Admin مدير المنتدى
![مدير المنتدى مدير المنتدى](https://2img.net/i/itest/ranks/stars/stars13.gif)
![Admin](https://2img.net/u/1711/56/32/51/avatars/1-20.jpg)
عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
![كتاب Heat Exchangers Volume II - Third Edition Empty](https://2img.net/i/fa/empty.gif) | موضوع: كتاب Heat Exchangers Volume II - Third Edition الإثنين 01 يوليو 2024, 2:26 am | |
| ![](https://i.servimg.com/u/f61/15/36/74/14/subscr10.gif)
أخواني في الله أحضرت لكم كتاب Heat Exchangers Volume II - Third Edition Mechanical Design, Materials Selection, Nondestructive Testing, and Manufacturing Methods Kuppan Thulukkanam
![كتاب Heat Exchangers Volume II - Third Edition H_e_3_10](https://i.servimg.com/u/f61/15/36/74/14/h_e_3_10.jpg) و المحتوى كما يلي :
Contents Preface .xi Acknowledgments xv About the Author xvii Chapter 1 Mechanical Design of Shell and Tube Heat Exchangers .1 1.1 Pressure Vessels .1 1.2 Mechanical Design of Pressure Vessels and Heat Exchangers 5 1.3 Stress Analysis .15 1.4 Stress Categories 16 1.5 Design Methods and Design Criteria .19 1.6 Key Terms in Pressure Vessel and Heat Exchanger Design .24 1.7 Pressure Vessels Design .25 1.8 Mechanical Design of STHE .30 1.9 Fundamentals of Tubesheet Design .35 1.10 Tubesheet Design Procedure: Historical Background .38 1.11 Tubesheet Design as per ASME Code Section VIII Div. 1 46 1.12 Tubesheet Design as per TEMA Standards (Appendix A-Non-mandatory Section) 49 1.13 Flanged Tubesheets: TEMA Design Procedure A.1.3.3 58 1.14 Rectangular Tubesheet Design .58 1.15 Curved Tubesheets .60 1.16 Conventional Double Tubesheet Design 60 1.17 Cylindrical Shell, End Closures, and Formed Heads Under Internal Pressure 61 1.18 Bolted Flange Joint (BFJ) 70 1.19 Taper-Lok Heat Exchanger Closure 100 1.20 Expansion Joints 102 1.21 Openings and Nozzles 119 1.22 Nozzles .120 1.23 Supports .124 1.24 Lifting Devices and Attachments .128 Chapter 2 Material Selection and Fabrication .135 2.1 Material Selection Principles .135 2.2 Equipment Design Features .151 2.3 Raw Material Forms Used in the Construction of Heat Exchangers .152 2.4 Materials for Heat Exchanger and Pressure Vessel Construction 155 2.5 Plate Steels .156 2.6 Pipes and Tubes 160 2.7 Plate Steels Weldability Problems .163 2.8 Hot Cracking 172 2.9 Laboratory Tests to Determine Susceptibility to Cracking 176 2.10 Service-Oriented Cracking .178 2.11 Welding-Related Failures .178viii Contents viii 2.12 Selection of Cast Iron .178 2.13 Selection of Carbon Steels .179 2.14 Low-Alloy Steels .183 2.15 Quenched and Tempered Steels .185 2.16 Chromium-Molybdenum Steels .187 2.17 Stainless Steels .192 2.18 Ferritic Stainless Steels 220 2.19 Duplex Stainless Steels 225 2.20 Super Duplex Stainless Steel .234 2.21 Superaustenitic Stainless Steels .235 2.22 Aluminum Alloys: Metallurgy .237 2.23 Copper 249 2.24 Nickel and Nickel-Base Alloys Metallurgy and Properties .260 2.25 Titanium: Properties and Metallurgy .269 2.26 Zirconium .281 2.27 Tantalum .284 2.28 Materials for High Temperature Heat Exchangers 285 2.29 Graphite 285 2.30 Glass .290 2.31 Teflon .291 2.32 Ceramics 292 2.33 Composite 294 2.34 Alloys for Subzero/Cryogenic Temperatures .294 2.35 Cladding .303 2.36 Post-Weld Heat Treatment of Welded Joints in Steel Pressure Vessels and Heat Exchangers .320 Chapter 3 Quality Control, Inspection, and Nondestructive Testing 337 3.1 Quality Control and Quality Assurance .337 3.2 Quality Control System (QC) 339 3.3 Quality Manual 341 3.4 Elements of Quality Costs .343 3.5 Quality Review and Evaluation Procedures .344 3.6 Documentation .344 3.7 Quality Management 345 3.8 Quality Tools and Quality Improvements Methods .347 3.9 Inspection .362 3.10 Welding Design 364 3.11 Nondestructive Testing Methods 374 3.12 Visual Examination 385 3.13 Liquid Penetrant Inspection .391 3.14 Magnetic Particle Inspection 396 3.15 Magnetic Rubber Technique (MRT) 403 3.16 Radiographic Testing .404 3.17 Ultrasonic Testing 418 3.18 Advanced UT Methods 439 3.19 Acoustic Emission Testing .444 3.20 Eddy Current Testing .449 3.21 Tube Inspection with Magnetic Flux Leakage .459 3.22 Remote Field Eddy Current Testing .460Contents ix ix 3.23 Tube Inspection with Near Field Testing .461 3.24 Pulsed Eddy Current (PEC) .462 3.25 Heat Exchanger Tube Inspection Methods 464 3.26 Tubesheet Diagram for Windows .465 3.27 Alternating Current Field Measurement (ACFM) .465 3.28 Acoustic Pulse Reflectometry (APR) .466 3.29 Barkhausen Noise Analysis 467 3.30 Automated Corrosion Mapping .468 3.31 Drones Use in Nondestructive Testing .468 3.32 Dynamic NDT Methods .468 3.33 Electromagnetic Sorting of Ferrous Metals .469 3.34 Electromagnetic Acoustic Transducers 469 3.35 Optical Holography NDT 470 3.36 Magnetic Flux Leakage 470 3.37 Microwave Nondestructive Testing 472 3.38 Smart Pig 472 3.39 Replication Metallography .472 3.40 Shearography .473 3.41 Thermography 474 3.42 PAIRT .474 3.43 Leak Testing .474 3.44 In-Service Examination of Heat Exchangers for Detection of Leaks 482 Chapter 4 Fabrication, Brazing, and Soldering of Heat Exchangers 494 4.1 Introduction 494 4.2 Fabrication of the Shell and Tube Heat Exchanger 494 4.3 Vendor’s Responsibilities .497 4.4 Details of Manufacturing Drawing 497 4.5 Details of Manufacture of STHE .501 4.6 Plate Bending .508 4.7 Welding of Shells, Checking the Dimensions, and Subjecting Pieces to Radiography 509 4.8 Tubesheet and Baffle Drilling 514 4.9 Tube Bundle Assembly 519 4.10 Tubesheet to Shell Welding 526 4.11 Tube-to-Tubesheet Joint Fabrication 527 4.12 Tube-to-Tubesheet Joint Welding 553 4.13 Assembly of Channels/End Closures with Shell Assembly .577 4.14 Preparation of Heat Exchangers for Shipment .581 4.15 Making Up Certificates 582 4.16 Foundation Loading Diagrams/Drawings 582 4.17 Heads and Closures 583 4.18 Heads and Closures Forming Methods 585 4.19 Brazing .593 4.20 Elements of Brazing .595 4.21 Quality Control and Quality Assurance System for Brazing of Heat Exchangers 605 4.22 Brazing Methods 605 4.23 Brazing of Aluminum 617x Contents 4.24 Microchannel Heat Exchangers .627 4.25 Cuprobraze Heat Exchanger 629 4.26 Brazing of Heat-Resistant Alloys, Stainless Steel, and Reactive Metals 632 4.27 Post-Braze Cleaning after Lucasmilhaupt .634 4.28 Inspection and Testing of Brazed Joint 634 4.29 Nondestructive Testing Methods 635 4.30 Destructive Testing Methods 636 4.31 Soldering of Heat Exchangers .637 4.32 Nondestructive Testing of Soldered Heat Exchanger 644 4.33 Properties of Brazed Joints 645 4.34 Corrosion of Brazed Joints and Corrosion Control Methods 645 4.35 Corrosion of Soldered Joints 649 4.36 Evaluation of Design and Materials of Automotive Radiators 650 Annexures .651 Index 661 Index A Acoustical holography, 437 merits, 437 Acoustic emission testing (AE/AET), 444–449 acousto-ultrasonics (AU), 449 AE methods applications, 447 AE methods applications as per ASME code sec V, 447 applications: role of AE in inspection and quality control of pressure vessels and heat exchangers, 448 emission types and characteristics, 444 equipment, 447–448 factors influencing AE data, 448 Kaiser effect, 445 merits of acoustic emission testing, 449 physical phenomena that can release AE, 447 principle of acoustic emission, 444 reference code, 447 signal analysis, 448 source of acoustic emission, 444 written procedure for AET, 446 Acoustic pulse reflectometry (APR), 466 ASTM E2906/E2906M-18, 466 Advanced UT methods 439–444 advanced ultrasonic backscatter technique (AUBT), 440 dry-coupled ultrasonic testing (DCUT), 440 internal rotating inspection systems(IRIS), 442 long range ultrasonic testing (LRUT)/guided wave long range UT, 441 rapid ultrasonic gridding (RUG), 440 time of flight diffraction (TOFD), 444 Alloys for subzero/cryogenic temperatures, 294–302 cryogenic vessels, 300 ductile–brittle transition