Welded Plate-Bloc Heat Exchangers - Application, Design and Fabrication

DEP SPECIFICATION
WELDED PLATE-BLOC HEAT EXCHANGERS –

APPLICATION, DESIGN AND FABRICATION
DEP 31.21.01.13-Gen.
February 2012
(Amendment A01 has been incorporated – February 2013)
ECCN EAR99
DESIGN AND ENGINEERING PRACTICE
© 2012 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.
This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Part 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Part 744)
ECCN EAR99 DEP 31.21.01.13-Gen.
February 2012
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
February 2012
Page 3
TABLE OF CONTENTS
PART I INTRODUCTION ........................................................................................................ 6
1.1 SCOPE........................................................................................................................ 6
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 6
1.3 DEFINITIONS ............................................................................................................. 6
1.4 CROSS-REFERENCES ............................................................................................. 7
1.5 SUMMARY OF CHANGES ......................................................................................... 7
1.6 COMMENTS ON THIS DEP ....................................................................................... 7
1.7 DUAL UNITS ............................................................................................................... 8
PART II SELECTION AND APPLICATION ............................................................................. 9
1. THERMAL AND HYDRAULIC DESIGN CONSIDERATIONS................................... 9
1.1 SCOPE........................................................................................................................ 9
1.2 TEMPERATURE AND PRESSURE LIMITATIONS.................................................... 9
1.3 SIZE LIMITATIONS .................................................................................................... 9
1.4 FLOW RATE ............................................................................................................... 9
1.5 MINIMUM TEMPERATURE APPROACH .................................................................. 9
1.6 MAXIMUM TEMPERATURE DIFFERENTIAL ............................................................ 9
1.7 THERMAL FATIGUE .................................................................................................. 9
1.8 PERFORMANCE MONITORING.............................................................................. 10
1.9 CORROSION ............................................................................................................ 10
1.10 PARTICULATES ....................................................................................................... 10
1.11 FOULING .................................................................................................................. 10
1.12 FLUID VELOCITIES ................................................................................................. 11
1.13 DEPRESSURISATION ............................................................................................. 11
2. MECHANICAL DESIGN CONSIDERATIONS ......................................................... 11
2.1 GENERAL ................................................................................................................. 11
2.2 DESIGN PRESSURE AND TEMPERATURE .......................................................... 11
2.3 LOAD CASES ........................................................................................................... 11
2.4 PRESSURE AND THERMAL CYCLING .................................................................. 11
2.5 STRUCTURAL INTEGRITY...................................................................................... 11
2.6 VENTS AND DRAINS ............................................................................................... 12
2.7 INTERSTREAM LEAKAGE ...................................................................................... 12
2.8 PRESSURE TESTING.............................................................................................. 12
PART III BASIC REQUIREMENTS ......................................................................................... 13
1. GENERAL................................................................................................................. 13
1.1 DOCUMENT HIERARCHY AND SUBMITTALS....................................................... 13
1.2 PRESSURE VESSEL CODE .................................................................................... 14
1.3 CERTIFYING AUTHORITY ...................................................................................... 15
1.4 SCOPE OF SUPPLY ................................................................................................ 15
1.5 EQUIPMENT NUMBERING...................................................................................... 15
2. THERMAL AND HYDRAULIC DESIGN .................................................................. 15
2.1 INFORMATION REQUIRED FROM CONTRACTOR............................................... 15
2.2 PRESSURE DROP ................................................................................................... 15
2.3 INFORMATION SUPPLIED BY THE MANUFACTURER ........................................ 16
2.4 OPTIMISATION OF PLATE GEOMETRY ................................................................ 16
2.5 THERMOSYPHON REBOILER ................................................................................ 16
2.6 FOULING MARGIN ................................................................................................... 16
2.7 STRAINER ................................................................................................................ 17
2.8 TWO-PHASE FLOW INLET DISTRIBUTORS.......................................................... 17
3. MECHANICAL DESIGN ........................................................................................... 17
3.1 GENERAL ................................................................................................................. 17
3.2 DESIGN PRESSURE AND TEMPERATURE .......................................................... 18
3.3 DESIGN CONDITIONS AND CALCULATIONS ....................................................... 18
3.4 CORROSION ALLOWANCE .................................................................................... 18
3.5 LOAD CASES ........................................................................................................... 18
February 2012
Page 4
3.6 ALLOWABLE STRESSES ........................................................................................ 19

3.7 PLATES .................................................................................................................... 19
3.8 PANELS, GIRDERS AND LINING ............................................................................ 19
3.9 UPPER AND LOWER HEADS ................................................................................. 20
3.10 BAFFLES (OR PASS PARTITION PLATES) ........................................................... 20
3.11 BOLTS AND NUTS ................................................................................................... 20
3.12 CONNECTIONS ....................................................................................................... 20
3.13 NOZZLE LOADS ....................................................................................................... 21
3.14 SUPPORTS .............................................................................................................. 21
3.15 EARTHING................................................................................................................ 21
3.16 INSULATION............................................................................................................. 22
3.17 VENTS AND DRAINS ............................................................................................... 22
3.18 THREADED CONNECTIONS................................................................................... 22
3.19 CLEANING CONNECTIONS .................................................................................... 22
3.20 INSTRUMENT CONNECTIONS ............................................................................... 22
3.21 SAFETY/RELIEF VALVE NOZZLE CONNECTIONS ............................................... 22
3.22 LIFTING LUGS ......................................................................................................... 22
3.23 DIMENSION AND TOLERANCES............................................................................ 22
3.24 SPARE AND REPLACEMENT PARTS .................................................................... 23
4. MATERIALS OF CONSTRUCTION ......................................................................... 23
4.1 GENERAL ................................................................................................................. 23
4.2 MATERIALS SELECTION ........................................................................................ 24
4.3 NON-PRESSURE PARTS ........................................................................................ 24
4.4 GASKETS ................................................................................................................. 24
4.5 NAMEPLATE ............................................................................................................ 24
4.6 MATERIALS CERTIFICATION AND TRACEABILITY.............................................. 24
5. WELDING ................................................................................................................. 24
5.1 GENERAL ................................................................................................................. 24
5.2 PROCEDURE APPROVAL....................................................................................... 25
5.3 PROCEDURES AND QUALIFICATIONS ................................................................. 25
5.4 WELD MAP ............................................................................................................... 25
5.5 WELD PREPARATION ............................................................................................. 25
6. NON-DESTRUCTIVE EXAMINATION ..................................................................... 25
6.1 GENERAL ................................................................................................................. 25
6.2 RADIOGRAPHY ....................................................................................................... 25
6.3 ULTRASONIC EXAMINATION ................................................................................. 25
6.4 MAGNETIC AND LIQUID PENETRANT EXAMINATION ........................................ 25
6.5 OTHER NON-DESTRUCTIVE EXAMINATION ........................................................ 26
7. INSPECTION ............................................................................................................ 26
7.1 QUALITY CONTROL ................................................................................................ 26
7.2 MATERIALS INSPECTION....................................................................................... 26
7.3 ASSEMBLY INSPECTION........................................................................................ 26
7.4 WELD INSPECTION ................................................................................................. 27
7.5 DIMENSIONAL INSPECTION .................................................................................. 27
7.6 NON-CONFORMANCES .......................................................................................... 27
8. TESTING................................................................................................................... 27
8.1 LEAK TESTING ........................................................................................................ 27
8.2 PRESSURE TESTING.............................................................................................. 28
8.3 WEIGHING................................................................................................................ 28
9. PREPARATION FOR SHIPMENT............................................................................ 28
9.1 PREPARATION ........................................................................................................ 28
9.2 SURFACE FINISH .................................................................................................... 29
9.3 PACKING .................................................................................................................. 29
9.4 MARKING ................................................................................................................. 29
PART IV REFERENCES ......................................................................................................... 30
February 2012
Page 5
APPENDICES
APPENDIX A REQUISITIONING AND DOCUMENT SUBMITTALS .................................... 32
February 2012
Page 6
PART I INTRODUCTION
1.1 SCOPE
This new DEP specifies requirements and gives recommendations for the selection,
application, design and fabrication of Welded Plate-Bloc Heat Exchangers (WPBHEs) with
an integral welded core of alternating stream corrugated plate flow channels and removable
cover panels on both stream sides. Other types of welded plate type heat exchangers are
excluded.
Part II of this DEP provides information on selection and application of welded plate-bloc
heat exchangers.
Part III of this DEP provides information on design and fabrication of welded plate-bloc heat
exchangers.
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regard to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
February 2012
Page 7
1.3.2 Abbreviations
Term Definition
BPVC Boiler and Pressure Vessel Code
PMI Positive Material Identification
PTFE polytetrafluoroethylene
QA Quality Assurance
UT Ultrasonic Testing
WPBHE Welded Plate-Bloc Heat Exchanger
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets ( ). Other documents referenced by this DEP are listed in
(Part IV).
1.5 SUMMARY OF CHANGES

