PRINTED CIRCUIT HEAT EXCHANGERS - DESIGN AND

FABRICATION

DEP 31.21.01.33-Gen.

January 2010

DESIGN AND ENGINEERING PRACTICE

This document is restricted. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell Global
Solutions International B.V., The Netherlands. The copyright of this document is vested in this company. All rights reserved. Neither the whole nor any part of this
document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise)
without the prior written consent of the copyright owner.
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January 2010
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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell Global Solutions International B.V. (Shell GSI)
and/or
Shell International Exploration and Production B.V. (SIEP)
and/or
other Shell Service Companies.
They are based on the experience acquired during their involvement with the design, construction, operation and
maintenance of processing units and facilities, and they are supplemented with the experience of Shell Operating Units.
Where appropriate they are based on, or reference is made to, international, regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice applied by Shell companies
operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such
facility, and thereby to achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at
each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the
attainment of the required design and engineering standards. In particular, for those requirements not specifically
covered, the Principal will expect them to follow those design and engineering practices which will achieve the same
level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting
from his own responsibility, consult the Principal or its technical advisor.
The right to use DEPs is granted by Shell GSI, in most cases under Service Agreements primarily with Shell companies
and other companies receiving technical advice and services from Shell GSI or another Shell Service Company.
Consequently, three categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or other Shell Service Company. The use of DEPs
by these Operating Units is subject in all respects to the terms and conditions of the relevant Service
Agreement.
2) Other parties who are authorized to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI
disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or
person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination
of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell
Service Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Service
Company, or companies affiliated to these companies, that may issue DEPs or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and
the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be
returned after use, including any copies which shall only be made by users with the express prior written consent of
Shell GSI. The copyright of DEPs vests in Shell GSI. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this
requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
 DEP 31.21.01.33-Gen.
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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................5
1.1 SCOPE........................................................................................................................5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........5
1.3 DEFINITIONS .............................................................................................................5
1.4 CROSS-REFERENCES .............................................................................................5
1.5 SUMMARY OF CHANGES.........................................................................................5
1.6 COMMENTS ON THIS DEP .......................................................................................6
2. GENERAL INFORMATION ........................................................................................7
2.1 DOCUMENT HIERARCHY AND SUBMITTALS.........................................................7
2.2 PRESSURE VESSEL CODE......................................................................................7
2.3 CERTIFYING AUTHORITY ........................................................................................7
2.4 SCOPE OF SUPPLY ..................................................................................................7
2.5 UNITS OF MEASUREMENT ......................................................................................7
2.6 EQUIPMENT NUMBERING........................................................................................7
3. THERMAL AND HYDRAULIC DESIGN ....................................................................9
3.1 INFORMATION SPECIFIED BY THE PRINCIPAL.....................................................9
3.2 PRESSURE DROP .....................................................................................................9
3.3 INFORMATION SUPPLIED BY THE MANUFACTURER ..........................................9
3.4 OPTIMISATION OF PLATE GEOMETRY ..................................................................9
3.5 THERMOSYPHON REBOILER ..................................................................................9
3.6 FOULING ....................................................................................................................9
3.7 STRAINER ..................................................................................................................9
3.8 TWO-PHASE FLOW INLET DISTRIBUTORS..........................................................10
3.9 DESIGN MARGINS ..................................................................................................10
4. MECHANICAL DESIGN ...........................................................................................11
4.1 GENERAL .................................................................................................................11
4.2 DESIGN PRESSURE AND TEMPERATURE ..........................................................11
4.4 DESIGN ANALYSIS..................................................................................................12
4.5 CORROSION ALLOWANCE ....................................................................................12
4.6 LOAD CASES ...........................................................................................................13
4.7 ALLOWABLE STRESSES ........................................................................................13
4.8 HEADERS.................................................................................................................13
4.9 NOZZLE CONSTRUCTION......................................................................................14
4.10 NOZZLE LOADS.......................................................................................................14
4.11 PIPING CONNECTIONS ..........................................................................................14
4.12 FLANGES .................................................................................................................14
4.13 SUPPORTS ..............................................................................................................14
4.14 EARTHING................................................................................................................15
4.15 INSULATION.............................................................................................................15
4.16 BLOCK-TO-BLOCK CONNECTIONS ......................................................................15
4.17 SHEATHING .............................................................................................................15
4.18 VENTING OF BLOCK-TO-BLOCK JOINTS .............................................................15
4.19 VENTS AND DRAINS...............................................................................................15
4.20 THREADED CONNECTIONS...................................................................................15
4.21 CLEANING CONNECTIONS ....................................................................................15
4.22 INSTRUMENT CONNECTIONS...............................................................................16
4.23 RELIEF SCENARIOS ...............................................................................................16
4.24 SAFETY/RELIEF VALVE NOZZLE CONNECTIONS...............................................16
4.25 LIFTING LUGS .........................................................................................................16
4.26 DIMENSION AND TOLERANCES............................................................................16
4.27 SPARE AND REPLACEMENT PARTS ....................................................................16
5. MATERIALS OF CONSTRUCTION .........................................................................17
5.1 GENERAL .................................................................................................................17
5.2 MATERIALS SELECTION ........................................................................................17
5.3 PRESSURE PARTS SPECIFICATIONS ..................................................................17
5.4 NON-PRESSURE PARTS ........................................................................................17
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5.5 GASKETS .................................................................................................................17

