Installation, Operation, and Maintenance Manual

ARRIVAL, INSTALLATION, AND STARTUP CHECKLISTS
The following checklists are for reference only, and are not intended to be comprehensive for all situations.
Serial Number:
Arrival, Installation,
Plant Item Number:
Chart Energy & Chemicals, Inc. is an ISO:9001, and Startup
ISO:14001, and OHSAS:18001 registered company Checklists BAHX Arrival Relevant IOM Section Checked By / Date
Inside 1. Verify nameplate and record serial number II. A.
2. Check for external damage II. A.
Chart Energy & Chemicals, Inc. Chart Lifecycle, Inc.
3. Verify shipping stream pressure II. A.
Brazed Aluminum Heat Exchangers 8665 New Trails Drive, Suite 100
(typically 15 psig, if applicable)
2191 Ward Avenue The Woodlands, TX 77381
4. Store per IOM instructions II. B.
La Crosse, WI 54601
BAHX Installation
Tel: 608-787-3333 Tel: 1-844-GTLS-911 (1-844-485-7911) 1. Verify nameplate serial number
E-mail: BAHX@ChartIndustries.com E-mail: info@ChartLifecycle.com 2. Lift into position following general lifting II. C.
www.ChartIndustries.com www.ChartLifecycle.com instructions in IOM and specific instructions
supplied with unit (if applicable)
3. Verify correct BAHX orientation and nozzle locations II. D. 1.
4. Install Micarta or equivalent insulation
®
II. D. 1. c.
between support angle mounts and mating
support surfaces (if applicable)
5. Tighten bolted support connections to finger tight only II. D. 1. e.
(does not apply to bolted flange pipe connections)
6. Verify no water or debris trapped in field piping III. B. 1.
to be attached to BAHX.
7. Connect all nozzles to pipes II. E.
INSTALLATION, OPERATION, AND INSTALLATION, OPERATION, AND 8. Connect Smart Layer (if applicable) II.1.4.
®
9. Remove all temporary shipping supports II. D. 1. a.
MAINTENANCE MANUAL MAINTENANCE MANUAL

10. Remove all vent plugs (if applicable) II. F.
11. Perform piping system leak / proof test III. A., IV. A.
12. Install insulation II. G.
for Chart Brazed Aluminum Heat Exchangers (BAHX) and Core-in-Kettle® Assemblies. for Chart Brazed Aluminum Heat Exchangers (BAHX) and Core-in-Kettle® Assemblies.
BAHX Initial Startup
1. Verify overpressure protection for all streams III. C. 2.
2. Verify filters installed for all applicable streams III. B. 1.
3. Verify no water trapped in or upstream of BAHX III. C. 1.
4. Bring to operation conditions following IOM instructions, III. C. 3.
with special attention to temperature
rate of change guidelines
JANUARY 2021 JANUARY 2021

Serial Number:
Plant Item Number:
La Crosse, WI 54601
BAHX Installation
®
II. D. 1. c.
®


Installation, Commissioning & Startup Services
CHART LIFECYCLE IS HERE TO HELP!
FIGURE I FIGURE II
Basic Components of a Chart How a Chart Core-in-Kettle® Works
Brazed Aluminum Heat Exchanger (BAHX)
1. The warm process stream fluid enters the Brazed Aluminum Heat
Exchanger (BAHX) through steel inlet nozzle(s) on the vessel shell.
The inlet nozzles are connected to the aluminum inlet pipes of the
Nozzle exchanger by an aluminum to stainless steel transition coupling.
2. Inside the BAHX the warm stream cools as it flows against a
Header cold stream.
3. The cold stream enters the vessel either as a liquid or 2-phase
fluid directly from a distillation column (or expansion valve in the
Distributor fin case of a refrigerant).
Parting sheet 4. A liquid level is formed outside the BAHX core to create a liquid
head that drives the cold stream liquid through the core
5. A disengagement space above the core causes the liquid and
Side bar
vapour to separate.
Wear plate 6. The cooled warm stream leaves the BAHX and vessel.
7. T
he cold stream vapour exits the vessel through the outlet
Heat transfer fin nozzles whilst the liquid falls back to be recirculated.
8. A manway is provided in the vessel shell.
Support angle
Cap sheet
Chart Lifecycle has qualified Field Service Engineering teams to provide full installation, commissioning and startup related
services. Chart highly recommends these OEM trained services to ensure a successful equipment startup. Chart also
provides best practices for the maintenance and management of Chart proprietary equipment for optimized performance
and lifespan. Chart Lifecycle, Inc., is also your 24/7 single point of contact for commissioning and startup services, spares,
repairs, warranties, technical expertise, project development, field services, and training. Other services include:
• Annual service agreements
• Extended warranties
• Enhanced operator training and best practices The Chart Energy & Chemicals, Inc. (“Chart”) brazed “Core-in-Kettle” is a registered trademark of Chart Energy &
aluminum heat exchanger (BAHX) business began in Chemicals, Inc.
1985 with the acquisition of The Trane Company’s BAHX
operation in La Crosse, Wisconsin. Chart is a recognized Brazed aluminum heat exchangers are also referred to as
global leader in the design and manufacture of large plate fin heat exchangers and abbreviated to PFHE within
Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline BAHX, battery assemblies, and cold boxes for cryogenic the industry.
E-mail: info@ChartLifecycle.com applications.
© 2021 Chart Energy & Chemicals, Inc. All rights reserved.
www.ChartLifecycle.com Chart incorporates the former Altec and Marston BAHX
brands and consequently all rights to engineering and
equipment produced by these companies.
JANUARY 2021 2
FIGURE I FIGURE II
Header cold stream.
Side bar
vapour to separate.
7. T
Support angle
Cap sheet
• Extended warranties The Chart Energy & Chemicals, Inc. (“Chart”) brazed
• Enhanced operator training and best practices aluminum heat exchanger (BAHX) business began in 1985
with the acquisition of The Trane Company’s BAHX operation
in La Crosse, Wisconsin. Chart is a recognized global leader Brazed aluminum heat exchangers are also referred to as
in the design and manufacture of large BAHX, battery plate fin heat exchangers and abbreviated to PFHE within the
assemblies, and cold boxes for cryogenic applications. industry.
Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline
E-mail: info@ChartLifecycle.com Chart incorporates the former Altec and Marston BAHX “Chart”, the Chart logo, and the
brands and consequently all rights to engineering and Cooler By Design® tagline are registered trademarks of Chart Inc.
www.ChartLifecycle.com equipment produced by these companies.
“Core-in-Kettle” is a registered trademark of Chart Energy & © 2021 Chart Energy & Chemicals, Inc. All rights reserved.
Chemicals, Inc.
JANUARY 2021 2
TABLE OF CONTENTS
FOREWORD TABLE OF FIGURES

I. INTRODUCTION FIGURE I
A. Configuration..................................................... 6 Basic components of a BAHX................................ 2
B. Codes and Materials of Construction ............... 8 FIGURE II
II. INSTALLATION Basic components of Core in Kettle®..................... 2
A. Arrival Inspection............................................. 10 FIGURE III
B. Storage ........................................................... 11 Typical Chart BAHX nameplate............................. 8
C. Lifting and Handling ....................................... 13 FIGURE IV
1. Single BAHX............................................. 14 Removing BAHX from metal shipping
2. Multiple BAHX Assemblies....................... 17 containers............................................................ 13
3. Core-in-Kettle® Assemblies...................... 17 FIGURE V
D. Mounting, Bracing, and Shipping Support ..... 19 Horizontal lifting and moving instructions
1. Support Angle Mounting System.............. 19 (Steel channel skidded BAHX)............................ 14
2. Pedestal Base Mounting System.............. 21 FIGURE VI
3. Core-in-Kettle® Assemblies...................... 21 Horizontal lifting and moving instructions
E. Pipe Connections............................................ 22 (Unpackaged BAHX)........................................... 15
1. Pipe Loads................................................ 22 FIGURE VII
2. Connection Configurations....................... 23 Typical method for rolling BAHX from shipping
3. Transition Joints........................................ 25 attitude to alternate sides.
F. Venting............................................................. 26 (Unpackaged BAHX)........................................... 16
G. Insulation......................................................... 27 FIGURE VIII
H. Instrumentation............................................... 28 Typical method lifting BAHX to vertical position
I. Smart Layers®................................................... 29 using provided lifting lugs.................................... 16
III. TESTING AND OPERATION FIGURE IX
A. Field Proof Testing.......................................... 33 Typical method lifting BAHX to vertical position
B. Fouling and Corrosion Protection....................34 using nozzles on the BAHX................................. 17
1. Filtering..................................................... 34 FIGURE X
2. Hydrate Suppression (Methanol Injection)...... 34 Typical support angle mounting system (Single or
3. Corrosion Protection................................. 35 multiple BAHX assemblies).................................. 18
C. Startup, Operation, and Shut Down................ 36 FIGURE XI
D. Operating Records.......................................... 40 Typical pedestal base mounting system (Single or
IV. MAINTENANCE multiple BAHX assemblies).................................. 20
A. Warning Signs................................................. 42 FIGURE XII
B. Field Leak Testing........................................... 43 Typical connections for BAHX and assemblies
1. Pressure Decay Test.................................44 shipped with pressure.......................................... 22
2. Air-Soap Test............................................44 FIGURE XIII
3. Internal Leak Testing................................. 45 Typical transition joints for piping connections.... 25
C. Cleaning.......................................................... 46 FIGURE XIV
1. Deriming, Back Flushing, and Drying........ 46 Vent plug tag........................................................ 26
2. Back Puffing.............................................. 47 FIGURE XV
D. Mothballing...................................................... 49 Smart Layer ® Connections................................... 31
E. Repair and Service.......................................... 50 FIGURE XVI
F. Disposal........................................................... 50 Typical methanol sparge system top view........... 34
FIGURE XVII
Temperature difference recommendations.......... 37
JANUARY 2021 3
FOREWORD
This manual includes Chart’s instructions, practices, This manual is updated periodically. Before attempting
and procedures regarding installation, operation, and any procedure you should verify with Chart that you are
maintenance of Chart BAHX, assemblies, and Core- using the current version.
in-Kettle® assemblies. Please contact Chart Lifecycle
for assistance in the installation, commissioning, and This manual cannot cover all possible variations in
startup services related to this equipment. Chart highly equipment design or provide answers to all specific
recommends these OEM trained services to assure a installation, operation, and maintenance questions that
successful equipment startup. may arise. If for any reason, any variations or questions
arise that are not addressed in this manual, or any of these
This manual is based on extensive experience, including instructions, practices, and procedures cannot be followed,
more than 60 years in the design and manufacture of the contractor or owner must contact Chart for further
BAHX for low temperature applications, including air information, interpretation, and guidance. Failure to follow
separation and liquefaction, natural gas processing and the instructions, practices, and procedures may result in
liquefaction, helium liquefaction, and hydrogen, ethylene, serious bodily injury or death, property damage, irreparable
and other light hydrocarbon product recoveries. damage to the Chart equipment, and the voiding of any
warranties applicable to the equipment.
THROUGHOUT THIS MANUAL, SAFETY ITEMS ARE
HIGHLIGHTED IN CAPITAL LETTERS AND LABELED When these instructions, practices, and procedures are
WITH THE CAUTION MARK SHOWN HERE. followed, extended and reliable service from BAHX and
Core-in-Kettle® assemblies can be expected.
THESE ITEMS SHOULD BE READ WITH EXTREME CARE AND THOROUGHLY