Amendment A01
Section Change
Part I, 1.6 DEP feedback process has been updated.
Part III, 1.2 Reference to pressure vessel DEPs have been updated to the new pressure
vessel DEP 31.22.00.31-Gen.
Part IV Reference to pressure vessel DEPs have been updated to the new pressure
vessel DEP 31.22.00.31-Gen.
Part IV Reference to the DEP feedback form - DEP 00.00.05.80-Gen. has been
added.
1.6 COMMENTS ON THIS DEP

Amendment A01
Comments on this DEP may be submitted to the Administrator using one of the following
options:
Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Shell DEPs Online) Select a DEP and then go to the details screen for
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.
DEP Feedback System Enter comments directly in the DEP Feedback

(Users with access to System which is accessible from the Technical
Shell Wide Web) Standards Portal http://sww.shell.com/standards.
Select “Submit DEP Feedback”, fill in the online form
and submit.
DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

(Other users) feedback and email the form to the Administrator at
standards@shell.com.
February 2012
Page 8
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
February 2012
Page 9
PART II SELECTION AND APPLICATION
1. THERMAL AND HYDRAULIC DESIGN CONSIDERATIONS
1.1 SCOPE
The heat transfer and pressure drop correlations and methods required for a satisfactory
thermal and hydraulic design shall reside with the Manufacturer.
1.2 TEMPERATURE AND PRESSURE LIMITATIONS

The maximum design pressure and temperature that can be accommodated in a WPBHE
can vary by Manufacturer. The Manufacturer should be consulted at an early stage of the
process design to determine the highest pressure and temperature that is feasible for the
applicable WPBHE(s).
Identical operating pressures for both streams in a WPBHE shall be avoided to prevent
pressure inversion/fluctuations which may create fatigue and damage the plate-pack and
cause leaks between the plates. A minimum differential pressure of 1 barg (15 psig) should
be maintained between the operating pressures of each stream.
The Manufacturer shall be responsible for acquiring all the design requirements on the data
sheets from the Contractor. The design shall satisfy all operating cases and design
conditions specified by the Contractor on the data sheets and supporting specifications.
1.3 SIZE LIMITATIONS

The Manufacturer should be consulted at an early stage of the process design to determine
the largest size and highest heat transfer area that can be accommodated in a single heat
exchanger.
1.4 FLOW RATE

Cold circuit flow stoppage which may lead to partial vaporization and recondensation shall
be prevented. Such frequently repeated operation can damage the exchanger.
1.5 MINIMUM TEMPERATURE APPROACH

For demanding applications, temperature approaches down to 3°C (5°F) can be obtained in
a WPBHE, however these should be used with caution because small upsets in process
conditions, changes in process stream physical properties or non-linearity in heat release
curves could prevent achieving the required thermal duty; this caution is especially
important for two-phase flow applications. Temperature approach refers to the difference
between the hot and cold stream bulk temperatures at the terminal ends of the heat
exchanger, where normally the lower of the two approach temperatures (hot or cold end of
the exchanger) is taken as the temperature approach.
1.6 MAXIMUM TEMPERATURE DIFFERENTIAL

The maximum temperature difference of process streams between adjacent plates in any
point in the heat exchanger should typically be limited to 80°C to 100°C (144°F to 180°F).
Should higher temperature differences be required, the Manufacturer should be consulted
for limitations in operation, e.g. in warm-up and cool-down rates.
1.7 THERMAL FATIGUE

The highest thermal stresses due to temperature differentials are likely to occur during
start-up, shutdown or upset conditions. The Contractor shall inform the Manufacturer of the
number of anticipated start-up, shutdown and identified upset conditions to be considered,
along with a definition of the operation under each case, so that the Manufacturer may
consider this in the mechanical design of the WPBHE.
February 2012
Page 10
Care should also be taken to avoid excessive flow fluctuations as these might cause
thermal fatigue. If flow of one or both streams is intermittent or is not in a steady state, the
Manufacturer shall be consulted for limits in operation. Expected or potential cyclic duties
shall be communicated by the Contractor to the Manufacturer as part of the specification of
the WPBHE.
WPBHE shall not be used for high cyclical heat duties having sudden temperature changes
exceeding 60°C/hour (108°F/hour). High cyclical temperature and/or pressure conditions
can create fatigue leading to a reduced lifetime of the exchanger.
The Manufacturer shall be consulted at an early stage of the process design to determine
the suitability of selecting WPBHE for cyclic conditions.
1.8 PERFORMANCE MONITORING

To ensure continued, trouble-free performance of WPBHE, the following instrumentation
should be installed and monitored:
• pressure drops across the heat exchanger for both streams;
• inlet and outlet temperatures of both streams;
• flow rates of both streams;
• pressure drop across the strainers for both streams.
1.9 CORROSION
The plate material shall be selected based on nil corrosion rate, unless otherwise approved
by the Principal.
1.10 PARTICULATES
If particulates of a size greater than 50 % of the gap between plates are likely to be present
in the process stream, upstream straining of the process stream shall be provided by the
Contractor unless otherwise approved by the Principal. In general, a filter or strainer of
mesh size 2 mm to 3 mm (0.08 in to 0.12 in) is recommended to be installed at the inlets of
process streams.
During commissioning, to prevent construction debris (mill scale, rust, welding electrode
etc) from accumulating in the WPBHE a temporary filter strainer of mesh size 1 mm
(0.04 in) or below is recommended.
The use of instrumentation to measure differential pressures across the filter to give an
early indication of blockage should be considered. Otherwise, the collapse of the filter
would pass additional debris to the WPBHE. Two parallel filters can be installed so that one
is always online, and have a pressure drop measurement [typically with a range of 0.1 bar
(1.5 psi) to 0.5 bar (7.0 psi)] across the filters so they can be cleaned at proper intervals.
1.11 FOULING
Rapidly fouling process streams should not be used with the WPBHE. Low to medium
fouling streams can be tolerated if the fouling is not likely to be rapid enough to block flow
channels and the fouling can be removed relatively easily either by hydro-blasting or with
chemical solvents that are compatible with both the process and the materials used for the
construction of the WPBHE.
Care should also be exercised with deposits that may be formed with high temperatures
(e.g. carbonisation, polymerisation) or low temperatures (waxes, hydrates). The thermal
design of the exchanger should ensure that there are no spots within the exchanger that
are excessively hot or cold, and that skin temperatures on the heat transfer surfaces have
sufficient margin to avoiding fouling deposition.
February 2012
Page 11
1.12 FLUID VELOCITIES

Fluid velocities are typically governed by pressure drop or thermal design criteria. If not
otherwise governed, the fluid velocities must be limited to a level that avoids potential
erosion problems.
1.13 DEPRESSURISATION
Depressurisation procedures, as applicable, shall be developed by the Contractor so as to
prevent the WPBHE from experiencing temperatures or conditions, including the cooling
medium utility fluid, that could freeze and cause damage to the plate-pack core.
2. MECHANICAL DESIGN CONSIDERATIONS
2.1 GENERAL
If a number of operating cases and design conditions are specified, the Manufacturer shall
select the most stringent case or combination of cases, as required, so that all design
conditions are met. These conditions extend to all pressure containing parts including
panels, linings, upper and lower heads, girders, nozzles and the plate pack.
The mechanical design shall be based on a standard pressure vessel code.
In addition to the steady state design operating condition(s), the mechanical design shall
satisfy all operating conditions, including transient conditions that might impose significant
stresses on the welded plate-bloc heat exchangers.
2.2 DESIGN PRESSURE AND TEMPERATURE

Each Manufacturer has their own maximum limits for mechanical design pressure and
design temperature and these shall be checked during selection of WPBHE.
2.3 LOAD CASES

The Manufacturer shall take into account external forces arising from nozzle loads, wind
loads, blast loads and reaction forces at supports and seismic and transportation
accelerations in the design of the WPBHE.
2.4 PRESSURE AND THERMAL CYCLING

Pressure and thermal cycling can lead to fatigue and shall be considered in the mechanical
design. Pressure vessel codes provide a basis for determining the need for fatigue analysis
and the procedure to be adopted when it is required.
2.5 STRUCTURAL INTEGRITY

