32-SAMSS-007

Previous Issue: 5 April 2008 Next Planned Update: 19 November 2012 Revised paragraphs are indicated in the right margin Page 1 of 38 Primary contact: Anizi, Salamah Salem on 966-3-8746139

Copyright©Saudi Aramco 2009. All rights reserved.

Materials System Specification

32-SAMSS-007 15 August 2009 Manufacture of Shell and Tube Heat Exchangers

Heat Transfer Equipment Standards Committee Members Anizi, Salamah Salem, Chairman Bagawi, Jamil Jarallah, Vice Chairman Anezi, Mohammed Ali Dossary, Musfir Abdullah Fernandez, Gabriel Thomas Gahtani, Moraya Saif Guthami, Mohammed Mohsen Hamam, Ibrahim Hassan Harbi, Abdullah Mohammed Saeed Mansour, Khalid Mohammad Naffaa, Mahmoud Youniss Rumaih, Abdullah Mohammad

Saudi Aramco DeskTop Standards Table of Contents 1 Scope............................................................. 2 2 Normative References.................................... 2 3 Terms and Definitions.................................... 5 4 General........................................................... 7 5 Proposals....................................................... 7 6 Drawings and Other Required Data............... 8 7 Design............................................................ 8 8 Materials....................................................... 18 9 Fabrication.................................................... 20 10 Inspection and Testing................................. 24 11 Preparation for Shipment............................. 31 12 Supplemental Requirements........................ 34 13 Drawings, Calculations and Data................. 34 Table 1 - Acceptable Materials for Carbon and Low - Alloy Steels.......................... 35 Table 2 - Charpy-V Impact Test Requirements.. 37 Table 3 - Material Classes.................................. 37 Table 4 - Radiography Requirements for Heat Exchangers............................. 38

Document Responsibility: Heat Transfer Equipment 32-SAMSS-007

Issue Date: 15 August 2009

Next Planned Update: 19 November 2012 Manufacture of Shell and Tube Heat Exchangers

Page 2 of 38

The following paragraph numbers refer to API STD 660, Seventh Edition, February 2003,

which is part of this specification. The text in each paragraph below is an addition,

exception, modification, or deletion to API STD 660 as noted. Paragraph numbers not

appearing in API STD 660 are new paragraphs to be inserted in numerical order.

1 Scope

1.1 This specification covers the minimum mandatory requirements for the

manufacture of shell and tube heat exchangers and new components

(herein referred to as exchangers). It does not cover exchangers that

undergo repairs or alterations.

1.2 This specification shall not be applied to the design of non-TEMA

exchangers, such as sometimes used for lube and seal oil cooling duties

for packaged equipment like compressors, pumps and turbines.

1.3 Conflicting Requirements

1.3.1 Any conflicts between this specification and other Saudi Aramco

Materials System Specifications (SAMSSs), Industry codes and

standards, and Forms shall be resolved in writing by the Company or

Buyer Representative through the Standards Committee Chairman,

Consulting Services Department of Saudi Aramco, Dhahran.

1.3.2 Direct all requests to deviate from this specification in writing to the

Company or Buyer Representative, who shall follow internal company

procedure SAEP-302 and forward such requests to the Manager,

Consulting Services Department of Saudi Aramco, Dhahran.

2 Normative References

Materials or equipment supplied to this specification shall comply with the latest edition

of the references listed below, unless otherwise noted.

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a

Mandatory Saudi Aramco Engineering

Requirement

Saudi Aramco Engineering Standards

SAES-A-007 Hydrostatic Testing Fluids

SAES-A-206 Positive Materials Identification

http://standards/docs/Saep/PDF/SAEP-302.PDF

http://standards/docs/Saep/PDF/SAEP-302.PDF

http://standards/docs/Saes/PDF/SAES-A-007.PDF





Page 3 of 38

SAES-A-112 Meteorological and Seismic Design Data

SAES-H-101 Approved Protective Coating Systems

SAES-H-101V Approved Saudi Aramco Data Sheets - Paints and

Coatings

SAES-N-001 Basic Criteria, Industrial Insulation

SAES-P-111 Grounding

SAES-W-010 Welding Requirements for Pressure Vessels

SAES-W-014 Weld Overlays and Welding of Clad Materials

Saudi Aramco Materials System Specifications

01-SAMSS-016 Qualification of Pipeline and Pressure Vessel

Steels for Resistance to Hydrogen-Induced

Cracking

32-SAMSS-031 Manufacture of Clad Vessels and Heat

Exchangers

Saudi Aramco Standard Drawings

AA-036322 Anchor Bolt Details – Inch and Metric Sizes

AE-036250 Ferrules for ¾ Inch Tubes (Sheets 1 & 2)

Saudi Aramco Inspection Requirements

Form 175-323100 Manufacture of Shell and Tube Heat Exchangers

Form 175-323500 Floating Heads or Tube Bundles

Saudi Aramco Forms and Data Sheets

Form 2714-ENG Shell and Tube Exchanger Data Sheet (herein

referred to as data sheet)

Form NMR-7922-1 Non-material Requirements for Shell and Tube

and Double-Pipe Heat Exchangers

2.1 Industry Codes and Standards

American Concrete Institute

ACI 318 Building Code Requirements for Structural

Concrete


http://standards/docs/Saes/PDF/SAES-H-101.PDF

http://standards/docs/Saes/PDF/SAES-H-101V.PDF

http://standards/docs/Saes/PDF/SAES-N-001.PDF

http://standards/docs/Saes/PDF/SAES-P-111.PDF

http://standards/docs/Saes/PDF/SAES-W-010.PDF


http://standards/docs/SAMSS/PDF/01-SAMSS-016.PDF


http://standards/docs/Standard_Drawings/PDF/AA-036322-001.PDF

http://standards/docs/Standard_Drawings/PDF/AE-036250-001.PDF



http://standards/docs/Inspection_Requirements/PDF/175-323100.PDF


http://standards/docs/Forms_Data_Sheets/XLS/SA-2714.XLS

http://standards/docs/Nonmaterial_Requirements/PDF/SA-7922-1.PDF




Page 4 of 38

American Petroleum Institute

API STD 660 Shell-and-tube Heat Exchangers for General

Refinery Services

API RP 934 Materials and Fabrication Requirements for

2¼Cr-1 Mo & 3Mo Steel Heavy Wall Pressure

Vessels for High Temperature, High Pressure

Hydrogen Service

API PUBL 941 Steels for Hydrogen Service at Elevated

Temperatures and Pressures in Petroleum and

Petrochemical Plants

API RP 945 Avoiding Environmental Cracking in Amine Units

American Society of Civil Engineers

ASCE 7 Minimum Design Loads for Buildings and Other

Structures

American Society of Mechanical Engineers (Boiler and Pressure Vessel Codes)

ASME SA-20 Specification for General Requirements for Steel

Plates for Pressure Vessels

ASME SA-388 Ultrasonic Examination of Heavy Steel Forgings

ASME SA-435 Straight Beam Ultrasonic Examination of Steel

Plates

ASME SA-450 Specification for General Requirements for

Carbon, Ferritic Alloy, and Austenitic Alloy

Steel Tubes

ASME SA-688 Specification for Welded Austenitic Stainless Steel

Feedwater Heater Tubes

ASME SEC IIC Specifications for Welding Rods, Electrodes, and

Filler Metals

ASME SEC V Nondestructive Examination

ASME SEC VIII D1 Rules for Construction of Pressure Vessels

ASME SEC VIII D2 Rules for Construction of Pressure Vessels,

Alternative Rules

ASME B2.1 National Pipe Threads

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.11 Forged Fittings, Socket-Welding and Threaded




Page 5 of 38

ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring-Joint,

Spiral-Wound, and Jacketed

ASME B16.21 Non-Metallic Gaskets for Pipe Flanges

ASME B16.25 Buttwelding Ends

ASME B16.47 Large Diameter Steel Flanges NPS 26 through

NPS 60

American Society for Nondestructive Testing

ASNT CP-189 Standard for Qualification and Certification of

Nondestructive Testing Personnel

National Association of Corrosion Engineers

NACE RP0472 Methods and Control to Prevent In-Service

Environmental Cracking of Carbon Steel

Weldments in Corrosive Petroleum Refining

Environments

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-Materials

for use in H2S-Containing Environments in Oil

and Gas Production

Tubular Exchanger Manufacturers Association (TEMA)

Process Industry Practices

PIP VEFV1100 Vessel/S&T Heat Exchanger Standard Details

Welding Research Council

WRC 107 Welding Research Council Bulletin

3 Terms and Definitions

AARH: Average arithmetic roughness height, which is a measure of surface texture.

Cyclic Service: Services that require fatigue analysis per AD-160 of ASME SEC VIII

D2. This applies to Division 1 and Division 2 of ASME SEC VIII.