temperature (DBTT), 295 fabrication of cryogenic vessels and heat exchangers, 300 materials for low-temperature and cryogenic applications, 295–300 aluminum for cryogenic applications, 296–297 austenitic stainless steel, 300 carbon steels and alloy plate steels, 298–299 copper and copper alloys, 297 nickel and high-nickel alloys, 297–298 products other than plate, 299–300 titanium and titanium alloys, 297 9% nickel steel, 300–301 guidelines for welding of 9% NI steel, 301 merits of 9% nickel steel, 301 postweld heat treatment, 301–302 welding problems with 9% NI steel, 301 notch toughness, 295 notch toughness: ASME code requirements, 295 requirements of materials for low-temperature applications, 295 safety in cryogenics, 303 selection of material for low-temperature applications, 295 welding of austenitic stainless steels for cryogenic application, 302–303 charpy V-notch impact properties, 302 ferrite content, 302–303 nitrogen pickup, 303 oxide inclusion content, 303 sensitization, 302 Alternating current field measurement (ACFM), 465–466 applications, 466 Aluminium alloys: metallurgy, 237 corrosion prevention and control measures, 245–247 alclad alloys, 246 alloy and temper selection, 245 aluminum diffused steels in petroleum refinery heat exchangers, 246 cathodic protection, 246 design aspects, 245 inhibitors, 246 modification of the environment, 246 thickened surface oxide film and organic coating, 246 corrosion resistance, 241–243 chemical nature of aluminum: passivity, 242 resistance to waters, 242 seawater, 243 surface oxide film on aluminum, 241 fabrication, 247–249 joint geometry, 248 parameters affecting aluminum welding, 247 preheating, 248 shielding gas, 248 surface preparation and surface cleanliness, 248 welding filler metals, 249 welding methods, 249 forms of corrosion, 243–245 corrosion fatigue, 245 corrosion of aluminum in diesel engine cooling water system, 245 crevice corrosion, 245 erosion corrosion, cavitation, and impingement attack, 245 exfoliation corrosion, 244 galvanic corrosion, 243 intergranularcorrosion, 244 pitting corrosion, 243 stress corrosion cracking, 243 uniform corrosion, 243 properties of aluminum, 238 aluminum for heat exchanger applications, 238 product forms and shapes, 240–241 temper designation system of aluminum and aluminum alloys, 240 wrought alloy designations, 238–240 classification of wrought alloys, 239662 Index 662 Assembly of channels/end closures, 577–580 bolt tightening, 577 hydrostatic testing, 578–580 cyclic hydrostatic testing of feedwater heater, 579 heaters, 579 Hydroproof , 579 hydrostatic test fluid, 579 improved method for hydrostatic testing of welded tube-to-tubesheet joint of feedwater, 579 pneumatic test, 579 pneumatic testing procedure, 580 stamping, 580 standard test, 578 TEMA Standard requirement RCB-1.3, 578 use of fluorescent or visible tracer dyes in hydrostatic test fluids, 579 Austenitic stainless steel, 194–219 alloying elements and microstructure, 196 composition of wrought alloys, 196 alloy types and their applications, 197 type 304, 197 type 310, 197 type 316, 197 austenitic stainless steel fabrication, 206 properties and metallurgy, 194–195 types of austenitic stainless steel, 194 alloy development, 194 welding, 206–219 control of distortion, 216 corrosion resistance of stainless steel welds, 219 ferrite content, 207 filler metal for various grades of stainless steel, 208 filler metal selection, 207 gas coverage, 216 hot cracking, 207 joining stainless and other steels, 215 joint design, 208 lining 219 mechanical properties at cryogenic temperature and elevated temperature, 196 mechanism of corrosion resistance, 197–198 passive versus active behavior, 198 resistance to chemicals, 198 sigma phase, 198 stainless steel in seawater, 198 microfissuring or liquation cracking in austenitic stainless steel weld, 209 nitrogen pickup, 212 porosity: beginning and end, 217 postweld cleaning 219 postweld heat treatment, 218 PWHT cracking, 218 properties of austenitic stainless steels, 195 protecting the roots of the welds against oxidation, 216–217 gas shielding, 216 root flux, 217 resistance to various forms of corrosion, 198–205 caustic SCC, 201 comparison of pitting and crevice corrosion of stainless steels, 200 crevice corrosion, 200 critical crevice corrosion temperature, 200 critical pitting corrosion temperature, 200 evaluation of sensitization of austenitic SS to PASCC, 203 factors influencing susceptibility to weld decay, 203 galvanic corrosion, 198 influence of nickel content on SCC, 201 intergranular corrosion, 203 knifelineattack, 205 laboratory tests to determine SCC, 203 localized forms of corrosion, 199 measures to overcome weld decay, 204 methods to prevent SCC of SS, 203 pitting corrosion, 199 pitting resistance number, 199 polythionic acid stress corrosion cracking (PASCC) , 202 prediction of IGC by laboratory tests, 205 prevention of scc in boiling water reactors, 203 SCC of welded austenitic stainless steels, 201 stress corrosion cracking, 201 sensitization (weld decay) and corrosion resistance, 215 shielding gases, 208 TIG welding techniques to overcome carbide precipitation, 216 variable weld penetration, 214 welding considerations, 208 welding consumables, 211 welding defects, 217 welding fumes, 216 welding practices to improve the weld performance, 216 welding procedure variations, 212 welding processes, 207, 212 welding stainless steels to dissimilar metals, 218–219 filler metals for welding SS with dissimilar metal, 219 methods to overcome dilution problems, 218 Automated corrosion mapping, 468 Automotive Radiators, see Evaluation of Design and Materials of Automotive Radiators B Barkhausen noise analysis, 467–468 applications, 468 Bolted flange joint (BFJ), 70–97 BFJ technical requirements, 72 bolting design, 94–97 bolt area at the root of the threads, 95 determination of bolt loads, 94 flange bolt load W, 96 gasket seating conditions, 94 load concentration factor, 97 maximum recommended bolt spacing, 96 minimum bolt size, 96 minimum recommended bolt spacing, 96 operating conditions, 95Index 663 663 pitch circle diameter, 96 relaxation of bolt stress at elevated temperature, 97 bolting material, 80 design of bolted flange joints, 87–93 design procedure, 87 gasket dimensions, 92 gasket factor, m, 92 gasket materials, 89 gasket or joint contact surface unit seating load, y, 92 gasket parameters, 89 gasket profile, 90 gasket size, 91 gasket width and diametral location of gasket load reaction, 93 selection of gasket material, 89 flange, 72–80 ASME code approved flange materials, 78 ASTM standards for flange material, 78 flange classes and types, 73 flanged joint construction, 73 flange face finish definition and common terminology, 74 flange facings, 73 flange finish on gasket performance, 73 flange material selection, 78 flange standards, 74 flange standards-ASME specifications, 76 flange types, 72 selection of flange, 78 flange design, 97–99 bolting procedures, 99 flange moments, 97 flange thickness, 98 flanged joints in shell and tube heat exchanger, 85–87 collar bolts in shell and tube heat exchanger, 86 flange types found in shell and tube exchangers, 86 girth flange, 86 heat exchanger gaskets, 85 forces acting on the bolted flange connection, 70 gaskets, 80–85 effecting or creating a seal, 80 gasket categories, 80 gasket material considerations, 80 gasket seating, 81 gasket standards, 81 gasket types based on material, 81 guidelines for bolted flanged joint assembly procedure, 82 maintaining the seal, 71 step-by-step procedure for integral/loose/optional flanges design, 99 Brazing, 593–595 brazing, 593 brazing advantages, 594 brazing codes and standards, 594–595 ASME code section IX, welding, brazing, and fusing qualifications, 594 AWS A2.4:2020: standard symbols for welding, brazing, and