The structural integrity of a WPBHE designed to a suitable pressure vessel code such as
ASME Section VIII is acceptable provided that the established design parameters within the
code are adhered to.
Standard non-destructive examination techniques may be employed to confirm satisfactory
welding.
The laser or plasma welded plate-pack integrity is basically analogous to automatic welding
integrity. The procedure is qualified similar to a welding procedure qualification. Production
bonding shall then be carried out in accordance with the qualified procedure, so specific
production tests are unnecessary.
If requested, the WPBHE welded plate-pack integrity shall be confirmed by production
testing, as follows:
• Prepare a tensile specimen by cutting-off the corner of the plate-pack;
• Make a test sample of a separate sandwich of a few corrugate plates to be laser or
plasma welded with a production block.
February 2012
Page 12
The fully assembled and pressure tested WPBHE shall be subjected to a helium leak test to
further confirm welding and bonding integrity.
The nozzles shall be designed considering the standard loads and moments as per
ISO 15547 Part 1. These standard loads and moments shall ensure nozzle and nozzle weld
integrity and include a safety factor for the exchanger stability.
2.6 VENTS AND DRAINS

Based on Manufacturer, certain small size WPBHE models are categorised as self-venting
and self-draining which means there is no necessity to provide separate vent and drain
connections for the WPBHE. For non-self venting and self-draining types, a dedicated vent
and drain shall be installed on the panels and piped to appropriate destinations (e.g. vent
and drain circuits that allow the draining and venting as required).
2.7 INTERSTREAM LEAKAGE

Repair of inter-stream leakage in a WPBHE typically should be carried out in a workshop
having equipment suitable for hot cutting and welding of WPBHE plate materials, and
equipment for helium leak and pressure testing. Welders and welding procedures must be
qualified to the appropriate code. Radiography of new welds may be required.
2.8 PRESSURE TESTING

The preferred method for pressure testing the WPBHE is hydrostatic. This should be
carried out prior to a leak test. The test pressure and method shall be derived from the
applicable pressure vessel code.
For some applications, if the WPBHE is not adequately dried, residual liquid that may have
been trapped in the unit after a hydrotest could lead to subsequent damage to the unit in
service. The Principal should consult the Manufacturer on this subject as part of selecting
and defining the pressure test method(s).
The Principal shall agree on the test method to be used for a particular installation.
February 2012
Page 13
PART III BASIC REQUIREMENTS
1. GENERAL
1.1 DOCUMENT HIERARCHY AND SUBMITTALS

1.1.1 Hierarchy
In case of conflict between documents relating to an order, the following hierarchy shall
apply:
1. the Purchase Order
2. the Project Specification and Data Requisition Sheets
3. this DEP
1.1.2 Document Submittals
The Manufacturer shall complete all information in accordance with (Appendix A).
For components of welded plate-bloc heat exchanger (WPBHE) whose terms and
definitions are not fully identified, the Manufacturer shall describe the details of construction
and assembly.
The Manufacturer shall include a detailed description of any exception to the specified
requirements.
The first-time use of a WPBHE design, component or material by the Manufacturer for the
Principal’s intended service shall be clearly indicated by the Manufacturer.
The Manufacturer shall state the anticipated life of the proposed gaskets in the specified
service and in storage. Special requirements for gasket storage to maintain gasket shelf-life
shall be specified.
The Manufacturer shall supply a recommended spare parts list for each WPBHE. The
Manufacturer shall state the cost of recommended spare parts, e.g., gaskets, in his
proposal.
1.1.3 Drawings
The Manufacturer shall submit general arrangement drawings for each WPBHE to the
Contractor for review. The drawings shall include the following information:
a) service, item number, project name and location, Manufacturer’s shop order number
and Contractor’s order number;
b) design pressure, test pressure, maximum design temperature, lower design
temperature, minimum design metal temperature and any restrictions regarding
testing or operation of the WPBHE;
c) dimensions and location of supports;
d) overall exchanger dimensions;
e) stacked plate pack length;
f) clearance required for panel removal;
g) mass of the WPBHE, both empty and full of water;
h) centre of gravity of the exchanger for empty and operating conditions;
i) corrosion allowance, if any;
j) material specifications for all components;
k) allowable forces and moments on connections;
l) size, flange rating and facing, location, orientation, and flow identification of all
connections;
February 2012
Page 14
m) applicable design codes;

n) number of plates installed;
o) gasket dimensions and material specifications, and associated panel cover closure
details
The Manufacturer shall recommend the tools required for the assembly and maintenance of
the WPBHE. If torquing of bolts is required, the Manufacturer shall provide torquing
procedures.
The review of general configuration drawings by the Contractor shall not relieve the
Manufacturer of the responsibility of meeting the requirements of the purchase order.
After receipt of the Contractor’s general arrangement drawing review comments, the
Manufacturer shall furnish the certified general configuration drawings and the detail
drawings.
The Manufacturer shall submit the Inspection and Test Plan (ITP) to the Contractor for
review and approval. Surveillance requirements identified by the Principal or the Contractor
shall be incorporated into the Manufacturer’s ITP.
The Manufacturer shall furnish copies of applicable welding procedures, procedure
qualification and weld maps for approval prior to the start of fabrication.
The Manufacturer shall furnish copies of applicable Code calculations and nozzle loading
calculations for approval prior to the start of fabrication.
1.1.4 Final Records
The Manufacturer shall furnish the Contractor with a user's manual, which shall contain the
following:
a) technical description;
b) assembly instructions;
c) operating instructions;
d) installation and maintenance instructions (including lifting and handling);
e) spare parts list;
f) data sheets and drawings (as-built).
The Manufacturer shall retain, for at least five years, records which confirm compliance of
the material and fabrication with the requirements of this DEP. The Manufacturer shall
provide the data book that shall contain:
a) certificate of conformance;
b) non-conformance report;
c) Manufacturer's data report, as specified by the design code;
d) code calculations;
e) material traceability, certified mill test reports for all pressure parts including plates;
f) weld and non-destructive testing (NDE) documentation;
g) hydrotest report/certificate or chart;
h) nameplate rubbings or photocopy;
i) Independent Certifying Authority verification and certification, if any.
1.2 PRESSURE VESSEL CODE

Welded plate-bloc heat exchangers (WPBHEs) shall be considered to be pressure vessels.
February 2012
Page 15
Amendment A01
Unless otherwise specified by the Contractor, the pressure vessel code shall be ASME
Section VIII, Division 1 or Division 2, as per DEP 31.22.00.31-Gen.
1.3 CERTIFYING AUTHORITY

The Contractor shall specify in the inquiry whether the design and construction of the
WPBHE is subject to the approval of an Independent Certifying Authority, and if required
the Manufacturer shall be responsible for obtaining the necessary design approvals and
meeting the inspection requirements.
1.4 SCOPE OF SUPPLY

Unless otherwise specified, the scope of supply shall be as specified on the data requisition
sheets.
The Contractor shall assure that all features necessary for reliable and safe operation will
be provided. These should include, where applicable, adequate means of control to
maintain mechanical and operational integrity throughout the specified variations in
operating conditions.
With regard to safety and reliability, unspecified but self-evident conditions may occur
during start-up, shut-down, power failure or interruption of the process flow. These
conditions shall be reflected in the WPBHE data sheets and supporting specifications and
shall be taken into account and satisfied by the Contractor and Manufacturer. Fatigue
analysis shall be performed as needed to confirm design adequacy.
1.5 EQUIPMENT NUMBERING

Heat transfer equipment shall be identified by a specific equipment number in accordance
with DEP 31.10.03.10-Gen.
2. THERMAL AND HYDRAULIC DESIGN
2.1 INFORMATION REQUIRED FROM CONTRACTOR

The Contractor shall specify the heat transfer duty, allowable pressure drop, minimum
shear stress, flow rates, terminal bulk temperatures, inlet pressures, stream compositions
and physical properties of the fluids passing through the heat exchanger.
The Manufacturer shall be responsible for acquiring all the design requirements on the data
sheets from the Contractor.
The welded plate-bloc heat exchangers are proprietary designs of the Manufacturer, and
therefore, the Manufacturer shall be totally responsible for the design and performance of
the heat exchanger.
The design shall satisfy all operating cases and design conditions specified by the
Contractor on the data requisition sheets and supporting specifications.
2.2 PRESSURE DROP