Design Engineer: The Engineering Company responsible for specifying on the data

sheet the hydraulic, thermal and mechanical design requirements for exchanger.

High - Alloy Steels: Steels with a total alloying content more than 5%.

Hot Forming: Forming operations carried out at an elevated temperature such that re-

crystallization occurs simultaneously with deformation.

http://linkmanager.ihs.com/LinkManagerService/LKMLink.aspx?LinkRefName=NACE+MR0175%2fISO+15156&RefGroupId=30


http://standards/docs/PIP/PDF/VEFV1100.PDF




Page 6 of 38

Hydrogen Service: Process streams containing relatively pure hydrogen and

component streams containing hydrogen with a partial pressure of 350 kpa abs (50 psia)

and higher.

Lethal Services: Process streams containing a concentration of hydrogen sulfide in

excess of 20% by volume shall be considered as lethal service. Other services as

determined by the process Licenser may also be designated as lethal services.

Low-Alloy Steels: Steels with nominal chromium content up to 5% and/or nominal

nickel content up to 3%.

Minimum Thickness: Thickness required for withstanding all primary loads,

excluding allowance for corrosion

MDMT: Minimum Design Metal Temperature, determined by the Design Engineer.

Nominal Thickness: Thickness required for withstanding all primary loads, including

allowance for corrosion.

Saudi Aramco Engineer: The Standards Committee Chairman.

Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco

Inspection Department to inspect heat exchangers to the requirements of this

specification.

Thick Wall Exchanger: An exchanger or portion of it with nominal thickness greater

than 50-mm.

Utility Services: Water, air, nitrogen and steam services.

Exchanger Manufacturer: The company responsible for the manufacture of new heat

exchangers in accordance with this specification.

Sour Service: Process streams containing hydrogen sulfide for the following

conditions:

1) Sour water with a hydrogen sulfide (H2S) concentration above 2 mg/L (2 ppmw)

and a total pressure of 400 kPa absolute (65 psia) or greater.

2) Hydrocarbon services meeting the definition of sour environments in NACE

MR0175/ISO 15156 as shown below:

a) Dissolved H2S in free water (liquid) with a concentration of >50 mg/L

(50 ppmw) or,

b) H2S in gas with a gas phase with 0.05 psia or greater partial pressure.

Commentary Note:










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HIC resistant steel is not required in caustic services, lean amine systems and rich amine DGA systems.

4 General

4.1 (Exception) Pressure design code shall be ASME Boiler and pressure

vessel code, Section VIII.

4.6 Should the Exchanger Manufacturer have any part of a stress analysis

executed by a third party, the Exchanger Manufacturer shall advise the

Saudi Aramco Engineer.

4.7 No proof testing shall be permitted unless specifically approved by the


4.8 Application of ASME Code Cases to the manufacture of exchangers

requires approval of the Saudi Aramco Engineer.

4.9 Exchangers having partial or complete cladding shall also conform to

32-SAMSS-031 in addition to the requirements of this specification.

4.10 The Exchanger Manufacturer is responsible for the thermal/hydraulic

design (rating) and verification of the Design Engineer's

thermal/hydraulic design, if applicable. The Exchanger Manufacturer is

also responsible for the manufacture of exchanger, which includes the

complete mechanical design, Code and structural calculations, flow

induced vibration, supply of all materials, fabrication, nondestructive

examination, inspection, testing, surface preparation, and preparation for

shipment, in accordance with the completed data sheet and the

requirements of this specification.

5 Proposals

5.1 Purchaser's Responsibilities

5.1.1 (Exception) The Design Engineer is responsible for specifying the

thermal/hydraulic design and basic mechanical design requirements as

noted on the Saudi Aramco data sheet.

5.1.2 The Design Engineer is responsible for specifying the requirements for

Cyclic Services stress analysis.

5.2 Vendor's Responsibilities

5.2.8 The Exchanger Manufacturer may offer an alternative design, and may

also quote on the base inquiry documents.





Page 8 of 38

5.3 Performance Guarantees

The following shall be guaranteed for the length of the warranty period

specified in the purchase order or contract documents:

1) Exchangers shall meet thermal/hydraulic performance

requirements under continuous operation at design conditions

specified on the data sheets. Thermal/hydraulic guarantee shall be

in accordance with TEMA paragraph G-5.

2) Exchangers shall be free from damaging flow induced tube

vibration and acoustic vibration.

6 Drawings and Other Required Data

6.1 Outline Drawings

6.1.2 Drawings and calculations that are approved by the Design Engineer

shall not relieve the Exchanger Manufacturer of the responsibility to

comply with the Codes and this specification.

6.1.3 The Exchanger Manufacturer shall prepare drawings, calculations and

data in accordance with Form NMR-7922-1, Nonmaterial Requirements.

6.2 Information Required after Drawings are reviewed

6.2.4(d) Flow induced and acoustic vibration analyses.

6.3 Reports and Records

The Exchanger Manufacturer shall furnish reports and records in

accordance with Form NMR-7922-1, Nonmaterial Requirements.

7 Design

7.1 Design Temperature

7.1.3 (Exception) The value(s) of design temperature(s) shall be as specified

on the data sheet.

7.1.4 The value of the minimum design metal temperature (MDMT) shall be

as specified on the data sheet.

7.1.5 The MDMT shall be used to determine the requirements for impact

testing in accordance with the code of this specification.






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7.2 Cladding for Corrosion Allowance

Cladding of exchangers, where required, shall be in accordance with

32-SAMSS-031.

7.3 Shell Supports

7.3.2(f) Horizontal exchangers shall be supported by two saddles. The

exchanger shall be fixed at one saddle support and free to slide at the

other saddle.

7.3.6 The shell at saddle supports shall be analyzed in accordance with the

"L.P. Zick" method. Saddle supports and the exchanger shell shall be

analyzed for operating and hydrotest loads including any piping, wind or

other external loads.

7.3.7 The allowable concrete bearing stress to be used for the design of base

plates shall be 10340 kPa (1400 psi).

7.3.8 The outline drawing for horizontal exchangers shall specify locations of

the fixed and sliding saddles and dimension from exchanger centerline to

underside of saddle base plate.

7.3.9 Anchor Bolts

7.3.9.1 The Exchanger Manufacturer shall determine the size and number of

anchor bolts required. Anchor bolts shall be in compliance with

Standard Drawing AA-036322 Sht. 001 (Rev. 07 or later).

7.3.9.2 Anchor bolts shall not be less than 20 mm minimum nominal diameter.

7.3.9.3 The design of anchor bolts shall be in accordance with the requirements

of Appendix D of ACI 318.

7.3.9.4 Anchor bolts that are exposed to the weather in coastal areas, subjected

to frequent wash downs, or subjected to firewater deluge testing shall

have their diameters increased by 3 mm as a corrosion allowance.

7.3.9.5 Saddles for horizontal exchangers shall be provided with an even number

of anchor bolts with a minimum of two anchor bolts per saddle.

7.5 Floating Head

7.5.2 (Exception) Floating head covers shall be attached to the backing device

or to the floating tubesheet with through bolting.

7.6 Tube Bundle


http://standards/docs/Standard_Drawings/PDF/AA-036322-001.PDF




Page 10 of 38

7.6.1 Tubes

7.6.1.5 Wall thickness of integral low-fin tubes, if used, shall be measured from

the inside diameter of the tube to the root of the fins. The specified wall

thickness shall be nominal, except that the actual wall thickness shall not

be less than 90% of that specified.

7.6.1.6 For expanded joints, the tubes shall extend 3 mm beyond the face of

tubesheets, except tubes shall be flush on the upper tubesheet of vertical

exchangers.

7.6.1.7 For exchangers with tube-side design pressures 13.8 MPa (2000 psi) and

above, all tubes shall be hydrostatically tested at the mill at the tube-side

design pressure and the variation from the tube outside diameter shall not

exceed the values specified in Table 5 of ASME SA-450.

7.6.1.8 For steam condensing services, when steam is in the 'U' tubes and the

process is controlled by flow control of condensate, the design engineer

shall consider wither the 'U' bends shall be in the horizontal or vertical

plane.

7.6.1.9 In exchangers with tube side as the high-pressure side, design pressure of

the shell side should be at least two-thirds of the tube side design

pressure if the shell side is not protected with a relief system. Other

options require the approval of Saudi Aramco Engineer.

Commentary Note:

This is to prevent any unexpected catastrophic failure in case of tube leak in exchangers.

7.6.2 Tubesheets

7.6.2.5 All stationary tubesheets with through bolting design shall have non-

threaded bolt holes.

7.6.2.6 Vertical exchangers with fixed tubesheets shall be provided with flanged

vents and drains through the tubesheets.

7.6.3 Transverse Baffles and Support Plates

7.6.3.1 (Exception) Minimum thickness of baffles and support plates shall be as

per TEMA requirements.

