32-SAMSS-011-2013_HE

Previous Issue: 23 June 2010 Next Planned Update: 19 August 2013

Revised paragraphs are indicated in the right margin Page 1 of 27

Primary contact: Al-Mansour, Khalid Mohammad on +966-3-8809575

Copyright©Saudi Aramco 2013. All rights reserved.

Materials System Specification

32-SAMSS-011 19 February 2013

Manufacture of Air-Cooled Heat Exchangers

Document Responsibility: Heat Transfer Equipment Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2

2 Normative References.................................... 3

3 Terms and Definitions.................................... 5

4 General........................................................... 7

5 Proposals....................................................... 7

6 Documentation............................................... 8

7 Design............................................................ 8

8 Materials....................................................... 15

9 Fabrication of the Tube Bundle.................... 17

10 Inspection, Examination, and Testing.......... 20

11 Preparation for Shipment............................. 24

12 Supplemental Requirements........................ 25 Table 1 - Acceptable Materials for Carbon and Low Alloy Steels.......... 26

Table 2 - Charpy-V Impact Test Requirements.... 27

Table 3 - Material Classes.................................... 27

Document Responsibility: Heat Transfer Equipment Standards Committee 32-SAMSS-011

Issue Date: 19 February 2013

Next Planned Update: 19 August 2013 Manufacture of Air-Cooled Heat Exchangers

Page 2 of 27

The following paragraph numbers refer to API STD 661, 5th

Edition, March 2002,

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

exception, modification, or deletion to API STD 661 as noted. Paragraph numbers not

appearing in API STD 661 are new paragraphs to be inserted in numerical order.

1 Scope

This specification covers the minimum mandatory requirements for the manufacture of

new air-cooled heat exchangers (herein referred to as exchangers). It does not cover

exchangers that undergo repairs or alterations.

This specification does not cover skid mounted exchangers, or exchangers that are part

of air conditioning equipment or exchangers that do not fall in the general exchanger

types covered in API STD 661.

1.1 GENERAL

1.1.1 The Design Engineer is responsible for specifying the process data, the

mechanical design requirements, and completing the API exchanger data sheet.

1.1.2 Exchangers shall be designed to minimize field assembly.

1.1.3 Individual exchanger within a group of exchangers shall be designed for

maximum practical inter-changeability of components.

1.1.4 When specified, compliance with the latest edition of ASME SEC VIII D2,

Pressure Vessels, Alternative Code Rules is mandatory.

1.1.5 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.

1.1.6 No proof testing shall be permitted unless specifically approved by the Saudi

Aramco Engineer.

1.1.7 Application of ASME Code Cases to the manufacture of exchangers requires

approval of the Saudi Aramco Engineer.

1.1.8 Clad exchangers shall also conform to 32-SAMSS-031 in addition to the

requirements of this specification.

1.1.9 Exchangers in lube and seal oil services shall also conform to 32-SAMSS-013.

1.1.9 Exchangers in lube and seal oil services shall also conform to in addition to

the requirements of this specification.

http://standards/docs/SAMSS/PDF/32-SAMSS-031.PDF





Page 3 of 27

1.1.10 The Exchanger Manufacturer is responsible for the thermal design (rating)

and verification of the Design Engineer's thermal design, if applicable.

The Exchanger Manufacturer is also responsible for the manufacture of

exchanger, which includes the complete mechanical design, Code and

structural calculations, 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.

1.1.11 The edition of the Code to be used for the manufacture of exchangers shall

be the edition in effect at time of purchase.

1.1.12 Where a licensor's specification requirement is more stringent than that of

this specification, this licensor's specific requirement shall govern.

1.2 CONFLICTING REQUIREMENTS

1.2.1 Unless an exception is specifically stated as such in the order, the vendor

shall obtain written approval from the purchaser before proceeding with the

work affected by a conflict between the proposal and the order.

1.2.2 Any conflicts between this specification and other Saudi Aramco Materials

System Specifications (SAMSSs), Saudi Aramco Engineering Standards

(SAESs), Industry codes and standards, and Saudi Aramco Standard

Drawings (SASDs) and Forms shall be resolved in writing by the Company

or Buyer Representative through the Manager, Consulting Services

Department of Saudi Aramco, Dhahran.