UNDERSTOOD BEFORE COMMENCING ANY INSTALLATION, OPERATION, OR
MAINTENANCE OF CHART EQUIPMENT. FAILURE TO PROPERLY FOLLOW INSTRUCTIONS SO DESIGNATED
COULD RESULT IN RUPTURES OR EXPLOSIONS OR OTHER DANGEROUS SITUATIONS WHICH MAY RESULT
IN SERIOUS BODILY INJURY OR DEATH AND PROPERTY DAMAGE AS WELL AS IRREPARABLE DAMAGE TO
THE CHART EQUIPMENT AND THE VOIDING OF ANY WARRANTIES APPLICABLE TO THE EQUIPMENT.
DO NOT MODIFY THE EQUIPMENT OR DEVIATE FROM THE INSTRUCTIONS, PRACTICES, AND PROCEDURES
IN THIS MANUAL.
THE CONTRACTOR OR OWNER INSTALLING CHART EQUIPMENT MUST COMPLY WITH THESE
INSTRUCTIONS, PRACTICES, AND PROCEDURES ALONG WITH ANY LIFTING AND HANDLING AND OTHER
INSTRUCTIONS, PRACTICES, AND PROCEDURES PROVIDED WITH INDIVIDUAL UNITS.
JANUARY 2021 4
I. INTRODUCTION
A. Configuration
B. Codes and Materials of

Construction
JANUARY 2021 5
I. INTRODUCTION
I. A. CONFIGURATION
I. A. Configuration (see Figure I, inside cover) I. A. 4. Distributor Fins

Chart BAHX are constructed of aluminum. The basic Distributor fins distribute the fluid between the port
construction consists of layers of corrugated fins and the heat transfer fins. The distributor fin used
which are furnace brazed between parting sheets. adjacent to a port is called a port fin. The distributor
The BAHX dimension created by this stack of layers is fin used between a port fin and a heat transfer fin is
referred to as the stack height dimension of the BAHX. called a turning fin.
The rectangular plate-fin “block” created by this I. A. 5. Heat Transfer Fins

stack of layers is also referred to as a “core” and is Heat transfer fins provide an extended heat transfer
normally specified by its outside block dimensions surface. All fins, both heat transfer and distributor,
of “W” (width) times “H” (stack height) times “L” provide a connecting structure between the parting
(length). A BAHX’s size, number of layers, type of fins, sheets, thereby creating the essential structural and
stacking arrangement, and stream circuiting will vary pressure holding integrity of the BAHX.
depending on the application requirements.
I. A. 6. Parting Sheets
The basic components of a brazed aluminum heat Parting sheets (sometimes referred to as separator
exchanger are described below in sections I. A. 1 sheets) contain the fluids within individual layers in
through 1. A. 10. Sections I. A. 11 through I. A. 15 the BAHX and also serve as the primary heat transfer
define the terminology used to describe the Chart heat surface.
exchanger assemblies and associated piping.
I. A. 7. Outside Sheets
I. A. 1. Nozzles Outside sheets (sometimes referred to as cap sheets)
Nozzles are the pipe sections used to connect the are the outermost parting sheets. They serve as the
BAHX headers to the customer piping. outer protective surface of the BAHX as well as a land
for weld attachment of the headers.
I. A. 2. Headers
Headers are the half cylinders that provide for the I. A. 8. Side and End Bars
distribution of fluid between the nozzles and the ports Side and end bars enclose individual layers and form
of each appropriate layer within the BAHX. the protective perimeter of the BAHX.
I. A. 3. Ports
Ports are the openings in either the side bar or the
end bar, located under the headers, through which the
fluids enter or leave individual layers.
JANUARY 2021 6
I. INTRODUCTION
I. A. CONFIGURATION
I. A. 9. Support Angles I. A. 13. Cold Box

Support angles are typically 90° extruded aluminum A cold box consists of a welded airtight carbon steel
angles welded to the BAHX bar face for the purpose of casing, usually rectangular in shape, which supports
supporting or securing a BAHX in its installed position. and houses BAHX, piping, other related
Other support configurations, such as pedestal bases, cryogenic equipment, and insulation material.
are also available (see Figure XI). More information can be found in the Cold Box
Installation, Operation, and Maintenance Manual.
I. A. 10. Lifting Lugs
Lifting lugs are lift attachment points strategically I. A. 14. Transition Joint
located and welded to the BAHX bar face or a header/ A transition joint is a bimetallic coupling used to make
nozzle assembly for the specific purpose of lifting the the transition from aluminum to stainless steel piping.
BAHX into its installed position. Transition joints are available in various configurations.
I. A. 11. Modular BAHX Assembly I. A. 15. Core-in-Kettle® Assembly

A modular BAHX assembly consists of two or more A Core-in-Kettle® assembly consists of a cylindrical
individually brazed BAHX blocks that are welded pressure vessel, usually carbon or stainless steel,
together prior to attaching the headers to form a single which contains and supports one or more BAHX
piece BAHX. This form of construction is used when and associated piping including transition joints. In
the customer’s heat exchange requirements exceed operation, one fluid is piped through the headered
the maximum block size that can be furnace brazed. stream of the BAHX and the other partially fills the
Modular construction eliminates the need for costly vessel and communicates with the open (unheadered)
piping to interconnect separate, individual BAHX. stream of the BAHX.
I. A. 12. Multiple BAHX Assembly

A multiple BAHX assembly, often referred to as a
“battery,” consists of two or more BAHX piped or
manifolded together into a single assembly with the
individual BAHX arranged either in a parallel, series,
or combination parallel series arrangement. Multiple
BAHX assemblies are used when the customer’s heat
transfer requirements are too large for either single
piece or modular BAHX construction.
JANUARY 2021 7
I. INTRODUCTION
I. B. CODES AND MATERIALS OF CONSTRUCTION
I. B. Codes and Materials of Construction

FIGURE III
Chart BAHX are normally designed and manufactured
Typical BAHX Nameplate
in accordance with Section VIII, Division I of the
ASME Pressure Vessel Code, carry the “U” stamp,
and are registered with the National Board of Boiler
and Pressure Vessel Inspectors. Associated piping is
normally designed and manufactured in accordance
with the ASME B31.3 Piping Code. The ASME
pressure vessel and piping code boundaries are
indicated on the Chart drawing.
Chart BAHX and piping are sometimes designed

and manufactured to other (international) codes. The
governing international code is specified on the Chart
drawing and BAHX nameplate.
The following table indicates the typical materials of

construction for the BAHX components.
COMPONENT TYPICAL MATERIALS (Aluminum Alloy)
Outside Sheets 3003

Parting Sheets 3003
Side and End Bars 3003
Heat Transfer Fins 3003
Distributor Fins 3003
Headers & Nozzles 5083*
Flanges 6061-T6*
Support Angles 6061-T6*
Lifting Lugs 5083*
*Actual materials may differ and are specified on the Chart assembly drawing.
JANUARY 2021 8
BRAND ARCHITECTURE
II. INSTALLATION
A. Arrival Inspection
B. Storage
C. Lifting and Handling
D. Mounting, Bracing, and Shipping
Support
E. Pipe Connections
F. Venting
G. Insulation
H. Instrumentation
I. Smart Layers®

JANUARY 2021 9
II. INSTALLATION
II. A. ARRIVAL INSPECTION
II. A. Arrival Inspection

Upon arrival, verify the nameplate matches the purchase
order. The BAHX should be inspected for shipping
damage and contamination. Closely examine all units
for external damage. For units shipped unpressurized,
check under the shipping covers for contamination of the
port openings. For units shipped pressurized (normally to
15 psig [1 barg]) with dry air or nitrogen, each headered
or manifolded stream is provided with a valve and
coupling to which a pressure gauge can be mounted
(see Figure XII). A positive pressure should be indicated
on the gauge when the valves are opened. If a stream
does not indicate a positive pressure and the valve and
coupling connections have been checked for leakage,
it should be repressurized with dry air or nitrogen to 15
psig (1 barg). If a leak in the BAHX, shipping damage,
or internal shipping contamination is confirmed, contact
Chart for further direction.
JANUARY 2021 10
II. INSTALLATION
II. B. STORAGE
II. B. Storage II. B. 3.

An indoor storage area away from any main work area The storage area should be located where the BAHX
is recommended. Indoor storage is required for BAHX is not subjected to fluids or atmospheres that are
having open layers or nozzles not covered with welded corrosive to aluminum.
or bolted covers. Any ingress of moisture into these
open layers should be avoided. In all storage areas, the II. B. 4.
following additional recommendations should be followed. The storage area should be located where the BAHX
is not subjected to vibration.
II. B. 1.
BAHX are typically shipped on wood or steel channel II. B. 5.
skids. Skidded BAHX may also be packaged in a Avoid a location where other work activity or falling
wooden crate or metal shipping container. Do not objects will be in the vicinity of the stored BAHX.
stack skidded or crated BAHX. External denting of the BAHX can damage the internal
matrix of the BAHX and cause leakage.
BAHX should be stored in the original packaging,
which is generally suitable for three years. For longer II. B. 6.
term storage, consideration should be given to special Avoid a location that is subject to large fluctuations in
packaging. Consult Chart for packaging options. temperature (especially below 32 °F [0° C]), or high
humidity when the BAHX is not sealed and weather-
II. B. 2. proofed, as this can cause condensed water to
The storage area should provide level, uniform accumulate in the BAHX and freeze when the BAHX
support with good drainage. is placed in storage or operation. Water freezing inside
the BAHX can damage its internal matrix.
If the BAHX has been removed from its packaging,
it should be laid on wooden sleepers in a horizontal
position on the outside sheet face of the BAHX. The
wooden sleepers should be at least 6 inches (152 mm)
NEVER STACK BAHX. STACKING OF BAHX
wide and extend beyond the edges of the BAHX. Failure
COULD RESULT IN A BAHX FALLING FROM
to extend sleepers beyond the edges of the BAHX can
ITS STACKED POSITION WHICH MAY RESULT
result in internal damage to the outside layers. Use only
IN SERIOUS BODILY INJURY OR DEATH
two sleepers – one near each end of the BAHX – at a
AND PROPERTY DAMAGE AS WELL AS
distance from each end that is approximately one fourth
IRREPARABLE DAMAGE TO THE CHART
the BAHX’s length. Avoid positioning the sleepers under
EQUIPMENT AND THE VOIDING OF ANY
any headers. Use a soft, resilient material such as fiber
WARRANTIES APPLICABLE TO THE EQUIPMENT.
board as a buffer between the sleeper and the BAHX.
JANUARY 2021 11
II. INSTALLATION
II. B. STORAGE
II. B. 7.
BAHX must be properly covered and sealed in such
a manner that dirt, sand, water, or foreign materials
cannot enter open nozzles, ports, or through any other
FAMILIARIZATION WITH ALL APPLICABLE
access into the BAHX. For BAHX that are shipped
CHART DRAWINGS IS REQUIRED BEFORE
pressurized, dry air or nitrogen with a dew point of
ANY INSTALLATION WORK PROCEEDS.
32 °F (0 °C) or less should be sealed in each stream
PARTICULAR CARE SHOULD BE TAKEN
during storage. The dry air or nitrogen pressure should
WHENEVER OFF-LOADING, MOVING, OR
be 15 psig (1 barg), or one third the stream design
LIFTING THE BAHX.
pressure, whichever is less. The BAHX should be
checked periodically to ensure that the pressure is
maintained.
For BAHX that are not shipped with pressure and do