nondestructive examination, 595 characteristics of brazing, 593 characteristics of soldering, 594 definition and general description of brazing and soldering process, 593 disadvantages of brazing, 594 Brazing, elements of- 595–604 Brazing alloy or filler metals, 596 capillary attraction and joint clearance, 597 composition of filler metals, 597–600 aluminium filler metals, 597 ASME Code specification for filler metals, 600 cladding alloys, 598 copper fillers, 598 forms of filler metal, 599 gold-based fillers, 599 nickel-based filler metals, 599 placement of filler metal, 599 silver-based filler metals, 599 specification for filler metals for brazing, 597 fixturing, 603 fluxing, 601–602 composition of the flux, 601 selection of a flux, 601 varieties of flux, 601 fluxing methods, 602–603 demerits of brazing using corrosive fluxes, 603 heating method, 603–604 diffuse heating techniques, 604 local heating, 603 joint gap, 596 joint design, 595 postbraze treatment and removing flux residues, 604 chemical cleaning, 604 mechanical cleaning, 604 ultrasonic cleaning, 604 properties of brazed joints, 645 corrosion resistance, 645 mechanical properties, 645 microstructure, 645 precleaning and surface preparation, 600–601 chemical cleaning, 600 protection of precleaned parts, 601 scale and oxide removal, 600 selection of filler and flux, 597 Brazing methods, 605–617 dip brazing, 609 furnace brazing, 611–616 batch furnaces, 613 brazing furnace selection, 611 brazing furnace: vacuum vs. continuous-belt, 611 brazing process cycle in a batch furnace, 614 brazing thermal cycle, 613 continuous furnaces, 615 fundamentals of brazing process control, 612 six fundamentals of brazing to follow, 605 torchor or flame brazing, 606–609 brazing of inlet/outlet tubes to end plate of brazed plate heat exchangers, 607 consumables–gas, 606 flame brazing of aluminium with copper, 607664 Index 664 flame brazing with hand-held filler or pre-placed filler, 606, 607 induction brazing of return bends of heat exchanger coil, 607 the induction brazing process, 607 joint clearances, 606 process parameters, 606 torch brazing of aluminum, 606 vacuum brazing, 616–617 braze stopoffs, 617 brazing process cycle in a vacuum furnace, 616 furnace brazing-safety awareness, 617 gases used in the process, 617 postbraze cleaning, 617 Brazing of aluminum, 617 AWS C3.7M/C3.7-2022: specification for aluminum brazing, 617 aluminum alloys that can be brazed, 618 aluminum brazing methods, 619–627 aluminum dip brazing, 620 brazing of radiators and condensers, 620 brazing process, 623 controlled-atmosphere brazing (CAB) process, 623 controlled dry air brazing, 622 CAB process advantages, 623 furnace brazing, 622 inert-gas or controlled-atmosphere brazing of aluminum, 622 key aspects of controlled atmosphere brazing (CAB), 622 postbraze cleaning and finishing, 627 vacuum brazing of aluminum, 625 elements of aluminium brazing, 618–619 aluminum filler metals, 619 fluxing, 619 joint clearance/ select capillary size (Gap), 618 need for closer temperature control, 618 precleaning, 618 surface oxide removal, 618 Brazing of heat-resistant alloys, stainless steel and reactive metals, 632–634 brazing of cobalt-based alloys, 633 brazing of nickel-based alloys, 632–633 brazing filler metals, 633 brazing of stainless steel, 633–634 brazeability of stainless steel, 633 brazing of reactive metals, 634 C Carbon steels, 180–182 carbon steel tubes for feedwater applications, 181 corrosion resistance, 181 fabrication, 182–183 arc welding of carbon steels, 182 hardness limitation for refinery service, 182 plate cutting, 182 weldability considerations, 182 welding defects, 183 welding processes, 182 product forms, 180 refinery operations, 181 steel making process improvements, 179 steels, 179 types of steel, 180 use of carbon steels, 180 Cast iron, 178 Ceramics, 292–293 classification of engineering ceramics, 292 Hexoloy silicon carbide heat exchanger tube, 293 suitability of ceramics for heat exchanger construction, 292 types of ceramic heat exchanger construction, 292 Chromium–molybdenum steels, 187–189 applications, 189 composition and properties, 188 creep strength, 189 welding metallurgy, 189–192 advanced 3 Cr–Mo–Ni steels, 192 control of temper embrittlement of weld metal, 191 CVN impact properties, 191 filler metal, 190 Larson–Miller tempering parameter, 191 modified 9 Cr–1Mo steel, 192 postweld heat treatment (stress relief), 191 preheating, 190 reheat cracking in Cr–Mo and Cr–Mo–V steels, 192 step-cooling heat treatment, 191 temper embrittlement of weld metal, 191 temper embrittlement susceptibility, 190 welding processes, 190 Cladding, 303 ASME Code requirements in using clad material, 317 clad tubesheets, 317 forming of clad steel plates, 318 cladding thickness, 304 clad plate, 304 backing materials, 304 corrosion resistance cladding grades, 304 explosive cladding, 313–316 angular geometry, 314, 316 explosion cladding process sequence, 314 inspection of joint quality, 316 plug welding, 316 tube-to-tubesheet welding, 316 welding geometries, 314 materials & standards of clad steel plates, 311–313 ASTM specification for clad plate, 312–313 stainless steel clad metal, 312 standard & specification, 312 titanium clad steel plate, 312 methods of cladding, 304–308 loose lining, 306 thermal spraying, 306 weld overlaying or weld surfacing, 307 weld dilution, 307–308 roll cladding, 310–311 inspection of overlays, 310Index 665 665 nickel alloy cladding, 310 procedure and welder qualification, 310 stainless steel strip cladding, 310 weld overlay cladding methods, 308–310 processing of explosion clad plates, 317 test and inspection [295], 313 inspection of stainless steel cladding, 313 welding of stainless steel clad plate, 317–320 selection of filler metals, 318–319 titanium clad steel repair, 319–320 welding clad plate by SMAW process, 318 Composite, 294 ASME code section X fiber-reinforced plastic pressure vessels, 294 fiberglass tanks and vessels, 294 Conventional double tubesheet design, 60 conventional double tubesheet design TEMA guidelines, 60 Copper, 249–260 copper alloy designation-UNS system, 250 wrought alloys, 250 copper and aquatic life, 257 copper corrosion, 254–257 biofouling, 256 condensate corrosion, 255 cooling-water applications, 256 corrosion fatigue, 256 corrosion resistance, 254 dealloying (dezincification), 254 dealuminification, 255 denickelification, 255 deposit attack, 256 erosion–corrosion, 255 exfoliation, 257 galvanic corrosion, 254 hot-spot corrosion, 256 intergranular corrosion, 254 pitting corrosion, 254 resistance to seawater corrosion, 256 snake skin formation, 256 steam-side stress corrosion cracking, 255 stress corrosion cracking, 255 sulfide attack, 256 copper heat exchanger applications, 250–253 copper in steam generation, 250 designation of copper and copper alloys used as heat exchanger materials, 25 product forms–copper tubes for heat exchanger, 251 copper welding, 257–259 brasses, 259 copper alloys, 259 copper–aluminum alloys (aluminum bronzes), 260 copper–nickel or cupronickel alloys, 260 factors affecting weldability, 258 hot cracking, 258 porosity, 259 preheating, 258 PWHT, 260 silicon bronzes, 259 thermal conductivity, 258 thermal expansion, 258 weldability, 257 weldability considerations, 259–260 welding precautions, 259 welding with dissimilar metal, 260 Corrosion of brazed joints and corrosion control methods, 645–649 corrosion protection, 647–649 corrosion tests [138], 648 multi-metal closed-loop systems, 648 protective coatings, 648 sacrificial zinc coatings, 648 trivalent chromium process coating, 648 corrosion protection in all aluminum microchannel coil, 647 forms of corrosion, 647 galvanic corrosion resistance, 646 influence of brazing process, 646 factors affecting corrosion of brazedjoints, 645 