1.2.3 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

in effect at time of purchase of the references listed below, unless otherwise noted.

Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory

Saudi Aramco Engineering Requirement

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

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




Page 4 of 27

Saudi Aramco Materials Systems Specifications

01-SAMSS-016 Qualifications of Pipeline and Pressure Vessel Steels

for Resistance to Hydrogen-Induced Cracking

17-SAMSS-503 Severe Duty, Totally Enclosed, Squirrel Cage

Induction motors to 250 HP

32-SAMSS-013 Lubrication, Shaft Sealing and Control Oil Systems

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

Saudi Aramco Engineering Standards

SAES-A-105 Noise Control

SAES-A-112 Meteorological and Seismic Design Data

SAES-A-206 Positive Materials Identification

SAES-H-001 Selection Requirements for Industrial Coatings

SAES-W-010 Welding Requirements for Pressure Vessels

Saudi Aramco Inspection Requirements

Form 175-323600 Manufacture of Air-Cooled Heat Exchangers

Saudi Aramco Forms and Data Sheets

Form 7305-ENG Equipment Noise Data Sheet

Form NMR-7922-2 Nonmaterial Requirements for Air-Cooled Heat

Exchangers

Industry Codes and Standards

American Petroleum Institute

API STD 661 Air-Cooled Heat Exchangers for General Refinery

Services

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





http://standards/docs/SAES/PDF/SAES-A-105.PDF

http://standards/docs/Saes/PDF/SAES-A-112.PDF


http://standards/docs/SAES/PDF/SAES-H-001.PDF

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

http://standards/docs/Inspection_Requirements/PDF/175-323600.PDF

http://standards/docs/Forms_Data_Sheets/XLS/SA-7305.XLS

http://standards/docs/Nonmaterial_Requirements/PDF/SA-7922-2.PDF




Page 5 of 27

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

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 B16.5 Pipe Flanges and Flanged Fittings

ASME SA-20 Specification for General Requirements for Steel

Plates for Pressure Vessels

ASME SA-435 Specification for Straight-Beam Ultrasonic

Examination of Steel Plates

National Association of Corrosion Engineers

NACE RP0472 Methods and Controls to Prevent In-Service

Environmental Cracking in Carbon Steel

Weldments in Corrosive Petroleum Refining

Environments

NACE MR0175 / Petroleum and Natural Gas Industries-

ISO 15156 Materials for use in H2S-Containing

Environments in Oil and Gas Production

Tubular Exchanger Manufacturers Association

TEMA Standards of the Tubular Exchanger Manufacturers

Association

3 Terms and Definitions

3.11 AARH: Average arithmetic roughness height, which is a measure of

surface texture.

3.12 Amine Services: All amine solutions including MEA, DGA and ADIP.

3.13 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.

3.14 Design Engineer: The Engineering Company responsible for specifying

on the data sheet the hydraulic, thermal and mechanical design

requirements for exchangers.

3.15 Exchanger Manufacturer: The company responsible for the manufacture

of exchangers.

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





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3.16 Exchanger Unit: One or more tube bundles in one or more bays for an

individual service.

3.17 Hydrogen Service: Process streams containing relatively pure hydrogen

and component streams containing hydrogen with a partial pressure of

350 kPa (50 psia) or higher.

3.18 Lethal Services: Process streams containing a concentration of hydrogen

sulfide in excess of 20% by volume shall be considered as lethal service.

3.19 Low Alloy Steels: Steels with nominal chromium content up to 5%

chrome and/or nominal nickel content up to 3%.

3.20 Minimum Thickness: Thickness required for withstanding all primary

loads, excluding allowance for corrosion.

3.21 MDMT: Minimum design metal temperature, determined by the Design

Engineer.

3.22 Nominal Thickness: Thickness required for withstanding all primary

loads, including allowance for corrosion.

3.23 Saudi Aramco Engineer: The Standards Committee Chairman.

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

Saudi Aramco Inspection Department to inspect exchangers to the

requirements of this specification.

3.25 Thick Wall Exchanger: An exchanger with header plates greater than

50 mm nominal thickness.

3.26 Critical Installations: Installations where unplanned shutdown of the fin

fan could cause substantial loss of production.