not have welded shipping covers on the nozzles, all
nozzle openings on the BAHX should be covered and FAILURE TO HANDLE EQUIPMENT
sealed while the unit is in a dry condition. PROPERLY COULD RESULT IN THE BAHX
BEING DROPPED OR SOME OTHER
EQUIPMENT ACCIDENT WHICH MAY RESULT
IRREPARABLE DAMAGE TO THE
CHART EQUIPMENT AND THE VOIDING OF
ANY WARRANTIES APPLICABLE TO THE
EQUIPMENT.
JANUARY 2021 12
II. INSTALLATION
II. C. LIFTING AND HANDLING
II. C. Lifting and Handling BAHX may be removed from metal shipping
Review lifting drawings that ship with each unit. containers by towing with a chain, cable, or fork lift
Confirm the weight, dimensions, and lift connection (see Figure IV). Only tow from the indicated end of the
locations of the BAHX. Select the appropriate hoisting skid, do not tow from any part of the BAHX.
machines, spreader beams, slings, shackles, and
other material handling tools in consideration of the
height, the BAHX weight, and the angle and direction
of the hoisting. Care should be taken to avoid impacts
to the BAHX. Rough or improper handling can cause
damage to the internal matrix of the BAHX.
FIGURE IV
Removing BAHX from metal shipping containers
Chain or cable method Fork lift method
JANUARY 2021 13
II. INSTALLATION
II. C. 1. Single BAHX

II. C. 1. a. Crated or Skidded (Lifting and Moving in
a Horizontal Position)
It is preferred to lift the exchanger with a crane. Crated
or skidded BAHX should be lifted with a crane or hoist
by using slings and a spreader beam (see Figure V).
Use nylon slings or polyester rope with scuff angles to
protect the exterior of the BAHX (see Figure VI). Wood
skidded or crated BAHX can be towed with a fork
truck , but do not tow steel channel skidded BAHX. If a
forklift is used ensure adequate protection against the
aluminum and the forks extend full width of the BAHX.
FIGURE V
Horizontal lifting and moving instructions
(Steel channel skidded BAHX)
Spreader beam
Sling method
JANUARY 2021 14
II. INSTALLATION
FIGURE VI II. C. 1. c. Rolling to Alternate Side

Rolling of the BAHX from the shipping attitude is
Horizontal lifting and moving instructions
permitted when specified on the Chart assembly
(Unpackaged BAHX)
drawing. When permitted, a rolling instruction is
Crane shipped with the BAHX.
Spreader II. C. 1. d. Rotating and Lifting to a Vertical

beam
Position
The method for lifting a BAHX from its horizontal
shipping position to the vertical installation position
Polyester Support angle
Half core (Bolt holes by customer
will depend upon BAHX configuration and weight.
rope or
length unless specified on Chart
nylon sling Lifting instructions are provided on the Chart drawings
drawing)
shipped with the unit.
LIFT DIRECTLY FROM THE BAHX BLOCK

ITSELF. DO NOT LIFT FROM ANY HEADER,
Scuff angle BAHX Outside sheet face NOZZLE, OR PIPING UNLESS SPECIFICALLY
protectors INDICATED ON THE CHART DRAWING.
Side bar face
90° bent angle
FAILURE TO HANDLE EQUIPMENT

II. C. 1. b. Unpackaged (Lifting and Moving in a
PROPERLY COULD RESULT IN THE BAHX
Horizontal Position)
Do not use cables directly on the exterior of the BAHX
EQUIPMENT ACCIDENT WHICH MAY
as they can dent or cut into the exterior of the BAHX
RESULT IN SERIOUS BODILY INJURY OR
and cause damage to its internal matrix. Scuff angles
DEATH AND PROPERTY DAMAGE AS
are 90° angles placed on the corners of the BAHX
WELL AS IRREPARABLE DAMAGE TO THE
under the sling or belt.
EQUIPMENT.
JANUARY 2021 15
II. INSTALLATION
FIGURE VII There are two basic methods for lifting to the vertical
position. Other methods are approved only if specified
Typical method for rolling BAHX from shipping
on the Chart drawing for the unit. Both methods are
attitude to alternate sides (Unpackaged BAHX)
similar except for the point of lifting attachment.
Use only when authorized on Chart assembly drawing.
Polyester rope or nylon sling One method involves the use of lifting lugs provided
Do not use steel cables
with the Chart unit (see Figure VIII).
Use sling
protection at
corners
FIGURE VIII
Typical method lifting BAHX to vertical position using
provided lifting lugs.
Lifting lug
Note: For BAHX exceeding

12 ft (3.7 m) in length, a
spreader beam and two belts Padding
should be used for the roll
IF LIFTING LUGS ARE PROVIDED, THEY

SHOULD BE USED AS THE ATTACHMENT
LIFTING POINT. IF LIFTING LUGS ARE
NOT PROVIDED, AND SPECIFIC LIFTING
INSTRUCTIONS FOR THE UNIT ARE NOT
AVAILABLE, CONTACT CHART. DO NOT
LIFT USING THE NOZZLES OR ANY OTHER
PIPING UNLESS SPECIFICALLY SHOWN IN
THE CHART DRAWING FOR THE UNIT.
JANUARY 2021 16
II. INSTALLATION
The other method involves lifting using the BAHX II. C. 3. Core-in-Kettle® Assemblies
nozzles (see Figure IX). These lifting methods are Core-in-Kettle® assemblies are either provided with
used for both support angle mounting and pedestal appropriate lifting lugs on the kettle or instructions as
base mounting of BAHX. to where to sling around the assembly.
FIGURE IX
Typical method lifting BAHX to vertical position
using nozzles on the BAHX
WHEN LIFTING LUGS ARE PROVIDED ON
Lifting with nozzle CHART CORE-IN-KETTLE® ASSEMBLIES FOR
LIFTING AND HANDLING THEY SHOULD BE
USED WHENEVER MOVING THE CORE-IN-
KETTLE® ASSEMBLY.
FAILURE TO HANDLE EQUIPMENT

PROPERLY COULD RESULT IN THE BAHX
EQUIPMENT ACCIDENT WHICH MAY
EQUIPMENT.
II. C. 2. Multiple BAHX Assemblies
Considering the numerous possible variations in BAHX
and piping assembly configurations, size, and weight,
a single lifting, handling, and erection procedure for
multiple BAHX assemblies is not possible.
For these assemblies, lifting instructions are included

on the Chart assembly drawing or on a separate
erection drawing. Multiple BAHX assemblies should be
handled with the same care afforded individual BAHX.
JANUARY 2021 17
II. INSTALLATION
FIGURE X
Typical support angle mounting system
(Single or multiple BAHX assemblies)
Warm end up (typical)
Stainless steel bolts, nuts, and washers (by

customer) Bolts must be finger tight and smaller
than bolt holes to provide clearance for thermal
expansion and/or contraction
Aluminum support angle

(holes by customer
unless specified on
Chart drawing)
0.5 inches (13 mm)

minimum thickness
Micarta® (by customer)
Continuous stainless
steel support beam (by
customer)
0.5 inches (13 mm) recommended - 1 inch

(25.4 mm) maximum from side bar face of
the BAHX
JANUARY 2021 18
II. INSTALLATION
II. D. MOUNTING, BRACING, AND SHIPPING SUPPORT
II. D. Mounting, Bracing, and Shipping Support II. D. 1. c.

II. D. 1. Support Angle Mounting System (Single or Since these BAHX are normally installed in cryogenic
Multiple BAHX Assemblies) services, some method of insulating between the
Chart BAHX are normally installed vertically with the Chart aluminum support angles and the customer
warm end up (see Figure X). Other orientations are mating support surface is recommended.
permissible only if specified on the Chart assembly
drawing. Chart BAHX are normally provided with A minimum of 0.5 inch (13 mm) thick piece of
aluminum support angles welded directly to the side Micarta® (phenolic canvas base laminate) block is
bar face of the BAHX for mounting purposes. recommended for this purpose. The insulation material
thickness should be sufficient to minimize heat
The following are general mounting recommendations leak and prevent frost spots from developing on the
for both single BAHX and for multiple BAHX supports or cold box walls during operating conditions.
assemblies utilizing support angle mounting systems
(see Figure X). II. D. 1. d.
Provisions for thermal expansion and contraction
II. D. 1. a. of the BAHX in the horizontal plane at the support
All shipping supports should be removed as shown on location must be provided.
the Chart drawings. Extreme care should be taken to
keep all steel working torches and flame-cutting tools The expected thermal movement should be calculated
at a proper distance from the aluminum BAHX in order in both horizontal directions by the following equation:
to prevent severe damage to brazed joints and to the
internal matrix. D=12.6 x 10-6 x L x ∆T
II. D. 1. b. where L is the distance in inches between extreme

The support angle surfaces on the BAHX are in plane bolts in the direction under consideration, ∆T is the
within 0.06 inches/foot (0.5%). The mating support change in temperature in °F at the support location
surface (by customer) should be a continuous member from the installed (ambient) temperature to the coldest
and be in plane to this same standard. Shimming is possible operating temperature, and D is the expected
acceptable but is not preferred. thermal movement in inches which will result from this
calculation.
JANUARY 2021 19
II. INSTALLATION
If the expected thermal movement in both directions is

FIGURE XI
0.5 inches (13 mm) or less, the bolt hole diameters in
Typical pedestal base mounting system
the aluminum support angles should be oversized by
(Single or multiple BAHX assemblies)
adding the maximum expected thermal movement to
Warm end up (typical)
the bolt diameter.
If the expected thermal movement exceeds 0.5 inches

(13 mm) in one of the horizontal directions, a slotted
hole should be used with a slot length equal to the
bolt diameter plus the maximum expected thermal
movement, and a slot width equal to the bolt diameter
plus the expected thermal movement in the other
direction.
If the expected movement exceeds 0.5 inches (13 mm)

in both directions, the holes in the aluminum support
angles should be slotted as per above in one direction
and the holes in the stainless steel support beam
should be slotted as per above in the other direction
with slot widths equal to the bolt diameter plus 0.12
inches (3 mm).
II. D. 1. e.
Bolts, nuts, and washers employed to secure the BAHX
to the supporting surface must be stainless steel, and
tightened to finger tight only (this requirement applies
to both angle type and pedestal base type mounting
systems). Do not use lock washers. Use a double nut
or interrupt the bolt threads to prevent the nut from
working loose. Wrench tightening the bolts could allow
relatively small horizontal pipe loads applied to either
Bolt locations 0.5 inches (13 mm)
end of the BAHX to develop bending moments on (Bolt holes by Chart, Minimum thickness
bolts, nuts, and washers Micarta® (by customer)
the BAHX which may produce unacceptable stress
by customer)
concentrations at the support angles.
JANUARY 2021 20
II. INSTALLATION
II. D. 1. f. II. D. 2. Pedestal Base Mounting System (Single