5.6 MATERIALS CERTIFICATION AND TRACEABILITY..............................................17
6. DIFFUSION BONDING AND WELDING..................................................................18
6.1 DIFFUSION BONDING .............................................................................................18
6.2 WELDING .................................................................................................................18
7. NON-DESTRUCTIVE EXAMINATION .....................................................................19
7.1 GENERAL .................................................................................................................19
7.2 RADIOGRAPHY .......................................................................................................19
7.3 ULTRASONIC EXAMINATION .................................................................................19
7.4 LIQUID PENETRANT EXAMINATION .....................................................................19
8. INSPECTION ............................................................................................................20
8.1 QUALITY CONTROL ................................................................................................20
8.2 MATERIALS INSPECTION.......................................................................................20
8.3 ASSEMBLY INSPECTION........................................................................................20
8.5 WELD INSPECTION.................................................................................................21
8.6 DIMENSIONAL INSPECTION ..................................................................................21
8.7 NON-CONFORMANCES..........................................................................................22
9. TESTING...................................................................................................................23
9.1 LEAK TESTING ........................................................................................................23
9.2 PRESSURE TESTING..............................................................................................23
9.3 WEIGHING................................................................................................................23
10. NAMEPLATE............................................................................................................24
11. PREPARATION FOR SHIPMENT............................................................................25
11.1 CLEANING AND PACKING......................................................................................25
11.2 MARKING .................................................................................................................25
11.3 OPENINGS ...............................................................................................................25
12. REFERENCES .........................................................................................................26

APPENDICES
APPENDIX A REQUISITIONING AND DOCUMENT SUBMITTALS.....................................28
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1. INTRODUCTION

1.1 SCOPE
This DEP specifies requirements and gives recommendations for the design and fabrication
of printed circuit heat exchangers (PCHEs).
Selection and application of PCHEs is covered by DEP 31.21.01.11-Gen.
This is a revision of the DEP of the same number dated January 2005; see (1.5) regarding
the changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them.
This DEP is intended for use in oil refineries, chemical plants, gas plants, exploration and
production facilities and, where applicable, supply/distribution installations.
When DEPs are applied, a Management of Change (MOC) process should be
implemented; this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regard to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The lower-case word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in (13).

1.5 SUMMARY OF CHANGES

The previous edition of this DEP was dated January 2005. The only non-editorial changes
made in this revision have been to indicate process safety requirements by the use of the
capitalised term "SHALL [PS]".
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1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the DEP Administrator at [email protected].
Shell staff may also post comments on this DEP on the Surface Global Network (SGN).
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2. GENERAL INFORMATION

2.1 DOCUMENT HIERARCHY AND SUBMITTALS

2.1.1 Hierarchy
In case of conflict between documents relating to an order, the following hierarchy shall
apply:
1. the Purchase Order
2. this DEP
Where alternative designs are offered, all deviations from this DEP shall be clearly
identified in the Manufacturer’s bid.
2.1.2 Document submittals
See Appendix A.

2.2 PRESSURE VESSEL CODE

Printed circuit heat exchangers SHALL [PS] be considered to be pressure vessels.
Unless otherwise specified by the Principal, the pressure vessel code shall be ASME VIII,
Division 1, as amended/supplemented by DEP 31.22.20.31-Gen.
NOTE: ASME VIII Div 1 Appendix 13 deals with non-cylindrical vessels and is therefore particularly relevant to
PCHEs.

2.3 CERTIFYING AUTHORITY

For certain applications the design and construction of the printed circuit heat exchanger
may be subject to approval of an Independent Certifying Authority. Where appropriate the
Certifying Authority will be specified by the Principal. In such cases, the Manufacturer shall
be responsible for obtaining the necessary design approvals and meeting the inspection
requirements.

2.4 SCOPE OF SUPPLY

Unless otherwise specified, the scope of supply shall be as specified on the data/requisition
sheets.
The Manufacturer shall include all special features necessary for reliable and safe
operation. These should include, where applicable, adequate means of control to cope with
the specified variations in operating conditions.
With regard to safety and reliability, unspecified but self-evident conditions may occur
during start-up, shut-down, power failure or interruption of the process flow. These
conditions will be reflected in the Principal’s printed circuit heat exchanger data sheets and
SHALL [PS] be taken into account by the Contractor.

2.5 UNITS OF MEASUREMENT

The SI unit system has been applied in this DEP but, where considered necessary, the
metric sizes are followed by their imperial equivalents in brackets.
Care shall always be taken to indicate whether absolute pressure or gauge pressure is
intended. The unit of pressure should be qualified as bar (abs) or bar (ga), whichever is
applicable.

2.6 EQUIPMENT NUMBERING

Heat transfer equipment shall be identified by a specific equipment number in accordance
with DEP 31.10.03.10-Gen.
Equipment consisting of two or more heat exchangers connected in series or parallel and
performing a common duty is termed a unit. In such cases, the unit as a whole is identified
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by the specific equipment number, and each heat exchanger within the unit is separately
identified by the addition of a capital letter in alphabetical progression, e.g. E-101-A, E-101-
B, E-101-C, etc.
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3. THERMAL AND HYDRAULIC DESIGN

3.1 INFORMATION SPECIFIED BY THE PRINCIPAL

The Principal shall specify the heat transfer duty, allowable pressure drop, flow rates,
compositions and physical, thermodynamic and transport properties of the fluids passing
through the heat exchanger. Where a number of operating cases and design conditions are
specified the Manufacturer shall select the most stringent case such that all design
conditions are met.
The Manufacturer shall notify the Principal if insufficient information has been supplied to
satisfactorily design the printed circuit heat exchanger.