3.27 Non-Critical Installations: Installations which are not defined as critical.

3.28 Utility Services: Water, air and nitrogen services.

3.29 Wet Sour Service: Following process streams containing water and

hydrogen sulfide:

1. Sour water service with a hydrogen sulfide (H2S) concentration

above 2 mg/L (2 ppm) and a total pressure of 450 KPa absolute

(65 psia) or greater.

2. Hydrocarbon services meeting the definition of sour environments in

NACE MR0175/ISO 15156, where the H2S concentration of 2 mg/L








Page 7 of 27

(2 ppm) or more in the water phase is equivalent to H2S partial

pressure of 0.05 psia. Sour crude systems upstream of a stabilization

facility and sour gas upstream of a sweetening or dehydration plant are

examples of such environments.

3.30 Wet Sour HIC Services: Hydrogen Induced Cracking (HIC) resistant

steel qualified in accordance with 01-SAMSS-016 shall be specified for

the following environments with normal operating temperatures between

0°C (32°F) and 150°C (302°F):

1. Sour water service with a hydrogen sulfide (H2S) concentration above

2 mg/L (2 ppm) and a total pressure of 450 KPa absolute (65 psia) or

greater.

2. Hydrocarbon services meeting the definition of sour environments in

NACE MR0175/ISO 15156, where the H2S concentration of 2 mg/L

(2 ppm) or more in the water phase is equivalent to H2S partial

pressure of 0.05 psia.

3. A hydrocarbon system exposed to an environment with a H2S

concentration above 50 mg/L (50 ppm) in the water phase, regardless

of H2S partial pressure.

Commentary Note:

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

4 General

5 Proposals

5.12 The Exchanger Manufacturer may offer an alternative design, but must

also quote on the base inquiry documents.

5.13 The number of copies of drawings, data sheets, specifications, data reports,

operating manuals, installation instructions, and spare part lists shall be in

accordance with Form NMR-7922-2, Nonmaterial Requirements.

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

specified in the purchase order or contract documents:

1) Exchangers shall perform under continuous operation at design

conditions specified on the data sheets. Thermal guarantee shall be

in accordance with TEMA SEC 3, (paragraph G 5).

2) Exchangers shall perform the required design heat duty without

exceeding design air flow rates and/or maximum allowable pressure










Page 8 of 27

drop.

3) Sound levels at all specified operating conditions based on the

procedures of SAES-A-105.

4) Vibration limits of the complete assembly in accordance with the

requirements specified in this specification.

6 Documentation

6.1 Approval Information

6.1.4 (Exception) The Exchanger Manufacturer shall prepare and submit for

approval all proposed welding maps, welding procedures, and welding

procedure qualifications prior to start of fabrication.

6.1.5 (Exception) The Exchanger Manufacturer shall prepare and submit for

review and approval the additional engineering information required for

installation, operation, maintenance, and inspection in accordance with

Form NMR-7922-2, Nonmaterial Requirements.

6.2 Final Records

(Exception) The Exchanger Manufacturer shall prepare and submit final

records in accordance with Form NMR-7922-2, Nonmaterial Requirements.

7 Design

7.1 Tube Bundle Design

7.1.1 General

7.1.1.14 Each tube bundle shall have one header free to move with thermal

expansion of the tubes and shall have sliding plates at the moving end both

on structure and on bundle.

7.1.3 Tube Bundle Design Temperature

7.1.3.4 The MDMT shall be used to determine the requirements for impact testing

in accordance with Section 8 of this specification.

7.1.4 Tube Bundle Design Pressure

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

the data sheet the external design pressure and corresponding temperature.







Page 9 of 27

7.1.4.3 The Exchanger Manufacturer shall calculate the maximum allowable

working pressure (MAWP) acting in the hot and corroded condition in

accordance with the applicable Code.

The calculations shall be based on as-built thicknesses excluding

thicknesses required for corrosion. The MAWP of an exchanger shall not

be limited by flange rating.

7.1.6 Headers

7.1.6.1 General

7.1.6.1.1 (Exception) The Exchanger Manufacturer shall investigate all temperature

conditions, temperature differentials, temperature shocks, start-up,

shutdown, and cyclic conditions specified on the data sheet to determine

that the design of headers is adequate.