7.6.3.3 Support plates for floating heads shall be located as close to the

tubesheet as the design and type of exchanger will permit. Support plate




Page 11 of 38

shall be cut at either top or bottom or in the center to minimize

ineffective heat transfer surface at the floating head end.

Commentary Note:

Typically, this distance is approximately 150 mm (6 inches).

7.6.3.4 'U' tube bundles shall have a support plate close to the tangent line of

tubes. The support plates shall be cut to allow some flow over 'U' bends,

provided that all tubes are supported.

Commentary Note:

Typically, support plates are 50 mm (2 inches) away from the tangent line.

7.6.4 Impingement Protection

7.6.4.7 Impingement rods, if used, shall be arranged in a pattern, which will

minimize bypassing of the shell side fluid and avoid the flow hitting the

tubes directly.

Commentary Note:

Typically, two rows of rods on a triangular layout are used as an impingement protection.

7.6.4.8 The use of distribution belts shall be considered when shell-side nozzles

are large resulting in long inlet and/or outlet unsupported tube lengths.

Commentary Note:

A properly designed belt should result in more effective use of the heat transfer area and a more rigid bundle with better tube support.

7.6.5 Bypass Sealing Devices

7.6.5.4 (Exception) The location of the sealing devices shall not interfere with

the continuous tube lanes for square and rotated square layouts.

7.7 Nozzles and Other Connections

7.7.2 (Exception) When butt welded connections are specified on the data

sheet the ends shall be in accordance with ASME B16.25.

7.7.3 (Exception) Threaded or socket-welded connections are prohibited in

hydrogen, lethal, wet sour and caustic services. However, for other

services, threaded or socket-welded connections with 6000-lb. rating




Page 12 of 38

conforming to ASME B16.11 may be used for NPS 1½ and smaller

vents, drains and instrument connections.

7.7.4 (Exception) Flanged connections shall be one of the following types:

1) Forged steel long welding neck.

2) Forged steel welding neck flange with seamless pipe, or rolled

plate with 100% radiography. The bores of nozzle flanges shall

match the nozzle neck bore.

3) Studded nozzles and proprietary designs may be offered as

alternatives provided their designs are in accordance with the Code

and with prior approval of the Saudi Aramco Engineer.

4) Lap-type joints with loose end flange can be used for utility

services with pressure up to 1.4 MPa (200 psi) and a temperature of

120°C (250°F).

7.7.5 (Exception) slip-on type flanges can only be used for utility services up

to 400°C (750°F) design temperature and 2.1 MPa (300 psi) design

pressure, with seamless pipe nozzle necks or rolled plate with 100%

radiography.

7.7.6 (Exception) Flanges shall be in accordance with ASME B16.5 pressure

rating.

7.7.11 The quantities, sizes, ratings (ASME pressure classes) and facings of

exchanger nozzles shall be as specified on the data sheet.

7.7.12 For exchanger drain connections and other connections, where a process

stream is likely to be stagnant, the projection shall be limited to 2.5 times

the connection nominal diameter for vertical connections and to 3.5

times the connection nominal diameter for horizontal connections.

7.7.13 Flange bolt holes shall straddle the normal horizontal and vertical

centerlines of the exchanger.

7.7.14 Threaded connections shall conform to ASME B2.1.

7.7.15 When 100% radiography is required, per table 4 of this specification, on

nozzle connection to an exchanger, integrally reinforced contour forged

connections according to the following shall be used:

a) For Division 1 exchangers: Figure UW-16.1: (f-1), (f-2), (f-3) or

(f-4).




Page 13 of 38

b) For Division 2 exchangers: Figure AD-613.1: (a), (b), (c), (c-1) (d)

or (e).

7.7.16 The calculated MAWP of an exchanger in the hot and corroded

condition shall not be limited by the nozzle reinforcement or the flange

rating.

7.7.17 All nozzles in thick wall exchangers shall be weld neck, long weld neck

or contour forged with inside corner radius of 13 mm minimum.

7.7.18 Integrally reinforced openings (with no reinforcing pads) shall be

provided under the following services and design conditions:

1) Cyclic services

2) Carbon steel with shell or channel thickness greater than 50 mm

3) Low-chrome steels with shell or channel thickness 25 mm and

greater

4) Openings which are 900 mm and larger with design temperature

400°C and greater

5) Exchangers with design metal temperatures greater than 425°C

6) Hydrogen service

7.7.19 All nozzles larger than NPS 4 necks shall be attached by welding

completely through the total thickness of the exchanger shell or channel,

including any reinforcement.

7.7.20 Permissible types of nozzle weld-attachments for exchangers with

shell/channel cylinder nominal thickness equal to or less than 50 mm are:

1) For Division 1 exchangers: Figure UW-16.1 (c), backing rings are

to be removed, (d), (e), (f-1), (f-2), (f-3), (f-4) or (g).

2) For Division 2 exchangers: Figure AD-610.1 (c), (d), (e), (e-1) and

(g) or weld attachments in paragraph 7.7.22 (2) of this

specification.

7.7.21 Permissible types of nozzle weld-attachments for thick wall exchangers

are:

1) For Division 1 exchangers: Figure UW-16.1 (f-1), (f-2), (f-3) or

(f-4).

2) For Division 2 exchangers: Figure AD-613.1: (a), (b), (c), (c-1),

(d) or (e), backing rings are to be removed.




Page 14 of 38

7.7.22 Permissible types of nozzle weld-attachments for exchangers with NPS 4

and smaller connections are:

1) For Division 1 exchangers: Figure UW-16.1 (a), (a-1), backing

rings are to be removed, (b) or those in paragraphs 7.7.21(1) or

7.7.22(1)

2) For Division 2 exchangers: Figure AD-610.1 (c), (d), (e), (e-1), (f)

or those in paragraphs 7.7.21(2) or 7.7.22(2).

7.7.23 Use of internal reinforcing elements is not permitted.

7.11 Handling Devices

7.11.5 Exchangers with a component weighing up to and including 27 kg

(60 lb.) shall be provided with at least one lifting lug per component.

Two lifting lugs shall be provided for heavier weights.

7.11.6 Shell lifting lugs shall be designed such that the lifted parts hang

vertically when suspended from the lugs. Lugs on insulated exchangers

shall be of sufficient standout to clear insulation.

7.11.7 Protective plugs shall be fully engaged.

7.11.8 Clad fixed tubesheets shall be drilled and tapped and provided with base

plugs of the same material as the cladding. Base plugs shall be seal

welded and ground flush with the tubesheet surface and re-drilled and

tapped for pulling eyes.

7.12 Hydrogen Service

(Exception) Where the tube and/or shell side will be exposed to hydrogen

at a partial pressure exceeding 350 kPa (50 psia), totally enclosed spaces

between welds shall be eliminated or vented with a 6 mm diameter hole.

7.13 Kettle Reboilers

Kettle type reboilers shall conform to the following:

1) The distance between the top of weir and top of tubes shall be a

minimum of 75 mm.

2) The distance from the weir to adjacent tangent line of the head

shall not be less than 900 mm.

3) Weirs shall be provided with a 50 mm semi-circular drain hole.

7.14 Design Pressure




Page 15 of 38

7.14.1 The value(s) of design pressure(s) shall be in accordance with the data

sheet.

7.14.2 For exchangers subjected to steam out, the Design Engineer shall specify

on the data sheet the external design pressure and corresponding

temperature.

7.15 Maximum Allowable Working Pressure

7.15.1 The Exchanger Manufacturer shall calculate the maximum allowable

working pressure (MAWP) acting on both sides of the exchanger, in the

hot and corroded condition in accordance with the applicable Code.

7.15.2 The MAWP of an exchanger shall not be limited by flange ratings.

7.16 Joint Efficiency

7.16.1 A joint efficiency of 85% or higher shall be used for the design of all

pressure containing components of ASME SEC VIII D1 exchangers.

7.17 Loads

7.17.1 Wind and Earthquake Loads

1) The Exchanger Manufacturer shall calculate the static effects of

loads due to wind and the effects due to earthquake loads acting on

the exchanger in the operating position in accordance with ASCE 7.

2) The design engineer shall determine the basic wind speed

corresponding to the Saudi Aramco in accordance to SAES-A-112.

The basic wind speed shall be specified on the data sheet.

3) Wind pressures shall be assumed to act on the projected surface

area of the exchanger and shall include due allowances for any

platforms, ladders, piping, insulation, and equipment supported

from the exchanger.

7.17.2 Piping, Equipment and External Loads

1) The design engineer shall provide piping and equipment loads

imposed on the exchanger.

2) The Exchanger Manufacturer shall ensure that local stresses imposed

on the exchanger due to piping and equipment, lifting, supports and

other external loads do not exceed the allowable in accordance with

the applicable Code. The stress analysis shall be completed in

accordance with the procedures as detailed in WRC 107 or a finite

element analysis.