Corrosion of soldered joints, 649–650 manufacturing procedures to control solder bloom corrosion, 650 solder bloom corrosion, 649 Cuprobraze heat exchanger, 629–632 brazing process, 630 high-performance coatings, 631 round tube versus flat tube, 631 tube fabrication, 629 Curved tubesheets, 60 Cylindrical shell, end closures, and formed heads under internal pressure, 61–64 cylindrical shell under internal pressure, 62 design for external pressure and/or internal vacuum, 63 end closures and formed heads, 64–69 ASME F&D head, 67 conical, 66 ellipsoidal, 65 elliptical head 2:1, 67 flat cover, 64 hemispherical, 64 Klöpper head, 67 Korbbogen head, 67 minimum thickness of heads and closures, 67 torispherical head (or flanged and dished head), 67 thick spherical shells, 63 thin cylindrical shells, 62 D Design methods and design criteria for heat exchanger, 19–22 allowable stress, 21 ASME code section VIII design criteria, 20 combined-thickness approach for clad plates, 21 design by analysis (DBA), 20 design by rule (DBR), 20 design criteria, 20 design loads, 19 strength theories, 21 stress categorization, 20666 Index 666 welded joints, 22–23 joint categories, 22 welded joint efficiencies, 22 weld joint types, 23 Destructive testing methods, 636–637 Details of manufacture of STHE, 497–509 details of manufacturing drawing, 497–501 fabrication requirements, 499 edge preparation and rolling of shell sections, tack welding, and alignment for welding of longitudinal seams, 505–508 fabrication of shell–general, 507 identification ofmaterials, 505 positive material identification (PMI), 505 plate bending, 508–509 roll bending, 508 quality control during assembly of parts, 503 quality control during production welding, 500–501 shell and tube heat exchanger fabrication and inspectionnes, 501 tube bundle assembly, see Tube bundle assembly tubesheet and baffle drilling, see Tubesheet and baffle drilling welding of shells, checking the dimensions, and subjecting pieces to radiography, 509–514 attachment of expansion joints, 513 checking the circularity of shell and the assembly fit, with nozzles and expansion joints welded, 513 dimensional check, 509 flanges, 512 operations checklist list for nozzles on shell/dish welding, 512 PWHT of shells, 513 reinforcing pads and testing, 512 supports, 513 welding of nozzles, 510 Drones use in nondestructive testing, 468 Duplex stainless steels, 225–234 advantages over the common austenitic stainless steels, 227 categories of duplex stainless steel, 226 characteristics of duplex SS, 226 comparison of duplex SS with austenitic and ferritic stainless steels, 228 composition, 227 corrosion resistance, 229–230 intergranular corrosion, 230 pitting and crevice corrosion, 229 PRE N of duplex stainless steels, 229 resistance to chemical environments, 229 expansion of tube to tubesheet joints, 234 metallurgy of duplex stainless steels, 227 Norsok standard, 233–234 process applications, 230 products, 228 welding methods, 231–233 balancing the austenite and ferrite phases, 231 ferrite in duplex stainless steels, 233 gas shielding, 232 heat input, 231 liquation cracking, 232 postweld stress relief, 233 precipitation of chromium nitrides, 232 sigma phase embrittlement and 475oC embrittlement, 232 weldability, 231 welding consumables, 232 welding practices to retain corrosion resistance, 233 welding methods for modern duplex stainless steels, 234 Dynamic NDT methods, 468 E Eddy current testing(ET/ECT), 449–459 ASTM specifications, 453 automated surface inspection using eddy current array technology, 459 calibration, 458 common applications, 450 eddy current arrays, 459 eddy current examinations methods as per ASME code Sec. V, 452 eddy current techniques, 450 eddy current test equipment, 454 eddy current testing, 451 eddy current testing principle, 449 inspection method for tube interior, 458 inspection of ferromagnetic tubes, 458 inspection or test frequency and its effect on flaw detectability, 456 limitations of eddy current testing, 458 merits of ET and comparison with other methods, 458 operating variables, 456–457 depth of penetration and frequency, 456 edge effect, 457 fill factor and probe size requirements, 457 skin effect, 457 probes, 454 probe configuration, 454 reference standards for eddy current testing, 453 signal processing, 455 testing of weldments, 458 tube inspection, 451 written procedure for eddy current testing, 453 Electromagnetic acoustic transducers (EMAT), 469–470 Electromagnetic sorting of ferrous metals, 469 ASTM E566-19, 469 Equipment design features, 151–152 access for inspection, 151 equipment life, 151 fail safe features, 151 field trials, 152 maintenance, 151 safety, 151 Evaluation of design and materials of automotive radiators, 650–651 Mechanical durability tests, 650 tests for corrosion resistance, 650–651 Expansion joints, 102–103 bellows or formed membrane, 111–119Index 667 667 applications, 113 ASME code sec VIII div 1 bellows expansion joints article 26, 117 bellows design: circular expansion joints, 115 bellows materials, 115 construction, 111 cycle life, 115 EJMA standards, 115 end fittings, 114 flow turbulence, 114 limitations and means to improve the operational capability of bellows, 117 movement capabilities, 113 classification of expansion joints, 103 flexibility of expansion joints, 103 formed head or flanged-and-flued head, 103–111 ASME code and TEMA procedure for design, 108 construction, 105 design method as per ASME code sec VIII div 1, 110 design of formed head expansion joints, 106 finite element analysis, 107 Kopp and Sayre model, 106 Singh and Soler model, 106 TEMA procedure, 108 TEMA RCB–8.1.1 analyis sequence, 110 F Fabrication of the shell and tube heat exchanger, 494–497 manufacturing and testing, 495 quality assurance plan (QAP), 495–497 hold points and witness points, 497 inspection and test plan, 495 features of ITP, 497 Ferritic stainless steels, 220 conventional ferritic stainless steels, 220 corrosion resistance, 224 intergranular corrosion, 224 fabricability, 224 “new” and “old” ferritic and austenitic stainless steels, 220 superferritic stainless steel, 220–224 applications, 222 characteristics, 222 ductile–brittle transition, 224 physical properties, 223 strength, 223 superferriticsalloy composition, 221 toughness and embrittling phenomena, 223 welding, 224–225 Flanged tubesheets: TEMA design procedure A.1.3.3, 58 tubesheet extended as flange, 58 Foundation loading diagrams drawings, 582–583 installation, maintenance, and operating instructions, 583 schematics or flow diagrams, 583 Fundamentals of tubesheet design, 35–38 fixed tubesheet heat exchanger, 35 floating head heat exchanger, 38 tubesheet connection with the shell and channel, 35 u-tube tubesheet, 36 G Glass, 290–291 applications, 290 construction types, 290 drawbacks of glass material, 290–291 glass-lined steel, 290 mechanical properties and resistance to chemicals, 290 Graphite, 285–289 applications of impervious graphite heat exchangers, 287 cubic graphite heat exchangers, 287 drawbacks associated with graphite, 287 equipment applications and service limitations, 286 graphite plate exchanger, 288 impregnated graphite, 285 shell and tube heat exchanger, 288 standard test method for impregnated graphite (mandatory appendix 38), 286 H Heads and closures, 583–585 ASME flanged and dished (ASME F&D) heads, 583 cones, 590 conical, 585 crown-and-segment (C and S) technique, 588 dimensional check of heads, 592 dished heads, 586 flat heads, 585 forming methods, 585–593 hemispherical head, 585 pressing, 587 pressure vessel heads, 583 purchased end closures, 592 PWHT of dished ends, 590 semi-elliptical (SE) heads, 584 spinning, 586 torispherical head, 585 Heat exchanger tube inspection methods, 464–465 eddy current testing of chiller tubes, 465 Hot cracking, 