7.1.6.1.10 Selection of header type shall be as follows:

Headers shall generally be of plug type design.

For vacuum services such as steam turbine surface condensers and for

design pressures in excess of 14000 kPa (2000 psi), pipe manifold or other

suitable header type may be proposed for approval by the Saudi Aramco

Engineer.

7.1.6.2 Removable Cover Plate and Removable Bonnet Headers

7.1.6.2.3 (Exception) Removable cover plate and removable bonnet designs shall be

through-bolt designs using stud bolts and nuts on both sides.

7.1.8 Gaskets

7.1.8.10 Cover plate and bonnet joints shall be designed with confined or semi-

confined gaskets.

7.1.8.11 The manufacturer shall supply the following:

1. Minimum two sets of spare gaskets with blind flanges.

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

size) per exchanger.

7.1.9 Nozzles and other Connections




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7.1.9.4 (Exceptions)

through

7.1.9.10 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. Nozzle flange bore shall match the nozzle

neck bore.

3) 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.

However, for utility services up to and including 120°C (250°F)

design temperature and 1.4 MPa ga (200 psig) design pressure,

nozzles may be slip-on type flanges with seamless pipe nozzle necks

or rolled plate with 100% radiography.

7.1.9.11 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 conforming to

ASME B16.11 may be used for smaller than NPS 1½ vents, drains and

instrument connections.

Commentary Note:

This requirement is intended for vents, drains and instrument connections that may be attached to header or nozzles.

7.1.9.23 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.

7.1.9.24 Integrally reinforced openings (with no reinforcing pads) shall be provided

for all services and design conditions.

7.1.9.25 All nozzles shall be attached to the header by full penetration welds.

7.1.9.27 Ends of butt-welded connections shall be in accordance with ASME B16.25.

7.1.10 Maximum Allowable Moments and Forces for Nozzles and Headers

7.1.10.4 The Design Engineer shall calculate the forces and moments acting on

inlet and outlet connections based on allowable bundle movements and

frictional forces advised by the Exchanger Manufacturer. The Design




Page 11 of 27

Engineer shall also take into account the moments and forces acting on the

headers due to piping loads.

7.1.11 Tubes

7.1.11.2 (Exception) Unless otherwise approved by the Saudi Aramco Engineer, the

maximum tube length shall be 15,000 mm.

7.1.11.7 (Exception) The fin type selection shall be as follows:

1) Fins shall be extruded (integral) type for process inlet temperature of

up to and including 300°C.

2) Mechanically embedded fins may be used for a process fluid inlet

temperature of up to 400°C.

3) Welded fins, carbon steel on carbon steel, may be specified for a

process fluid inlet temperature of up to 450°C.

4) Embedded fins shall be used for cyclic service.

5) Fins, which are bonded to the outside surface of the tubes by hot-dip

galvanizing or brazing, shall not be used.

6) Other types of fins shall require approval by the Saudi Aramco

Engineer.

7.1.11.14 Design and selection of fins shall be such that fins will not suffer any

distortion when subjected to the design requirements with fans out of service.

7.1.11.15 Tube sizes and spacing shall be uniform throughout bundles in the same Unit.

7.2 Air-side Design

7.2.1 General

7.2.1.1 The Design Engineer shall specify all meteorological data, and location of

exchanger with respect to other buildings and equipment on the data sheet.

7.2.1.5 Hot-air re-circulation units shall be designed so that the motors and the

drivers are not exposed to heated re-circulated air temperature higher than

their design temperature.

7.2.1.6 Gear- box vents, oil filters, sight glasses and lubrication connections shall

be located outside the plenums.

7.2.1.7 When requested, Exchanger Manufacturer shall quote for the supply of a

centralized lubrication grease system. The grease pump shall be designed

for an automatic operation.




Page 12 of 27

7.2.2 Noise Control

7.2.2.1 (Exception) Design Engineer shall specify limits for the sound pressure

levels (SPL) per fan at the designated locations, on Form 7305-ENG.

The Exchanger Manufacturer shall complete Form 7305-ENG and ensure

that the required limits as specified for SPL can be achieved by supplying

test results of a representative bay.

7.2.3 Fans and Fan Hubs

7.2.3.14 (Exception) To avoid damage to fan blades due to vibration, the blade

passing frequency shall not fall within 80 to 120% of fan blade assembly

fundamental operating natural frequency.