To avoid excessive bending moments on the support or Multiple BAHX Assemblies)
angle itself, the edge of the support surface must be An alternative method to the support angle mounting
no more than 1.0 inches (25.4 mm) from the BAHX system is an aluminum pedestal base mounting
side bar face. A distance of 0.5 inches (13 mm) is system provided with the BAHX (see Figure XI). The
recommended (see Figure X). pedestal base mounting system is generally employed
when cold box installation is not required and the
II. D. 1. g. BAHX can be mounted at ground level as this is
The support system should be safeguarded by the usually a less costly method for mounting.
provision of a sway brace, located at the opposite end
of the BAHX away from the main support angles or The same recommendations regarding shimming,
pedestal base, whenever the total external loads insulation, bolt hole size, bolt tightness, and bracing
(pipe, wind, and earthquake) are sufficient to cause for support angle mounting systems in Section II. D. 1.
lateral movement of the BAHX. should be followed for pedestal base mount systems.
A close fit between the BAHX wear plate and the II. D. 3. Core-in-Kettle® Assemblies
sway brace is required since changing from ambient The holes for the anchor bolts are slotted in the sliding
to operating at cryogenic temperatures at this position saddle to allow for thermal contraction and expansion.
can produce 0.12 inches (3 mm) of movement from When installing a Core-in-Kettle® assembly it is critical
thermal contraction. If requested, wear plates can be to align the anchor bolts in the center of the slots.
furnished on the BAHX by Chart. In rare cases the saddle geometry may require the
anchor bolts be installed offset in the slots. In these
Do not fasten any sway brace directly to the BAHX. The cases the required positioning is specified on the
BAHX must be free to move in the vertical direction. Core-in-Kettle® assembly drawing.
II. D. 1. h.
For reversing (air separation service) BAHX, supporting
directly from the bottom (warm end) manifolds is
acceptable if provided for on the Chart assembly
drawing. Warm end manifolds for reversing BAHX
should always be provided with sumps and drains of
adequate size to return any condensed water from the
manifold piping so that water will not be entrained in the
fluid stream or slugged into the BAHX during pressure
reversals.
JANUARY 2021 21
II. INSTALLATION
II. E. PIPE CONNECTIONS
II. E. Pipe Connections

FIGURE XII
II. E. 1. Pipe Loads
Typical connections for BAHX and assemblies
A table indicating maximum allowable pipe loads for
shipped with pressure
the BAHX or assembly is provided with the Chart
drawing. This table indicates the maximum allowable
bending moment and the axial load that can be
Valve and coupling
applied at each header location on the BAHX. These
maximum loads are not to be applied simultaneously. Slugged end
Instructions for summing applied moments and forces
are supplied with this table.
Location for
It is the customer’s responsibility to provide sufficient field cut off
piping flexibility or anchor points in the customer
piping to ensure that the combined loads on each
nozzle and on the BAHX are within the allowable limits
specified by Chart.
Typical slugged connection
Blind flange
FAILURE TO PROVIDE SUFFICIENT PIPE

Raised face weld
FLEXIBILITY OR ANCHOR POINTS COULD neck aluminum
flange
RESULT IN COMBINED PRESSURE AND
EXTERNAL PIPE LOADS BEING APPLIED
WHICH EXCEED THE ALLOWABLE LOADS
OF THE BAHX AND MAY RESULT IN
Instructional tag
SERIOUS BODILY INJURY OR DEATH showing 15 PSIG dry
AND PROPERTY DAMAGE AS WELL AS air or N2 charge

EQUIPMENT AND THE VOIDING OF ANY Typical flanged connection
WARRANTIES APPLICABLE TO THE
EQUIPMENT.
JANUARY 2021 22
II. INSTALLATION
Prior to removing the plug or pressure gauge from II. E. 2. b. Flanged Connections
the shipping valve, be sure the valve is in the closed Aluminum or steel (stainless for cryogenic service)
position. Exercise caution and accepted safety mating flanges are typically used with the Chart
procedures for removal of a plug from a pressure flanged connection.
vessel.
Care should be exercised to protect the machined
face of the flange against scratches, dents, and other
damage that will reduce the effectiveness of the
gasket in making a proper seal.
FAILURE TO CONFIRM THE SHIPPING
VALVE IS IN THE CLOSED POSITION
The two mating surfaces of the flanges should be
PRIOR TO REMOVAL OF THE PLUG OR
parallel with each other prior to connecting. Flange
PRESSURE GAUGE CAN RESULT IN THE
faces must be aligned to the design plane to within
PLUG OR GAUGE BECOMING A
0.06 inches/foot (0.5%) maximum, measured across
PROJECTILE WHICH MAY RESULT IN
the diameter of the flange mating face, and flange bolt
SERIOUS BODILY INJURY OR DEATH
holes must be aligned to within 0.12 inches (3 mm)
maximum offset.
Connections should be made by gradually tightening
diametrically opposite bolt pairs and tightening the
EQUIPMENT.
pairs in a sequence that uniformly loads the gasket.
Installed bolts and gaskets shipped with the blind
II. E. 2. Connection Configurations flange must not be used for making final connections
II. E. 2. a. Slugged Connections as they are not designed for cryogenic service.
The proper cut off location of the nozzle or pipe Stainless steel bolts and nuts must be used for the
can be found on the Chart assembly drawing (see final field connection for cryogenic service. Stainless
Figure XII). Beveling and welding procedures must be steel washers must be used under the bolt heads or
followed per the applicable code requirements. Before nuts on the aluminum flange, and threads should be
making final connections to the BAHX, care should lubricated for proper torque wrench applications.
be exercised to remove any saw chips, torch slag,
or other foreign material from the pipe, nozzle, and
header area. These items can plug the BAHX.
JANUARY 2021 23
II. INSTALLATION
Gasket Recommendations For Use With Aluminum Bolt torques for use with flanges:
Flanges:
Bolt Size TPI Torque Torque
Chart recommends Flexitallic Flexpro gaskets (in) (ft-lbs) Increments
or equivalent (m=2.0, y=2500 psi [17.2 MPa]). If 1/2 13 30 Snug, then full torque
stainless steel spiral wound gaskets are used, Chart 5/8 11 60
recommends they be low seating stress such as 3/4 10 100
Flexitallic LS (m=3.0, y=5000 psi [34.5 MPa]). If higher 7/8 9 160 Snug, 1/2 torque,
seating stress gaskets are selected consult Chart 1 8 245 then full torque
to determine if Chart’s standard recommended bolt 1-1/8 8 355
torques are adequate. 1-1/4 8 500
1-3/8 8 680
Bolting recommendations: 1-1/2 8 800 Snug, 1/3 torque, 2/3
1-5/8 8 1100 torque, then full torque

Down to Below -50 °F Below -50 °F
-50 °F (-45 °C) (-45 °C) (-45 °C) 1-3/4 8 1500
Stud Diameters Stud Diameters
thru 1.5 inches above 1.5 inches 1-7/8 8 2000
(38 mm) (38 mm) 2 8 2200 Snug, 1/4 torque,
Studs SA193 B7 SA320 B8 CL2 SA193 B8M2 2-1/4 8 3180 1/2 torque, 3/4 torque,
Nuts A194 GR 2H SA194 GR 8 SA194 GR 8 2-1/2 8 4400 then full torque
2-3/4 8 5920
Recommended Bolt Torques:
3 8 7720
All bolting must be given a final tightening by torque
wrench. Bolts are to be torqued to the full value II. E. 2. c. Weld Prepared Connections
shown in the table below and then re-torqued after 15 Weld prepared connections are properly trimmed to
minutes. Torque values are based on a resultant bolt length and beveled for welding. The trim length and
stress of 30,000 psi assuming well lubricated studs, beveling detail is provided on the Chart drawing.
nuts, and washers. Connections prepared for welding are covered during
shipments. The BAHX or assembly does not ship with
pressure.
Beveling of the mating pipe and welding procedures

must be per the applicable code requirements. Before
making final connections to the BAHX, remove any
saw chips, torch slag, or other foreign material from
the pipe, nozzle, and header area. These items can
plug the BAHX.
JANUARY 2021 24
II. INSTALLATION
II. E. 3 Transition Joints (see Figure XIII)

FIGURE XIII
Unless authorized by the joint manufacturer, transition
Typical transition joints for piping connections
joints are to be attached only to piping components.
To prevent failure of the bond during welding,

precautions must be taken to avoid overstressing
the bond due to differential expansion between the
aluminum and stainless steel joint components. These
stresses can be maintained within allowable limits by
taking the following precautions:
• Place a chill block or damp rags on the aluminum/

steel overlapping bond area. If damp rags are used,
care should be taken to keep the rags or cloths
damp. A dry cloth will allow the joint to become
excessively hot. Temperature in the aluminum/
steel overlapping area must be held to a maximum
of 300 °F (149 °C), unless higher temperatures are Photo courtesy of Groupe RBDH
permitted by the joint manufacturer.
• When installing a loose transition joint, weld the

stainless steel end first whenever possible. This will
provide a larger sink for the heat generated by the
aluminum welding.
• Use weld techniques and sequences to minimize the

heat input.
• Care should be taken to avoid non-uniform heating,

Photo courtesy of Asahi Kasei Corporation
weld sequences, or weld techniques that would cause
isolated high stress areas, i.e. “Block Welding,” local
repair welds, or other similar types of localized welding.
JANUARY 2021 25
II. INSTALLATION
II. F. VENTING
II. F. Venting
FIGURE XIV
External venting of inactive or non-operational internal
Vent plug tag
zones of some BAHX is required when specified
on the Chart drawing. Examples of inactive zones that
require venting are:
• the modular space formed by welding together two

BAHX blocks.
• the dead corner of a reversing stream warm end

distributor employing the slant bar drainability
feature.
• the space formed between two tandem streams

having adjacent side headers at mid BAHX.
• other special cases.
Chart BAHX that have an inactive zone are normally

FAILURE TO LIMIT THE PRESSURIZATION
designed to be self venting and simply require that
OF INACTIVE ZONES IN THE BAHX TO A
the plastic shipping plugs be removed just prior
MAXIMUM OF 15 PSIG COULD RESULT IN
to insulating and pressurizing any stream. This
A RUPTURE OF THE BAHX WHICH MAY
requirement is stated on the Chart drawing and on a
RESULT IN SERIOUS BODILY INJURY
tag attached to BAHX.
OR DEATH AND PROPERTY DAMAGE
AS WELL AS IRREPARABLE DAMAGE
If you wish to monitor an inactive zone by attaching a
TO THE CHART EQUIPMENT AND
vent line, be sure to extend the vent line outside the
THE VOIDING OF ANY WARRANTIES
cold box or insulation and provide a relief valve on
APPLICABLE TO THE EQUIPMENT.
the vent line to protect the inactive zone of the BAHX
against pressurization over 15 psig (1 barg). Maintain
the vent line in an internally frost free condition
to eliminate the possibility of line blockage from
freezing liquids. A 3/4” NPS (20DN) or larger line is
recommended to avoid potential flow restriction.
JANUARY 2021 26
II. INSTALLATION
II. G. INSULATION
II. G. Insulation In all installations, some form of insulation such as a