In calculating the pressure drop, losses shall include all those occurring in nozzles,
manifold areas and plate pack sections.
For two-phase streams, the pressure drop shall include frictional, static head, acceleration,
and momentum recovery components.
For allowable pressure drops and pressure drop margins for individual services see Part III,
(2.6).
The Contractor shall verify strainer requirements with the Principal. If a strainer is specified,
the Contractor shall integrally assess the design of the heat exchanger, strainer and
intermediate piping to optimize the overall design. The pressure drop for the strainer is
February 2012
Page 16
additional to the stated welded plate-bloc heat exchanger allowable pressure drop and
usually the strainer is not provided by the heat exchanger Manufacturer.
2.3 INFORMATION SUPPLIED BY THE MANUFACTURER

The Manufacturer shall provide completed data requisition sheets and outline drawings for
the Contractor’s review. Sufficient information shall be provided for the Contractor to assess
the thermal and hydraulic performance and mechanical integrity of the unit
The Manufacturer shall indicate any operation limitations in the operations manual, e.g.
maximum number of cycles the WPBHE could sustain basis the results of a fatigue
analysis.
2.4 OPTIMISATION OF PLATE GEOMETRY

Within the mechanical, thermal and hydraulic constraints detailed in the requisition, the
Manufacturer shall optimise the design of the WPBHE by selecting suitable geometry to
balance the following objectives:
• minimise cost of heat exchanger;
• minimise size and weight of heat exchanger.
2.5 THERMOSYPHON REBOILER

For thermosyphon reboilers, the Manufacturer shall verify that the calculated flow
circulation for the applicable system flow loop (e.g. piping configuration, equivalent piping
lengths, installation of pressure reducing valve in reboiler inlet piping ) are consistent with
the data requisition sheet requirements. The Contractor shall confirm that suitable control
provisions are provided to ensure reliable operation for all specified operating conditions.
The Manufacturer shall inform the Principal or Contractor of any conflicts and resolve
accordingly.
For vaporizing streams provided by thermosyphon action the effective mean temperature
difference shall consider the effect of boiling point elevation due to the liquid static head.
The Contractor should ensure that thermosyphon reboiler outlet piping is routed vertically
from the reboiler to the column with only one 90° elbow and one horizontal section.
2.6 FOULING MARGIN

Fouling margins, minimum shear stresses and pressure drop requirements shall be applied
in accordance with Table 2. For more severe fouling duties, the Principal may specify
higher shear stress values. The Manufacturer shall state the actual wall shear stress in the
data sheets. If lower shear stress values are considered unavoidable, the Principal shall be
consulted to determine the optimum balance between shear stress and hydraulics.
Table 2 Fouling margin, shear stress and pressure drop requirements for
welded plate-bloc heat exchangers
Fluid Fouling Shear Stress Allowable Pressure

Margin (Minimum) Pressure Drop
drop (clean) Multiplier
% Pa psi kPa psi
Demineralised water 5 - - 100 15 1.10
Potable water 10 30 0.00435 100 15 1.20
Cooling tower water 15 50 0.00725 100 15 1.25
Dirty sea water 15 75 0.01088 150 22 1.30
February 2012
Page 17
Clear sea water 10 50 0.00725 100 15 1.20

Lubricating oil 15 50 0.00725 100 15 1.20
Crude oil 20 75 0.01088 150 22 1.30
Process streams, clean 10 30 0.00435 100 15 1.20
Process streams, dirty 20 75 0.01088 150 22 1.30
Amine/Sulfinol® solutions 15 75 0.01088 150 22 1.25
Steam 5 - - 100 15 1.10
Glycol/water solutions 10 30 0.00725 100 15 1.20
(non-contaminated)
NOTES:
1. The overall fouling margin to be applied shall be equal to the individual fouling margin of the hot
stream OR of the cold stream, whichever is greater. Where both streams have fouling margins
in excess of 15 %, the overall fouling margin shall be 25 %.
2. The fouling margin shall be applied to the Overall Clean Coefficient only, not to surface area.
3. In services where waxing can occur, the fouling margin shall be agreed with the Principal.
4. The fouled design pressure drop shall be calculated by multiplying the clean design pressure drop with the
multiplier provided in this table, and shall be used in system hydraulic calculations and pump sizing. Both
fouled and clean pressure drop shall be mentioned on the datasheet.
For the services, which are not mentioned in Table 2, which require greater than 10 %
excess surface area for fouling, the WPBHE shall be designed for a minimum wall shear-
stress of 50 Pa (0.00725 psi).
The plate profile shall allow for hydro-lance cleaning, with continuous cleaning lanes,
whenever a process fluid requires ≥ 15 % surface area margin for fouling.
2.7 STRAINER
The Manufacturer shall state on the WPBHE data sheet the minimum equipment aperture
size for each stream and the maximum size of particles that can reliably pass through the
heat exchanger.
The Contractor shall specify the strainer requirements for each stream. Strainers shall be
provided when particles are expected within a stream that exceed the Manufacturer’s
maximum size reference.
The strainer is usually not supplied by the Manufacturer.
2.8 TWO-PHASE FLOW INLET DISTRIBUTORS

The Manufacturer shall provide a design that prevents any mal-distribution issues due to
two-phase flow at the entry or exit from the WPBHE.
3. MECHANICAL DESIGN
3.1 GENERAL
The mechanical design shall satisfy all design conditions specified in the requisition. These
conditions extend to all pressure containing parts including panels, linings, upper and lower
heads, girders, nozzles and the plate-pack.
The Contractor shall specify the pressure design code that applies to the mechanical
design. Unless otherwise specified by the Contractor, the design of the WPBHE shall be in
accordance with ASME Section VIII, Division 1 or Division 2.
Registration shall be in accordance with the regulations applicable at the location of
installation. If no such regulations are in place, the Principal shall specify if the WPBHE
shall be registered with the National Board of Pressure Vessel Inspectors.
February 2012
Page 18
NOTE: Registration with the National Board is recommended to ensure continuous access to an accurate
copy of the Manufacturer’s data report.
The Manufacturer shall confirm that the design provides the required structural integrity
necessary to meet the applicable standards and codes and this shall be fully demonstrated
in the design documentation.
The structural welding code shall be specified or agreed by the Contractor.
3.2 DESIGN PRESSURE AND TEMPERATURE

The Contractor shall specify the design pressure and design temperature including lower
design temperature and minimum design metal temperature for each stream through the
heat exchanger separately as defined in DEP 01.00.01.30-Gen.
WPBHE shall not be based on differential pressure design.
WPBHE with metal linings on the panels shall always be designed for full vacuum.
The effect of the temperature profile through the WPBHE shall be taken into account in the
design because this may have a significant consequence on the "mean metal temperature"
as well as on the stresses within the WPBHE.
The possibility of exposure to system pressure waves, e.g. water hammer, pressure
inversion and pressure or temperature fluctuations shall be taken into proper account.
The Contractor shall provide the Manufacturer with the typical transient operating condition
cases, e.g. start-up, flow trip, shut-down, for which the Manufacturer shall verify mechanical
design adequacy.
3.3 DESIGN CONDITIONS AND CALCULATIONS

The Manufacturer shall have an in-house standard calculation method for assessing the
stresses in component parts of a WPBHE.
The Manufacturer shall provide calculations to confirm that the design satisfies the code
requirements for:
a) panels;
b) upper and lower heads;
c) lining;
d) girders;
e) nozzles under local loads;
f) panel cover gasket seating;
g) supports and lifting lugs;
h) hydrotest pressures.
3.4 CORROSION ALLOWANCE

Corrosion allowance shall be zero for the plate-pack and all lining material.
Corrosion allowance for other parts (e.g. panels, nozzles, girders, and heads) shall be as
specified on the datasheet.
Environmental corrosion effects shall be considered in establishing the external corrosion
allowance, as applicable.
3.5 LOAD CASES

The mechanical design of the WPBHE shall satisfy the following loads acting individually or
in combination.
a) pressure loads;
February 2012
Page 19
b) reaction forces at nozzles and supports, including start-up, shut-down and

emergency;
c) depressurising conditions;
d) loads due to seismic, wind or other motion;
e) snow, impact and blast loads;
f) loads associated with installation at site.
The Contractor shall specify which load cases will be applicable for the WPBHE.
Furthermore, the Contractor shall inform the Manufacturer about any pressure or thermal
cyclic loading including start-up, shutdown, cycles over life, blow-down, back-flushing, etc.
The Manufacturer shall prove, by a mutually agreed calculation method, that the heat
exchanger will be able to sustain this loading during service life. If the unit will be subjected
to pressure cycling or thermal cycling, the effects of fatigue of materials shall also be
satisfied.
3.6 ALLOWABLE STRESSES