7.2.3.18 Actuators for auto-variable pitch fans must be provided with maximum

pitch stops. The maximum design blade setting shall be marked on the

hub nameplate.

7.2.3.19 Induced draft fans shall have all mounting and bearing arrangements

designed to allow removal and installation of fans and hubs without

damaging the bundles.

7.2.4 Fan Shafts and Bearings

7.2.4.7 Exchangers with enclosed plenums with hot air re-circulation shall be

equipped with fan shaft bearing vibration transducers to permit monitoring

of bearings from outside the enclosure.

7.2.4.8 Thrust bearings shall be mounted so as to allow removal without

dismantling shaft or hub and located at the lower end of shafts.

7.2.4.9 Bearings shall be of a re-greasable type. Grease supply tubing shall be

installed and brought to an accessible location. Bearing housing shall be

dust and drip proof.

7.2.6 Fan Guards

7.2.6.1 (Exception) Removable fan guards shall be provided for both the forced

and the induced draft exchangers.

7.2.7 Drivers

7.2.7.1 General

7.2.7.1.3 All drives shall be mounted beneath the tube bundles.

7.2.7.2 Electric Motor Drivers






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7.2.7.2.10 Electric motors shall be manufactured in accordance with 17-SAMSS-503.

7.2.8.2 Belt Drives

7.2.8.2.1 (Exception) Belt drives shall be of the synchronous high torque (toothed)

type.

7.2.8.2.14 Belt tensioning adjustment shall be possible without removal of fan guards.

7.2.9 Vibration Cut-out Switches

7.2.9.1 (Exception) Shutdown protection device shall be activated by an electric

signal from a seismic vibration.

7.2.10 Louvers

7.2.10.18 (Exception) Design Engineer shall specify louver position at loss of

control-air pressure, and design motive air pressure for louver actuation.

7.2.10.26 All control louvers shall be provided with side mounted hand handles.

7.3 Structural design

7.3.1 General

7.3.1.7 Exchanger Manufacturer shall supply all structural steel including

platforms, hand-railing, and ladders, as specified by the Design Engineer

in accordance with this specification.

7.3.1.9 For grade mounted exchangers, headroom clearance below unit, excluding

driver arrangement, shall not be less than 2150 mm between fan ring and

grade for forced draft units and between tube bundle and grade for induced

draft units.

7.3.1.10 For pipe-rack supported exchangers, the supporting of drivers shall be as

follows:

For bottom supported drivers, the Exchanger Manufacturer shall supply

supporting columns and beams, including motor access platforms, hand-

railing, and ladders with a minimum headroom of 2150 mm for support of

fan and driver.

7.3.1.12 The Exchanger Manufacturer shall supply and install 12 mm minimum

hexagonal nuts welded on edge on 250 mm random pattern to structural

steel members that are specified to be fireproofed.





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7.3.1.13 Each tube bank shall be provided with a grounding lug connection welded

to the support of each unit.

7.3.1.15 Natural frequencies of structural members shall not be within 10% of the

fundamental excitation frequencies resulting from the fan speed and motor

speed. This applies to both shop-tested and field-tested structure.

7.3.2 Vibration Testing

7.3.2.2 (Exception) The Exchanger Manufacturer shall verify compliance with the

structural vibration requirements of this specification by shop testing and

during commissioning. On multi-bay identical exchanger units, a

minimum of one bay shall be shop tested.

7.3.2.4 Vibration in any axis on all bearings shall be less than 4 mm/sec, and

10 m/sec. sec. (1 g) RMS in the frequency range of 0-5 kHz.

7.3.2.5 Structural members shall be designed such that vibration is less than

6 mm/sec root mean square (RMS) and 150 micrometers peak to peak

unfiltered.

7.3.2.6 For multi-bay exchangers, the differences in driver speeds shall be a

maximum of 7-8% from one unit to another at maximum fan speeds.

7.3.3 Structural Design Loads and Forces

7.3.3.1 (Exceptions) Exchangers shall be designed for wind and earthquake loads

in accordance with ASCE 7.

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.