Since BAHX usually operate at cryogenic Micarta® spacer should be used between the BAHX
temperatures, highly efficient insulation should support member and the supporting beam or platform
be applied by the customer to minimize heat leak. (see Section II. D. 1. c.).
Insulation material is normally applied after the unit is
installed at the job site. Flammable materials should Caution should always be exercised whenever welding
be avoided for insulation. Insulation materials are or flame cutting near insulation materials.
not normally applied to the BAHX prior to installation
because insulation materials are easily damaged in Refer to the Cold Box Installation, Operation, and
transit, they restrict the use of shipping tie downs Maintenance Manual for instructions on insulating
and supports, and they would impair accessibility to BAHX installed in cold box assemblies.
the unit for lifting, mounting, leak testing, and other
installation preparations.
When the BAHX is not mounted inside a cold box,

the BAHX’s exterior is normally insulated with rigid
polyurethane foam, or other alternatives such as
Foamglass® insulation, according to the thickness and
requirements specified by the engineering contractor.
These insulations are positioned and fastened around
the BAHX and covered with a vapor barrier. Protective
metal coverings or flashing can be used for this
purpose.
JANUARY 2021 27
II. INSTALLATION
II. H. INSTRUMENTATION
II. H. Instrumentation
Proper instrumentation must be installed to properly
operate BAHX within the guidelines (see Section Ill. C.).
Fluid temperatures and pressures should be monitored

at the inlet and outlet of every stream at intervals of 1
minute. For boiling streams in reboiler services external
to the column, a dedicated differential pressure
instrument should be used to monitor for pressure
oscillations indicating unstable flow. Fluid flow rates
should be monitored with flow meters, or approximated
with valve positions, pressure drop, or vessel liquid
levels, at intervals of 1 minute. Fluid composition should
be measured and logged at intervals of 1 month at a
minimum or as frequently as the composition changes.
If desired, core block temperature can be directly

measured using temperature devices installed by
Chart.
Gas detectors should be installed in the vicinity to alert

if any external leaks exist.
JANUARY 2021 28
II. INSTALLATION
II. I. SMART LAYER®
II. I. 1. Smart Layer® components. Fill the Smart Layer with nitrogen to a charge
Smart Layer is a warning system comprised of inactive layers pressure as described below. Smart Layer is not intended to
located on the outside of the stack that have been designed be connected to a continuously regulating nitrogen system.
and proof tested for the full design pressure of the adjacent Soap bubble test all Smart Layer connections to ensure leak
process stream(s). They are equipped with connections for tightness.
a pressure monitor, pressure relief valve, and a Nitrogen
charging port. The purpose of Smart Layer is to alert II. I. 5. Smart Layer® Charge Pressure Setpoint
operators when a critical threshold of thermal stress damage Charge Smart Layer’s nitrogen blanket to a level
has occurred, prior to any external leak occurring. sufficient to allow for proper operation of the PSV. The
Charge pressure must also be set between the high and
Smart Layer is an optional feature not included on all low level alarms described below.
designs. The nameplate will indicate if a unit is equipped
with Smart Layer. II. I. 6. Smart Layer® High-Level Alarm Setpoint
Set the high level alarm below operating pressure of the
II. I. 2. Function stream(s) designated in the Smart Layer notes on the General
Smart Layer functions by accumulating thermal stress Assembly Drawing. Ensure there is a measurable pressure
damage faster than other parts of the BAHX. When a difference between the charge pressure and the high level alarm.
critical threshold of damage has accumulated, it will result
in an “indication leak” in the Smart Layer. The indication II. I. 7. Smart Layer® Low-Level Alarm Setpoint
leak is part of the intended function of Smart Layer, and will The low-level alarm setpoint is slightly above atmospheric
not cause any process fluids to leak to atmosphere. When pressure. The charge pressure will decrease during cool down.
an indication leak occurs, the DCS will signal the operator Ensure this pressure decrease will not trip the low level alarm.
that a Smart Layer alarm has been activated.
II. I. 3. Smart Layer Hardware

Typical hardware includes a pressure transmitter to monitor the
Smart Layer pressure, a pressure relief device that vents either
FAILURE TO INSTALL THE SMART LAYER
to atmosphere or to flare, and a connection for charging and
PRESSURE RELIEF VALVE MAY RESULT IN
draining the Smart Layers
OVER PRESSURIZATION OF THE SMART
LAYER WHICH MAY RESULT IN SERIOUS
II. I. 4. Smart Layer Field Installation
BODILY INJURY OR DEATH AND PROPERTY
Smart Layer is shipped with temporary shipping blinds. The
DAMAGE AS WELL AS IRREPARABLE
balance of the Smart Layer components supplied by Chart
DAMAGE TO THE CHART EQUIPMENT
(if any) are shipped loose to reduce the risk of damage
AND THE VOIDING OF ANY WARRANTIES
during transport. After the BAHX has been installed, remove
APPLICABLE TO THE EQUIPMENT.
the temporary shipping blinds and install the Smart Layer
JANUARY 2021 29
II. INSTALLATION
II. I. 8. DCS Integration

The pressure transmitter should be connected to the
plant DCS to record and monitor the Smart Layer
pressure. Pressure should be recorded (typically at 1
minute intervals) to aid in root cause analysis in the
event of a Smart Layer alarm.
II. I. 9. Smart Layer® Alarm

The DCS should be configured to alarm the operator if
the Smart Layer pressure drops below or rises above
the Alarm setpoints. A Smart Layer alarm is triggered
by an indication leak in Smart Layer and signifies one
or more stress cracks have occurred in the BAHX.
This is most likely thermal fatigue damage caused by
operation outside of the IOM guidelines. Contact Chart
for guidance if a Smart Layer alarm is received.
JANUARY 2021 30
II. INSTALLATION
High Level Alarm

FIGURE XV
A high level alarm indicates
Smart Layer ® Examples
communication between the Smart Layer
and the adjacent process stream(s). This ®
is most likely due to a parting sheet crack.
Low Level Alarm

A low level alarm indicates
communication between the
Smart Layer and the atmosphere. This
is most likely due a cap sheet crack,
but may also be a result of a non-stress OPERATIONAL
TOP END
related leak through a gasket, fitting, or
instrument.
®
Maintenance
The Smart Layer pressure relief device
and pressure transmitter should be
included in the plant maintenance
program.
Prior to shipping from the factory, the

Smart Layer is leak tested to ensure a
leak tightness sufficient to contain the
Smart Layer charge pressure. After
installation in the field, gasket degradation
or differential thermal expansion may
result in a persistent leak from Smart
Layer to atmosphere that is not indicative
of thermal stress damage. If this is the
case, the Smart Layer may be recharged
periodically to maintain function. Monitor
the leak rate for changes that may
indicate thermal stress cracking.
JANUARY 2021 31
BRAND ARCHITECTURE
III. TESTING AND

OPERATION
A. Field Proof Testing
B. Fouling and Corrosion Protection
C. Startup, Operation, and Shut Down
D. Operating Records
JANUARY 2021 32
III. TESTING AND OPERATION
III. A. FIELD PROOF TESTING
III. A. Field Proof Testing

Most codes require a pressure test of the piping
system after the BAHX or assembly is installed.
A pneumatic test is most often performed. OVERPRESSURIZATION OF THE BAHX
COULD RESULT IN A RUPTURE OF
Only clean, dry gases should be used for pneumatic THE BAHX WHICH MAY RESULT IN
proof and subsequent leak testing. Water, or any fluid SERIOUS BODILY INJURY OR DEATH
that may freeze under operating conditions, should not AND PROPERTY DAMAGE AS WELL AS
be used in any testing or cleaning of the Chart BAHX IRREPARABLE DAMAGE TO THE CHART
as it is extremely difficult to dry the BAHX in the field. EQUIPMENT AND THE VOIDING OF ANY
Trapped water can freeze in the BAHX matrix and WARRANTIES APPLICABLE TO THE
develop hydraulic pressures sufficient to rupture the EQUIPMENT.
internals of the BAHX without any external evidence.
If water is accidentally introduced into the BAHX, see
Section IV. C. 1. for drying procedures. In Section IV.
B., several practical field tests are recommended for
determining leaks.
The pneumatic proof test pressure must comply

INTRODUCTION OF WATER TO ANY
with National Board Inspection Code requirements
BAHX EXPOSED TO MERCURY
or, if applicable, international pressure vessel code
CONTAMINATION CAN RESULT IN
inspection requirements and must not exceed 1.1
ACCELERATED CORROSION AND CAN
times the maximum working pressure specified on the
CAUSE IRREPARABLE DAMAGE AND
Chart nameplate.
POTENTIAL CATASTROPIC FAILURE AND
EXPOSE PERSONNEL TO HAZARDOUS
AND UNSAFE WORKING CONDITIONS.
JANUARY 2021 33
III. B. FOULING AND CORROSION PROTECTION
III. B. Fouling and Corrosion Protection III. B. 2. Hydrate Suppression (Methanol Injection)
BAHX are capable of handling a wide variety of fluids. During startup, upset, or even normal operating
Fluids should be clean, dry, and non-corrosive to conditions, the presence of hydrates or heavy
aluminum. Fluids containing particulate matter, waxy hydrocarbons in the feed or other streams may
components, or corrosive elements should not be freeze in the BAHX at operating temperatures. These
used in the BAHX. hydrates or heavy hydrocarbons may eventually block
some or all of the layers in the BAHX.
III. B. 1. Filtering
The presence of particulates in the process streams
may not only lead to BAHX plugging and fouling, but
FIGURE XVI
Typical methanol sparge system top view
may also cause erosion in the high velocity areas of
(warm end)
the BAHX. Fouling of the BAHX can be detected by
a gradual or sudden increase in pressure drop and a
Methanol
loss of heat transfer performance. Feed gas
Sparge pipe
All connecting pipelines carrying BAHX fluids should
be thoroughly cleaned of all pipe scale, dirt, sand, and
other debris before placing the BAHX in service.
All streams should be filtered with a 177 micron