172 factors responsible for hot cracking, 172 susceptible alloys, 172 types of hot cracking, 172–176 chevron cracking, 176 crater cracks, 176 ductility dip cracking, 176 heat-affected zone liquation cracking, 173 reheat cracking or stress-relief cracking, 174–176 avoidance of reheat cracking, 175 susceptible alloys, 175 underclad cracking, 175 solidification cracking, 173 elements contributing to solidification cracking, 173 welding procedure-related factors responsible for solidification cracking, 173 Hydrogen damage, 147–150 detecting hydrogen damage, 149 fabricability, 150 high temperature hydrogen attack, 148 hydrogen embrittlement, 147668 Index 668 MR 0175/ISO 15156, 149 Nelson curves, 148 prevention of hydrogen attack, 148 sources of hydrogen, 147 types of hydrogen damage, 147 I In-service examination of heat exchangers for detection of leaks, 482–485 Inspection, 362–364 definitions, 362 design and inspection, 363 detailed checklist for components, 364 inspection guidelines, 363 master traveler, 364 objectives of inspection, 362 scope of inspection of heat exchangers, 363 material control and raw material inspection, 363 positive material identification, 363 TEMA Standards for inspection, 364 third-party inspection, 364 hold points and witness points, 364 Inspection and testing of brazed joint, 634–635 discontinuities, 635 quality of the brazed joints, 634 K Key terms in pressure vessel and heat exchanger design, 24–25 corrosion allowance, 25 design pressure, 24 design temperature, 24 maximum allowable working pressure, 24 operating pressure or working pressure, 25 operating temperature or working temperature, 25 L Laboratory tests for determining susceptibility to cracking, 176–178 multitask varestraint weldability testing system, 177 varestraint (variable restraint) test, 177 weldability tests, 176 Leak testing (LI), 474–482 ASTM standards for LT, 475 helium mass leak detection methods, 480–482 helium mass spectrometer test—detector probe technique, 481 helium mass spectrometer test—tracer probe technique, 481 helium mass spectrometer vacuum test—hood technique, 481 leak test methods, 476–480 acoustical leak detection, 476 acoustic emission leak testing, 479 “bombing” test, 478 bubble leak testing, 476 dye penetrant method, 477 gas leak lake testing, 476 halogen diode detector probe test method, 479 inside-out helium vacuum chamber leak testing, 477 outside-in helium leak testing, 477 pressure change testing, 477 pressure decay test, 477 vacuum decay test or pressure rise test, 477 radiotracer technique, 478 tracer gas leak testing, 479 ultrasonic leak detection, 476 water immersion bubble test method, 476 LT methods as per ASME code Sec V, 475 requirements of leak testing, 475 written procedure, 474 Lifting devices and attachments, 128 Liquid penetrant inspection (PT), 391–396 acceptance standards, 395 applications, 392 developments in PT, 395 evaluation of indications, 395 excess penetrant removal, 395 limitations, 392 merits of PT, 392 method of inspection, 394 penetrants, 393 approved material, 394 penetrant application, 394 penetration time or dwell time, 394 postcleaning, 395 principle of inspection, 391 selection of developer, 394 standards, 393 standardization of light levels for penetrant and magnetic inspection, 395 surface preparation, 394 techniques, 391 test procedure, 393 written procedure, 392 Low-alloy steels, 183–185 applications of low-alloy steel plates, 184 carbon–manganese steels, 184 carbon–manganese–molybdenum steels, 185 carbon–molybdenum steels, 184 low-alloy steels for pressure vessel constructions, 184 selection of steels for pressure vessel construction, 183 M Magnetic flux leakage technique, 470–471 Magnetic particle inspection (MT), 396–403 acceptance standards, 403 application of examination medium, 402 demagnetization, 402 equipment for magnetic particle inspection, 400 evaluation of indications, 402 examination coverage, 401 factors affecting the formation and appearance of the magnetic particles pattern, 398 inspection medium (magnetic particles), 401 inspection method, 402 dry method, 402 wet method, 402 interpretation of indications, 403Index 669 669 limitations of the method, 398 magnetizing current, 399 magnetizing technique, 400–401 coil magnetization, 400 prod magnetization, 401 yoke magnetization, 401 merits of MT, 398 MT techniques, 396 principle, 396 record of test data, 402 reference documents, 398 surface preparation for testing, 399 test procedure, 398 written procedure, 399 magnetic particle examination procedure deficiencies, 399 Magnetic rubber techniques (MRT), 403 Making up certificates, 582 Material selection principles, 135–136 ASME code material requirements, 136–137 Section II materials, 137 Section VIII div.1, 137 Section VIII div.1 requirements for pressure vessels constructed of nonferrous materials, 137 cost, 150 cost-effective material selection, 150 desired material requirements features, 135 evaluation of materials, 150 functional requirements of materials, 138–146 brittle fracture, 139 corrosion failures, 146 corrosion resistance, 145 creep, 141 fatigue strength, 139 heat and corrosion, 144 hydrogen damage, see Hydrogen damage strength, 138 temperature resistance, 142 toughness, 140 international material specifications, 138 material selection factors, 136 possible failure modes and damage in service, 150–151 review of operating process, 136 sources of material data, 146 unified numbering system, 137 Materials for heat exchanger and pressure vessel construction, 155–156 metals, 155 materials for high-temperature heat exchangers, 285 non-metals, 156 Mechanical design of pressure vessels and heat exchangers, 5–15 ASME codes, 10–15 Code interpretations, 15 comparison of ASME code section VIII div. 1 versus div. 2, 14 scope of the ASME code section VIII pressure vessels, 12 section X fiber-reinforced plastic pressure vessels, 14 section XIII, rules for overpressure protection, 14 structure of section VIII, division 1, 13 submittals, 15 codes, 9–10 introduction to few international codes for unfired pressure vessels, 10 structure of the codes, 9 design standards used for the mechanical design of heat exchangers (STHE), 7–9 differences among TEMA classes R, C, and B, 8 other standards for STHE, 8 TEMA standards (section 5, RCB-1.1.1), 7 Standards and Codes, 5–6 benefits of standardization, 6 national standards, 6 trade or manufacturer’s association standards, 6 Mechanical design of STHE, 30–35 ASME code sec VIII div 1 part UHX rules for STHE, 31 content of mechanical design of STHE, 33 design loadings, 35 design of STHE components, 35 mechanical design and pressure vessel codes and standards, 31 mechanical design procedure, 33 required information for mechanical design, 31 sequence of decisions to be made during mechanical design, 32 software for mechanical design of heat exchanger, 33 STHE types, 30 Microchannel heat exchangers (MCHE), 627–629 brazing of MCHE, 627 Microwave non-destructive testing, 472 N Nickel and nickel-base alloys: metallurgy and properties, 260–269 classification of nickel alloys, 261–264 commercially pure nickel, 261 Inconel and inco alloy, 261 magnetic properties and differentiation of nickels, 264 nickel–copper alloys and copper–nickel alloys, 261 nickel–iron–chromium alloys and Inco nickel– iron–chromium alloys for high-temperature applications, 263 90-10 and 70-30 copper–nickel alloys, 261 corrosion resistance, 264–267 galvanic corrosion, 264 intergranular corrosion, 264 pitting resistance, 264 stress corrosion cracking, 266 Hastelloy 269 welding, 267–269 carbide precipitation, 268 considerations while welding nickel, 267 heat input, 268 hot cracking, 268 joint designs, 267 lead embrittlement, 268 pitting corrosion of weldments, 269 strainage cracking, 269670 Index 670 sulfur embrittlement, 