3.2 PRESSURE DROP

For potentially fouling systems, as advised by the Principal, the pressure drop for the clean
printed circuit heat exchanger shall be restricted to 90 % of the allowable value.
In calculating the pressure drop, losses shall include all those occurring in nozzles, header
tanks, bends, fittings, manifolds, distribution and thermal sections.
The pressure drop for the strainer shall be additional to the stated printed circuit heat
exchanger pressure drop.

3.3 INFORMATION SUPPLIED BY THE MANUFACTURER

The Manufacturer shall provide completed data/requisition sheets and outline drawings for
the Principal’s review. This shall include sufficient information for the Principal to assess the
thermal and hydraulic performance of the unit.
The Manufacturer SHALL [PS] indicate any start-up or shutdown operation limitations in the
operations manual.

3.4 OPTIMISATION OF PLATE GEOMETRY

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

3.5 THERMOSYPHON REBOILER

For thermosyphon reboilers, the Manufacturer shall check the fluid dynamics (piping
configuration, equivalent length) of the thermosyphon reboilers and inform the Principal or
Contractor if the results of the calculation of the actual situation deviate from the
requirements laid down in the data/requisition sheets.
The reboiler outlet piping shall be routed vertically from the reboiler to the column with only
one 90° elbow and one horizontal part.

3.6 FOULING
The Manufacturer shall state on the printed circuit heat exchanger data sheet the maximum
size of particles that can freely pass through the heat exchanger.
The Principal shall specify if instrumentation shall be installed to measure differential
pressure across the printed circuit heat exchanger to give an early indication of blockage.

3.7 STRAINER
Strainers are normally not in the scope of supply of the Manufacturer. The Manufacturer
shall provide recommended strainer requirements for each stream.
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Refer to DEP 31.21.01.11-Gen for additional guidelines for strainers.

3.8 TWO-PHASE FLOW INLET DISTRIBUTORS

To ensure effective distribution of two-phase flows at the inlet to a printed circuit heat
exchanger, a separator may be used upstream of the printed circuit heat exchanger to
separate liquid and vapour. The liquid and vapour streams may then be introduced via
separate flow paths into the printed circuit heat exchanger core.
The design of the separator vessel is normally not included in the scope of the
Manufacturer. For the final design the layout of the separator vessel and the liquid static
head to be used for the design shall be reviewed by and agreed with the Manufacturer. The
Manufacturer shall ensure that the design of the distributor section ensures even flow
distribution of the two phases into the printed circuit heat exchanger channels over the full
range of turndown.
Other alternatives to properly distribute the two-phase flow into the printed circuit channels
may be proposed by the Manufacturer only if they have been proven to be successful in
operation in similar printed circuit heat exchanger designs.

3.9 DESIGN MARGINS

A minimum of 10 % excess surface area shall be provided over the surface area required to
satisfy the specified thermal duty requirements. This 10 % margin is required to ensure the
exchanger design is flexible enough to accommodate potential variations in the heat
exchange duty, e.g. unexpected fouling, inaccuracies in process modelling and fluid
characterisation etc. This minimum 10 % margin is normally inclusive of fouling and should
not be applied in addition to any specified fouling resistances.
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4. MECHANICAL DESIGN

4.1 GENERAL
The mechanical design shall be based on the design conditions specified in the requisition.
Where a number of operating cases and design conditions are specified, the Manufacturer
shall select the most stringent case so that all design conditions are met.
The design of the printed circuit heat exchanger shall be in accordance with the relevant
codes and standards defined in (2.2) or as otherwise specified in the Purchase Order. The
specified code shall be agreed with the Principal prior to design and construction.
All pressure containing parts shall be considered in the printed circuit heat exchanger
design including headers, nozzle compensations, nozzles, manifold(s) and the printed
circuit heat exchanger block itself.
Structural integrity shall be considered in the design, application of standards and codes
and fully demonstrated in the design documentation.

4.2 DESIGN PRESSURE AND TEMPERATURE

For the determination of the design pressure on the low pressure side, the initial design
pressure on the low pressure side or 2/3 of the design pressure on the high pressure side,
whichever is greater, shall be taken (refer to DEP 01.00.01.30-Gen. for limitations).
However, if it is economic to maintain the initial design pressure on the low-pressure side
by installing a relief device, this may be considered. The size of the relief device then
SHALL [PS] be determined in accordance with DEP 80.45.10.11-Gen.
The core of a printed circuit heat exchanger can withstand very high pressures due to the
nature of heat exchanger. The determination of the design pressure is relevant for the
design of the headers and nozzles. The Principal SHALL [PS] specify the design pressure
and temperature for each stream through the heat exchanger separately (refer to
DEP 01.00.01.30-Gen.). The possibility of exposure to system pressure waves, e.g. water
hammer, shall be taken into account.
The effect of the temperature profile through the printed circuit heat exchanger shall be
taken into account in the design because this may have a significant consequence on the
"mean metal temperature" as well as on the stresses within the printed circuit heat
exchanger.
In addition to the design operating condition(s), the Principal SHALL [PS] specify all
operating conditions that might impose significant stresses on the printed circuit heat
exchanger. This shall consider any alternate operating cases, turn down operation, upset
operation cases (with particular attention to cases where a stream’s flowing condition may
change or cease abruptly), and the process control philosophy being applied to the printed
circuit heat exchanger.
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4.3 DESIGN CONDITIONS AND CALCULATIONS

The Manufacturer shall provide calculations to the code requirements for:
• diffusion bonded block internals;
• block-to-block joints;
• headers;
• nozzles and compensation;
• nozzles under local loads;
• supports and lifting lugs;
• hydrotest pressures.