(80 Mesh Tyler Standard) screen or finer, directly
upstream of the BAHX, BAHX assembly or cold box.
The filters should remain in place at all times while the
BAHX is operating. The user should consider a dual
filter system with sufficient valving to allow a filter to be
changed without shutting down. Heavy duty, cleanable
filters or strainers are recommended.
0.125 inches (3 mm) diameter methanol injection
holes spaced 0.5 inches (13 mm) apart (extra
drain holes provided on opposite side of sparge
pipe)
JANUARY 2021 34
III. B. FOULING AND CORROSION PROTECTION
When complete shut down for deriming is undesirable Carefully guard against the ingress of water vapor or
(see Section IV. C. 1.) methanol injection can be used liquid, either during commissioning or similar plant events
to remove hydrates during operation if the operating where the BAHX is vulnerable to water ingress (for
temperature is warmer than -170 °F (-112.2 °C) (methanol example, during core repair involving removal of piping
freezes at approximately -170 °F). This method of hydrate to the BAHX), or by process fluids containing water. If
suppression involves injecting methanol into the process allowed to freeze, accumulated water in trapped areas of
fluid upstream of the Chart BAHX. An aluminum sparge the BAHX can structurally damage the internals of
pipe injector can be provided for this purpose inside the the BAHX.
header of the Chart BAHX (see Figure XVI). Methanol is
injected into the incoming feed gas via this sparge pipe. External surface corrosion can be avoided by keeping
The feed gas then carries the methanol into the BAHX. the externals of the BAHX under a dry environment
during installation and operation. Such precautions will
If a methanol injection sparge system is not used for an eliminate the potential for intergranular corrosion attack
extended period of time, the methanol should be purged or stress corrosion cracking of the BAHX components.
from the piping to eliminate the potential for methanol
corrosion. This can be accomplished by blowing dry air Under certain conditions, mercury can corrode
or nitrogen through the methanol piping. Drain holes aluminum and therefore caution must be used when
on the underside of the sparge pipe are provided for handling process fluids containing mercury. However,
draining purposes. Chart BAHX have been successfully used with fluids
containing mercury provided the proper equipment
If hydrate contamination is an ongoing problem, any design and operating procedures are implemented.
upstream equipment where water could enter the BAHX
stream should be inspected for leaks. If mercury is suspected or anticipated:
III. B. 3. Corrosion Protection • BAHX should not be exposed to process fluids

Trace impurities of H2S, NH2, CO2, SO2, NO2, CO, CI and containing mercury concentrations greater than 0.1
other acid-forming gases may cause corrosion when μg/Nm3. Above this limit, mercury guard beds should
liquid water is present in the stream. Additionally, certain be installed and mercury tolerant features should be
water acidity levels can cause corrosion of aluminum. considered in the design of the exchanger.
To avoid corrosion, the pH level of the water condensate
should be between 5 and 7. • Below 0.1 μg/Nm3, purchasers should consider using
exchangers with mercury tolerant features and mercury
guard beds because the same gas field can sometimes
contain large variations in mercury levels over time.
JANUARY 2021 35
III. C. STARTUP, OPERATION, AND SHUT DOWN
III. C. Startup, Operation, and Shut Down

Chart BAHX can be expected to provide many years
of useful life when operated in strict accordance with
the instructions, practices, and procedures outlined
ALL OPERATING CONDITIONS MUST
in this manual. The range of life can vary depending
BE WITHIN THE SPECIFIED CHART
on the process design, how demanding the operating
NAMEPLATE LIMITS AND THE CHART
conditions are, and other factors. A typical useful life is
SPECIFICATIONS FOR THE BAHX BEING
20 years or more.
OPERATED. THE MAXIMUM WORKING
PRESSURE AND TEMPERATURES ARE
SHOWN ON THE CHART NAMEPLATE AND
THE CHART DRAWING (SEE FIGURE III).
FAILURE TO OPERATE WITHIN THE
GUIDELINES MAY RESULT IN SERIOUS THE BAHX MUST BE OPERATED AT
BODILY INJURY OR DEATH AND PRESSURES THAT DO NOT EXCEED
PROPERTY DAMAGE AS WELL AS THE MAXIMUM WORKING PRESSURE
IRREPARABLE DAMAGE TO THE CHART FOR EACH STREAM ON THE CHART
EQUIPMENT AND THE VOIDING OF ANY NAMEPLATE. THE BAHX MUST BE
WARRANTIES APPLICABLE TO THE OPERATED AT TEMPERATURES WITHIN
EQUIPMENT. THE LIMITS OF THE CHART NAMEPLATE
WORKING TEMPERATURES.
III. C. 1.
Prior to startup, purge and dryout procedures
must be completed to remove moisture and heavy
hydrocarbons which may freeze at cryogenic
operating temperatures. A thorough dryout must be
carried out at the commissioning and after every
subsequent shutdown where moisture may reach
the cryogenic equipment. A warm (70 to 100 °F) (21
to 38 °C) dry gas must be used to achieve adequate
dryness. All dead legs in the piping must be drained
and purged.
JANUARY 2021 36
Chart offers the following guidelines to minimize

thermal fatigue.
1. Limit the temperature difference between the
EXCEEDING ANY OF THE MAXIMUM streams at any point along the exchanger length to
WORKING PRESSURES OR 50 °F (28 °C) (See Figure XVII).
TEMPERATURES SPECIFIED ON THE 2. If a stream temperature difference at introduction
CHART NAMEPLATE COULD RESULT IN exceeds 50 °F (28 °C), introduce the flow slowly
A RUPTURE OF THE BAHX WHICH MAY (crack the valve) until the stream temperature
RESULT IN SERIOUS BODILY INJURY OR difference is within 50 °F (28 °C) and then slowly
DEATH AND PROPERTY DAMAGE AS ramp the flow rate to full flow.
WELL AS IRREPARABLE DAMAGE TO THE 3. For frequent events (what could be labeled steady
CHART EQUIPMENT AND THE VOIDING OF state flow) limit the cyclic stream temperature
ANY WARRANTIES APPLICABLE TO THE fluctuations to 1.8 °F (1 °C).
EQUIPMENT. 4. For infrequent events like startup and shutdown,

limit the stream inlet and outlet temperature rates
of change to less than 108 °F/hr (60 °C/hr) with
III. C. 2. allowance up to 3.8 °F/min (2 °C/min).
Appropriate pressure relief valves with settings below
the Chart nameplate maximum working pressures FIGURE XVII
must be provided by the user. Temperature Difference Recommendations
Warm end max
III. C. 3. stream-to-stream
As with any pressure containing equipment, stresses and stream-to-metal
in each component of a BAHX must be maintained temperature difference
within allowable limits during operation. Pressure < 50 °F (28 °C)
loads, externally applied loads (e.g. piping forces and
moments), and thermally induced loads each produce Max temperature
stress in the components. The resultant stress from difference < 50 °F
these loadings must be controlled within allowable (28 °C)
limits to prevent component damage or failure.
Limit pressure and external loads in the BAHX to Cold end max
those specified by Chart. temperature difference
< 50 °F (28 °C)
JANUARY 2021 37
Note that all temperature rates of change should be exchanger will have much lower adjacent parting sheet
calculated using the time interval specified in the rate wall temperature differences than stream temperature
of change time unit, i.e. use one minute intervals when differences.
calculating temperature rates of change against rates
of change per minute and use one hour intervals when Fatigue is defined as repeated stresses resulting in
comparing against rates of change per hour. Do not use fracture. A standard tool in fatigue is the S-N curve,
instantaneous rates of change calculations. For example stress versus the number of cycles. Fatigue is influenced
if a stream temperature changed by 0.5°C in 3 seconds by both the magnitude of the stress and the number of
(an instantaneous rate of change of 10°C/min) but then occurrences of the stress. An assumption in the guideline
only changed by a total of 1°C over a one-minute interval, is when the guidelines are followed, one would expect to
the temperature rate of change is 1°C/min. achieve uninterrupted heat exchanger operation without a
fracture (leak) for the expected life of the heat exchanger.
If the flow in one stream stops suddenly, often the It is also why the temperature rate of change of 2 °C /
recommended course of action is to immediately stop the minute is allowed for infrequent events like startup and
flow of all other streams to avoid a rapid warm-up or cool- shutdown since the assumption is the number of events
down. This should be evaluated by the system designer is not frequent. But for steady state operation where
/ operator on a case-by-case basis for importance (e.g., the number of events is greater, the rate of temperature
stopping a stream with insignificant contribution to the change is reduced to 1 °C /minute.
overall heat exchange might not be cause for stopping
flow of all other streams). For many situations, exceeding the guidelines will
not produce fractures. However, as the magnitude of
III. C. 4. exceeding the guidelines increases and as the number
The guidelines above reference stream temperatures of occurrences increase, the probability to produce
since stream temperatures are readily available to plant fractures increase. Highly specialized software tools
operations. However, these guidelines were developed are required to assess the impact of thermal events and
for local metal temperature differences and local metal the calculated number of occurrences before fracture
temperature rates of change. Thermal stress arises from occurs. The calculated number of occurrences have
local metal temperature differences in BAHX components a range since no two identically manufactured heat
that are close and rigidly attached in all directions. exchangers would fracture at the exact same magnitude
of loads and occurrences. The calculations are limited
However, local metal temperature differences are not to a few selected examples of excursions. This means
readily available nor easily measured. Commercially that predicting exactly when a BAHX will fail or the exact
available software tools calculate adjacent parting lifetime left in the unit is not possible. The calculated
sheet wall temperatures; one can substitute adjacent number of cycles to fatigue should be viewed as an
parting sheet temperatures for stream temperatures in estimate with a range.
the guideline. In most cases, a properly designed heat
JANUARY 2021 38
III. C. 5. • Continuously monitor the BAHX in applications

The high thermal conductivity of aluminum helps to where the fluid must be totally vaporized in the
minimize temperature differences in BAHX, but large BAHX and there is potential for unstable boiling.
local metal temperature differences can arise from Adjust the process conditions (flow, temperature,
operational instabilities, changes in operating conditions, pressure) when necessary to avoid this condition
or transient events associated with startup, shutdown, (e.g., increasing flow often helps to stabilize
or upset conditions. Operational instabilities can result this condition).The relatively large temperature
from unstable boiling within the BAHX or from externally differences associated with unstable boiling along
produced hydraulic fluctuations caused by improperly with surging of the vaporizing fluid within the BAHX
designed piping systems or inadequate control systems. can cause thermally induced fatigue failure.
Detrimental transient events associated with startup,
shutdown, or upset conditions can result from improper • Design and operate the plant equipment and piping
procedures or inadequate control systems. connected to the BAHX to prevent flow instabilities
(for example, intermittent slugging of liquid to the
To prevent damage from these conditions the following BAHX). This is extremely important with boiling
is recommended: streams.
• Review plant operations to identify operating conditions
that have the potential to create high thermal stress and • Maintain cleanliness of all streams feeding the
develop procedures to minimize the impact of these BAHX at all times during operation, and properly
events. Typical conditions causing high thermal stress protect the BAHX from contamination when not in
include cold and warm restarts. A cold restart is defined use. Contamination from solid debris, foulants, and
as restarting flow while the BAHX is cold from prior material freezing out of the streams internal to the
operations. A warm restart is restarting flow after the BAHX may lead to stream maldistribution within the
BAHX has been warmed to near ambient conditions. BAHX. Internal metal temperature differences can
increase with maldistribution and may have the same
• Flow control is particularly critical when introducing detrimental effect as stream temperature differences.
liquid or two-phase streams. Liquid and two-phase The internal metal temperature differences are often
fluids have a large capacity to rapidly change metal impossible to observe, so preventing contamination
temperature in the BAHX. Flow control is less critical and maldistribution in the BAHX is critical to
when introducing and sensibly heating or cooling eliminate this possibility.
vapors due to the limited capacity of the vapor to
rapidly change metal temperature in the BAHX.
For this reason, cooling or warming of the BAHX to
or from operating conditions with a vapor prior to
introducing a liquid or two-phase stream is highly
recommended.
JANUARY 2021 39
III. C. STARTUP, OPERATION, AND SHUT DOWN,

