5 Shell-And-tube Heat Exchanger - Eckrich

Concept for quality surveillance
exemplary at a shell-and-tube heat

exchanger
ACHEMASIA 2013
Joining in Chemical Apparatus and Plant Construction
May, 13th-16th, 2013, Beijing
BASF SE
Technical Inspection/Materials Engineering
Dr. Rainer Eckrich
BASF Company Ltd.

Quality Management/Materials Engineering
Dr. Guang BinRao
Requirements of the "Internal Tightness"

of shell-and-tube heat exchangers
Possible impact of presumed leakage:
1) - No impact on "SHE" and environment
- Impact on product quality is not relevant
2) - No immediate impact on "SHE"
- Product contamination is relevant
3) - Immediate impact on "SHE"
- Product contamination is unacceptable
Operator must define additional measurements
SHE: = Safety, Health and Environment
AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction
Requirements of tube-tube-sheet joints

(load criteria and tightness requirements)
- Design (minimum tube wall

thickness)
- Manufacturing process
(rolling/expanding, welding,
number of layers)
- Type and scope of nondestructive testing
- Quality surveillance/
inspections during fabrication
Requirements of tube-tube-sheet joints

(load criteria and tightness requirements)
Load criteria
A, B, C, D
Tightness requirement
(impact of a presumed
leakage)
1: No impact
2: No immediate impact
3: immediate impact
Example C3:
s = 2 mm; 2 layers
Including RT testing
In-fabrication inspection
Recommended weld preparation and

execution
a
a
Throat thickness shall be greater
than tube wall thickness (a t)

Deviating weld preparation
is possible but approval

is required
Implementing quality surveillance (1)

Measures before fabrication
Measures before fabrication starts
Advising the requisitioner/orderer
Inspection of the technical
documentation
Actions before beginning the

tube-to-tube-sheet welding
Mock-up welding/procedure
qualification
Monitoring of test welding/welders
Evaluation of the test samples
Implementing quality surveillance (2)

Fabrication and testing
Measures during welding infabrication inspections

Weld preparation
Cleanliness
Executing the tube-to-tube-sheet
welding (skills/welding parameters)
Measures after welding "final
inspection"
Visual inspection
Manufacturer tests and inspections
(VT, PT, MT, LT)
RT inspection for heat exchangers
with tightness requirement "3"
NDT - Procedures at shell-and-tube heat

exchangers
Leakage testing always

before pressure testing
VT
RT
UT
LT
PT
ET
Volume Procederes
Simple but
effective
procedure for:
Tubes
Weld structure
Surface defects
With isotope or xray technology

For all weld
preparation
up to 15 mm tube
projection
St, CrNi, Ni, Ti
Internal Diameter
8 mm
Sample testing, but
for critical heat
exchangers
100% inspection
Tube-to-tubesheet joints
(joint design
according
ASME IX)
Larger tube
dimensions
and with
projection
Surface
procedure
(good contrast performance )
Leakage testing
depending on the
requirement and
agreement
Nekal
Ammonia
Helium
Depending on the
construction type
Vacuum
Sleeve procedure
For critical
heat exchangers
Integral
inspection
of the tube
Zero
condition
test
Result of radiographic test on tube-to-tube-sheet

joints
Pores in tube-to-tubesheet welding
Inspection of shell-and-tube heat exchangers

Test equipment RT Back Radiation Technique
with Gammamat B3
Test setup with isotope Ir 192
Additional inspection
Gammamat B3, 1 x 0.5 mm

source, activity max. 110 GBq
Scope of inspection graduated by the

number of tubes and test result
(1st/2nd sample 100% or new)
Film C3, 10 x 12 cm, Pb 0.02 /

0.02, with holes
Improved Radiation-test-system (x-ray)

Anode grounded tubes, Warrikhoff, Berlin
Metal-ceramic tube MCTS 130 - 0.6
Transformer unit
130 kV, 300 W, focal spot 0.6 mm
Operating unit
Emission angle 168 x 360
kV cable
Film-based application / detector
Rod anode (Diameter 6 mm)
Limits of application
Gammamat B3 versus Grounded tube
Limits of application lr 192:

Dimensions tube-to-tubesheet joints
from 16 x 1.5 mm to 76 x 4 mm
Carbon steel, high-alloy steel,
Ni-basis materials,
Tube-to-tubesheet joints with up to
15 mm projection
Areas of application of x-ray tube:

From 8 mm inner tube diameter
Carbon steel, high-alloy steel,
nickel and titanium
For customized design (projection
of tubes, material) - test piece
required
Oval tubes
Improved RT test system for