Page 16 of 38

7.18 Load Combinations

7.18.1 All components of an exchanger, including supports, shall be designed to

withstand the combined stresses resulting from the following:

1) Internal and/or external design pressures.

2) All other loads exerted on the component and specified in section

7.17.

3) All exchanger components whether shop or field fabricated shall be

designed to withstand a full hydrostatic test in the erected position.

Combined stresses due to full hydrostatic test and wind or

earthquake loads shall not exceed 90% of the lowest Specified

Minimum Yield Strength (SMYS) of the materials of construction

at test temperature. However, forces produced, due to wind or

earthquake design conditions, may be reduced to 40% of its values.

The use of a pneumatic test may be considered when it will result in

significant cost savings in the exchanger and/or its supporting

structural/foundation. Such test requires prior approval of the Saudi

Aramco Inspector.

7.19 Shell and Channel Covers

7.19.1 ASME flanged and dished heads (torispherical) may be used for utility

services up to a design pressure of 690 kPa (100 psi).

7.19.2 One piece construction shall be used for heads of minimum thickness

greater than 50 mm and for heads in heat exchangers in cyclic, hydrogen

or lethal services. Other types of head construction shall require prior

approval of Saudi Aramco Engineer.

7.19.3 Where a forged shell-and-head junction according to ASME SEC VIII

D2, Figure AD-912-1(k) is used, one piece construction shall be used for

the remaining portion of heads mentioned in paragraph 7.19.2 of this

specification. Other types of head construction shall require prior

approval of Saudi Aramco Engineer.

7.19.4 Dished heads in thick wall exchangers shall be specified as

hemispherical unless 2:1 ellipsoidal heads are deemed economical.

7.19.5 Minimum inside radius of knuckles for conical transition sections or

torispherical heads shall be as follows:

a) Not be less than 15% of the outside diameter of the adjoining

cylindrical section with conical section of thickness more than




Page 17 of 38

2 inches.

b) Not be less than 10% of the outside diameter of the adjoining

cylindrical section with conical section of transition sections or

torispherical heads with thickness more than 0.75 inch or less than

2 inches.

c) Not be less than 6% of the outside diameter of the adjoining

cylindrical section with conical section of transition sections or

torispherical heads with thickness 0.75 inch and less.

7.19.6 Reinforcing for conical transition sections in thick wall exchangers shall

be provided by increased plate thickness. The use of reinforcing rings is

prohibited.

7.20 Longitudinal Baffles (TEMA 'F' shells)

7.20.1 Baffles shall be designed for 1.5 times the shell-side allowable pressure

drop and with a maximum deflection in the corroded condition of 6 mm.

7.21 Clips and Attachments

7.21.1 For insulation support attachment, refer to exchanger data sheet for the

extent and thickness of external insulation.

7.21.2 The Exchanger Manufacturer shall supply and install all clips and

attachments as specified by the Design Engineer.

7.21.3 All internal and external attachments, including clips, welded directly to

pressure parts are to be attached by continuous welding except for blank

nuts used for external insulation where tack welding is allowed.

7.21.4 All exchangers shall be provided with a grounding lug connection

welded to the fixed exchanger support.

7.21.5 The Exchanger Manufacturer shall supply and install supports required

for fireproofing materials.

7.21.6 Vertical exchangers, which are externally insulated, shall be provided

with insulation supports in accordance with SAES-N-001.

7.22 Coatings and Painting

7.22.1 The types of coating and painting systems to be used shall be in

accordance with the data sheet and the Saudi Aramco Coating Systems

attached to the purchase order.

http://standards/docs/Saes/PDF/SAES-N-001.PDF




Page 18 of 38

7.22.2 Gasket contact surfaces shall not be painted.

7.23 General

7.23.1 Single tube pass TEMA rear end floating head type exchangers shall be

designed with a removable shell cover to provide easy access to the

expansion joint in the tube side nozzle.

7.23.2 Where more than one exchanger of identical design, pressure rating and

materials is required for the same service, the tube bundles shall be inter-

changeable.

7.23.3 Kettle type reboilers shall be provided with guide rails and a hold down

angle located above the floating end, in order to keep the bundle in place

during shipment.

7.23.4 For tube bundles that can be rotated 180 degrees, additional

impingement plate, bundle runners etc. shall be provided.

7.23.5 Exchangers with sea water on the tube side shall be fitted with ferrules

(tube end protectors) at the inlet end of tubes at each tube pass. For tube

materials other than given in paragraph 8.4.4, the requirement for

ferrules shall be confirmed with the Saudi Aramco Engineer.

Commentary Note:

Saudi Aramco Standard Drawing AE-036250 gives ferrules details for 0.75 inch outside diameter tubes. For larger tube diameters, Exchanger Manufacturer shall propose ferrule details for the consideration of the Saudi Aramco Engineer.

8 Materials

8.1 General

8.1.1 (Exception) All materials required for pressure and non-pressure

components shall be specified on the data sheet in accordance with Table

1, Acceptable Materials for Carbon and Low Alloy Steels.

8.1.2 (Exception) The Exchanger Manufacturer may propose alternative

materials at the time of proposal, but the alternative materials must

comply with all the requirements of the applicable Code and this

specification.

8.1.3 (Exception) Materials other than those listed in Table 1 of this

specification shall not be permitted without the prior approval of the






Page 19 of 38

8.1.5 Material test report is requested to be certified as per 175-323100.

8.1.6 Suitability of low chrome alloy steels for use for exchangers in hydrogen

services above 205°C (400°F) shall be qualified through chemical

analysis, mechanical testing including but not limited to tensile,

hardness, microhardness, temper embrittlement tests and nondestructive

examinations (ultrasonic, wet fluorescent magnetic particle, etc.).

Materials specifications and tests procedures for base and weldments

materials shall be submitted to Saudi Aramco Engineer for review and

approval prior to ordering the materials from the mill.

8.1.7 All materials, except carbon steels, shall be alloy verified by the

Exchanger Manufacturer in accordance with SAES-A-206.

8.1.8 The use of C-½ Mo steels in hydrogen services is prohibited.

8.1.9 Materials with properties enhanced by heat treatment cycles such as

tempering, intermediate stress relief (ISR) and the final post weld heat

treatment shall be tested to verify that their mechanical properties have

been retained after all heat treatment cycles. These tests shall also

include two additional postweld heat treatment cycles to account for

future repairs or alteration.

8.1.10 HIC Resistant Materials

8.1.10.1 For exchangers designated for wet sour HIC (hydrogen induced

cracking) services as defined in Section 3 of this specification with

normal operating temperatures between 0°C and 150°C, all plates for

shells and heads shall be made of HIC resistant steel. HIC resistant steel

shall be qualified in accordance with 01-SAMSS-016.

8.2 Gaskets

8.2.3 (Exception) The materials of construction for spiral wound gaskets shall

be as follows:

1) For exchangers with design temperatures from -100°C to 0°C:

Type 304 or 316 stainless steel (SS) windings with solid Type 304

or 316 stainless steel outer centering rings.

2) For exchangers with design temperatures from 1°C to 425°C:

Type 304 or 316 SS windings with solid carbon steel outer

centering rings.

3) For exchangers with design temperatures above 425°C:







Page 20 of 38

Type 321 or 347 SS windings with solid; Type 304 or 316 outer

centering rings.

4) For exchangers in vacuum service, inner ring shall be either

Type 304 or 316 SS.

8.4 Impact Testing

8.4.1 The Exchanger Manufacturer shall determine impact testing

requirements of materials based on the values of the minimum design

metal temperature (MDMT), unless lower test temperature is specified

on the data sheet.

8.4.2 Baffle plates, sealing strips, tie-rods, sliding bars, tubes, spacers, and

support plates are exempt from impact testing requirements.

8.4.3 Impact testing requirements for materials not listed in Table 1, shall be

obtained from the Saudi Aramco Engineer.

8.4.4 The minimum acceptable Charpy impact energy values for steels listed

in Table 3 shall be per Table-2 unless larger values are specified on the

data sheet. Materials that are not listed in Table 3 shall be referred to

Saudi Aramco Engineer for classification.

8.4.5 For Div. 1 exchangers the impact testing exemptions of UG-20 (f),

UCS-66 (b)(1) and (3), UCS-68(c), UG-84 (b)(2) and by reference to

Table UG-84.4 are not permitted. For Div. 2 exchangers the exemptions

of AM-213.1 and AM-218.2 are not permitted.

9 Fabrication

9.1 Shells

9.1.4 Each shell section shall be completely welded longitudinally and

corrected for out of roundness and peaking of the weld seam prior to

welding to the adjoining shell section or cover.

9.1.5 All re-rolling or forming of the shell sections is to be completed prior to

radiography.

9.1.6 The beveled edges of carbon steel plates with thickness 25 mm and thicker

and all ferrous alloy plates shall be magnetic particle examined for linear

discontinuities. Defects shall not exceed limits as per ASME SA-20.