4.4 DESIGN ANALYSIS

4.4.1 Headers
For the design of headers the pressure vessel code rules associated with the design of
conventional pressure vessels can be used to assess the levels of stress resulting from
internal pressure, thermal stresses (e.g. resulting from temperature gradient over the core
and/or temperature differences between stream) and external forces.
4.4.2 Block
The printed circuit heat exchanger block is a pressure vessel. The separating forces
between plates caused by internal pressure create tensile stresses in the regions of metal
bonding, particularly where the metal ridges between channels are bonded to the adjacent
plate. Design calculations also take into account stresses in the other two planes. The width
of the ridges can thus be chosen to provide sufficient metal to maintain acceptable stress
levels.
4.4.3 Stress calculations
The Manufacturer shall have an in-house standard calculation method for assessing the
stresses in component parts of a printed circuit heat exchanger block. Design calculations
shall take into account the following joint and bond factors:
Type of joint Factor
Diffusion bonds 0.70
Non-radiographed welds 0.70
Header-to-block welds, spot RT/UT 0.85
Fully inspected welds RT/UT 1.00

The resultant membrane and bending stresses are compared with those permitted by the
pressure vessel code for the particular material grade under consideration.
The calculation method shall be approved by the appropriate pressure vessel authority and
must demonstrate that the effects of all design requirements including external loads have
been taken into consideration.

4.5 CORROSION ALLOWANCE

Corrosion allowance shall be zero unless specifically requested by the Principal.
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4.6 LOAD CASES

The mechanical design of the printed circuit heat exchanger shall take into account the
following loads acting individually or in combination.
• pressure loads;
• reaction forces at nozzles and supports, including start-up, shut-down and emergency ;
• depressurising conditions;
• loads due to seismic, wind or other motion;
• snow, impact and blast loads;
• loads associated with installation at site.
The Principal shall specify which load cases will be applicable for the printed circuit heat
exchanger.
Furthermore, the Principal shall inform the Manufacturer about any pressure or thermal
cyclic loading including start-up, shutdown, cycles over life, blowdown etc. The
Manufacturer shall prove, by a mutually agreed calculation method, that the heat exchanger
will be able to sustain this loading during service life. If the unit will be subjected to pressure
cycling or thermal cycling, the effects of fatigue of materials shall be considered; see also
(4.7).

4.7 ALLOWABLE STRESSES

The maximum allowable design stresses shall be taken from the pressure vessel code and
shall be based on the final material condition.
If special design conditions exist, the Manufacturer shall ensure that safety factors are
applied in accordance with the general practice of the pressure vessel code.
Where the Principal specifies that operation will subject the equipment to cyclic loading,
fatigue analysis shall be considered. In determining whether or not fatigue analysis is
required, reference may be made to experience with comparable units operating under
identical conditions. In the absence of applicable service experience a fatigue analysis
SHALL [PS] be performed in accordance with the provisions of:
ASME Boiler and Pressure Vessel Code Div 2:
• Para AD-160: For evaluation of the need for fatigue analysis.
• Appendix 6 6-170: For the procedure to be adopted for measuring the fatigue life of a
pressure vessel based on tests carried out on a scale or full size model of the unit.
PD 5500
• Appendix C
• Enquiry Case 79: For guidance on the need for fatigue analysis and determination of
fatigue strength reduction factors.

4.8 HEADERS
The minimum required plate thickness for fluid headers shall be as per Table 1.
TABLE 1 Mimimum required plate thickness for fluid headers
Header diameter Minimum plate thickness
≤ 1200 mm 6 mm
> 1200 mm 8 mm

Headers or tees should preferably be sufficiently thick to provide the required reinforcement
for openings and nozzle loads.
All reinforcement pads or rings shall be leak tested via a ¼” NPT tapped tell-tale hole,
which shall be filled with heavy grease prior to shipment.
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Headers shall contain no longitudinal welds other than the header-to-block joints.

4.9 NOZZLE CONSTRUCTION

The nozzle construction shall be in accordance with the selected pressure vessel standard.
If the nozzle diameter approaches that of the header, it is often impossible to use set-in
nozzles and the use of set-on nozzles may be considered in such circumstances.
Nozzles which protrude beyond the inside contour of the header shall be self-venting or
draining by notching at their intersection with the high or low point of the cylinder. If
separate vent and drain connections are used, they shall be flush with the inside contour of
the header.
Seam welded nozzles shall be subjected to 100 % radiography.
The minimum nozzle size shall be DN 50, except for the venting of the sheathing (see 4.16)
or venting of the block-to-block joints (see 4.17).

4.10 NOZZLE LOADS

In view of the large nozzle-to-header diameter ratios typically encountered in printed circuit
heat exchangers, the calculation method employed for stresses due to external loads on
nozzles shall depend upon the relative nozzle and header sizes, as follows:
a) Where the nozzle internal diameter is less than one-half the header internal
diameter, stresses shall be calculated according to WRC 107 and WRC 297,
employing the ASME VIII Div. 1 design stress.
b) Where the nozzle internal diameter equals or exceeds one-half of the internal
diameter of the header, the stresses shall be calculated by a finite element
calculation.
For design, the maximum allowable moments and forces for nozzles and headers shall be
equal to, or greater than those specified in the requisition.

4.11 PIPING CONNECTIONS

Piping connections shall be either flanged or butt-welded.

4.12 FLANGES
Flanges for nozzles shall have pressure/temperature ratings, dimensions and flange facing
in accordance with ASME B16.5 or ASME B16.47A. Special mechanical couplings may be
used for higher pressures (to further reduce dimensions and mass) if approved by the
Principal.
Flange bolt holes shall straddle the exchanger centrelines.

