joint configuration. This 

shall be performed in the shop for all sulfur service equipment due to the 

difficulty to weld this type equipment after it has been in service. The 

following requirements shall apply: 

1. The joint design shall be such that the rolled joint is 100 % 

retaining and the strength weld is independently 100% retaining. 

2. The tube ends shall extend a minimum of 3/16 minus 1/16 inch 

plus up to the limits of TEMA RB-7.513. 

3. The detail of the cut for the strength weld shall be of a "J" bevel 

design. The depth of cut into the tubesheet shall be 0.125 inches or 

the thickness of the tube wall, which ever is greater. Alternate 

designs may be used if approved by client. 

4. Tubes shall be rolled into the tubesheet prior to strength welding. 

A preheat to 300ºF is required. The weld shall consist of two 

passes for tempering of the weld, followed by a light contact roll to

Polaris 

Engineering 


X. SECTION 7 - INSPECTION AND TESTING 

7.1 Quality Assurance 

put the weld in compression after the second pass. 

610.1 

Rev.: 10 


7.1.7 New - Client's Inspector or Representative will be consulted concerning 

repairs and shall, at his option, witness all repair work. 

7.2 Quality Control 

New - Requirements of Polaris Engineering Standard 140.10, General Welding, 

Fabrication and Inspection Specification, shall be followed. 

7.2.12 New - Exchangers having a design pressure of 500 psig or greater shall 

have all external attachment welds to pressure containing parts examined 

by the magnetic particle (DC prod. contact) or liquid penetrant method. 

This examination shall be performed after any required postweld heat 

treatment and hydrostatic testing. 

7.2.13 New - Complete radiography is required, regardless of material, thickness 

or service, of any welded seam that has been subjected to severe working 

(as defined in the Code Para. UG-79) after welding. Radiography shall be 

carried out after postweld heat treatment. 

7.3 Pressure Testing 

7.3.2 Exception - Exchangers and testing medium shall not be less than 70ºF 

during hydrostatic tests. Where the ductile to brittle transition temperature 

of the steel is known to be, or suspected of being 40ºF or higher, it is the 

Fabricator's responsibility to raise the temperature of the exchanger and 

testing medium to be at least 30ºF higher than the transition temperature. 

7.3.3 Substitution - All exchangers shall be hydrostatically tested at 1.3 times 

the maximum allowable working pressure for the new, uncorroded 

condition at 60ºF in accordance with the ASME Code Section VIII, 

Division I, section UG-99. This test is recorded on the nameplate as "shop 

test." The hydrostatic test will be maintained for a minimum of one hour 

and for no less than one hour per one inch of thickness. The thickness of 

the shell or channel barrels or heads will determine the length of the test 

period. When hydrostatic tests are performed either two indicating gages 

or one indicating and one recording gage shall be attached to the 

exchanger. 

A pressure of not less than 100% of the design pressure shall be 

maintained for sufficient time to determine if there are any leaks, but not 

less than one hour following the application of the hydrostatic test 

pressure per UG-99 of the code.

Polaris 

Engineering 


610.1 

Rev.: 10 


7.3.4 Substitution - Clean fresh water shall be the primary hydrostatic test 

medium unless use of a different medium is approved by the Client or 

Client's Representative. Hydrostatic testing of exchangers with austenitic 

stainless steel internals shall be done with potable quality water having a 

chloride content of not more than 50 ppm (parts per million). If chloride 

content is greater than 50 ppm, up to a maximum of 250 ppm, a sufficient 

quantity of sodium nitrate shall be added to provide a test medium of 0.5% 

by weight sodium nitrate solution. Water with a chloride content of 

greater than 250 ppm shall not be used for hydrotesting. Exchangers shall 

be dried thoroughly, immediately after draining, to prevent the possibility 

of evaporation and concentration of chlorides. Water may be blown out of 

packet by using clean and cold compressed air as alternate. 

7.3.11 New - After hydrotest the tubeside shall be air tested by pressuring the 

tubeside with air at 25 psig with the shell sloped, full of water, and the 

topmost shell nozzle open to observe air bubbles. Bubbles shall be cause 

for rejection. 

7.3.12 New - Welded attachments shall be tested with 15 psig air and soap 

solution before hydrotest of the exchanger. Vent holes shall remain open 

during hydrotest. Plug vent holes with stiff grease before shipment. 

7.4 Nameplates and Stampings 

7.4.2 Modification - The nameplate shall be made of austenitic stainless steel or 

monel and shall be seal welded to the nameplate bracket. The bracket 

shall be in accordance with Polaris Engineering Standard 592.2.1. 

7.4.3 Modification - In addition to the manufacturers serial number being 

stamped also stamp the Client's item number to the parts listed. Note in 

the case of multiple bundles, identify each, i.e., E-7306 C, stamped 

differently from E-7306 D. 

7.4.4 New - A supplemental nameplate shall be provided in order to 

accommodate Polaris required information in addition to code 

information, as follows: 

1. Exchanger service and item number 

2. P.O. Number 

3. M.A.W.P. (New and cold) and "shop test pressure" 

4. Field test pressure each side based on M.A.W.P. (hot and 

corroded) 

5. Any test of operating limits such as differential pressure. 

6. Tube material, number and size of tubes, BWG minimum or 

average wall, length, and square feet of surface area. 

7. Minimum design metal temperatures and specified vacuum service 

and temperature.

Polaris 

Engineering 


610.1 

Rev.: 10 


8. PWHT information and warning of no welding allowed after 

PWHT. 