If special design conditions exist, the Manufacturer shall ensure that safety factors are
applied in accordance with the general practice of the pressure vessel code.
If the Contractor specifies that operation will subject the equipment to cyclic loading, the
need for fatigue analysis shall be assessed and documented.
In the absence of applicable service experience, a fatigue analysis shall be performed in
accordance with the provisions of:
ASME Boiler and Pressure Vessel Code, Section VIII, Division 2:
• Part 5 Section 5.5: For evaluation of the need for fatigue analysis.
• Appendix 5.F3: For the procedure to be adopted for measuring the fatigue life of a
pressure vessel based on tests carried out on a scale or full size model of the unit.
The maximum allowable design stresses shall be taken from the pressure vessel code and
shall be based on the final material condition.
3.7 PLATES
The plates in the plate-pack shall conform to the following:
1. The nominal thickness of plates before being pressed shall be sufficient to meet
design conditions but shall not be less than 0.8 mm (0.03 in).
2. The plates shall be designed to meet the design conditions, without stiffeners or
reinforcement welds.
3. The Manufacturer shall specify the fraction of the plate pack that is incapable of
being lance-through cleaned, without obstruction, for services with greater than a
10 % fouling margin. The Contractor shall review any fraction greater than zero with
the Principal for approval.
3.8 PANELS, GIRDERS AND LINING

The panels and girders shall conform to the following:
1. The four panels and four girders shall be of carbon steel. If required from process,
the carbon steel panels and girders shall be lined with the same material as the
plate-pack material. The material specification of the panels, girders and lining shall
be indicated in the datasheet.
2. The Manufacturer fabrication drawings shall provide details of the method employed
to connect the lining with the panels and girders. The Manufacturer shall take
approval from the Principal on the method used.
February 2012
Page 20
3. All non-integrally lined components shall be clearly labelled externally to identify

their lined status.
4. Full face panel gasket closure types shall not be applied for services other than non-
process water, without the approval of the Principal.
5. Panel closures shall apply a fully confined gasket arrangement unless otherwise
approved by the Principal.
3.9 UPPER AND LOWER HEADS

The upper and lower head portions which are in contact with WPBHE end plates shall be
lined with PTFE (polytetrafluoroethylene) sheet or other equivalent material. The material
specification of the heads and PTFE or coating shall be indicated in the datasheet.
The Manufacturer shall provide details of the method used to attach the lining with the
heads or the coating application process and shall take approval from the Principal on the
method used.
3.10 BAFFLES (OR PASS PARTITION PLATES)

Baffles are used to make a multi-pass arrangement in the unit. Reinforcement baffles shall
be used and designed such that the baffle is rigidly secured in position.
The baffle material shall be of the same material as the plate-pack.
For two-pass exchangers, the baffle shall be designed for 150 % of the clean total stream
pressure drop without yielding or becoming unsecured. For exchangers with three or more
passes, each baffle shall be capable of tolerating a pressure differential across the baffle of
no less than the design clean total stream pressure drop.
3.11 BOLTS AND NUTS

Bolts and nuts shall conform to the following:
1. Bolts shall not be less than 16 mm (5/8 in) nominal diameter.
2. The length of each nut will be equal to or greater than a heavy hexagonal type, in
accordance with the pressure design code.
3. Hardened flat steel washers shall be provided under all nuts.
4. For amine and Sulfinol® solvent service (or any other streams defined as sour or
wet hydrogen sulphide service), SA-193 B7 and SA-194 2H nuts shall be supplied
as M-grade.
3.12 CONNECTIONS
1. Connections shall be of flanged design, with the connection welded to the panel.
2. Flanged connections on WPBHE panels shall use full penetration welds of the set-
on type in accordance with ASME VIII section UW-16(a) or (b).
3. The nozzle construction shall be in accordance with the selected pressure vessel
standard (see Part III, 3.1)
4. Seam welded nozzles shall be subjected to 100 % radiography.
5. The minimum nozzle or connection size shall be DN 40 (NPS 1-1/2).
6. Connection sizes of DN65 (NPS 2-1/2), DN90 (NPS 3-1/2) or DN125 (NPS 5) shall
not be used.
7. For wet hydrogen sulphide service or corrosive service, all carbon steel nozzle and
flanged connections in contact with the process fluid shall be provided with alloy
liners or weld overlay (with the liner or overlay material matching that of the plate
pack). Solid alloy nozzle necks with dissimilar welds between the alloy nozzle and
February 2012
Page 21
carbon steel covers shall not be used due to their susceptibility to hydrogen-induced
cracking.
For alloy-lined connections, the minimum thickness of the lining shall not be less
than the lining plate thickness on the panels.
8. All non-integrally lined nozzles or connections shall be clearly labelled externally to
identify their lined status.
Temperature and pressure gauge connections, if provided, shall be located in the
adjacent piping.
In all cases, the construction details of alloy linings and connections shall be
provided in the Manufacturer's proposal, and subject to approval by the Contractor.
9. The projection of flanged connections shall be of sufficient length to allow
installation and removal of the flange bolts from either side of the flange.
10. All bolt holes for flanged connections shall straddle centrelines.
11. Weld-neck flanges or long weld-neck flanges shall be used with flanged
connections, and shall have the same bore as the nozzle necks. Flanges for nozzles
shall have pressure/temperature ratings, dimensions and flange facing in
accordance with ASME B16.5 or ASME B16.47. Special mechanical couplings may
be used for higher pressures (to further reduce dimensions and mass) if approved
by the Contractor.
12. Slip-on flanges or lap-joint flanges shall not be used without approval of the
Principal.
13. Nozzle necks shall comply with the following:
a) their thickness shall be at least that required by the pressure design code plus
the appropriate corrosion allowance; and
b) they shall be of a standard pipe schedule; and
c) Carbon steel nozzles DN 80 (NPS 3) or less shall be minimum schedule 160;
and
d) Austenitic stainless steel or other high alloy nozzles DN 80 (NPS 3) or less shall
be minimum schedule 80S.
e) Electric Resistance Welded (ERW) pipe shall not be used for nozzle necks.
3.13 NOZZLE LOADS

Nozzle connections shall be designed to withstand the loads and moments specified in
ISO 15547 Part 1, clause 7.7.10, Table 1 and Table 2. Acceptable piping loads shall be
stated on the general assembly drawing.
3.14 SUPPORTS
The WPBHE support shall be provided to withstand applicable loads (e.g.: seismic, wind,
blast).
The Manufacturer shall provide details of the loads generated on the supports/foundation
due to dead weight of the WPBHE plus loads resulting from external applied forces and
moments.
3.15 EARTHING
The WPBHE shall be provided with two earthing bosses.
Earthing bosses shall be in accordance with Standard Drawing S 68.004.
February 2012
Page 22
3.16 INSULATION
If specified by the Contractor, the Manufacturer shall provide insulation supports. The
thickness of the insulation shall be specified by the Contractor in the equipment data sheet
or requisition sheets.
The Manufacturer shall secure specification for the thickness of insulation to be applied to
the WPBHE external surfaces, the type of insulation clips required for attachment of the
insulation, and the required nozzle stand-out beyond the insulation from the Contractor.
WPBHEs shall be insulated in accordance with DEP 30.46.00.31-Gen.
3.17 VENTS AND DRAINS

The vent and drain sizes shall be at least DN 40.
The Contractor shall indicate all vents and drains of WPBHEs on the relevant Process
Engineering Flow Schemes (PEFS).
3.18 THREADED CONNECTIONS

Threaded connections shall not be used.
3.19 CLEANING CONNECTIONS

If the datasheet specifies that WPBHEs will require in-service cleaning with hot water,
steam, solvents or other chemical methods, suitable flanged nozzle connections of DN 80
(NPS 3) minimum size shall be provided on main connecting pipe to the exchanger nozzle.
There shall be no cleaning connections on exchanger nozzles.
The Contractor shall assure that the cleaning nozzles will be easily accessible after
installation of the WPBHE.
The Contractor shall confirm cleaning connection requirements with the Principal, and
specify them on the datasheet and on the relevant Process Engineering Flow Schemes
(PEFS).
3.20 INSTRUMENT CONNECTIONS

Temperature instrument and pressure gauge connections shall be as specified on the
data/requisition sheets.
There shall be no temperature instrument or pressure gauge connections located in
WPBHE nozzles. Only when the WPBHE is provided with an integral Tee type strainer
housing the use of pressure tapping points is allowed as these are required to monitor the
strainer pressure drop.
3.21 SAFETY/RELIEF VALVE NOZZLE CONNECTIONS

Flanges for safety/relief valve nozzles shall have a minimum rating of ASME Class 300.
3.22 LIFTING LUGS

The WPBHE shall be provided with suitable lifting lugs. Lifting lugs shall be designed for a
total load of 2.0 times the lifted weight of the exchanger to allow for dynamic effects. For
offshore lifts the lifting lugs shall be designed for a total of 3.0 times the lifted weight of the
exchanger.
The lifting devices shall be located above the centre of gravity of the parts to which they are
welded.
The lifting lug hole diameter shall be at least 28 mm (1.1 in) diameter.
3.23 DIMENSION AND TOLERANCES

Nozzles shall be positioned within ± 3 mm (1/8 in) of the position relative to the datum
shown on the Manufacturer’s General Arrangement drawing.
February 2012
Page 23
Flange-to-flange dimensions shall be ± 6 mm (¼ in).