268 weldability, 267–269 postweld heat treatment, 269 welding methods, 269 Nondestructive testing methods, 374–385 acceptance criteria, 377 auditing the NDT procedures, 384 cost of NDT, 377–380 the benefits of NDT for a business, 380 the economic aspects of NDT, 377 destructive testing (mechanical testing), 374 discontinuities, 384–385 defect detection, 385 defect detection capability, 385 surface techniques, 385 volumetric techniques, 385 examination procedure-general requirements, 376 inspection equipment, 381 level I, II and III qualifications as per SNT-TC-1A- 2020, 380 NDT personnel qualifications, 380 personnel, 380 qualification(s), 376 reference codes and standards, 381 ASME code section V: nondestructive examination, 381 training of NDT personnel, 380 NDT standards, 374–375 ASME Code section V nondestructive examination, 375 ASNT standards, 375 ASTM E1316-21 standard terminology for nondestructive examinations, 375 ASTM standards, 375 AWS B1.10M/B1.10:2016 guide for the nondestructive examination of welds, 375 NDT symbols, 381–382 specify NDT locations, 382 NDT techniques, 375–376 advanced NDT techniques, 375 conventional NDT techniques, 375 scope of NDT, 374 selection of NDT methods, 377 capabilities and limitations of NDT methods, 377 third-party inspection in NDT, 384 written procedures, 383 content of NDT procedures, 383 deficiencies in NDT procedures, 383 general details of requirements in the NDT procedure document, 383 Nondestructive testing methods of brazed joints, 635–636 Nondestructive testing of soldered heat exchanger, 644 destructive testing, 644 discontinuities, 644 pressure and leak testing, 644 removal of residual flux, 644 visual inspection, 644 Nozzles, 120–123 design of pressure vessel nozzles, 122 nozzle openings reinforcement, 123 standards for nozzle design, 123–124 WRC 107/537 analysis, 124 types of nozzles, 121 O Opening and nozzles, 119–120 openings, 119 reinforcement pad, 120 reinforcement pad and air–soap solution testing, 120 Optical holography NDT, 470 holographic interferometry in crack detection, 470 real-time holographic interferometry, 470 P PAIRT, 474 Pipefittings, 100 Pipes and tubes, 160 selection of tubes for heat exchangers, 160–163 ASTM specifications for ferrous alloys tubings 162 corrosion tests 161 defect detection 160 dimensional tolerance tests 161 hydrostatic pressure testing 161 pneumatic test 161 specifications for tubes 160 standard testing for tubular products 161 tubing requirements, 160 Plate steels, 156–160 classifications and designations of plate steels: carbon and alloy steels, 156–158 ASTM specifications on plate steels used for pressure vessel fabrications and heat exchangers, 157 how do plate steels gain their properties?, 156 mill scale, 159–160 processing of plate steels, 158–159 Plate steels weldability problems, 163 cold cracking, 163 hydrogen-induced cracking, 163–168 avoiding hydrogen cracking, 163 preheating, interpass temperature, and postheating, 164 lamellar tearing, 168–172 conditions that promote lamellar tearing 169 detection of lamellar tearing after welding 172 prevention of lamellar tearing 170 structures/locations prone to lamellar tearing 170 underbead cracking, 168 fish-eye cracking 172 hot cracking, see Hot cracling Post braze cleaning, 634 cleaning methods for post-braze flux removal, 634 Postweld heat treatment (PWHT) of welded joints in steel pressure vessels and heat exchangers, 320–324 ASME code requirements for PWHT, 321 defects arising due to heat treatment, 323 effectiveness of heat treatment, 323 effects of changes in steel quality and PWHT, 321 methods of PWHT, 323 NDT after PWHT, 324Index 671 671 objectives of heat treatment, 320 possible welding-related failures, 324 PWHT cycle, 322 quality control during heat treatment, 322–323 types of heat treatment, 320–321 Preparation of heat exchangers for shipment, 581–582 nitrogen filling, 582 other protection considerations, 581 painting, 582 TEMA guidelines G-6, 581–582 Pressure vessels, 1–5 fired and unfired pressure vessel, 1–5 heat exchangers, 3 hazards due to failures of pressure vessels, 5 unfired pressure vessels, 2 types of pressure vessels, 1 Pressure vessels design, 25–30 common causes of failures and explosions in pressure vessels, 30 compliance with ASME code, 30 construction details of pressure vessels, 25 data required for a pressure vessel design, 27 design considerations, 27 design parameters, 28 geometry definition, 27 materials of construction, 28 methods of construction of pressure vessels, 29 minimum wall thickness, 28 outlets and drains, 26 pressure equipment devices, 26 pressure vessel design codes, 26 pressure vessel shapes, 25 types of pressure vessel heads, 25 venting and relief devices, 26 Pulsed eddy current (PEC) examination, 462–464 Q Quality and quality control, 337–338 aims of quality control, 338 Quality assurance program (QAP), 338–339 contents of QAP for pressure vessels and heat exchangers, 339 essential elements of QAP, 338 need for quality assurance, 338 quality assurance in fabrication of heat exchangers and pressure vessels, 338 Quality control and quality assurance system for brazing of heat exchangers, 605 Quality control (QC) and quality assurance(QA), 337 Quality costs, 343–344 appraisal costs, 343 external failure costs, 343 internal failure costs, 343 optimum cost of quality, 343 prevention costs, 343 Quality management, 345 quality Gurus–their contribution for quality management, 345–346 quality philosophies of Deming, Juran, and Crosby, 346–347 Crosby four absolutes of quality, 347 Crosby vaccine, 347 Deming PDCA cycle, 346 Juran’s contribution to concepts of quality, 346 Quality management in industry, 337 Quality manual, 341–343 contents of manual, 342 main documents of the quality system, 342–343 checklist, 343 operation process sheet, 342 quality assurance program, 342 Quality review and evaluation procedures, 344 auditing, 344 Quality system, 339–341 ASME code: elements of quality control system, 341 correction of nonconformities, 341 inspection of vessels and vessel parts, 341 material control, 341 records retention, 341 features of QC system, 339 Quality tools and quality improvements methods, 347–362 5S, 355–356 ISO 9000, 352–354 benefits of ISO 9000, 353 ISO 9000 series, 352–353 ISO 9001 quality management system, 353 Kaizen , 357–358 the core of Kaizen , 358 lean, 358–359 lean manufacturing, 359 lean tools, 360 lean-six sigma, 362 lean vs. six sigma, 361 MBNQA, 355 plan-do-check-act (PDCA) cycle, 354 PDSA technique, 354 7 quality control (7-QC) tools, 348–352 check sheets, 350 fishbone diagram or cause and effect diagram, 349–350 histogram, 348 Pareto analysis (80-20 rule), 349 scatter diagram, 351 statistical quality control and control chart, 351–352 stratification, 351 six big losses, 359 six sigma quality management methodology, 360–362 six sigma tools and methods, 361 total quality management, 355 elements of total quality management, 355 total productive maintenance(TPM), 356–357 TPM pillars and 5S, 357 goals of TPM, 357 Quenched and tempered steels, 185–187 ASTM specifications, 185 compositions and properties, 185 joint design, 187 postweld heat treatment, 187672 Index 672 preheat, 187 stress-relief cracking, 187 weldability, 186 welding processes, 187 R Radiographic testing, 404–418 acceptance criteria, 415 application, 405 ASTM standards, 407 computed tomography, 415 density of radiographs, 412 digital radiography, 416–417 digitization of radiographs and laser scanner system, 418 documentation, 415 examination of radiographs, 414 full radiography, 409 gamma radiography, 418 gammascopy, 418 general procedure in radiography, 407 high-energy radiography, 418 identification marks, 407 image quality indicators, 412 how to calculate IQI sensitivity, 412–414 number of IQIs, 