9.1.7 Plate edge laminations revealed by magnetic particle examination shall

be completely removed and repaired per SAES-W-010.





Page 21 of 38

9.1.8 External welded attachment pads shall have their corners rounded to a

minimum radius ¼ of the length or width of the pad whichever is less

with a maximum of 50 mm and shall be fully seal welded.

9.1.9 External attachment pads shall be vented through a ¼" NPT telltale hole.

Vent holes shall be plugged with grease, wooden plugs or other non-

pressure retaining material to prevent moisture from entering.

9.1.10 Attachment pad for supports, lifting lugs and other attachments shall be a

minimum of 10 mm (3/8") thick or equal to the shell thickness,

whichever is less. Attachment loads must comply with paragraph 7.17.2

above and pads shall not cover pressure-retaining welds.

9.1.11 Tapped tell-tale holes ¼"NPT shall be provided in reinforcing pads as

follows:

1) One hole in single piece reinforcing pad.

2) Where a pad is split, each segment shall have at least one tapped

hole.

9.2 Pass Partition Plates

Pass partition plate shall be provided with a 6 mm (¼") drain hole.

9.3 Connection Junctions

(Exception) All nozzles shall be ground flush to the inside curvature of

the exchanger inside diameters with smooth inside corner radius equal to

the nozzle wall thickness.

9.5 Welding

(Exception) All welding shall be in accordance with the requirements of

SAES-W-010.

9.5.3 (Exception) All welded joints of category A, B, C and D shall be

complete full penetration welds, except for joint welds of slip-on flanges.

9.5.11 Welds attaching nozzles and their reinforcement pads and other

attachments to pressure components shall not be closer than 20 mm from

any pressure retaining welds. See also paragraph 10.2.1.4.

9.5.12 Where a split-reinforcing pad is required, the weld joining the pad

sections shall be oriented with the circumferential direction of the shell.

Welding the pad sections together shall be done without using a backing

strip.





Page 22 of 38

9.6 Heat Treatment

9.6.2 (Exception)

1) The following tubes shall be stress relief heat treated after cold

forming and bending:

a) U bends, including 150 mm of straight portions measured

from the tangent line of all carbon steel tubes for exchangers

in caustic, wet sour and amine services.

b) Monel, brass and all chrome alloy tubes in all services.

2) The following tubes shall be solution annealed:

a) Entire tubes manufactured of unstabilized or non low carbon

stainless steels or Nickel base alloys in accordance with

ASME SA-688.

b) U bends, including 150 mm of straight portions measured

from the tangent lines of all stabilized or low carbon stainless

steels or Nickel base alloys.

9.6.3 Code exemptions for PWHT of P4 and P5 materials are not permitted for

applications involving either wet sour service or hydrogen or materials

exceeding 1.5% nominal chromium content.

9.6.8 PWHT shall be done when required by the applicable Code or when

required by SAES-W-010.

9.6.9 The maximum PWHT soaking temperature for quenched and tempered

carbon and low alloy steels, including C-0.5 Mo, shall not exceed the

temperature at which the test pieces were heat treated as shown on the

Mill Test Certificates or 650°C maximum for carbon steel, 690°C

maximum for C-0.5 Mo and 700°C for low alloy steels.

9.6.10 Final PWHT shall follow all welding and repairs but shall be performed

prior to any hydrotest or other load test.

9.6.11 A sign shall be painted on a postweld heat treated exchanger and located

such that it is clearly visible from grade:

"Caution – Exchanger Has Been Postweld Heat Treated – Do Not Weld".

9.6.12 PWHT shall be in accordance with the requirements of SAES-W-010.

9.8 Gasket Contact Surfaces other than Nozzle Flange Facings






Page 23 of 38

9.8.6 Gasket seating surfaces shall comply with the following:

1) For spiral wound gaskets, 125 to 250 AARH, in all services, except

hydrogen.

2) For spiral wound gaskets in hydrogen service, 125 to 150 AARH.

3) The side-walls of ring joint flanges in all services, 63 AARH.

4) For non-metallic gaskets, 250 to 500 AARH.

The surface roughness of machined surfaces, other than gasket contact

faces, shall not exceed 500 AARH.

9.9 Tube-Hole Grooves

9.9.4 Tubesheet tube hole diameters and tolerances shall be special close fit

when tube bundle vibration is suspected or when exchanger is in cyclic

service.

9.9.5 Tube expanding procedures shall incorporate stops to prevent tube

expansion past tubesheet faces.

9.9.6 Tube expansion and tube-end welding (where specified) procedures shall

be submitted to the Saudi Aramco Inspector for review and approval

before start of fabrication.

9.9.7 The Exchanger Manufacturer shall submit a mock-up sample of the tube

to tubesheet weld when tubes are strength welded to the tubesheet. This

sample shall contain a minimum of four tubes and shall be prepared

using the same materials and fabrication procedures (including heat

treatment) as are to be used in actual production. Approval from the

Saudi Aramco Inspector is required prior to start of production. No need

to repeat the test if similar joint design was done in the past 6-months.

9.12 Forming and Heat Treatment

9.12.1 Heat-treatment, as a separate operation, shall be performed after a

forming operation (hot or cold) for any of the conditions listed below.

The heat treatment shall be annealing, normalizing, normalizing and

tempering, or quench and tempering, as required.

Heads and other double-curvature components with nominal

thickness exceeding 50 mm.

Heads and other double-curvature components made of P-No. 3, 4, 5,

9A or 9B materials.

Any hot-formed component.




Page 24 of 38

9.12.2 For any hot forming operation, the procedure shall be submitted to Saudi

Aramco Engineer for approval prior to commencement of any

fabrication requiring hot forming. The procedure shall describe all heat

treatment operations and tests to be performed. The tests shall include,

but not limited to, all of the mechanical tests required by the original

material specification.

10 Inspection and Testing

10.1 Quality Assurance

10.1.7 The responsibility for quality assurance rests with the Exchanger

Manufacturer in accordance with the applicable Code and the

requirements of this specification.

10.1.8 Exchangers manufactured in accordance with this specification are

subject to verification by the Saudi Aramco Inspector in accordance with

Saudi Aramco Inspection Requirements Form 175-323100.

10.1.9 All required Nondestructive Examination shall be included in inspection

procedures established according to ASME SEC V and this specification.

A written procedure shall address each inspection method and technique

used including acceptance criteria. When required by the purchase order

the procedure(s) shall be submitted to Saudi Aramco Inspection

Department for approval.

10.1.10 All Nondestructive Examination, including Magnetic Particle and Liquid

Penetrant examinations, shall be performed by personnel certified in

accordance with ASNT CP-189, or equivalent National Certification

Programs that has been approved by the Saudi Aramco Inspection

Department. Personnel responsible for interpretation of Nondestructive

Examination results shall be certified to a minimum of Level II.

10.1.11 Magnetic-particle, liquid-penetrant, ultrasonic and radiographic

examinations on exchangers to be postweld heat-treated shall be made

after completion of final heat treatment.

10.1.12 All pressure and non-pressure welds shall be visually inspected where

accessible. All segments of longitudinal, circumferential or built-up

head pressure weld seams covered or rendered inaccessible by internals,

lifting lugs or other attachments shall be fully radiographed the entire

affected length plus 10 inches either side prior to installation of the

attachment.





Page 25 of 38

10.1.13 Additional examination of any weld joint at any stage of the fabrication

may be requested by the Saudi Aramco Inspector, including re-

examination of previously examined joints. The Saudi Aramco Inspector

also has the right to request or conduct independent NDE of any joint. If

such examination should disclose gross non-conformance to the

requirements of the applicable Code or this specification, all repair and

NDE costs shall be done at the Exchanger Manufacturer's expense.

10.1.14 All necessary safety precautions shall be taken for each examination

method.

10.1.15 Surface irregularities, including weld reinforcement, inhibiting accurate

interpretation of the specified method of examination shall be ground

smooth.

10.1.16 Examination of all welds shall include a band of base metal at least one

inch wide on each side of the weld.

10.1.17 The Saudi Aramco Inspector shall have free access to the work at all

times.

101.1.18 Saudi Aramco shall have the right to inspect the fabrication at any stage

and to reject material or workmanship which does not conform to the

specified requirements.

10.1.19 Saudi Aramco reserves the right to inspect, photograph, and/or videotape

all material, fabrication, coating, and workmanship and any materials,

equipment, or tools used or to be used for any part of the work to be

performed.

10.1.20 Saudi Aramco may reject the use of any materials, equipment, or tools

that do not conform to the specification requirements, jeopardize safety

of personnel, or impose hazard of damage to Saudi Aramco property.

10.1.21 All of the rights of Saudi Aramco and their designated representatives

for access, documentation, inspection, and rejection shall include any

work done by sub-contractors or sub-vendors.