7.3.5 Mechanical Access Facilities

7.3.5.9 Maintenance platforms shall be provided if the bottom elevation of the

inlet headers, return headers, or drive equipment is greater than 3000 mm.

7.3.5.10 A 1070 mm wide platform shall be provided for each header for the length

of each header. Crosswalks 760 mm wide shall connect header access

platforms at the ends of each bank. An intermediate walkways intervals

shall be provided when the bank length exceeded 40 m. Interconnections

between maintenance and header walkways shall not be used to satisfy the

intermediate connection requirements.

http://standards/docs/Saes/PDF/SAES-A-112.PDF




Page 15 of 27

7.3.5.11 One stairway from grade to both header walkway and maintenance walkway

shall be provided and one ladder at the other end. For banks 60 m or more

in length one stairway shall be provided at each end of each bank.

7.3.5.12 Pipe- rack -mounted banks 60 m and shorter shall be provided with one

stairway at one end and ladder at the other. Banks greater than 60 m shall

have intermediate ladders to grade on each side and spaced not more than

30 m with access to both maintenance and header walkways.

Auxiliary stairs shall be used at changes in walkway elevations and offsets

around obstructions.

7.3.5.13 Stairways shall be 915 mm wide minimum.

7.3.6 Lifting Devices

7.3.6.7 Structures shall be designed to permit use for the handling and rigging of

driver assemblies that are not accessible to mobile handling and lifting

equipment.

7.3.6.8 Structure shall be designed to lift the heaviest piece of equipment, which

may be lifted with a 25% impact allowance, but not less than 460 kg

(1000 lb.).

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) Cast iron pressure parts shall not be used for any service.

8.1.3 (Exception) Structural supports shall be coated in accordance with

through SAES-H-001.

8.1.5

8.1.7 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. Materials other

than those listed in Table 1 of this specification shall not be permitted

without the prior approval of the Saudi Aramco Engineer.

8.1.8 All materials for pressure retaining parts must be clearly identified and

provided with Mill Test Certificates. Lack of adequate identification and

certification shall be cause for rejection.





Page 16 of 27

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

Exchanger Manufacturer in accordance with SAES-A-206.

8.1.10 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, micro

hardness, 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.

8.1.11 Use of C-1/2 Mo steels in hydrogen services is prohibited.

8.1.12 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.

8.1.13 Resistant Materials

8.1.13.1 For exchangers designated for wet sour HIC (hydrogen induced cracking)

services as defined in this specification with normal operating design

temperatures between 0°C (32°F) and 150°C (212°F), all plates for headers

shall be made of HIC resistant steel qualified in accordance with

01-SAMSS-016.

8.1.14 All the components (header, plain tube, fin tube, nozzle, blade, shaft, fan

ring, plenum, motor and plug) shall be fabricated by Saudi Aramco

approved exchanger manufacturer.

8.2 Headers

8.4 Other Components

8.4.2 (Exception) Fiber-glass-reinforced plastic (phenolic or epoxy resins) fan

blades and fan components shall not be used when the air outlet

temperature for induced draft fans exceeds 107°C with fans switched-off.

8.4.7 Steel used for slide plates shall be type 316 stainless steel. Carbon steel

slide plates shall not be used.

8.4.8 The materials of construction for spiral wound gaskets shall be as follows:






Page 17 of 27

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

Type 304 or 316 stainless steel windings with solid Type 304 or 316

stainless steel outer centering rings.

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

Type 304 or 316 stainless steel windings with solid carbon steel outer

centering rings.

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

Type 321 or 347 stainless steel windings with solid Type 304 or 316

outer centering rings.

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

the same material as the windings corresponding to the design metal

temperature.

8.5 Impact testing

8.5.1 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.

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

obtained from the Saudi Aramco Engineer.

8.5.3 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

8.5.4 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 of the Tube Bundle

9.1 Welding

9.1.1 General

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

through of SAES-W-010.

9.1.1.4





Page 18 of 27

9.1.1.5 Corner weld joints in box headers shall be in accordance with ASME SEC

VIII D1.

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

and all ferrous alloy plates shall be magnetic particle or liquid penetrant

examined, after cutting, for linear discontinuities. Defects shall not exceed

limits as per ASME SA-20.

9.1.1.7 Plate edge laminations revealed by magnetic particle testing shall be

completely removed and repaired per SAES-W-010.