Flange faces shall be oriented within ±1° (maximum 5 mm (0.2 in) at flange periphery).
3.24 SPARE AND REPLACEMENT PARTS

Spares and replacement parts shall be in accordance with DEP 70.10.90.11-Gen.
4. MATERIALS OF CONSTRUCTION
4.1 GENERAL
Materials shall be selected in accordance with ASME Boiler and Pressure Vessel Code
Section II, Part A, Ferrous Material Specifications; or Part B, Nonferrous Material
Specifications, and in accordance with DEP 30.10.02.11-Gen. Equivalent material in
accordance with EN standards is permitted, subject to the approval of the Contractor. It is
the responsibility of the Contractor to specify the relevant additional requirements from this
DEP on the equipment datasheet.
All pressure containing parts of carbon steel plate shall be manufactured from fully killed
fine-grained steel, unless otherwise approved by the Contractor.
Cast iron parts shall not be used.
Welded components in contact with the process fluid, such as nozzle necks, flanges, liners,
and plates which are specified as 304, 316, or 317 austenitic stainless steel shall be low
carbon (L) grade. Dual certification to low carbon grade is also acceptable.
Pressure components made from austenitic stainless steel grades 304, 316, and 317 shall
be capable of passing an inter-granular corrosion testing in accordance with ASTM A262
Practice E or ISO 3651-2 Method A. If the test is required by the Principal, the results shall
be reported on the material certificate.
The Manufacturer shall provide a material certificate from the gasket supplier. Additionally,
if specified by the Principal, PMI shall also be performed on a gasket sample that is
representative of the batch being used in assembly of the unit(s). The Principal shall
approve the testing method for the specific gasket type.
In general the use of stainless steel WPBHE plates is not recommended in cooling water
service due to the presence of crevices in the WPBHE, and cooling water fouling/scaling
concerns, as stainless steel WPBHE plates are susceptible to severe pitting and the risk of
cracking. Only if the following conditions are satisfied, may the application of stainless steel
plates in cooling water services be considered (but not in any case for closed-cooling water
systems):
• Only type SS 316 L or super austenitic stainless steel should be considered. Type
SS 304L or other non-molybdenum bearing austenitic stainless steel grades shall not
be used because of their insufficient resistance to under-deposit pitting and crevice
corrosion.
• The chloride content of the cooling water should be below 50 mg/kg for SS 316 L.
• Graphite and full density PTFE gaskets shall not be applied on the water side, in
order to avoid crevice corrosion. Expanded PTFE may be used. Only PTFE that
contains no free Fluoride (F-) ions may be put into contact with SS. Non-asbestos
panel gaskets may be used on the water side in contact with the stainless steel.
For closed-cooling water systems, the Principal shall be consulted.
The wetted areas in the WPBHE shall be of similar material as the plate-pack unless
accepted by the Principal.
Materials in sour and/or wet H2S services shall conform to DEP 30.10.02.15-Gen. or
DEP 30.10.02.17-Gen. when and as specified by the Contractor.
February 2012
Page 24
4.2 MATERIALS SELECTION

The Contractor shall specify the materials of construction following consultation with the
Principal. The Manufacturer shall confirm that the requested materials are compatible with
and qualified for the WPBHE design and manufacturing process.
4.3 NON-PRESSURE PARTS

All attachments, such as supports, lifting points shall be of a similar material specification
as the material to which they are attached.
4.4 GASKETS
Only gaskets suitable for a particular fluid in service and its design temperature and
pressure shall be used. The complete composition of the fluid shall be considered in gasket
selection.
The gasket selection for the 4 panels shall be based on the proven reliable selection by the
Manufacturer and approval of the Contractor. The typical gaskets used should be:
• Gylon® Blue
• Graphite PSM
• Sigraflex®
• Klingersil®
The type of gasket used for the panels shall be indicated in the datasheet.
Panel gaskets shall be of one integral piece construction. For larger size panel gaskets
where a single piece gasket is not feasible, a multiple piece construction adapted to avoid
leakage may be accepted with prior approval from the Principal.
The selection of gaskets for connecting piping shall be in accordance with the appropriate
piping class (see DEP 31.38.01.12-Gen. or DEP 31.38.01.15-Gen., as applicable).
4.5 NAMEPLATE
All nameplates shall be austenitic stainless steel.
The nameplate shall be in accordance with Standard Drawing S 10.114.
The nameplate shall be permanently attached to each individual WPBHE.
4.6 MATERIALS CERTIFICATION AND TRACEABILITY

All materials of construction shall be supplied with full chemical and mechanical property
certificates in accordance with ISO 10474 type 3.1 or equivalent. All materials and welding
consumables shall be traceable to their test certificates.
Where it is not practical to transfer markings from the parent material to component parts,
the Manufacturer shall operate approved alternative QA procedures to maintain traceability.
5. WELDING
5.1 GENERAL
All pressure-containing welding shall be in accordance with the pressure design code, and
structural welding shall be in accordance with the structural welding code, unless otherwise
specified by the Principal.
Welding processes on pressure parts shall be in accordance with DEP 30.10.60.18-Gen.
February 2012
Page 25
5.2 PROCEDURE APPROVAL

All Manufacturer Welding Procedure Qualifications and Procedure Qualification Records
(including weld details) shall be approved by the Independent Certifying Authority, if any,
prior to commencing any production welding. The Contractor may review the applicable
welding documentation at the Manufacturer’s premises, if desired.
5.3 PROCEDURES AND QUALIFICATIONS

Welding procedures and welders shall be qualified in accordance with the pressure vessel
code.
5.4 WELD MAP

A weld map shall be prepared, which includes an outline drawing that identifies all welds
and relates them to the relevant welding procedure number and non destructive
examination requirements.
5.5 WELD PREPARATION

The weld bevels and surrounding area shall be clean and free from moisture, oxides or any
other foreign matter that could interfere with welding. A visual inspection of all weld
preparations shall be made to ensure they are correctly profiled and smooth and free from
any defects that might affect weld quality.
6. NON-DESTRUCTIVE EXAMINATION
6.1 GENERAL
Test procedures shall be submitted to the Independent Certifying Authority, if any, for
approval prior to the commencement of fabrication. The Contractor has the right to review
the applicable NDE documentation at the Manufacturer’s premises.
NDE personnel shall be qualified in accordance with the pressure vessel code.
6.2 RADIOGRAPHY
Radiography shall be performed in accordance with ASME V, Article 2 or the applicable
pressure design code.
Each radiograph shall contain sufficient information to identify the following:
• weld identification;
• radiograph location;
• original or repaired weld;
• welder’s identification.
6.3 ULTRASONIC EXAMINATION

Where set-on connections are used on panels fabricated from plate, 100 % UT examination
in accordance with ASME Section II, Part A, shall be performed on a 100 mm (4 in) wide
band around the nozzle opening prior to attachment of the nozzle, and shall meet the
requirements of SA-578 Acceptance Standard Level C.
Where allowed by the pressure vessel code the use of Phased Array Ultrasonic testing
shall be acceptable as a substitute for or in addition to Radiographic examination.
6.4 MAGNETIC AND LIQUID PENETRANT EXAMINATION

All plate-pack welds shall be subjected to 100 % liquid penetrant examination.
All nozzle welds (nozzle to flange and nozzle to panel) shall be subjected to 100 %
magnetic particle examination for ferritic materials or 100 % liquid penetrant examination for
February 2012
Page 26
non-ferritic materials. All attachment welds for alloy liners on ports or nozzles shall be
100 % liquid penetrant examined.
6.5 OTHER NON-DESTRUCTIVE EXAMINATION

All plates shall be inspected after pressing for any plate cracks (e.g.: by means of light test
or other approved method).
7. INSPECTION
7.1 QUALITY CONTROL