412 imaging plate, 418 location markers, 407 merits and limitations, 405 microfocus radiography, 415 neutron radiography, 417 other methods in radiography, 415 panoramic radiography with isotopes, 408 principle of radiography, 404 processing of X-ray films, 408 radiographic quality, 411 radiographic sensitivity, 411 radiation sources (X-rays and gamma rays), 405 comparison of X-ray and gamma-ray radiography, 405 radiographic techniques for weldments of pressure vessels, 408 radioscopy, 417 ASME code sec V reference documents, 407 requirements of radiography, 406 RT methods, 404 safety in RT, 407 spot radiography, 410 surface preparation, 408 written procedure, 406 X-ray clues to welding discontinuities, 414 X-ray fluoroscopy, 418 Raw material forms used in the construction of heat exchangers, 152–154 castings, 152 forgings, 152 handling of materials, 154 material selection for pressure boundary components, 154–155 baffles, 155 shell, channel, covers, and bonnets, 154 testing and inspection, 155 tubes, 154 tubesheet, 155 tubing forms, 154 tubing materials, 154 materials selection for bolted joints, 153 rods and bars, 153 Rectangular tubesheet design, 58–59 methods of tubesheet analysis, 59 Remote field eddy current testing((RFEC), 460–461 Replication metallography, 472–473 applications, 473 S Selection of carbon steels, 179–180 Selection of cast iron, 178–179 Service-oriented cracking, 178 temper embrittlement or creep embrittlement, 178 Shearography, 473–474 digital shearography, 474 Smart PIG, 472 Soldering, definition, 593 Soldering of heat exchangers, 637–644 elements of soldering, 637–639 cleaning and descaling, 639 joint design, 637 soldering fluxes, 639 solders, 637 tube joints, 637 tube-to-header solder joints, 637 soldering processes, 639–640 flux residue removal, 640 stages of radiator manufacture, 639 ultrasonic soldering of aluminum heat exchangers, 640–644 basic processes for soldering all-aluminum coils, 640 material that can be ultrasonically soldered, 640 Stainless steels, 192–195 ASTM specification for stainless steels, 193 classification and designation, 192 designations, 193 guidance for stainless steel selection, 193 martensitic stainless steel, 193 newer stainless steels for heat exchanger service, 195 stainless steel for heat exchanger applications, 195 Stress analysis, 15–16 classes and categories of stresses, 15 membrane stress, 16 primary stress, 16 stress categories, 15 stress classification, 15 Stress categories, 16–19 discontinuity stresses, 19 failure modes, stress limits and stress categories, 18 fatigue analysis, 19 local membrane stress, Pl, 17 peak stress, F, 18 primary bending stress, Pb, 17 primary membrane stress, Pm, 16 secondary stress, 17Index 673 673 stress intensity, 19 thermal stresses, 18 Superaustenitic stainless steels, 235–237 applications, 236 corrosion resistance, 236 4.5% Mo superaustenitic steels, 235 6% Mo superaustenitic stainless steel, 235 welding, 237 postweld heat treatment, 237 Super duplex stainless steel, 234–235 difference between duplex and super duplex stainless steels, 235 properties and characteristics, 234 Supports, 124–125 design basics, 125 design loads, 125 horizontal vessel supports, 125–127 leg supports, 127 ring supports, 127 saddle supports, 125 zickstress, 126 procedure for support design, 128 ASME code, 128 TEMA rules for supports design (G-7.1), 128 vertical vessels, 127–128 lug supports, 128 skirt supports, 127 T Tantalum, 284–285 corrosionresistance, 284 heat transfer properties, 284 performance compared with other materials, 284 welding, 285 Taper-Lok heat exchanger closure, 100–102 zero-gap flange, 101–102 Teflon, 291–292 design considerations, 291 fluoropolymer resin development, 292 heat exchanger fabrication technology, 292 heat exchangers of teflon in the chemical processing industry, 291 teflon as heat exchanger material, 291 Titanium: properties and metallurgy, 269–281 alloy specification, 270 applications, 274–275 applications in PHE, 275 chemical processing, 275 refinery and chemical processing, 275 titanium tubing for surface condensers, 274 corrosion resistance, 273 resistance to waters, 273 surface oxide film, 273 crystallographic structures of titanium, 270 fabrication, 275–276 tubesheet materials-galvanic consideration, 275 tube vibration and rigidity, 275 forming of titanium-clad steel plate, 281 forms of corrosion, 273–274 crevice corrosion, 274 erosion–corrosion, 274 galvanic corrosion, 273 hydrogen embrittlement, 273 MIC, 274 stress corrosion cracking, 274 properties that favour heat exchanger applications, 270 thermal performance, 274 fouling, 274 titanium grades and alloys, 272 ASTM and ASME specifications for mill product forms, 272 titanium tubes for condensers and heat exchangers, 272 unalloyed and alloyed grades, 272 welding of titanium, 276–281 cleaning titanium, 277 degreasing, 277 descaling or oxide removal, 278 filler metal, 278 heat treatment, 281 joint design, 277 manufacturing facilities, 277 method to evaluate the gas shielding, 280 MIG welding, 280 precleaning and surface preparation, 277 preheating, 278 rinsing, 278 shielding gases, 276 weldability considerations, 276 weld defects, 280 welding methods, 276 welding of titanium to dissimilar metals, 276 welding procedures, 279 welding titanium in an open-air environment with three shielding gases, 279 Thermography, 474 Tube bundle assembly, 519–526 assembly of tube bundle inside the shell, 523 assembly of tube bundle outside the shell, 519 assembly of U-tube bundle, 520 cautions to exercise while inserting tubes, 522 impingement plate attachment, 522 tube bundle assembly methods, 519 tube bundle insertion inside the shell, 523 tube nest assembly of large steam condensers, 526 Tube inspection, 459–465 automated tube inspection system, 465 tube inspection with magnetic flux leakage, 459–460 tube inspection with near field testing, 461–462 Tubesheet and baffle drilling, 514–519 checklist for tubesheet inspection after fabrication, 517 drilling of baffles, 518 preparation of tube holes, 517 tube hole finish, 517 tubesheet drilling, 514 Tubesheet design as per ASME code Sec VIII div 1, 46–47 design considerations, 46 general conditions of applicability for tubesheets, 46674 Index 674 design of fixed tubesheets of fixed tubesheet heat exchanger, 47 conditions of applicability, 47 design considerations, 47 design of floating head heat exchanger tubesheets, 48 conditions of applicability, 48 design considerations, 48 design of U-tube heat exchanger tubesheets, 47–48 calculation procedure for simply supported U-tube tubesheets, 48 design considerations, 48 tubesheet characteristics, 46 tubesheet extension, 49 design considerations, 49 Tubesheet design as per TEMA Standards (appendix A-nonmandatory section), 49–58 compressive stress induced in the tubes located at the periphery of the tube bundle, 57 determination of effective design pressure, 53 differential pressure design, after Yokell, 56 effective differential design pressure, P, 56 merits of differential pressure design, 56 equivalent differential expansion pressure, Pd, 53 longitudinal stress induced in the shell and tube bundle, 56 in the tubes located at the periphery of the tube bundle, σ t,l, 57 maximum allowable joint loads, 58 minimum tubesheet thickness as per TEMA, 52 parameter F, 50 shear formula, 51 shell longitudinal stress, σs,l (A.2.2), 56 stress category concept in TEMA, 53 tubesheet formula for bending, 49 tube-to-tubesheet joint loads (A.2.5), 58 Tubesheet design procedure: historical background, 38–40 assumptions in tubesheet analysis, 38 basis of tubesheet design, 40–46 analytical treatment of tubesheets, 41 deflection, slope, and bending moment, 43 design analysis, 41 factors that control tubesheet thickness, 45 parameter Z, 45 supported tubesheet and