10.1.22 The Exchanger Manufacturer shall provide the Saudi Aramco Inspector

all reasonable facilities to satisfy him that the work is being performed as

specified.

10.1.23 The Exchanger Manufacturer shall furnish, install, and maintain in a safe

operating condition all necessary scaffolding, ladders, walkways, and

lighting for a safe and thorough inspection.




Page 26 of 38

10.1.24 Prior to final inspection and pressure testing, the inside and outside of

the exchanger shall be thoroughly cleaned of all slag, scale, dirt, grit,

weld spatter, paint, oil, etc.

10.1.25 Inspection at the mill, shop, or fabrication yard shall not release the

Exchanger Manufacturer from responsibility for repairing or replacing

any defective material or workmanship that may be subsequently

discovered in the field.

10.2 Quality Control

10.2.1 Radiographic testing shall be performed as follows:

10.2.1.1 All radiography shall be performed with intensifying screens. Only lead

or lead foil (fluoro-metallic) screens shall be permitted unless otherwise

approved by the Saudi Aramco Inspection Department.

10.2.1.2 Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as

individual rounded indications. Clustered or aligned tungsten inclusions

shall be removed and repaired.

10.2.1.3 Radiography requirements for heat exchangers are outlined in table 4 of

this specification.

10.2.1.4 Where it is not practicable to meet the spacing requirement in paragraph

9.5.11 of this specification such that a nozzle or an attachment weld of a

reinforcing pad or a structural component will either intersect or

encroach on a butt weld, the following shall be performed.

10.2.1.4.1 If the nozzle is installed onto or encroaching on a butt weld in the

exchanger wall:

1) Radiography of the butt weld in the exchanger wall for a length

equal to three times the diameter of the opening with the center of

the opening at mid-length.

2) Where a reinforcing pad is required, the butt weld shall be ground

flush and radiographed, prior to the installation of the reinforcing

pad.

10.2.1.4.2 Where an attachment weld of a reinforcing pad or a structural component

will either intersect or encroach on a butt-weld in the exchanger wall:

1) The butt weld shall be radiographed for a length of the projection

of the intersecting or encroaching segment of the attachment weld

plus a minimum of 50 mm on either side.




Page 27 of 38

2) Perform magnetic particle examination on the exchanger side of the

joint attaching the reinforcing pad or structural component.

10.2.12 Weld hardness testing shall be in accordance with the requirements of

SAES-W-010.

10.2.13 Ultrasonic Examination

10.2.13.1 For thick wall exchangers

10.2.13.1.1 Ultrasonic Examination of Plates and Welds

a) All plates, including plate-like forgings, such as shell rings shall be

ultrasonically examined in accordance with ASME SA-435.

b) All category A and B welds are to be 100% ultrasonically

examined in accordance with the applicable Code in all services.

c) All category C and D welds shall be ultrasonically examined in

cyclic, hydrogen or lethal services in accordance with the

applicable Code.

d) If ultrasonic examination is not practical, the whole joint shall

either be magnetic particle or liquid penetrant examined after each

6 mm of weld deposit.

f) All pressure retaining welds and exchanger support attachment full

penetration welds shall be 100% ultrasonically examined after final

heat treatment.

10.2.13.1.2 Ultrasonic Examination of Forgings

All forgings, except plate-like forgings and standard flanges in accordance

with ASME and API material specification shall be ultrasonically

examined in accordance with ASME SA-388. Acceptance criteria shall be

in accordance with ASME SEC VIII D2, paragraph AM-203.2(c).

10.2.14 Magnetic Particle Examination

10.2.14.1 Permanent magnetic yokes are not permitted.

10.2.14.2 Prods are not permitted for use on: air-hardenable materials, materials

which require impact testing, and on the fluid side of pressured

components for exchangers in wet sour service.

10.2.14.3 Magnetic particle examination or liquid penetrant examination shall be

performed on the surfaces of hot formed and reheat treated as per the

applicable Code.





Page 28 of 38

10.2.14.4 Except for non-ferromagnetic materials, wet fluorescent magnetic

particle examination using an AC yoke is required for the following:

1) All internal welds and areas where temporary welds have been

removed, for exchangers in wet sour, caustic, amine, and hydrogen

services.

2) All internal and external welds and areas where temporary welds

have been removed when the nominal thickness of pressured

components is 25 mm and thicker.

3) Exchanger support attachment welds.

10.2.14.5 Final acceptance of the exchanger shall be based on completion of all

required NDE after the final postweld heat treatment.

10.2.14.6 For thick wall exchangers:

10.2.14.6.1 All edges prepared for welding and all openings shall be magnetic

particle examined in accordance with the applicable Code.

10.2.14.6.2 Forgings shall be examined on all surfaces, utilizing wet fluorescent

magnetic particle method after final machining. All defects shall be

removed and repaired by welding in accordance with SAES-W-010.

Except for welding edges, liquid penetrant examination is acceptable as

an alternative to magnetic particle examination.

10.2.14.6.3 All ferro-magnetic welds are to be wet fluorescent magnetic particle

examined after final heat treatment.

10.3 Pressure Testing

10.3.1 For Division 1 exchangers: Test pressure shall be 1.3 times its

calculated MAWP in the hot and corroded condition multiplied by the

lowest ratio (for the materials of which the tube side is constructed) of

the allowable stress for the test temperature to the allowable stress for the

design temperature.

For Division 2 exchangers: Test pressure be 1.25 times its calculated

MAWP in the hot and corroded condition multiplied by the lowest ratio

(for the materials of which the tube side is constructed) of the stress

intensity for the test temperature to the stress intensity for the design

temperature.

10.3.2 (Exception) An independent hydrostatic test of shell-side and tube-side

shall be performed. The temperature of the water during hydrostatic





Page 29 of 38

testing shall be maintained at not less than 17°C throughout the testing

cycle.

10.3.3 (Exception) Hydrostatic test pressure shall be held for a minimum of one

hour per 25 mm of exchanger shell/channel thickness and in no case less

than one hour.

10.3.4 Water used for pressure testing shall be potable.

10.3.11 After completion of all external and internal welding and heat treatment

and prior to painting, exchangers shall be pressure tested using water as

the testing media in accordance with the applicable Code and this

specification. Pneumatic testing in lieu of hydrostatic testing requires

the approval from Saudi Aramco Inspection Department.

10.3.12 No preliminary pressure testing shall be made prior to postweld heat

treatment.

10.3.13 The use of shellacs, glues, lead, etc., on gaskets during testing is

prohibited. No paint or primer shall be applied to an exchanger prior to

hydrostatic testing.

10.3.14 The Exchanger Manufacturer shall furnish all test materials and

facilities, including blinds, bolting, and gaskets.

10.3.15 Hydrostatic pressure testing shall be performed with gaskets and bolting

identical to those required in service and as specified on the data sheet.

These gaskets may be used as service gaskets if the bolted joint is not

disassembled after completion of hydrostatic pressure testing.

10.3.16 The manufacturer shall supply the following:

1) Minimum two sets of spare gaskets with a blind flange for all

nozzles.

2) Minimum one set of service gaskets and two sets of spare gaskets

for each nozzle with companion flanges in the exchanger.

3) All bolting with minimum 10% spare bolting (3 minimum for each

size) per exchanger.

10.3.17 After testing, the exchanger shall be completely drained and thoroughly

dried including around the internals.

10.3.18 For other than differential-pressure design exchangers, test pressure for

the shell side and the tube side shall be as per the applicable code




Page 30 of 38

10.3.19 For differential-pressure design exchangers, test pressure shall be as per

the applicable code.

10.3.20 Vertical exchangers that are tested in the horizontal position shall be

adequately supported such that the primary stresses in any part of the

exchanger do not exceed 90% of the minimum specified yield strength of

the exchanger material.

10.3.21 Horizontal exchangers are to be tested while resting on their permanent

support saddles, without additional supports or cribbing. Primary

stresses in any part of the exchanger for this case shall not exceed 90%

of the minimum specified yield strength of the exchanger material.

10.3.22 All welded attachments provided with tell-tale holes shall be

pneumatically tested at minimum 35 kPa (5 psi) prior to heat treatment

and exchanger pressure testing. Tell-tale holes must not be plugged

during the exchanger pressure test.

10.4 Nameplates and Stampings

10.4.1 (Exception) Each exchanger shall be identified by a nameplate and

marked with the information required by the applicable Code and the

requirements of this specification. The nameplate and its mounting

bracket shall be located such that the nameplate is easily readable from

grade or platform. The brackets shall extend from the outside of the

exchanger to clear insulation, and with sufficient access for surface

preparation and painting. The nameplate markings as required by

UG-116 of the Code shall be stamped or engraved such that the

nameplate material is permanently deformed with the symbols.