Materials, welding inspection, non-destructive testing and other stages of fabrication shall
be subject to inspection by any of the following parties:
• Contractor;
• Contractor’s nominated representative;
• Independent Certifying Authority, if any;
• Nominated Inspection Authority.
The Manufacturer shall submit a fabrication schedule and a QA/Inspection plan detailing
proposed hold points to be witnessed by one or more of the above parties. Fabrication shall
not continue beyond these hold points without written approval from the Contractor.
Test procedures shall be submitted for approval prior to the commencement of fabrication.
The Contractor reserves the right to review the applicable inspection documentation at the
Manufacturer’s premises.
The Manufacturer shall provide the Contractor with a minimum of seven working days’
notice prior to carrying out inspection or testing activities identified in the QA/Inspection as
hold/witness points.
Reports of the findings from each inspection shall be made available to the Contractor for
review.
7.2 MATERIALS INSPECTION

The Manufacturer shall perform Positive Material Identification (PMI) on all alloy pressure
components and welding consumables used in the manufacturing of the WPBHE in
accordance with DEP 31.10.00.10-Gen.
5 % of bolting and plate-pack plates per heat exchanger shall be subjected to PMI. PMI
reports shall be included in the Manufacturer’s data book.
All pressure retaining parts shall be subjected to 100 % positive material identification (refer
to DEP 31.10.00.10-Gen.)
7.3 ASSEMBLY INSPECTION

The Manufacturer shall inspect the plates following plate forming to confirm that the plate
geometry is consistent with the basis applied for thermal and mechanical design
calculations.
The Manufacturer shall subject all plates to full visual inspection prior to stacking. Plates
shall be clean, free of gross forming defects, within dimensional tolerances and correctly
oriented.
The Manufacturer shall inspect the stacked plates to confirm that the stack has the
specified number of plates and the specified plate sequence.
February 2012
Page 27
7.4 WELD INSPECTION

The Manufacturer shall perform the maximum practical amount of non-destructive weld
inspection and secure the approval of the Contractor concerning welds that won’t be
inspected.
All inspection and non-destructive testing of welds shall be carried out in accordance with
procedures approved by the Contractor.
The extent of non destructive examination and the proposed non destructive examination
techniques shall be detailed in the Manufacturer’s QA and Inspection Plan and General
Arrangement drawings. As a minimum, the proposed level of inspection shall meet the
requirements of the pressure vessel code.
Liquid penetrant inspection shall be performed at the various stages of the welding.
7.5 DIMENSIONAL INSPECTION

The Contractor shall inspect the finished and assembled unit for correct fit-up and nozzle
positions relative to an agreed datum point.
7.6 NON-CONFORMANCES
Defects resulting from fabricating operations shall be repaired or the item shall be rejected.
Repairs shall be performed in accordance with a procedure agreed by the Principal prior to
the repair; this includes re-examination for defects and retesting for pressure leaks and
leaks in the original manner.
If rectification requires the blocking of a channel/passage, the Manufacturer shall use a
proven procedure developed for this purpose. Any blocking of a channel/passage shall be
notified to the Principal for approval.
If the heat exchanger is supplied with blocked channel(s), the Manufacturer shall supply
calculations that confirm the adequacy of the unit to the originally specified requirements.
8. TESTING
8.1 LEAK TESTING

Helium leak testing shall be independently carried out for each stream side of the
completed equipment following pressure testing.
The non-testing stream side shall be freely vented to atmosphere during the testing. The
Manufacturer shall determine the need for all four panels to be securely in place to safely
perform leak testing; however, free venting of the non-tested side can be readily achieved
through the associated nozzle connections even with all four panels securely assembled.
No detectable leak shall be permitted in complete equipment between:
• The two fluid stream sides in the exchanger.
• Either of the fluids in the exchanger and the surroundings.
Unless otherwise agreed between the Contractor and the Manufacturer, the following
allowable leakage rate shall be applied:
• for an external leakage: 1x10–4 kPa m3/s (at a pressure difference of 100 kPa
[15 psi]);
• for an internal leakage: 1x10–3 kPa m3/s (at a pressure difference equal to the design
pressure) or 1x10–4 kPa m3/s (at a pressure difference of 100 kPa [15 psi]).
Leak testing shall be conducted in the presence of the parties specified in the Quality Test
and Inspection Plan.
February 2012
Page 28
8.2 PRESSURE TESTING

All WPBHEs shall be tested by a hydrostatic pressure test in accordance with the pressure
vessel standard (see Part III, 3.1).
Pressure testing shall be carried out on the completed equipment prior to leak testing.
Each individual fluid stream side shall be independently tested to the pressure stipulated by
the design code. The test shall be carried out with the adjacent stream side freely vented to
the atmosphere. It is expected that all four panels will need to be securely in place to safely
perform pressure testing, however free venting of the non-tested side can be readily
achieved through the associated nozzle connections.
The test shall be carried out in accordance with a pressure test procedure approved by the
Contractor.
The hydrostatic test pressure shall be maintained for a sufficient time to permit a thorough
inspection and detection of small seepage leaks, but not less than 30 min.
For each hydrostatic test, two indicating gauges (or one indicating gauge and one recording
gauge) shall be attached to the WPBHE.
Water used for hydrostatic testing of exchangers made from 18-8 stainless steel plates
(300 series austenitic), martensitic and ferritic grades, 12 Cr and 17 Cr stainless steels
(Types 405, 410, and 430), and Alloy 400 (Monel), shall be performed with good quality
water that contains less than 50 mg/kg chloride and is free from sediment. Good quality
water includes demineralised water, steam condensate (including boiler feed water) and
potable (drinking) water. The water quality shall have been tested for chloride content within
the last 3 months and a certificate shall be made available for inspection.
On completion of the hydrotest, the equipment shall be drained, cleared of residual test
fluid and dried immediately after testing. The WPBHE shall be dried by blowing through air
at a maximum temperature of 66°C (150°F).
If a WPBHE will be operated in cryogenic services, the exchanger shall be dried to a dew
point less than -25°C (-13°F).Stacked WPBHEs shall be pressure tested in the stacked
position.
Service nozzle connection bolts and gaskets furnished by the Manufacturer shall not be
used in testing or shipping the WPBHE.
Pressure testing shall be carried out in the presence of the parties specified in the Quality
Test and Inspection Plan.
8.3 WEIGHING
When specified by the Contractor, all exchangers shall be weighed on completion. The
Manufacturer shall submit a weight certificate and centre of gravity data completed with
calculated and weighed data for dry, operating and lift conditions.
9. PREPARATION FOR SHIPMENT
9.1 PREPARATION
Exchangers shall be thoroughly cleaned both internally and externally of all foreign
material, such as grinding dust, weld flux and weld spatter. Water or other liquids used for
cleaning or hydrostatic testing shall be drained and the equipment thoroughly dried.
Special preparation for shipment measures shall be applied for exchangers made from
18-8 stainless steels (300 series austenitic), martensitic and ferritic grades, 12 Cr and 17 Cr
stainless steels (AISI Types 405, 410 and 430), and Alloy 400 (Monel). Special preparation
measures shall comprise the following:
a. WPBHEs shall be prepared for shipping immediately after they have been
hydrotested and dried;
February 2012
Page 29
b. Openings shall be sealed with gasketed and fully bolted blind flanges;
c. A connection with a valve and a pressure gauge shall be installed;
d. If specified by the Contractor on the data sheet the WPBHE shall be pressurized
and depressurized twice to a gauge pressure of 100 kPa (15 psi) with dry nitrogen
or argon, and then re-pressurized to a gauge pressure of 100 kPa (15 psi) with
nitrogen or argon that has a dew point of -29°C (-20°F);
e. Exchanger blind flanges, and headers, as applicable, shall be tagged with brightly
coloured waterproof labels that state: “Contents Under Nitrogen (or Argon)
Pressure; Do Not Open Without Principal’s Approval”;
Special preparation shall also be applied to equipment that will be transported over-seas,
regardless of the material;
Bolts and nuts shall be coated with a suitable thread lubricant to prevent corrosion during
transport and outdoor storage. Copper or molybdenum di-sulfide containing thread
lubricants shall not be used;
9.2 SURFACE FINISH

Surfaces to be painted shall be degreased and cleaned by wire brushing or a similar means
to remove loose scale, dirt and other foreign materials.
Surface protection and paint, shall be in accordance with DEP 30.48.00.31-Gen. for
onshore applications or DEP 70.48.11.30-Gen. for offshore applications.
Parts that are not accessible after assembly for painting may be painted before the
pressure test as required.
9.3 PACKING
The exchangers shall be properly packed and protected from damage during shipment by
road, rail and containerised sea transport.
9.4 MARKING
Each crate or package shall be clearly identified in accordance with the customer’s
specification. At minimum, the package shall be marked with the Purchase Order number,
the item number, the shipping mass and the delivery address.
February 2012
Page 30
PART IV REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
Amendment A01
DEP feedback form DEP 00.00.05.80-Gen.