9.1.1.8 Set-in nozzles shall be ground flush to the inside of the headers with a

smooth inner edge radius.

9.1.1.9 Vent holes shall be provided in external non-pressure welded attachments.

9.1.1.10 All external non-pressure welded attachments shall have their corners

rounded to a minimum radius of 20 mm and shall be fully seal welded.

9.2 Postweld Heat Treatment

9.2.5 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.

9.2.6 The maximum PWHT soaking temperature for quenched and tempered

carbon steel and C-0.5 Mo materials 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.

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

prior to any hydrotest or other load test.

9.2.8 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"

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

9.3 Tube-to-tubesheet Joints

9.3.1.2 (Exception) Special close-fit tube-hole diameter tolerances shall be used

for exchangers with stainless steel, monel, and non-ferrous tubes, and for

exchangers classified in hydrogen, cyclic, or lethal services.






Page 19 of 27

9.3.4.4 Welded tube to tube sheet joint shall not be used for services that require

postweld heat treatment for resistance due to the service such as caustic or

amine.

9.4 Gasket Contact Surfaces

9.4.4 (Exception) Nozzle 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 sidewalls of rings joint flanges, in all services, 63 AARH.

9.5 Thread lubrication

9.8 Heat Treatment of Tubes

The following tubes shall be stress relief heat treated after cold form bending:

1) 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

2) Monel, brass and all chrome alloy tubes in all services

The following tubes shall be solution annealed:

1) Entire tubes manufactured of unstabilized stainless steels or non-low

carbon or Nickel base alloys in accordance with ASME SA-688.

2) U bends, including 150 mm of straight portions measured from the

tangent lines of all stabilized stainless steels and low carbon stainless

steels or Nickel base alloys.

9.9 Hot Forming

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

operation (hot or cold) for components made of P-No. 3, 4, 5, 8, 9A or 9B

materials.

The heat treatment shall be annealing, normalizing, normalizing and

tempering, or quench and tempering, as required.

9.9.2 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




Page 20 of 27

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, Examination, and Testing

10.1 General

10.1.3 (Exception) Exchangers manufactured in accordance with this specification

are subject to verification by the Saudi Aramco Inspector in accordance with

Saudi Aramco Inspection Requirements Form 175-323600.

10.1.5 Examination procedures shall be established in accordance with

ASME SEC V. A written procedure for each examination method and

technique, including acceptance criteria to be used, shall be submitted to

the Saudi Aramco Inspector for approval. Qualification of the Exchanger

Manufacturer's procedure may be required, as determined by the Saudi

Aramco Inspector.

10.1.6 Written reports and evaluations of all examinations performed by the

Exchanger Manufacturer shall be made and submitted to the Saudi Aramco

Inspector, at a frequency to be determined by the Saudi Aramco Inspector.

10.1.7 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 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.

10.1.8 Surface irregularities, including weld reinforcement, preventing accurate

interpretation of the specified method of NDE shall be ground smooth.

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

inch wide on each side of the weld.

10.1.10 The Saudi Aramco Inspector shall have free access to the work at all times.

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. 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.

http://standards/docs/Inspection_Requirements/PDF/175-323600.PDF




Page 21 of 27

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

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

equipment used or to be used for any part of the work to be performed.

10.1.12 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.

10.1.13 The Exchanger Manufacturer shall provide the Saudi Aramco Inspector all

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

specified.

10.1.14 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.

10.1.15 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.

10.1.16 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 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.

10.2.1.3 100% radiography is required for category C joint for nozzle connections

in exchangers for the following services and design conditions:

1) Lethal services

2) Hydrogen services

3) Cyclic services

4) Weld joints where any of the pressure retaining materials requires

impact testing per the applicable Code or this specification.




Page 22 of 27

5) Exchanger weld joints requiring full radiography per the applicable

Code (see UW-11 for Division 1 exchangers and AF-220 for

Division 2 exchangers).

10.2.1.4 Where nozzles are installed onto or encroaching on a corner weld in the

header, 100% ultrasonic testing shall be performed on the corner weld

prior to the installation of the nozzle.

1) The corner weld shall be 100% ultrasonically tested after the

installation of the nozzle.