10.4.4 Nameplates shall be 3 mm minimum thickness and manufactured from

type 304 stainless steel or Monel and welded to the mounting bracket

according to PIP VEFV1100.

10.4.5 Exchangers shall be Code stamped for all services, in accordance with

the applicable Code.

10.4.6 The mounting bracket material shall conform to Table 1 and it shall be

continuously seal welded and positioned such as not to allow for

collection of moisture or rain.

10.5 Repairs during Fabrication

10.5.1 The Saudi Aramco Engineer must review and approve crack repair

procedures, required by the applicable Code, prior to commencement of

the repair work. It is the responsibility of the manufacturer to ensure that

http://standards/docs/PIP/PDF/VEFV1100.PDF




Page 31 of 38

repairs done by the mill of any material defects, per the applicable Code,

are documented.

10.5.2 After completion of repairs required by the applicable Code, the

following shall be repeated:

a) Heat treat the repaired section if it has been heat-treated prior to the

repairs.

b) All nondestructive examinations performed on the repaired section

prior to the repairs.

11 Preparation for Shipment

11.1 Protection

11.1.1 The Manufacture shall protect the equipment from mechanical and

corrosion damage in order to assure that the equipment will be serviceable

after shipping, storage, and construction. The duration of these activities

is assumed to be 24 months. If longer period is specified, the required

protection measures shall be determined on a case-by-case basis.

11.1.2 Prior to shipping, exchangers are to be completely dried.

11.1.3 After drying, the equipment is to be cleaned from all loose scales, weld

slags, dirt and debris to the satisfaction of the Saudi Aramco Inspector.

11.1.4 Temporary covers, 3 mm thick steel or wood cover with neoprene

gasket, for flanges shall be bolted in place with a minimum of 4 bolts

equally spaced and sufficient to contain the protective media inside the

exchanger. Bolts shall be protected from external corrosion by a rust

preventive grease or equivalent substance liberally applied over the bolt

surface. Flanges with permanent blind flanges shall be secured with the

gaskets and bolting specified for service.

11.1.5 Threaded nozzle connections shall be protected with threaded plugs and

by the use of an appropriate lubricant with rust preventive compound

such as Cortec VpCI-369 or equivalent.

11.1.6 Tell-tale holes in reinforcing pads shall be protected with wooden plugs

or packed with rust preventative grease such as Denso paste.

11.1.7 Flanged connections and all other machined surfaces not described

elsewhere in this section shall be protected by use of an appropriate

lubricant with rust preventive compound such as Cortec VpCI-369 or

equivalent.




Page 32 of 38

11.1.8 Export packing, marking, and shipping shall be in accordance with the

purchase order.

11.1.9 The exchanger manufacturer is responsible for ensuring that the

exchangers being shipped are adequately braced and shall provide

temporary supports where appropriate to ensure adequate support of the

exchanger during shipment.

11.1.10 Internal & External Protection

11.1.10.1 For carbon steel and stainless steel fully assembled heat exchangers,

spray interior surfaces (both shell and tube side) with a vapor phase

inhibitor such as Cortec VpCI-307 or 309 or equivalent. Apply the

Cortec product at a rate of 0.3 kg/m³. Other manufacturer's products

should be applied at treatment rates recommended by the manufacturer if

greater than the specified treatment rates of 0.3 kg/m³. If possible, vapor

phase inhibitor powder shall be sprayed directly into the tubes so that it

can be easily detected exiting from the opposite end of the tube. For

copper alloy construction, VpCI-307 or equivalent shall be specified.

Exchangers must be sealed vapor tight using metallic covers for the

inhibitor to be effective.

11.1.10.2 The shell and external surfaces shall be protected by preparing the

surface and fully coating the external surfaces using the specified Saudi

Aramco coating specification prior to shipment.

11.1.10.3 Solid stainless steel exchangers which are to be shipped by ocean freight

or are to be stored in a coastal or near coastal location but are not

specified to be coated in service shall be protected by the application of a

temporary soft external coating such as Cortec VpCI 368 or Daubert

Chemical's Tectyl 506 or equivalent. Coating shall be removed prior to

service using a non-caustic steam wash. Alternatively, solid stainless

steel exchangers shall be 100% wrapped and sealed in a 4-mil thick

anticorrosion polyethylene film containing vapor phase corrosion

inhibitor such as Cortec VpCI 126 Blue or equivalent. Equipment that is

an emergency spare for long term storage shall be wrapped in Cortec's

10-mil thick MillCorr film or equivalent. Stainless steel exchangers

shipped by ocean freight must be protected from sea spray, rain, etcetera.

11.1.10.4 Tube bundles shipped separately from shells must be adequately

protected and supported to prevent mechanical and corrosion damage.

Tube internals shall be protected using Cortec VpCI-307 or VpCI-309 or

equivalent as detailed in Paragraph 11.1.7.1, above. External surfaces

shall be protected by spraying with Cortec VpCI 368 or Tectyl 506 or

equivalent. These coatings must be removed prior to operation in cases




Page 33 of 38

where they might cause a contamination problem. Alternatively, the

complete tube bundle shall be 100% wrapped and sealed in a 4-mil thick

anticorrosion polyethylene film containing vapor phase corrosion

inhibitor such as Cortec VpCI 126 Blue or equivalent. Equipment that is

an emergency spare for long term storage shall be wrapped in Cortec's

10-mil thick MillCorr film or equivalent.

11.1.11 Use of Nitrogen blanketing with temporary rust preventive substance

such as Tectyl 846 or a vapor proof bag with moisture control is an

acceptable protection measure for carbon and low chrome alloy steels

without Austenitic Stainless Steels internally cladded or Austenitic

Stainless Steels weld over-layed exchangers.

11.1.12 Nitrogen blanketing at a pressure of 35 kPa (5 psi) shall be provided for

Austenitic Stainless Steels or internally cladded or Austenitic Stainless

Steels weld over-layed exchangers in the following conditions:

1) During transportation (Ocean and Land).

2) At fabrication shop/site after completion of its fabrication.

3) At construction site from its arrival until its commissioning.

11.1.13 Nitrogen blanketing at a pressure of 35 kPa (5 psi) shall be provided for

components that can not be protected properly by the use of vapor phase

inhibitor due to inaccessible difficulties such as shell's internal surface for

fixed tubesheet heat exchangers.

11.1.14 Temporary internal coatings for use on exchangers with corrosion

resistant linings (such as stainless steel and Monel clad) must be chloride

free, suitable for its intended use and not result in crevice corrosion.

11.1.15 For exchangers which have permanent internal coatings, the Exchanger

Manufacturer shall contact the Saudi Aramco Engineer for any corrosion

protection required.

11.1.16 Martensitic stainless steels such as Type 410 and Type 420 are

particularly prone to atmospheric corrosion especially when shipped by

sea. The Manufacturer shall prepare a preservation and shipping plan for

approval by CSD.

11.1.17 For dry gas and liquefied gas systems, excess powder vapor phase

inhibitors shall be removed from major equipment at a convenient point

in construction operations before start-up if there could be a risk of

compressor fouling, filter plugging, or similar problems.




Page 34 of 38

11.1.18 Bolt heads shall also be protected with a rust preventative compound to

prevent corrosion during shipment, storage and construction.

11.1.19 Spare bolts shall be protected with a rust preventative compound to

prevent corrosion during shipment, storage and construction.

11.2 Identification

11.2.4 Marking shall be done with water-insoluble materials that contain no

harmful substances that would attack or harmfully affect the exchanger

at ambient and operating temperatures.

11.2.5 Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury,

chlorine, or other halogens.

12 Supplemental Requirements

12.1 General

(Exception) Exchangers with cylindrical pressure components greater

than 50 mm thick shall be manufactured in accordance with Section 9

and the requirements for thick wall exchangers as detailed in this

specification.

13 Drawings, Calculations and Data

13.1 The Exchanger Manufacturer shall prepare drawings, calculations, and

data in accordance with NMR-7922-1, Nonmaterial Requirements.

13.2 Drawings and calculations that are approved by the Design Engineer

shall not relieve the Exchanger Manufacturer from the responsibility to

comply with the Codes, and this specification.

13.3 Exchanger manufacturer shall prepare drawings which indicate the

ultrasonic readings thickness of the exchanger shell, heads and nozzles.

An adequate number of readings shall be taken to represent the actual

thickness of the components.

13.4 All approved data sheets, drawings and forms are to be typed and

submitted to Engineering Drawings Services (EDSD) for inclusion into

Corporate Drawings Management System.

Revision Summary

20 November 2007 Major revision. 5 April 2008 Editorial revision. 15 August 2009 Editorial revision to replace cancelled SAES-A-301 with NACE MR0175/ISO 15156.