4.13 SUPPORTS
The printed circuit heat exchanger shall be provided with support brackets or saddles.
Supports shall be designed to withstand seismic, wind, blast, transportation and the
applicable loads referred to in clause (4.5).
Supports shall be provided with sufficient oversize or slotted holes to accommodate any
change in block dimensions or block position under operating or upset conditions and
during start up and shut down.
Saddles shall protrude beyond the bottom nozzles, including the drain nozzle with blind
flange, by at least 50 mm to prevent damage to flange facings during transport, storage and
maintenance.
When required, the Manufacturer shall provide details of the loads generated on the
supports due to dead weight of the printed circuit plus loads resulting from external applied
forces and moments.
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4.14 EARTHING
The printed circuit heat exchanger shall be provided with two earthing bosses.
The Manufacturer shall ensure electrical continuity is provided between the printed circuit
heat exchanger block and the earthing bosses.

4.15 INSULATION
The Principal shall specify the thickness of insulation to be applied to the printed heat
exchanger external surfaces, the type of insulation clips required for attachment of the
insulation, and the required nozzle stand-out beyond the insulation.

4.16 BLOCK-TO-BLOCK CONNECTIONS

In order to build the required thermal capacity, the diffusion-bonded blocks are welded
together endplate-to-endplate separated by a picture frame, used as backing strip to form
an all welded heat exchanger core. As the backing strip welds are not pressure retaining
nor in contact with the process fluids the use of these backing strips is allowed.

4.17 SHEATHING
Where protection of hot austenitic stainless steel against the external saliferous
atmosphere is required the exposed areas of austenitic steel SHALL [PS] be sheathed with
duplex stainless steel sheet (UNS S31803) of at least 1.5 mm thick or other material as
agreed with the Principal.
The sheathing shall be attached by welding, and vented by means of DN 15 vent pipe
incorporating a spring loaded pressure relief device with an opening pressure of
0.3 bar (ga). The pressure relief device shall be packed with heavy grease. Alternatively,
the vent nozzle could be combined with the vent nozzle for the venting the block-to-block
cavities (see 4.18). The sheathing welds shall be examined using the liquid penetrant
method.

4.18 VENTING OF BLOCK-TO-BLOCK JOINTS

In order to confirm the absence of pressure between the blocks all of the cavities enclosed
by the block-to-block joints are connected to a single vent. The vent nozzle shall be a
DN 15 vent pipe incorporating a spring-loaded pressure relief device with an opening
pressure of 0.3 bar (ga). The pressure relief device shall be packed with heavy grease.

4.19 VENTS AND DRAINS

All high and low points of a printed circuit heat exchanger not otherwise vented or drained
by nozzles shall be provided with vent and drain nozzles. The vent and drain sizes shall be
at least DN 40 x DN 25 (reducer).
All vent drain connections shall be flanged and provided with a blind flange unless
otherwise noted on the data/requisition sheets.
The location of all vents and drains shall be agreed with the Principal prior to fabrication.
The vents and drains of printed circuit heat exchangers shall be indicated on the relevant
Process Engineering Flow Schemes.

4.20 THREADED CONNECTIONS

Threaded connections shall not be used.

4.21 CLEANING CONNECTIONS

If printed circuit heat exchangers will require in-service cleaning with hot water, steam,
solvents or other chemical methods, suitable flanged nozzle connections of DN 50
minimum size shall be provided. There shall be no cleaning connections on exchanger
 DEP 31.21.01.33-Gen.
January 2010
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nozzles, but they may be located on the connecting piping. Requirements and
recommendations for cleaning are given in DEP 70.10.80.11-Gen.

4.22 INSTRUMENT CONNECTIONS

If required, temperature instrument and pressure gauge connections shall be specified on
the data/requisition sheets. There shall be no temperature instrument or pressure gauge
connections in printed circuit heat exchanger nozzles.

4.23 RELIEF SCENARIOS

In case a relief device would be required, the relief rate SHALL [PS] be based on the
requirements as specified in DEP 80.45.10.11-Gen.

4.24 SAFETY/RELIEF VALVE NOZZLE CONNECTIONS

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

4.25 LIFTING LUGS

The lifting devices shall be located above the centre of gravity of the parts to which they are
welded or cast.
Where welded plate type lugs are used, these shall be welded on with full penetration
employing either double welding or by single welding with a GTAW root pass.
The hole diameter shall be at least 28 mm diameter.
The load bearing capacity of the lugs in supporting the required load shall be demonstrated
by calculation. In any case the lugs shall be designed for a static force of at least twice the
mass of the heat exchanger part(s).

4.26 DIMENSION AND TOLERANCES

Nozzles shall be positioned within ± 3 mm of the position relative to the datum shown on
the Manufacturer’s General Arrangement drawing.
Flange-to-flange dimensions shall be ± 6 mm.
Flange faces shall be oriented within ±1° (maximum 5 mm at flange periphery).

4.27 SPARE AND REPLACEMENT PARTS

Spares and replacement parts shall be in accordance with DEP 70.10.90.11-Gen
 DEP 31.21.01.33-Gen.
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5. MATERIALS OF CONSTRUCTION

5.1 GENERAL
Materials shall be in accordance with DEP 30.10.02.11-Gen.
Stainless steel materials, other than the diffusion-bonded core, shall be delivered in the
"white" pickled and passivated condition.
Cast iron parts shall not be used.
Materials shall conform to NACE MR0175 or NACE MR0103 and shall be solution
annealed if hardness limits are exceeded after forming.

