ASME U Stamp TEMA Heat Exchanger Class R for Refinery Hydrogen Stage 1 Discharge Intercooler

ASME U Stamp TEMA Heat Exchanger Class R for Refinery Hydrogen Stage 1 Discharge Intercooler

Our custom-engineered ASME TEMA Class R Heat Exchanger is meticulously manufactured as a premium replacement component for heavy-duty refinery applications, specifically benchmarked against the rigorous P-428302 Stage-1 Discharge Intercooler specification. Designed in absolute compliance with ASME Section VIII Div.1, TEMA Class R, and API-660, this floating-head type heat exchanger is structurally and metallurgically optimized for severe Hydrogen Service (H2 Service) on the shell side, operating under strict environment protocols like PETROBRAS N-1704. It serves as a vital component in Diesel Hydrotreating Units (HDT) and petrochemical downstream refineries.

CORE COMPONENTS & MATERIAL SPECIFICATIONS

To ensure zero risk of hydrogen embrittlement and catastrophic failure under thermal stress, all materials follow advanced structural upgrades:

• Heat Exchanger Tubes: 236 pieces of SA-179 Seamless Carbon Steel Tubes. Strictly 100% seamless configuration to eliminate the hazards of welded SA-214 options in hydrogen environments.

• Tubesheets (Fixed & Floating): Fabricated from premium Forged Steel SA-266 Gr. 2, upgrading the raw integrity from basic SA-516 Gr. 70 plates to provide superior microstructural density near joints.

• Baffles & Support Plates: Precision-machined from ASTM A-36 / SA-516 Gr. 60, featuring exact outer diameter tolerances scaled downward strictly per TEMA Table RCB-4.3 to guarantee perfect internal shell alignment without bypass flow.

• Tie Rods & Spacers: High-tensile carbon steel/stainless steel built to drawing alignment standards for robust bundle rigidness.

• Maintenance Accessories: Integrated specialized lifting lug options and precision stainless steel threaded plug holes on the tubesheet to assist secure field extraction during refinery maintenance turnaround periods.

CORE TECHNOLOGY & MANUFACTURING ADVANTAGES

• ASME Qualified Hydrogen-Service Welding: Every pressure-retaining joint and tube-to-tubesheet connection undergoes elite welding execution governed by qualified WPS/PQR documentation. Tube joints are precision-expanded and strength-welded to establish an airtight, leak-proof seal barrier.

• TEMA RCB-4.3 Strict Tolerance Adherence: Baffle clear distances and diameters are cross-checked via customized manufacturing jigs/gauges to secure absolute alignment, completely preventing shell-side bypass and guaranteeing design thermal efficiency.

• Simulated PWHT Capability: Materials are processed under advanced heat treatment protocols, including Simulated Post-Weld Heat Treatment (Simulated PWHT) according to PETROBRAS N-268/N-1704 requirements, ensuring maximum stress relief across heat-affected zones.

• Sliding Rails Integration: Built-in heavy-duty sliding bars (barras de deslizamento) are configured onto the support frame to minimize friction, facilitating smooth sliding installation and future inspection pull-outs.

STRICT QUALITY CONTROL & TESTING (QA/QC SPECIFICATION)

• 100% Non-Destructive Testing (NDT): Comprehensive inspection tracking including Radiographic Testing (RT), Ultrasonic Testing (UT), Liquid Penetrant Testing (PT), and Magnetic Particle Testing (MT) across all high-stress forge areas and weld pathways.

• Tube-to-Tubesheet Tightness Guarantee: Advanced electronic tube expanding logging coupled with continuous expansion audits (supported with photographic documentation for each sample lot) to ensure ultimate joint integrity.

• Comprehensive Turnaround Databook: Delivery includes a fully traceable Technical Databook stamped by qualified engineering inspectors, housing Material Test Reports (MTRs), welding logs, dimensional alignment reports, and NDT verification.

INTERNATIONAL LOGISTICS & TARGET MARKET SUPPORT

• 6-Month Unsheltered Storage Preservation: The complete bundle assembly is packed utilizing heavy-duty ocean freight preservation methods. The critical tubesheet faces and sealing surfaces are protected with specialized anti-rust coatings and high-durability shielding gaskets, certified to withstand open-air, unsheltered storage conditions at project sites for a minimum of 6 months.

• Global EPC Logistics & Documentation Compliance: Fully experienced in handling complex international logistics, documentation tracking, and verification frameworks. We provide comprehensive export packaging, loading layouts on transport vehicles, and documentation compliance support across major global regions, including regulatory import frameworks for South America, the Middle East, and West Africa (SONCAP/Form M processing).