III. D. OPERATING RECORDS
• While the guidelines can be useful to determine
plant control alarm settings, the guidelines are not
recommended plant alarm settings. The process
licensor should be consulted on alarm settings.
While exceeding the guidelines is not recommended
it is not beneficial to install nuisance alarms that
may be turned off by operations. Some operations
benefit from temperature rate of change indicators
rather than alarms.
In instances where it is not possible to adhere to these

guidelines, contact Chart to discuss your specific
application.
III. D. Operating Records

Operating outside the guidelines stated in Section
III. C. may lead to excessive thermal stress which
could result in failure of BAHX components or lead to
rupture even when operating within the design limits
on the nameplate. An operating log should be kept to
record normal operation procedures, any plant upsets,
shut downs, and any other operating conditions. It
is critical the operating data be monitored to ensure
operation is within the IOM stated guidelines.
Given their criticality in determining cause, resolution

and responsibility for any issues with the BAHX,
the owner should maintain adequate installation,
operation, and maintenance records to ensure
compliance with the guidelines (see Section II. H. and
III. C.).
JANUARY 2021 40
IV. MAINTENANCE
BRAND ARCHITECTURE
IV. MAINTENANCE
A. Warning Signs
B. Field Leak Testing
C. Cleaning
D. Mothballing
E. Repair and Service
F. Disposal
JANUARY 2021 41
IV. MAINTENANCE
IV. A. WARNING SIGNS
IV. A. Warning Signs

Potential warning signs where equipment requires
inspection or repair prior to continued operation:
PRIOR TO THE INSPECTION, TESTING,

• Operating data indicates equipment is being OR REPAIRING OF ANY UNIT, EITHER IN
subjected to operating conditions exceeding SERVICE OR RECENTLY REMOVED FROM
guidelines in Section III. C. OPERATION, THE SYSTEM MUST BE
SAFETY CHECKED AND CLEARED PRIOR
• Measurement of stream compositions indicating TO THE ADMITTANCE OF PERSONNEL
cross contamination has developed FOR ANY SERVICE FUNCTION.
• Other BAHX at the facility have developed leaks or

failures
• Frost spots on cold box wall or insulation sheeting
• Liquid drainage from BAHX or from under insulation
• Indications from gas detection sensors
• Venting from the BAHX
• Smart Layer ® Alarm
If any of these warning signs are present contact Chart.
JANUARY 2021 42
IV. MAINTENANCE
IV. B. FIELD LEAK TESTING
IV. B. Field Leak Testing

Internal leaks in a BAHX are generally indicated by a
change of purity in any of the fluid streams. External
CAUTION MUST BE EXERCISED WITH leaks can be determined by sight, smell, audible
REGARD TO THE FLAMMABILITY, sounds of leaking fluid, external gas monitoring
TOXICITY, EXPLOSION POTENTIAL, OR equipment, or localized cold spots appearing on the
PRESSURE POTENTIAL OF ANY FLUID OR external insulation or cold box casing. External leaks
STREAM WITHIN OR IN THE PROXIMITY in BAHX mounted in a cold box are also generally
OF THE BAHX. ALL PERSONNEL INVOLVED indicated by excessive venting through the breather
WITH INSTALLATION OR MAINTENANCE valve or cold spots on the cold box casing. Breather
OF COLD BOX ASSEMBLIES MUST BE valve gas detection methods are within the scope of
MADE AWARE OF THE DANGERS OF operator.
SUFFOCATION, ESPECIALLY IN NITROGEN
FILLED CONTAINERS.
DO NOT EXCEED THE MAXIMUM

WORKING PRESSURE SPECIFIED
FAILURE TO OBSERVE PROPER SAFETY
FOR EACH STREAM ON THE CHART
PRECAUTIONS IN THIS REGARD COULD
NAMEPLATE. OVER–PRESSURIZATION
RESULT IN EQUIPMENT RUPTURE, FIRES,
COULD RESULT IN A RUPTURE OF
TOXIC GAS OR FLUID ESCAPE,
THE BAHX WHICH MAY RESULT IN
SUFFOCATING GAS ATMOSPHERES OR
SERIOUS BODILY INJURY OR DEATH
OTHER ACCIDENTS WHICH MAY RESULT
EQUIPMENT.
EQUIPMENT.
JANUARY 2021 43
IV. MAINTENANCE
It is critical that any leaking BAHX be repaired P1 T2

immediately and that the cause of the leak be identified P2 = ---------
and corrected. Prolonged operation may lead to further T1
damage of the unit when the cause is due to cyclical Where
thermal or mechanical fatigue. Prolonged operation of P = Absolute Pressure
an externally leaking BAHX installed in a perlite insulated T = Absolute Temperature (°R or K)
cold box may lead to further damage and increased 1 = Initial Reading
leakage due to perlite erosion of the BAHX metal. 2 = Final Reading
Common field tests used for determining leaks are For individual recommendations, contact Chart.
described below.
IV. B. 2. Air-Soap Test (External Leaks)
IV. B. 1. Pressure Decay Test If the stream does not maintain the original pressure
Pressurize a stream with dry air or nitrogen. during the decay test, above, determine what kind of
leak exists by repressurizing the stream and checking
A stream is considered leak free if it maintains the the exterior of the BAHX with a soap bubble test. If the
original pressure for over eight hours with correction for BAHX passes this test, the leak is internal.
temperature changes. Keep in mind that the pressure
decay time test is a function not only of the leak size but
the test pressure, temperature, and BAHX size,
as well.
DO NOT EXCEED THE MAXIMUM
For large BAHX and assemblies with large internal WORKING PRESSURE SPECIFIED
volumes, and/or for leak tests at lower pressures (less FOR EACH STREAM ON THE CHART
than 50 psig [3.4 barg]), leaks may take longer than eight NAMEPLATE. OVER–PRESSURIZATION
hours to detect, depending upon the size of the leak. COULD RESULT IN A RUPTURE OF
THE BAHX WHICH MAY RESULT IN
The BAHX temperature should be the same at the two SERIOUS BODILY INJURY OR DEATH
pressure checks since any change in temperature will AND PROPERTY DAMAGE AS WELL AS
change the air pressure in the BAHX. If it is impractical IRREPARABLE DAMAGE TO THE CHART
to make the two pressure checks when the temperatures EQUIPMENT AND THE VOIDING OF ANY
are the same, the following pressure correction can be WARRANTIES APPLICABLE TO THE
used: EQUIPMENT.
JANUARY 2021 44
IV. MAINTENANCE
IV. B. 3. Internal Leak Testing

The method used to locate the individual layer leak
involves a soap test over each port of the stream in
question while air or nitrogen pressure is applied to
the other stream. This operation normally involves
removal of the header and should only be performed
by Chart authorized service personnel.
JANUARY 2021 45
IV. MAINTENANCE
IV. C. CLEANING
IV. C. Cleaning When systems for injecting methanol during operation

If the BAHX is fouled or plugged, several options are have not been provided (see Section III. B. 2.), shut
available to the user for cleaning the BAHX. When down and purge the BAHX and allow it to warm and
the fouling is solid and coats the fins in the BAHX, defrost itself by natural heat leak or by an approved
the BAHX should be cleaned by chemical removal derime procedure. Normally, the combination of
through a series of deriming, back flushing, and drying warming and back flushing with a solvent rinse such
procedures (see Section IV. C. 1.). as trichloroethane, toluene, propanol, or methanol is
successful for this purpose.
If the BAHX is fouled or plugged by hydrates and/
or ice, a warm derime is required and consideration Prior to startup, purge and dryout the BAHX in
given to other methods for hydrate suppression (see accordance with III. C. 1.
Section III. B. 2.).
If a water based solvent is used to derime or back
If the BAHX is fouled or plugged by particulate matter, flush, or if water accidentally gets introduced into the
back puffing procedures are usually successful in BAHX, the BAHX must be completely dried before
cleaning the BAHX (see Section IV. C. 2.). returning to service in order to prevent plugging or
rupture caused by freezing. Use dry air or nitrogen or
The piping and instrumentation diagrams should other dry gas as the drying medium.
be carefully reviewed at the plant design phase to
ensure adequate nozzles and valves on the piping IV. C. 1. a.
are available to carry out any of the above cleaning The derime, back flushing, or drying temperature
procedures that are anticipated. should not exceed 150 °F (65 °C), unless the
maximum working temperature on the Chart
IV. C. 1. Deriming, Back Flushing, and Drying nameplate is higher. Do not exceed the maximum
Deriming and back flushing involves the use of working temperature specified on the Chart
heat and/or solvents to remove hydrates, heavy nameplate.
hydrocarbons, waxy materials, compressor oils, or
other soluble matter which freeze or collect in the IV. C. 1. b.
BAHX. The presence of these materials is detected by The derime, back flushing or drying media must be
an increase in the stream pressure drop and/or loss non-corrosive to aluminum. Always use clean fluids.
of heat transfer performance. As a general guideline, If any vessels, piping, or temporary pipe sections
if the measured pressure drop begins to exceed 2 are used during the cleaning, it is important to clean
to 3 times the design pressure drop, Chart would them of pipe scale, dirt, weld slag, or any other foreign
recommend cleaning efforts be undertaken. material which could enter and plug the BAHX.
JANUARY 2021 46
IV. MAINTENANCE
IV. C. CLEANING
IV. C. 1. c. IV. C. 2. Back Puffing

When liquid solvents are used for purposes of When proper precautions are taken regarding filtering,
deriming or back flushing the BAHX, the nozzle fluid many years of clean service can be expected.
velocity should not exceed 10 feet (3 meters) per However, when foreign material (pipe scale, perlite,
second to prevent erosion inside the BAHX. Liquid desiccant, mole sieve, etc.) is introduced into the
solvents or any cleaning fluids should always be BAHX itself, by accident or misoperation, back puffing
circulated through the BAHX in the reverse direction of can be an effective method for removing entrained
normal operating flow. particulates.
IV. C. 1. d. Since particulates normally cause blockages in the

Cleaning solvents should always be chosen with BAHX at the inlet ports and distributors, puffing in the
regard to the suspected fouling agent. If the fouling reverse direction of normal operating flow is required
agent is unknown, a sample of it should be chemically to prevent pushing the particulates farther into the
analyzed to determine its composition. BAHX. The back puffing procedure involves attaching
a rupture disk to the inlet nozzle or flange of the BAHX
stream to be backpuffed.
ONLY CLEANING SOLVENTS THAT ARE