Page 35 of 38

Table 1 – Acceptable Materials for Carbon and Low - Alloy Steels

[Note: The numbers in ( ) refer to the specific notes at the end of the table]

Design Temperature

Exchanger Component

-100°C to -47°C -46°C to 0°C 1°C to 425°C 351°C to 645°C

Shells, channels, dished heads, tubesheets, rolled nozzle necks, covers, and reinforcing pads

SA-203 Grade D or E

SA-516 Grade 70N, or SA-537 Class 1

SA-516 Grade 70, or SA-537 Class 1 or SA-285 Grade C

(1)

SA-387 Grade 5(6)

SA-387 Grades 11, 12 or 22

Pipe, nozzle necks

SA-333 Grade 3 SA-333 Grade 6 SA-106 Grade B SA-53 Grade B

(1)

SA-335 Grade P5(6)

SA-335 Grades P11, 12 or 22

Tubes(2)

SA-249 Type 304

SA-334 or SA-249 Type 304

SA-179 or SA-214 SA-213 Grade T5

(6)

SA-179 or SA-214 or SA-213 Type 304

Forged flanges SA-350 LF3 SA-350 LF2 SA-105 SA-182 Grade F5

(6)

SA-182, Grades F11, 12 or 22

Wought fittings SA-420 WPL3 SA-420 WPL6 SA-234 WPB SA-234 Grade WP5

(6)

SA-234, Grades WP11, 12 or 22

Studs/nuts for pressure connections

SA-320 L43/ SA-194 Grades 4 or 7

SA-320 L7/SA-194 Grade 2H

SA-193 B7/SA-194 Grade 2H

SA-193 B5, or B16/ SA-194 Grade 3

Internal attachment clips

(4)

SA-203 Grades D or E


SA-516 Grade 70, or SA-537 Class 1, or SA-285 Grade C

(1)

SA-387 Grades 11, 12 or 22

External attachment clips

(4)



SA-516 Grade 70, or SA-537 Class 1, or SA-285 Grade C, or SA-36

(1)

SA-387 Grades 11, 12 or 22

Saddle(3)

Supports and Lugs


SA-516 Grade 70N, or SA-537 Class 1 or SA-285 Grade C

SA-516 Grade 70, or SA-285 Grade C, or SA-36

(1)

SA-387 Grades 11, 12 or 22

Anchor bolts SA-307 Grade B SA-307 Grade B SA-307 Grade B SA-307 Grade B




Page 36 of 38

Table 1 – Acceptable Materials for Carbon and Low - Alloy Steels (cont'd)

General Notes:

A) Materials for hydrogen service shall be selected in accordance with API PUBL 941 using a value for the hydrogen partial pressure 10% above the design partial pressure and a temperature of 30°C above the design temperature.

B) Materials for exchangers in amine service shall be selected in accordance with Table 1 and API RP 945.

C) Materials for exchangers in wet sour service, with design temperature up to 100°C (212°F), shall be in accordance with Table 1, with the following revisions:

1) Forged flanges and forged fittings are restricted to: SA-350 LF1 or LF2 or SA-266, Class 4 S2, S9. Flanges above 24-inch diameter shall be SA-266, Grade 4, S2, S9.

2) Studs and nuts are restricted to: SA-193 B7M or L7M and SA-194 Grade 2HM.

3) It shall satisfy the requirements of NACE MR0175/ISO 15156 and NACE RP0472.

4) For exchangers under the service conditions specified in paragraph 8.1.9.1, shells and heads formed from plate shall be manufactured from HIC resistant steel.

D) Materials for pressure components in sea water service shall be in accordance with Table 1 with the following revisions:

1) Carbon steel pressure components in contact with seawater shall be clad or weld overlayed with Monel in accordance with 32-SAMSS-031.

2) Tube material shall be either Cu/Ni SB-111 (Alloy Number C71500) or Titanium SB-338 Grade 2.

E) Low alloy steels shall not be mixed, i.e. an exchanger requiring 1 ¼ Cr- ½ Mo materials shall have all components manufactured from 1 ¼ Cr- ½ Mo.

F) Low alloy steels shall be specified in the normalized and tempered heat treated condition.

G) The material for nameplate mounting brackets shall be of the same type and material grade as the shell material.

H) Impact testing of materials and welding procedures are required when MDMT is lower than -28°C.

I) Impact testing of materials is only required when MDMT is -27 to -18°C. Impact testing of welding procedures is not required for this temperature range, (unless otherwise required by the applicable Codes), if the consumable classifications per ASME SEC IIC has impact property requirements at -46°C or lower.

Specific Notes:

1) SA-36, SA-53, SA-283, and SA-285 materials shall only be used for utility services.

2) Tubes in hydrogen, wet sour, amine and caustic services shall be seamless.

3) Saddle support wear plates shall be of the same ASME material as the shell material.

4) All internal and external clips and attachments on exchangers shall be of the same ASME material as the attached pressure component.

5) Baffles, tube supports, tie rods, spacers and impingement protection shall be of the same basic material as the tubes except for high alloy steel tubes when these components may be of carbon steel provided shell side fluid does not require more corrosion resistant material. For titanium tubes, the materials for these components shall be subject to approval from Saudi Aramco Engineer.

6) For hydrocarbon services containing hydrogen sulfide or organic sulfides at temperatures exceeding 550°F.









Page 37 of 38

Table 2 – Charpy-V Impact Test Requirements

Minimum Required Impact Value for Full Size Specimen at MDMT, Joules Reference Thickness, t, inch

Material Class t < ½ ½ < t < 1 1 < t < 2 t > 2

1a 34/27 34/27 34/27 34/27

1b 34/27 34/27 34/27 34/27

2a 34/27 34/27 34/27 34/27

2b 34/27 34/27 34/27 47/38

2c 34/27 34/27 47/38 61/48

3 34/27 34/27 34/27 34/27

Notes:

1) In the notation such as 34/27, the first number is the minimum average energy of three specimens and the second number is the minimum for one specimen impact test results.

2) See Table 3 for material specification.

Table 3 – Material Classes

Class Material Specification

1a SA 53 Gr. B

2b SA 105

2a SA106 Gr. B

2b SA 182 Gr. F11 and F12

2c SA 182 Gr. F22

3 SA 203 Gr. D and E

2b SA 204 Gr. A, B and C

2b SA 266 Cl. 1

2c SA 266 Cl. 2 and 4

1a SA 333 Gr. 1

3 SA 333 Gr. 3

2a SA 333 Gr. 6

2b SA 335 Gr. P11, P12 and P22

2b SA 336 Gr. F12

2c SA 336 Gr. F11 and F22

2b SA 350 Gr. LF2

3 SA 350 Gr. LF3

2b SA 387 Cl. 1, Gr. 11, 12 and 22; Cl. 2, Gr. 12

2c SA 387 Cl. 2, Gr. 11 and 22

2a SA 442 Gr. 55 and 60

2b SA 516 Gr. 70

2c SA 533 Cl. 1

2b SA 537 Cl. 1

2c SA 420 Gr. WPP3 and WPL6

2c SA 234 Gr. WPB

2c SA 234 Gr. WP11, WP12 and WP22




Page 38 of 38

Table 4 – Radiography Requirements for Heat Exchangers

Weld Joint Category Radiography (RT) Notes

A and B Per Code Design Criteria

(Spot or 100%) (1) and (4)

C 100% (1), (3) and (4)

D 100% (1), (2), (3), (4) and (5)

Notes:

1. 100% RT is required in heat exchangers under any of the following services or design conditions:

Lethal services.

Hydrogen services.

Cyclic services.

Unfired steam boilers with design pressure exceeding 50 psi.

Heat exchanger weld joints requiring full radiography per the applicable Code (see UW-11 for Division 1 exchangers and AF-220 for Division 2 exchangers).

Thick wall heat exchangers.

Butt welds in nozzles attached to weld neck flanges.

Butt welds in integrally reinforced contoured fittings.

2. UT for Category-D weld joint in attachments with a reinforcing plate must be performed prior to installing reinforcing plate.

3. UT from accessible side must be conducted after any heat treatment, if applicable.

4. UT methods which generate permanent records may be used as a substitute to radiography in heat exchangers that require 100% RT per the applicable Code and this specification. Such UT methods must be approved by Inspection Department prior to commencement of any work.

5. UT methods which generate permanent records may be used as a substitute to RT where a weld joint can not be readily radiographed, because of the joint geometry, e.g., Category D weld joint using integrally reinforced nozzle without a contour that would facilitate radiography or a nozzle with a reinforcing pad. Such UT methods must be approved by Inspection Department prior to commencement of any work.

6. UT may be substituted for RT for NPS 4 and smaller connections to nozzles and manways.

7. To facilitate 100% radiography of category-D weld joint, it shall be according to:

a) For Division 1 exchangers: Figures UW-16.1: (f-1), (f-2) (f-3) or (f-4).

b) For Division 2 exchangers: Figures AD-613.1: (a), (b) (c), (c-1) (d) or (e).

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