5.2 MATERIALS SELECTION

The Principal shall specify the material to meet the specified service conditions following
consultation with the Manufacturer.

5.3 PRESSURE PARTS SPECIFICATIONS

Materials of construction for vessel parts subject to internal or external pressure shall
comply with the selected pressure vessel code (see 2.2)

5.4 NON-PRESSURE PARTS

All attachments, such as supports, lifting points or reinforcements shall be of a similar
material specification as the material to which they are attached.

5.5 GASKETS
The selection of gaskets shall be in accordance with the appropriate piping class of the
connecting piping (see DEP 31.38.01.12-Gen. or DEP 31.38.01.15-Gen., as applicable).

5.6 MATERIALS CERTIFICATION AND TRACEABILITY

All materials of construction shall be supplied with full chemical and mechanical property
certificates in accordance with ISO 10474 type 3.1.B. All materials and welding
consumables shall be traceable to their test certificates.
Where it is not practical to transfer markings from the parent material to component parts,
the Manufacturer shall operate approved alternative QA procedures to maintain traceability.
 DEP 31.21.01.33-Gen.
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6. DIFFUSION BONDING AND WELDING

6.1 DIFFUSION BONDING

Diffusion bonding procedures shall be qualified by transverse tensile testing of a diffusion-
bonded stack of un-etched plates.
The transverse tensile strength test specimen shall contain no fewer than 10 diffusion-
bonded joints
The acceptance criteria for procedure test of diffusion bonded joints shall be that the UTS,
yield stress and elongation exceeding parent metal specification.
Where full parent material properties are not achievable for diffusion bonded joints in a
particular material, the microstructure shall show substantial crystal growth through the
bond plane and the Manufacturer shall obtain written agreement from the Principal and the
Certifying Authority for a suitable joint efficiency to apply to the diffusion bonded joints for
mechanical design purposes.

6.2 WELDING
6.2.1 GENERAL
After diffusion bonding of the block and required testing, header tanks, nozzles and
supports shall be welded to the printed circuit heat exchanger blocks.
6.2.2 PROCEDURE APPROVAL
The Manufacturer shall submit proposed Welding Procedure Qualifications, Procedure
Qualification Records (including weld details) for Certifying Authority approval prior to
commencing any production welding. The Principal has the right to review the applicable
welding documentation at the Manufacturer’s premises.
The Welding Procedures shall be qualified in accordance with relevant sections of the
design code.
6.2.3 PROCEDURES AND QUALIFICATIONS
Welding procedures and welders shall be qualified in accordance with the pressure vessel
code (see 2.2).
6.2.3 WELD MAP
A weld map shall be prepared which includes an outline drawing that identifies all welds
and relates them to the relevant welding procedure number and non destructive
examination requirements.
6.2.4 WELD PREPARATION
The weld bevels and surrounding area shall be clean and free from moisture, oxides or any
other foreign matter that could interfere with welding. A visual inspection shall be made on
all weld preparations to ensure they are correctly profiled and smooth and free from any
defects that might affect weld quality.
 DEP 31.21.01.33-Gen.
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7. NON-DESTRUCTIVE EXAMINATION

7.1 GENERAL
Test procedures shall be submitted to the Certifying Authority for approval prior to the
commencement of fabrication. The Principal reserves the right to review the applicable
NDE documentation at the manufacturer’s premises.
NDE personnel shall be qualified in accordance with the pressure vessel code (see 2.2).

7.2 RADIOGRAPHY
Radiography shall be performed in accordance with ASME V, Article 2.
Each radiograph shall contain sufficient information to identify the following:
• weld identification;
• radiograph location;
• original or repaired weld;
• welder's identification.

7.3 ULTRASONIC EXAMINATION

Ultrasonic examination shall be performed on header apertures for set-on nozzles to verify
the absence of plate laminations

7.4 LIQUID PENETRANT EXAMINATION

The liquid penetrant examination procedure shall be in accordance with the pressure vessel
code (see 2.2)
Liquid penetrant examination shall be applied to:
• All GTAW root runs and adjacent diffusion-bonded material;
• The capping run of all weld runs and adjacent diffusion-bonded material.
 DEP 31.21.01.33-Gen.
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8. INSPECTION

8.1 QUALITY CONTROL

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

8.2 MATERIALS INSPECTION

Prior to the cutting of sheet, plate or other material, the Principal or the Principal’s
Nominated Representative may inspect the materials and material certification to ensure
they meet the requirements of the requisition.
All pressure retaining parts shall be subjected to 100% positive material identification.

8.3 ASSEMBLY INSPECTION

The Manufacturer shall inspect the plates following etching to confirm that the etched
channel geometry is consistent with the thermal and mechanical design calculations.
The Manufacturer shall subject all plates to full visual inspection prior to stacking. Plates
shall be clean of etching agent and mask, free of gross etching defects, within dimensional
tolerances and correctly oriented.
The Manufacturer shall inspect the stacked plates to confirm that the stack has the
specified number of plates, the specified plate sequence and square sides.
Stacked heat exchangers shall be assembled in the Manufacturer’s workshop to verify that
all intermediate nozzles will bolt together.
 DEP 31.21.01.33-Gen.
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8.4 WELDING REQUIREMENTS

Printed circuit heat exchanger welds are often close together, and some will even partially
overlap (see Figure 1).

y x
A

z
Figure 1 Typical PCHE geometry
In Figure 1 the header to core welds for headers A and B will overlap at ‘y’, and there will
be a similar overlap at least at the opposite corner of the core. Also, where the nozzle is
relatively large compared to the header, the nozzle attachment weld may be close to, or
even overlap, the header-to-core weld.
The joining of multiple welds is replicated by using a single groove with multiple passes
using identical welding parameters and materials, even to the extent that a partly filled weld
might need to be left overnight to cool down to room temperature before completing the
weld. This practice is acceptable to ASME IX and verification of weld integrity is achieved in
strict accordance with procedure qualification and production weld testing. Welding
thicknesses up to 100 mm have been qualified in this way. The welding shall be carried out
strictly in accordance with the qualified welding procedure specification (WPS).
Under the conditions described above, the use of overlapping and close welds is
acceptable for printed circuit heat exchangers.