NON-CORROSIVE TO ALUMINUM MUST BE
USED. CORROSIVE CLEANING SOLVENTS INTRODUCTION OF WATER/AQUAEOUS
CAN WEAKEN PRESSURE RETAINING CLEANING SOLUTIONS TO ANY BAHX
STRUCTURES WHICH MAY RESULT IN EXPOSED TO MERCURY CONTAMINATION
SERIOUS BODILY INJURY OR DEATH CAN RESULT IN ACCELERATED
AND PROPERTY DAMAGE AS WELL AS CORROSION AND CAN CAUSE
IRREPARABLE DAMAGE TO THE CHART IRREPARABLE DAMAGE AND POTENTIAL
EQUIPMENT AND THE VOIDING OF ANY CATASTROPIC FAILURE AND EXPOSE
WARRANTIES APPLICABLE TO THE PERSONNEL TO HAZARDOUS AND
EQUIPMENT. UNSAFE WORKING CONDITIONS.
If any special procedures are required to meet

uncommon derime, back flushing, or drying conditions,
contact Chart for further evaluation.
JANUARY 2021 47
IV. MAINTENANCE
IV. C. CLEANING
IT IS THE USER’S RESPONSIBILITY TO EXTREME CAUTION MUST BE EXERCISED

TAKE THE APPROPRIATE SAFETY SO AS NOT TO EXCEED THE MAXIMUM
PRECAUTIONS REGARDING PERSONNEL, WORKING PRESSURE OF THE STREAM
CLEARING THE TEST AREA, AND THE ON THE CHART NAMEPLATE, OR 100 PSIG,
SUITABILITY OF THE SUPPORTS AND WHICHEVER IS LESS.
BRACING TO WITHSTAND THE REACTION
FORCES DEVELOPED WHEN THE
RUPTURE DISK BURSTS.
FAILURE TO LIMIT PRESSURIZATION
TO THESE LIMITS COULD RESULT IN A
RUPTURE OF THE BAHX WHICH MAY
EXTREME CAUTION MUST BE EXERCISED RESULT IN SERIOUS BODILY INJURY OR
AS THE RUPTURE OF THE DISK AND DEATH AND PROPERTY DAMAGE AS
THE RELEASE OF GAS CAN RESULT IN A WELL AS IRREPARABLE DAMAGE TO THE
RAPID DISCHARGE OF GAS AND FLYING CHART EQUIPMENT AND THE VOIDING OF
DEBRIS WHICH MAY RESULT IN SERIOUS ANY WARRANTIES APPLICABLE TO THE
BODILY INJURY OR DEATH AND PROPERTY EQUIPMENT.
DAMAGE AS WELL AS IRREPARABLE
DAMAGE TO THE CHART EQUIPMENT
AND THE VOIDING OF ANY WARRANTIES Contact Chart for guidance on the maximum allowed
APPLICABLE TO THE EQUIPMENT. backpuffing pressure. If the maximum allowable

pressure is reached and the rupture disk has not
burst, the stream should be depressurized and a new
The plugged stream is slowly filled with dry air or rupture disk installed.
nitrogen until the rupture disk bursts. The sudden
release of gas out of the BAHX will help dislodge A back puffing event does not reduce the life of
particulate matter. This back puffing procedure should the equipment. However, remaining residue in the
be repeated five to ten times, or until the amount equipment has the potential to distort the thermal
of particulate removed becomes minimal and the profile and induce thermal stress, which may reduce
discharge cloud is clear. the life of the equipment.
JANUARY 2021 48
IV. MAINTENANCE
IV. D. MOTHBALLING
IV. D. Mothballing
BAHX which have seen prior service should be dried
and pressurized prior to storage. An eight hour or
longer purge with dry air or nitrogen having a dew
point less than 32 °F (0 °C) is recommended to dry
the BAHX.
Following the drying operation, each stream should be

pressurized with dry air or nitrogen with a dew point of
less than -40 °F (-40 °C). This low dew point is
recommended to prevent galvanic corrosion in the
BAHX which could result if traces of rust or other
foreign materials have gained access to the BAHX
during operation. The dry air or nitrogen pressure
should be 15 psig (1 barg) or one third the stream
design pressure, whichever is less.
The 15 psig (1 barg) pressure level should be checked

periodically to assure that there are no leaks in the
BAHX. In addition, the storage recommendations in
Section II. B. should also be followed.
JANUARY 2021 49
IV. MAINTENANCE
IV. E. REPAIR AND SERVICE, IV. F. DISPOSAL
IV. E. Repair and Service

If a leak is detected, Chart should be notified for repair
recommendations. Chart is well qualified and staffed
to perform field or factory service and repair on this IMPROPERLY REPAIRED BAHX MAY
type of BAHX equipment. NOT BE SUITABLE TO WITHSTAND THE
NAMEPLATE MAXIMUM WORKING
Refer to the National Board Number and the Chart PRESSURE RATINGS.
serial number shown on the ASME U-1 data report
form or unit nameplate when contacting Chart.
PRESSURIZATION OF AN IMPROPERLY
All ASME repairs must be certified by an “R”
REPAIRED BAHX COULD RESULT
stamp and must be in accordance with the Chart
IN A RUPTURE OF THE BAHX WHICH MAY
Quality Assurance Policy, the National Board
Inspection Code, and the ASME Code, and any local
jurisdictional requirements.
Repair to the BAHX should be made only by Chart
authorized personnel. The Chart warranty will be
EQUIPMENT.
voided if repairs made to the Chart BAHX during the
warranty period are made by unauthorized service
personnel. IV. F. Disposal
When disposing of a BAHX, Chart encourages
Improper welding on the BAHX block can damage recycling whenever possible. A drained heat exchanger
the braze joints. Repairs not made in accordance with may have residual compounds inside from prior use.
ASME procedure, and identified by the “R” stamp on Due to accumulation over time, the residual compounds
the Chart nameplate, will invalidate the National Board may be present in more concentrated amounts than
registration of the BAHX. experienced in the product stream. Owners should be
aware that their BAHX may have residual compounds
of sufficient quantity to pose a safety or environmental
hazard. Owners should know the composition of
the residual compounds and consider the safety and
environmental impacts of those compounds before
sending their BAHX to a metal recycler. Disposal
must be in accordance with all applicable laws and
regulations.
JANUARY 2021 50
FIGURE I FIGURE II
Header cold stream.
Side bar
vapour to separate.
7. T
Support angle
Cap sheet
• Extended warranties
• Enhanced operator training and best practices The Chart Energy & Chemicals, Inc. (“Chart”) brazed “Core-in-Kettle” is a registered trademark of Chart Energy &
aluminum heat exchanger (BAHX) business began in Chemicals, Inc.
1985 with the acquisition of The Trane Company’s BAHX
operation in La Crosse, Wisconsin. Chart is a recognized Brazed aluminum heat exchangers are also referred to as
global leader in the design and manufacture of large plate fin heat exchangers and abbreviated to PFHE within
Tel: 1-844-GTLS-911 (1-844-485-7911) – 24/7 hotline BAHX, battery assemblies, and cold boxes for cryogenic the industry.
E-mail: info@ChartLifecycle.com applications.
© 2021 Chart Energy & Chemicals, Inc. All rights reserved.
www.ChartLifecycle.com Chart incorporates the former Altec and Marston BAHX
brands and consequently all rights to engineering and
equipment produced by these companies.
JANUARY 2021 2
Serial Number:
Plant Item Number:
La Crosse, WI 54601
BAHX Installation
®
II. D. 1. c.
®


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ARRIVAL, INSTALLATION, AND STARTUP CHECKLISTS

9. Remove all temporary shipping supports II. D. 1. a.

MAINTENANCE MANUAL MAINTENANCE MANUAL

JANUARY 2021 JANUARY 2021

9. Remove all temporary shipping supports II. D. 1. a.

MAINTENANCE MANUAL MAINTENANCE MANUAL

JANUARY 2021 JANUARY 2021

• Annual service agreements

• Annual service agreements

FOREWORD TABLE OF FIGURES

THESE ITEMS SHOULD BE READ WITH EXTREME CARE AND THOROUGHLY

B. Codes and Materials of

I. A. Configuration (see Figure I, inside cover) I. A. 4. Distributor Fins

The rectangular plate-fin “block” created by this I. A. 5. Heat Transfer Fins

I. A. 9. Support Angles I. A. 13. Cold Box

I. A. 11. Modular BAHX Assembly I. A. 15. Core-in-Kettle® Assembly

I. A. 12. Multiple BAHX Assembly

I. B. CODES AND MATERIALS OF CONSTRUCTION

I. B. Codes and Materials of Construction

Chart BAHX and piping are sometimes designed

The following table indicates the typical materials of

COMPONENT TYPICAL MATERIALS (Aluminum Alloy)

Outside Sheets 3003

II. A. ARRIVAL INSPECTION

II. A. Arrival Inspection

II. B. Storage II. B. 3.

For BAHX that are not shipped with pressure and do

II. C. LIFTING AND HANDLING

Chain or cable method Fork lift method

II. C. LIFTING AND HANDLING

II. C. 1. Single BAHX

II. C. LIFTING AND HANDLING

FIGURE VI II. C. 1. c. Rolling to Alternate Side

Spreader II. C. 1. d. Rotating and Lifting to a Vertical

LIFT DIRECTLY FROM THE BAHX BLOCK

90° bent angle

FAILURE TO HANDLE EQUIPMENT

II. C. LIFTING AND HANDLING

Note: For BAHX exceeding

IF LIFTING LUGS ARE PROVIDED, THEY

II. C. LIFTING AND HANDLING

FAILURE TO HANDLE EQUIPMENT

For these assemblies, lifting instructions are included

II. C. LIFTING AND HANDLING

Stainless steel bolts, nuts, and washers (by

Aluminum support angle

0.5 inches (13 mm)

0.5 inches (13 mm) recommended - 1 inch

II. D. MOUNTING, BRACING, AND SHIPPING SUPPORT

II. D. Mounting, Bracing, and Shipping Support II. D. 1. c.

II. D. 1. b. where L is the distance in inches between extreme

II. D. MOUNTING, BRACING, AND SHIPPING SUPPORT

If the expected thermal movement in both directions is

If the expected thermal movement exceeds 0.5 inches

If the expected movement exceeds 0.5 inches (13 mm)

II. D. MOUNTING, BRACING, AND SHIPPING SUPPORT

II. D. 1. f. II. D. 2. Pedestal Base Mounting System (Single

• Place a chill block or damp rags on the aluminum/

• When installing a loose transition joint, weld the

• Use weld techniques and sequences to minimize the

• Care should be taken to avoid non-uniform heating,

• the modular space formed by welding together two

• the dead corner of a reversing stream warm end

• the space formed between two tandem streams

• other special cases.

III. TESTING AND

III. B. 3. Corrosion Protection • BAHX should not be exposed to process fluids

TEMPERATURES SPECIFIED ON THE 2. If a stream temperature difference at introduction

EQUIPMENT. 4. For infrequent events like startup and shutdown,

III. C. 5. • Continuously monitor the BAHX in applications

• Other BAHX at the facility have developed leaks or

• Frost spots on cold box wall or insulation sheeting

• Liquid drainage from BAHX or from under insulation

• Indications from gas detection sensors

• Venting from the BAHX