Definition of temperature, pressure and toxicity levels DEP 01.00.01.30-Gen.
Metallic materials – Selected standards DEP 30.10.02.11-Gen.
Materials for use in H2S containing environments in oil and gas DEP 30.10.02.15-Gen.
production (amendments and supplements to ISO 15156:2009)
Wet H2S requirements for downstream pressure vessels and DEP 30.10.02.17-Gen.
piping
Welding of metals (amendments/supplements to API RP 582) DEP 30.10.60.18-Gen.
Thermal insulation DEP 30.46.00.31-Gen.
Protective coatings for onshore facilities DEP 30.48.00.31-Gen.
Positive material identification (PMI) program DEP 31.10.00.10-Gen.
Symbols and identification system – Mechanical DEP 31.10.03.10-Gen.
Amendment A01
Unfired pressure vessels DEP 31.22.00.31-Gen.

Piping classes – Refining and chemicals DEP 31.38.01.12-Gen.
Piping classes – Exploration and production DEP 31.38.01.15-Gen.
Spare parts DEP 70.10.90.11-Gen.
Protective coatings for offshore facilities DEP 70.48.11.30-Gen.
DATA/REQUISITION SHEETS
Plate heat exchangers DEP 31.21.01.93-Gen.
EDP supplement DEP 40.00.10.93-Gen.
Engineering documents (“RED” form) DEP 40.10.01.93-Gen.
STANDARD FORMS
Heat exchanger summary sheet DEP 01.00.03.84-Gen.
Specification of design and engineering documents DEP 05.00.50.82-Gen.
Approval drawing specification (ADS) DEP 05.00.54.81-Gen.
Final drawing specification (FDS) DEP 05.00.54.82-Gen.
STANDARD DRAWINGS
Nameplate with bracket for vessel and heat exchange S 10.114
equipment
February 2012
Page 31
Earthing boss for steel structures, tanks, vessels, etc. S 68.004
INTERNATIONAL STANDARDS
Steel and steel products – Inspection documents ISO 10474
Petroleum, petrochemical and natural gas industries – ISO 15547-1
Plate-type heat exchangers – Part 1: Plate-and-frame heat
exchangers
Determination of resistance to intergranular corrosion of ISO 3651-2 Method A
stainless steels - Part 2: Ferritic,austenitic and ferritic-austenitic
(duplex) stainless steels - Corrosion test in media containing
sulfuric acid - Method A: the 16 % sulfuric acid/copper sulfate
test (Monypenny Strauss test);
AMERICAN STANDARDS
ASME Boiler and Pressure Vessel Code: (ASME/BPVC)
Section II A Ferrous Material Specifications (Beginning to Section II A
SA-450) Materials - Includes 2011 Addenda
Section II B Nonferrous Material Specifications - Materials - Section II B
Includes 2011 Addenda
Section V Nondestructive Examination - Includes 2011 Addenda Section V, Article 2
Rules for construction of pressure vessels ASME VIII
Alternative rules for construction of pressure vessels ASME VIII, Division 2
Part 5 – Design Analysis Requirements
5.5 Protection against failure from cyclic loading and
Annex 5-F.3 Protection against cyclic loading
Pipe flanges and flanged fittings NPS ½ through NPS 24 ASME B16.5
Large diameter steel flanges NPS 26 through NPS 60 ASME B16.47
Copper - Copper Sulfate - 16% sulfuric acid, ASTM A262 - ASTM A262
Practice E (Strauss Test)
Standard specification for straight –beam ultrasonic examination ASME – Section V
of plain and clad steel plates for special applications SA578
BRITISH STANDARDS
Specification for unfired fusion welded pressure vessels – AMD PD 5500 + A3
September 2009; AMD September 2010; AMD September 2011
February 2012
Page 32
APPENDIX A REQUISITIONING AND DOCUMENT SUBMITTALS

The Principal's inquiry shall specify the number of copies of outline drawings, construction
drawings, data/requisition sheets, data reports and final records to be supplied by the
Manufacturer, all as specified in DEP 40.10.01.93-Gen.
The following Standard Forms shall be used for the specification of WPBHEs in conjunction
with this DEP:
Specification of design and engineering documents DEP 05.00.50.82-Gen.

Approval drawing specification DEP 05.00.54.81-Gen.
Final drawing specification DEP 05.00.54.82-Gen.
To be submitted during Project Specification phase (design phase):
Data/requisition sheets for plate heat exchangers DEP 31.21.01.93-Gen.

Requisition for engineering documents (“RED” form) DEP 40.10.01.93-Gen.
To be submitted during Detailed Engineering phase (purchasing phase):
Heat exchanger summary sheet DEP 01.00.03.84-Gen.

EDP supplement DEP 40.00.10.93-Gen.
The complete set of data/requisition sheets shall be used, even if only one equipment item
is ordered.

Welded Plate-Bloc Heat Exchangers - Application, Design and Fabrication

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Welded Plate-Bloc Heat Exchangers - Application, Design and Fabrication

Enviado por

Direitos autorais:

Formatos disponíveis

DEP SPECIFICATION

WELDED PLATE-BLOC HEAT EXCHANGERS –

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies

3.6 ALLOWABLE STRESSES ........................................................................................ 19

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

1.5 SUMMARY OF CHANGES

1.6 COMMENTS ON THIS DEP

Shell DEPs Online Enter the Shell DEPs Online system at

DEP Feedback System Enter comments directly in the DEP Feedback

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

1.7 DUAL UNITS

PART II SELECTION AND APPLICATION

1. THERMAL AND HYDRAULIC DESIGN CONSIDERATIONS

1.2 TEMPERATURE AND PRESSURE LIMITATIONS

1.3 SIZE LIMITATIONS

1.4 FLOW RATE

1.5 MINIMUM TEMPERATURE APPROACH

1.6 MAXIMUM TEMPERATURE DIFFERENTIAL

1.7 THERMAL FATIGUE

1.8 PERFORMANCE MONITORING

1.12 FLUID VELOCITIES

2. MECHANICAL DESIGN CONSIDERATIONS

2.2 DESIGN PRESSURE AND TEMPERATURE

2.3 LOAD CASES

2.4 PRESSURE AND THERMAL CYCLING

2.5 STRUCTURAL INTEGRITY

2.6 VENTS AND DRAINS

2.7 INTERSTREAM LEAKAGE

2.8 PRESSURE TESTING

PART III BASIC REQUIREMENTS

1.1 DOCUMENT HIERARCHY AND SUBMITTALS

m) applicable design codes;

1.2 PRESSURE VESSEL CODE

1.3 CERTIFYING AUTHORITY

1.4 SCOPE OF SUPPLY

1.5 EQUIPMENT NUMBERING

2. THERMAL AND HYDRAULIC DESIGN

2.1 INFORMATION REQUIRED FROM CONTRACTOR

2.2 PRESSURE DROP

2.3 INFORMATION SUPPLIED BY THE MANUFACTURER

2.4 OPTIMISATION OF PLATE GEOMETRY

2.5 THERMOSYPHON REBOILER

2.6 FOULING MARGIN

Fluid Fouling Shear Stress Allowable Pressure

Clear sea water 10 50 0.00725 100 15 1.20

2.8 TWO-PHASE FLOW INLET DISTRIBUTORS

3.2 DESIGN PRESSURE AND TEMPERATURE

3.3 DESIGN CONDITIONS AND CALCULATIONS

3.4 CORROSION ALLOWANCE

3.5 LOAD CASES

b) reaction forces at nozzles and supports, including start-up, shut-down and

3.6 ALLOWABLE STRESSES

3.8 PANELS, GIRDERS AND LINING

3. All non-integrally lined components shall be clearly labelled externally to identify

3.9 UPPER AND LOWER HEADS

3.10 BAFFLES (OR PASS PARTITION PLATES)

3.11 BOLTS AND NUTS

3.13 NOZZLE LOADS

3.17 VENTS AND DRAINS

3.18 THREADED CONNECTIONS

3.19 CLEANING CONNECTIONS

3.20 INSTRUMENT CONNECTIONS