8.5 WELD INSPECTION

Non-destructive examination of the welds is limited by accessibility and some header welds
are not accessible at all. The Manufacturer shall perform maximum practical amount
radiographic weld inspection. Figure 1 shows that the weld at ‘x’ on header A is always
accessible for radiography since it is near the corner of the printed circuit heat exchanger
core. The weld ‘z’ on header B however is not accessible for radiography. At corner ‘y’, only
the weld of the first header to be welded to the printed circuit heat exchanger core will be
accessible for radiography.
It has been found that in austenitic stainless steel the use of ultrasonic weld inspection is
not feasible as an alternative to radiography because it is not possible to obtain a
meaningful signal through welded joints on printed circuit heat exchangers.
All inspection and non-destructive testing of welds shall be carried out in accordance with
procedures approved by the Principal.
The extent of non destructive examination and the proposed non destructive examination
techniques shall be detailed in the Manufacturer’s QA and Inspection Plan and General
Arrangement drawings. As a minimum, the proposed level of inspection shall meet the
requirements of the pressure vessel code.
Liquid penetrant inspection shall be performed at the various stages of the welding.

8.6 DIMENSIONAL INSPECTION

The Principal shall inspect the finished and assembled unit for correct fit-up and positions
and nozzle relative to an agreed datum point.
 DEP 31.21.01.33-Gen.
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8.7 NON-CONFORMANCES
Defects resulting from fabricating operations shall be repaired or the item shall be
discarded. Repairs shall be performed in accordance with a procedure accepted by the
Principal prior to the repair; this includes re-examination for defects and retesting for
pressure leaks and leaks in the original manner.
If rectification requires blocking of a layer, the Manufacturer shall use a proven procedure
developed for this purpose. Any blocking of a layer shall be notified to the Principal.
If the heat exchanger is supplied with blocked layer(s), the Manufacturer shall supply
calculations that confirm the adequacy of the unit to the originally specified requirements.
 DEP 31.21.01.33-Gen.
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9. TESTING

9.1 LEAK TESTING

A helium leak test shall be carried out on the completed equipment prior to pressure
testing.
No detectable leak shall be permitted in complete equipment between:
• The various fluid circuits in the exchanger
• Any of the fluid circuits in the exchanger and the surroundings.
Leak testing shall be carried out in the presence of the parties specified in the Quality Test
and Inspection Plan.
The test shall be carried out in accordance with a leak test procedure approved by the
Principal.
Unless otherwise agreed between the Principal and the Manufacturer the following
allowable leakage rate shall be applied:
• for an external leakage: 1x10–4 kPa m3/s (at a pressure difference of 100 kPa);
• for an internal leakage: 1x10–3 kPa m3/s (at a pressure difference equal to the design
pressure) or 1x10–4 kPa m3/s (at a pressure difference of 100 kPa).

9.2 PRESSURE TESTING

All printed circuit heat exchangers shall be tested by a hydrostatic pressure test in
accordance with the pressure vessel standard (see 2.2).
If the heat exchanger is to operate in a cryogenic service, pneumatic testing shall be
applied unless otherwise agreed with the Principal.
Pressure testing shall be carried out on the completed equipment following satisfactory leak
testing.
Each individual process stream shall be tested to the pressure stipulated by the design
code. The test shall be carried out with atmospheric pressure in the adjacent stream
passages.
The hydrostatic testing shall be undertaken with water containing not more than 30 mg/kg
chlorides.
Pressure testing shall be carried out in the presence of the parties specified in the Quality
Test and Inspection Plan.
The test shall be carried out in accordance with a pressure test procedure approved by the
Principal.
Stacked printed circuit heat exchangers shall be pressure tested in the stacked position.
Service bolts and gaskets furnished by the Manufacturer shall not be used in testing or
shipping the printed circuit heat exchanger.
Immediately following the hydrostatic-test, the vessel shall be thoroughly cleaned and dried
prior to final inspection, preservation and shipment.

9.3 WEIGHING
All exchangers shall be weighed on completion. The Manufacturer shall submit a weight
certificate and Centre of Gravity data completed with calculated and weighed data for dry,
operating and lift conditions.
 DEP 31.21.01.33-Gen.
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10. NAMEPLATE

A nameplate shall be permanently attached to each individual printed circuit heat

exchanger.
The nameplate shall be of corrosion resistant material. The nameplate shall be attached to
a bracket welded to the printed circuit heat exchanger. If the printed circuit heat exchanger
is to be installed in a permanent enclosure, (e.g. a cold box), a second identical (duplicate)
nameplate shall be supplied loose by the Manufacturer, for attachment onto the enclosure
by others.
Because printed circuit heat exchangers are capable of accommodating more than two
streams, i.e. containing more than two independent pressure chambers, it is required to
specify data for the several streams. Alternatively, different nameplates can be used for
each stream.
Standard nameplate data shall include:
• Manufacturer’s name and printed circuit heat exchanger serial number;
• Principal’s item number;
• Principal’s order number;
• Manufacturers serial number;
• date of manufacture;
• pressure vessel code and, if required, code stamping;
• design temperature and minimum design metal temperature for each stream;
• design/maximum allowable working pressure (vacuum if applicable) for each stream;
• test pressure for each stream;
• type of pressure test (pneumatic/hydrostatic);
• mass (empty);
• space for stamping by relevant inspection authority.
 DEP 31.21.01.33-Gen.
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11. PREPARATION FOR SHIPMENT