Anode grounded tubes with digital detector
Anode grounded tubes

MCTS 130-0.6
Digital detector DIC 100 TH
Detectability of irregularities
Comparison of test systems
1.
With gamma ray source (Ir192)

Back-radiation technique
(d = 1 x 0.5 mm) or forwardradiation technique (d = 2 x 1 mm)
2.
With x-ray tubes

(grounded anode tubes, d = 1mm )
back-radiation technique on film
basis
3.
With x-ray tube (grounded anode

tube) back-radiation with CdTe
detector
Detectability of irregularities
1.0
Detectable size of flaw (mm)
Radiographic testing of the

tube-to-tube-sheet joints
mm
0.5
1. Ir192
0.3
2. Rod anode on film basis
0.2
3. Rod anode with detector
RT scope of inspection and evaluation criteria

(E-S-MC331)
RT scope of inspection of the tube-to-tubesheet joints as per table 6.3.1, BASF E-SMC 331
Evaluation and acceptance

criteria do not depend on
test-system
Evaluation criteria as per table 6.3.2.1
Improved RT test system

Comparison of tests systems
Ir192 + film
Rod anode + film
Rod anode + detector

0.3 mm
0.5 mm
0.8 mm
85 GBq, 1 x 0.5, film C3, 130 kV, 0.5 mA, film C3,
2 x 0.02 Pb film
1 mm Sn pre-filter, 2 x 0.02 Pb
tB = 1 min
t = 0.5 min
B
75 kV, 0.5 mA,

tB = 0.5 min
High pass filter

x-ray film / detector pictures
Tube dimension 25 x 2 mm, exposure data: 80 kV/ 0.5 mA / 30 sec
Pore
and
tungsten
inclusion
X-ray film
Detector picture

Tube dimension 25 x 2 mm
X-ray film
PT Inspection
Detector picture
Comparison of RT-test systems

Summary
Isotope Ir192
film-based
X-ray tube
film-based
X-ray tube detector-based
Advantage:
Advantage:
Advantage:
large scope of object
high detectability of details
see x-ray tubes
easy to use
fixed recording parameters
lower radiation exposure
Disadvantage:
simple transport
permanent source of
radiation
Disadvantage:
immediate evaluation
possible
disintegration of the
isotope
reduced detectability of
details
lower scope of object
Disadvantage:
sensitive technology
high investment cost
Classification of shell-and-tube heat exchangers

purchased in 2012
Quantity
Total: 342
Classification
Summary and Outlook
Number of leakages in shell-and-tube heat exchangers due to

fabrication-related errors substantially reduced
Wide acceptance of this BASF standard in projects and while procuring
heat-exchangers
Procedure successfully implemented in Europe, Asia and in the US
Inclusion of heat exchanger tubes in this quality surveillance concept
Application of Risk based quality assurance (RisQ) to further welded
constructions and standards

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Concept for quality surveillance

exemplary at a shell-and-tube heat

BASF Company Ltd.

Requirements of the "Internal Tightness"

SHE: = Safety, Health and Environment

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Requirements of tube-tube-sheet joints

- Design (minimum tube wall

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Requirements of tube-tube-sheet joints

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Recommended weld preparation and

Throat thickness shall be greater

than tube wall thickness (a t)

is possible but approval

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Implementing quality surveillance (1)

Actions before beginning the

Implementing quality surveillance (2)

Measures during welding infabrication inspections

NDT - Procedures at shell-and-tube heat

Leakage testing always

With isotope or xray technology

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Result of radiographic test on tube-to-tube-sheet

Pores in tube-to-tubesheet welding

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Inspection of shell-and-tube heat exchangers

Test setup with isotope Ir 192

Gammamat B3, 1 x 0.5 mm

Scope of inspection graduated by the

Film C3, 10 x 12 cm, Pb 0.02 /

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Improved Radiation-test-system (x-ray)

Metal-ceramic tube MCTS 130 - 0.6

130 kV, 300 W, focal spot 0.6 mm

Emission angle 168 x 360

Film-based application / detector

Rod anode (Diameter 6 mm)

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Limits of application lr 192:

Areas of application of x-ray tube:

Improved RT test system for

Anode grounded tubes

Digital detector DIC 100 TH

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

With gamma ray source (Ir192)

With x-ray tubes

With x-ray tube (grounded anode

Radiographic testing of the

2. Rod anode on film basis

3. Rod anode with detector

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

RT scope of inspection and evaluation criteria

Evaluation and acceptance

Evaluation criteria as per table 6.3.2.1

AchemAsia 2013 - Joining in Chemical Apparatus and Plant Construction

Improved RT test system

Rod anode + film