This custom-fabricated ASME TEMA Class R team heat exchanger finned tube bundle functions as the central thermal core for the W-03 Light Gas Oil (LGO) Trim Cooler operating inside downstream Crude Distillation Units. Constructed to process liquid-phase LGO on the shell side through 32 segmented horizontal baffles while running cooling water through a 4-pass tube layout, this heat exchanger assembly transfers a design heat duty of 0.769 MM kcal/hr. The mechanical configuration complies with ASME Section VIII Division 1 requirements to sustain continuous chemical refinery processing operations.
Tubes Layout: 404 pieces of ASME SB-111 C44300 Admiralty Brass seamless exchange tubes measuring 20mm OD x 1.8mm thickness x 6000mm length to resist saltwater/cooling water mineral attack within the heat exchanger.
Tubesheets: Single-piece ASME SB-171 C44300 alloy brass plates machined with a 45-degree pitch configuration and 26mm spacing to secure rigid mechanical tube-to-tubesheet boundaries.
Baffle & Support Plates: 32 segmented pieces of ASME SA-285 Grade B carbon steel structural plates spaced at 156mm intervals to establish cross-flow fluid velocity and prevent tube vibration.
Shell & Channel Sections: Heavy-wall ASME SA-516 Grade 70 silicon-killed carbon steel plates providing a baseline 3.0mm corrosion allowance for hot hydrocarbon processing.
Channel Flanges & Nozzles: Forged ASME SA-105 carbon steel components matched with SA-106 Grade B piping sections for all primary cooling water (DN200/PN16) and LGO process connections (DN150/PN16).
Frame Internals: ASME SA-36 carbon steel tie rods, spacers, and integrated pair seal strips (4 pieces total) to eliminate fluid bypass along the inner shell diameter.
TEMA Class R Refinery Execution: Internal clearances, bypass sealing strip quantities (4 strips), and tube-to-tubesheet joints adhere strictly to TEMA Class R industrial design parameters for high-fouling hydrocarbon services.
Precision Horizontal Baffle Pitch: Advanced CNC machining generates 32 cross-flow baffle paths utilizing a strict 156mm horizontal layout, ensuring the team heat exchanger maintains precise fluid velocities without localized hot spots.
Combined Floating Frame System: Configured with 1 fixed saddle and 1 sliding saddle integrated with sliding plates, allowing the entire heat exchanger finned tube bundle to slide and expand axially up to its 70°C/100°C design temperature boundaries without bending stresses.
ASME Code Compliant PWHT: All carbon steel pressure components, channel shells, and nozzle attachment welds undergo Post-Weld Heat Treatment (PWHT) according to mandatory ASME code rules to mitigate residual fabrication stress.
Full Radiographic Testing (RT): 100% volumetric radiography examination executed across all primary longitudinal and circumferential welding seams on both the shell and channel cylinders.
Manufacturer Hydrostatic Qualification: Completely assembled team heat exchanger bundles undergo multi-hour pressure holding tests (Hydrostatic Test at Manufacturer Facility) across separate tube-side and shell-side circuits.
Dual Geometric Inspection: Final physical configurations and machining dimensions are audited against EN ISO 13920-BF (welding execution tolerances) and EN ISO 2768-d(mK) (machined geometry parameters).
Absolute Material Verification: Delivery includes fully certified ASME Section II Material Test Reports (MTRs) for SB-111, SB-171, and SA-516 metals, combined with complete NDT tracking logs and hydro-test certificates.