9. Year built. 

All nameplate data shall be in US customary units. 

XI. SECTION 8 - PREPARATION FOR SHIPMENT 

8.1.3 Substitution - The following shall be applied to all exchangers: 

(a) All exchanger openings shall be made watertight. 

(b) All flanged connections which are not furnished with permanent 

blinds shall be covered with 1/4 inch minimum thickness, full 

diameter, steel plate covers. The covers shall be installed with 1/8 

inch thick cloth inserted neoprene gasket, and secured with full 

bolting. Covers need not be drilled for bolting. Covers need not 

be drilled for bolting larger than 3/4 inch diameter bolts and 

suitable cut washers if a seal can be maintained. 

(c) When the exchanger has surfaces made from austenitic materials 

the exchanger fabricator shall provide a positive nitrogen pressure 

of 3 psig minimum in the exchanger to provide protection against 

possible chloride attack by the sea water. Protection of outside 

surface is required also. Fabricator is invited to submit alternate 

methods for consideration. Vessels and exchangers shall be 

assumed to be deck cargo. All blinds shall be marked 

"NITROGEN PURGED - DO NOT OPEN." 

(d) Loose items shipped apart from the exchanger shall be crated for 

protection against physical damage and sealed in sheet plastic 

against water damage. 

(e) Protective measures shall be subject to inspection and rejection by 

client or client’s inspector. All costs occasioned by any rejection 

shall be for the account of the Fabricator. 

8.1.4 Modification - Machined surfaces and flange faces shall be covered with 

an acceptable rust preventive grease. 

8.1.10 New - Spare gaskets shall be enclosed in a plywood container marked with 

the client's purchase order number and equipment number and shipped 

with the exchanger. 

8.1.11 New - All exchangers shall be provided with a desiccant during shipment. 

All desiccant shall be removed by others at the jobsite. 

8.1.12 New

Polaris 

Engineering 


610.1 

Rev.: 10 


(a) Each exchanger shall be thoroughly cleaned inside and outside and 

shall be free from grease, weld spatter, scale, slag, rust and any 

other foreign material. 

(b) All uninsulated as well as insulated external surfaces of carbon 

steel and low alloy exchangers including saddles shall be 

sandblasted and primed in accordance with Polaris Engineering 

Standard 1400.1, unless noted otherwise. All nozzle faces shall be 

adequately protected from damage during sandblasting. 

XII. SECTION 9 - SUPPLEMENTAL REQUIREMENTS 

9.2 Design 

9.2.1 Modification - Refer to paragraphs 4.7 and 6.3 for acceptable connections.

Polaris 

Engineering 


APPENDIX I 

Shell and Tube Exchanger Anchor Location 

610.1 

Rev.: 10 


Note 1: Support spacing = 12 feet for 20 foot tube length (except Type “H” = 14 feet) 

Support spacing = 10 feet for 16 foot tube length (except Type “H” = 12 feet)

Fabricator Name: 

Polaris P.O. #: 

Polaris 

Engineering 


APPENDIX II 

610.1 

Rev.: 10 


PREPARATION OF ROLLED TUBE JOINTS IN TUBESHEETS >4" (thick) 

Item # and Service: 

Tube Hole Details 

(a) Tubesheet Material – Stationary ; Floating 

(Note 1) (b) Tube Material, Thickness, O.D., Gauge, Length 

(c) Tubesheet holes drilled by Radial or N.C. Machine - Describe 

(d) Per TEMA Table RCB-7.4.2 (1999 Edition) 

Minimum Permissible ligament width = 

Drill Drift Tolerance @ .0016 x Thickness of Tubesheet = 

% of Ligaments Violating Above Values = 

Identify on Tubesheet drawing holes outside this value No. = 

Tubesheet O.D. before rolling = Stationery Floating 

Tubesheet O.D. after rolling = Stationery Floating 

Tube Rolling Details: 

Lubricant Used 

Tube Rolling Equipment Used 

3 Roll, 5 Roll Expander? 

Torque Cut-Off, Roller Speed, 

Cleaner Used, Roll Angle Relative to Axis, 

Output Torque Calibrations Every Rollings 

Type of Dynamometer used 

Which Tubesheet was rolled first? 

Were Tubes "set" in second tubesheet? Tool Used

Polaris 

Engineering 


Apparent % Tube Wall Reduction = (I.D. - (Initial I.D. + Clearance)) x 100 

2 x (Measured unrolled Wall Thickness) 

Where I.D. = Measured Tube Inside Diameter in. 

O.D. = Measured Tube Outside Diameter in. 

Clearance = Measured Tubesheet Hole Diameter Ins minus O.D. of Tube 

Advise Average % Wall Reduction Per Above 

Tack & Rolling Sequence 

610.1 

Rev.: 10 


Provide a sketch similar to below giving tacking and rolling procedures used per tubesheet. 

The above form is to be completed by the Fabricator, witnessed by Inspector of the client and/or 

Polaris, and included with "as-built" drawing submittal to the client and/or Polaris. 

NOTE 1. Where yield strengths of tubes used in an Exchanger shell exceed 10% variation due to 

heat or mill differences, the Vendor will complete this form for each heat and provide an "asbuilt" 

tubesheet drawing locating the groups of tubes to assist the client in future re-rollings 

when confronted with such variation. 

NOTE 2. For background on data revealed by the above, reference is made to a McGraw Hill 

Book # ISBN 0-07-072281-1 "A working Guide to Shell & Tube Heat Exchangers" by Stanley 

Yokell, Chapter 4, Tube to Tubesheet Joints.

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