11.1 CLEANING AND PACKING

Exchangers shall be thoroughly cleaned both internally and externally of all foreign
material, such as grinding dust, weld flux and weld spatter. Water or other liquids used for
cleaning or hydrostatic testing shall be drained and the equipment thoroughly dried.
In case an exchanger will be operated in cryogenic services, the exchanger shall be dried
to a dew point less than –40 °C.
The exchangers shall be properly packed and protected from damage during shipment by
road, rail and containerised sea transport.

11.2 MARKING
Each crate or package shall be clearly identified in accordance with the customer’s
specification. As a minimum the package shall be marked with the Purchase Order number,
the item number, the shipping mass and the delivery address.

11.3 OPENINGS
11.3.1 Cryogenic service
To avoid ingress of any moisture or dust during transport, printed circuit heat exchangers
shall be shipped with nozzles hermetically sealed and all pressure chambers pressurised
with dry, oil-free nitrogen or air to between 0.2 bar (ga) and 1.2 bar (ga) if these units will
be operating in cryogenic service. In addition all connections must carry warning labels
stating that the heat exchanger is under pressure.
All nozzles and branches shall be protected against damage during transportation and
erection.
11.3.2 Other services
Steel cover plates, bolted in place with at least four bolts then sealed with heavy-duty tape,
shall be fitted to protect the flanged process connections.
All nozzles and branches shall be protected against damage during transportation and
erection.
 DEP 31.21.01.33-Gen.
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12. REFERENCES

In this DEP, reference is made to the following publications:

NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards.

SHELL STANDARDS
Definition and determination of temperature, pressure and DEP 01.00.01.30-Gen.
toxicity levels
Symbols and identification system – Mechanical DEP 31.10.03.10-Gen.
Welding of metals (amendments/supplements to API RP 582) DEP 30.10.60.18-Gen.
Printed circuit heat exchangers – Selection and application DEP 31.21.01.11-Gen.
Pressure vessels (based on ASME Section VIII) DEP 31.22.20.31-Gen.
Piping classes – Refining and chemicals DEP 31.38.01.12-Gen.
Piping classes – Exploration and production DEP 31.38.01.15-Gen.
Cleaning of equipment DEP 70.10.80.11-Gen.
Spare parts DEP 70.10.90.11-Gen.
Overpressure and underpressure – Prevention and protection DEP 80.45.10.11-Gen.
DATA/REQUISITION SHEETS
Printed circuit heat exchangers DEP 31.21.01.94-Gen.
EDP supplement DEP 40.00.10.93-Gen.
Engineering documents (“RED” form) DEP 40.10.01.93-Gen.
STANDARD FORMS
Heat exchanger summary DEP 01.00.03.84-Gen.
Specification of design and engineering documents DEP 05.00.50.82-Gen.
Approval drawing specification (ADS) DEP 05.00.54.81-Gen.
Final drawing specification (FDS) DEP 05.00.54.82-Gen.
BRITISH STANDARDS
Unfired fusion welded pressure vessels PD 5500
Issued by:
British Standards Institution
389 Chiswick High Road
London W4 4AL, United Kingdom

AMERICAN STANDARDS
ASME Boiler and Pressure Vessel Code – Rules for ASME VIII
construction of pressure vessels
Pipe flanges and flanged fittings NPS 1/2 through NPS 24 ASME B16.5
Large diameter steel flanges NPS 26 Through NPS 60 ASME B16.47
Issued by:
American Society of Mechanical Engineers
ASME International
Three Park Avenue, M/S 10E
New York, NY 10016, USA
 DEP 31.21.01.33-Gen.
January 2010
Page 27

Local stresses in spherical and cylindrical shells due to external WRC 107
loadings
Local stresses in cylindrical shells due to external loadings on WRC 297
nozzles
Issued by:
Welding Research Council
PO Box 201547
Shaker Heights, OH 44120, USA
 DEP 31.21.01.33-Gen.
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Page 28

APPENDIX A REQUISITIONING AND DOCUMENT SUBMITTALS

The Principal's enquiry shall specify the number of copies of outline drawings, construction
drawings, data/requisition sheets, data reports and final records to be supplied by the
Manufacturer, all as specified in DEP 40.10.01.93-Gen.
The following Standard Forms shall be used for the specification of plate-and-frame heat
exchangers in conjunction with this DEP:
Specification of design and engineering documents DEP 05.00.50.82-Gen.
Approval drawing specification DEP 05.00.54.81-Gen.
Final drawing specification DEP 05.00.54.82-Gen.

To be submitted during Project Specification phase (design phase):

Data/requisition sheets for printed circuit heat exchangers DEP 31.21.01.94-Gen.
Requisition for engineering documents (“RED” form) DEP 40.10.01.93-Gen.

To be submitted during Detailed Engineering phase (purchasing phase):

Heat exchanger summary. DEP 01.00.03.84-Gen.
EDP supplement DEP 40.00.10.93-Gen.

The complete set of data/requisition sheets shall be used, even if only one equipment item
is ordered

Last page of this DEP