unsupported tubesheet, 45 Tubesheet diagram for windows, 465 Tubesheet to shell welding, 526–527 Tube-to-tubesheet joint fabrication, 527–553 mock-up test, 529 ASME code requirements, 530 preferred method of making the tube-to-tubesheet joint, 529 quality assurance program for tube-to-tubesheet joint, 529 requirements for expanded tube-to-tubesheet joints, 532 major causes of joint leaks, 532 tube expansion, 527 tube expansion by rolling, 534–553 amount of thinning of tubes, 544 basic rolling process, 535 common causes of tube joint failure, 546 correct tube wall reduction, 544 criterion for rolling-in adequacy, 542 determining 3, 4, or 5 roll expander design, 544 expanding in double tubesheets, 552 factors affecting rolling process, 539 full-depth rolling, 546 hydraulic expansion, 548 joint cleanliness, 546 joint leak tightness, 551 joint reinforcements, 551 leak testing, 553 length of tube expansion, 545 mechanical rolling methods, 534 methods to check the degree of expansion, 541 optimum degree of expansion, 541 phenomenon of tube end growth during rolling, 546 residual stresses in tube-to-tubesheet joints, 553 roller expander for tube extending beyond the tubesheet, 552 rolling equipment, 534 size of tube holes, 547 step rolling, 552 strength and leak tightness of rolled joints, 549 TEMA guidelines for tube wall reduction RGP-RCB- 7.3, 542 tube hole grooving, RB-7.2.4, 542 wall reduction as the criterion of rolling-in adequacy, 543 tube-to-tubesheet joint expansion and /or welding sequence, 528 tube-to-tubesheet joint expansion methods, 532–533 explosive joining, 533 hydraulic expansion, 532 rolling-in process, 532 Tube-to-tubesheet joint welding, 553–577 certain preparation for tube to tubesheet welding, 556–558 automated or manual welding decision, 558 preparation of the tubes, 556 tube welding and expansion, 558 full-depth, full-strength expanding after welding, 556 methods of tube-to-tubesheet joint welding, 554 requirements for the welding and testing of tube to tubesheet joints, 556 sequence of completion of expanded and welded joints, 554 welding methods, 558–564 considerations in tube-to-tubesheet welding, 562 mock-ups for tube-to-tubesheet joint welding, 563 orbital welding, 558 tube-to-tubesheet joint configuration, 559 welding machine, 558 welding process, 564, 577 ARC voltage control (AVC) options, 567 both ends of the tubes welded with tubesheets, 577 brazing method for tube-to-tubesheet joints, 574 ductility of welded joint in feedwater heaters, 573 enclosed orbital tube-to-tubesheet welding heads without filler wire, 567 heat treatment, 575, 577 inspection of tube-to-tubesheet joint weld, 574 internal bore welding, 569Index 675 675 internal bore welding behind the tubesheet, 570 leak testing of tube-to-tubesheet joint, 574 open tube-to-tubesheet welding heads with or without filler wire, 567 orbital welding, 566 seal-welded and strength-welded joints, 571 specific requirements of tubes and weld preparations, 568 testing of tube-to-tubesheet joints, 574 welding equipments, 567 welding of flush tubes, 569 welding of flush tubes with addition of filler wire, 569 welding of protruding tubes, 569 welding of recessed tubes, 569 welding of sections of unequal thickness, 571 welding of titanium tubes to tubesheet, 572 with tubes welded in one tubesheet and left free in the other tubesheet, 577 U Ultrasonic testing (UT), 418–439 advantages of ultrasonic inspection, 424 air coupled testing, 421 angle beam technique, 425 application of ultrasonic technique for thickness measurement, 434–436 application of ultrasonic technique in pressure vessel industry, 423 ASME code coverage, 423 ASTM standard for UT, 423 automated and on-line ultrasonic testing, 439 automated ultrasonic examinations, 437–438 components of a UT instrumentation, 425 corrosion mapping, 438 couplant, 426 quantitative wall thickness measurements, 436 ultrasonic coating thickness gages, 435 ultrasonic examination of nozzle welds, 436 ultrasonic plate tester, 434 ultrasonic thickness gauges, 434 different techniques of automated ultrasonic testing, 438–439 full matrix capture (FMC), 439 phased array ultrasonic testing, 439 rapid automated ultrasonic testing, 439 rapid ultrasonic gridding, 438 examination procedure, 424 pulse-echo technique, 424 fracture mechanics, 436–437 crack evaluation, 436 hydrogen damage detection, 438 limitations of ultrasonic inspection, 424 other developments in UT, 437 other methods, 439 phased array corrosion mapping, 438 phased array ultrasonic testing(PAUT), 429–434 industry applications, 432 merits of PAUT, 432 notable disadvantages of PAUT, 433 what do the images look like, 432–433 A-scan displays, 432 B-scan displays, 432 C-scan displays, 433 presentation, 421 probes, 425 surface preparation, 425 surface wave technique, 425 test method, 419–421 contact and immersion testing, 421 pulse echo inspection, 420 through transmission testing, 420 ultrasonic testing of welds, 426–429 acceptance criteria, 429 calibration, 429 defect location, 428 examination coverage, 429 plate thickness and angle of probe recommended, 428 reference blocks, 429 sensitivity and resolution, 429 UT calculators, 429 weld inspection (by Pulse-Echo and TOFD methods), 438 written procedure for UT, 423 ultrasonic examination procedure deficiencies, 423 V Vendors responsibilities, 497 scope of supply, 497 Visual examination (VT), 385–391 developments in visual examination optical instruments, 389–391 borescopes, 389 combining computers and visual inspection, 391 high-speed video, 391 remote visual inspection, 389 video image scopes, 391 video microscopes, 391 direct vision examination, 386 importance of visual inspection, 385 merits of visual examination, 387 NDT of raw materials, 388 parameters that impact inspection performance, 386 principle of VT, 386 reference document, 387 remote visual examination, 386 translucent visual examination, 386 visual examination during various stages of fabrication by welding, 388–389 visual examination after welding, 389 visual examination before welding, 389 visual examination during welding, 389 visual examination equipment, 388 visual examination: prerequisites, 387 VT technique applications, 388 written procedure, 387 W Welding design 364–374 parameters affecting welding quality, 364 procedure qualification record, PQR, 369676 Index 676 scheme of symbols for welding, 366 standard for welding and welding design, 366–369 A numbers, 369 ASME code section IX, 366 filler metals, 368 F numbers, 369 NDT of weldment, 368 P numbers, 368 selection of consumables, 368 variables affecting welding quality, 366 weld defects and inspection of weld quality, 370–374 approach to weld defect acceptance levels, 374 causes of discontinuities, 371 faults in fusion welds in constructional steels, 371 general types of defects and their significance, 371 weld defects (discontinuities), 370 welder’s performance qualification, 369 welding positions and qualifications, 370 welding procedure specification, 369 welding qualitydesign, 365 welding-related failures, 178 Written procedure, 383, 387, 392, 399, 406, 423, 453, 474 Z Zirconium, 281–284 alloy classification, 281 applications, 282 corrosion resistance, 282–283 hydrogen embrittlement of zirconium alloys, 283 resistance to chemicals, 282 fabrication, 283 limitations of zirconium, 282 product forms, 281 properties and metallurgy, 281 welding method, 283–284 filler metals, 284 surface cleaning, 284 weld metal shielding, 283
كلمة سر فك الضغط : books-world.net The Unzip Password : books-world.net أتمنى أن تستفيدوا من محتوى الموضوع وأن ينال إعجابكم رابط من موقع عالم الكتب لتنزيل كتاب Heat Exchangers Volume II - Third Edition رابط مباشر لتنزيل كتاب Heat Exchangers Volume II - Third Edition ![](https://i.servimg.com/u/f61/15/36/74/14/sign_110.gif)
|
|