2) Magnetic particle examination shall be performed on the root pass

and final pass of the weld joint attaching the nozzle.

10.2.1.5 Plates for exchangers in hydrogen and wet sour services shall be

ultrasonically tested in accordance with ASME SA-435.

10.2.8 (Exception) Weld hardness testing shall be in accordance with the

requirements of SAES-W-010.

10.2.13 Radiographic film interpretation shall be done by personnel certified in

accordance with ASNT CP-189 to ASNT Level II Film Interpreter or

approved equivalent.

10.2.14 Ultrasonic testing may be substituted for radiography if approved by the

Saudi Aramco Inspector, unless radiography is required by the Code.

10.2.15 100% ultrasonic examination is required for corner joints in headers and

category D joint for nozzle connections in exchangers for the services and

design conditions stipulated in paragraph 10.2.1.3 of this specification.

10.2.16 For ferro-magnetic materials, wet fluorescent magnetic particle testing,

using an AC yoke is required for all accessible welds as follows:

1) All internal welds, including temporary internal welds for exchangers

in wet sour, caustic, amine, hydrogen and hydrocarbon services

2) All internal and external welds for all services made using the

SMAW welding process when the nominal thickness of pressured

components is 25 mm and thicker

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

required NDE after the final postweld heat treatment.

10.3 Pressure Test

10.3.3 (Exception) Fluids used for pressure testing shall be as follows:





Page 23 of 27

1) Clean potable water, treated for control of bacteria and corrosion

2) For exchangers with stainless steel, monel or non-ferrous tubes, the

water shall not contain more than 50 ppm chlorides.

3) For lube-oil and seal-oil exchangers the fluid to be used for pressure

testing shall be the system fluid.

10.3.4 (Exception) Pressure tests shall be performed after completion of all

external and internal welding and heat treatment , in accordance with the

Code and this specification.

10.3.8 Use of shellacs, glues, lead, etc., on gaskets during testing is prohibited.

10.3.9 After testing, exchangers shall be completely drained and thoroughly dried

with dry air.

10.3.10 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.

10.3.11 Temperature of water during hydrostatic testing shall be maintained at not

less than 17°C throughout the testing cycle.

10.5 Nameplates

10.5.1 The name plate should indicate the test pressure.

10.5.4 All exchangers shall be Code stamped.

10.5.5 Nameplates and nameplate mounting brackets shall be located such that

they are easily readable from a platform. Brackets with continuous

welding shall extend from the outside of exchanger with sufficient access

for surface preparation, and painting.

10.5.6 Nameplates shall be 3 mm minimum thickness and welded or riveted to

the mounting bracket.

10.5.7 The empty and water flooded weights of bundles shall be marked on the

nameplates.




Page 24 of 27

11 Preparation for Shipment

11.2 Surfaces and Finishes

11.2.1 Coating systems to be used shall be in accordance with SAES-H-001.

through

11.2.4

11.2.5 Prior to coating, the internal and external surfaces shall be cleaned to

remove all scale, rust, grease dirt, weld spatter and foreign objects.

11.2.6 Gasket contact surfaces shall not be painted.

11.3 Identification, Conditioning and Notification

11.3.1 (Exception) Marking shall be done with water-insoluble material that

contains no harmful substances that would attack or harmfully affect the

material at ambient or elevated temperatures. The marking material shall

be free of lead, sulfur, zinc, cadmium, mercury, chlorine, or other

halogens.

11.4 The internals of exchangers shall be protected from corrosion by use of a

non-toxic vapor phase corrosion inhibitor such as CORTEC VCI-309 or

307 or equivalent, applied at a rate of 0.3 kg/m³ fogged into the space.

The inhibitor selected must be appropriate for the metallurgy of the

exchanger. Exchangers must be sealed vapor tight for the inhibitor to be

effective. Corrosion inhibitors for use on exchangers with stainless steel

and Monel tubes must be chloride free, suitable for its intended use and not

result in crevice corrosion.

Alternatively, nitrogen blanketing at a pressure of 5 psig may be used.

11.5 Flanged connections and all other machined surfaces shall be protected by

a suitable coating, which is easily removed in the field and fitted with a

steel or wood cover, 3 mm thick and neoprene gaskets. Covers shall be

securely attached by a minimum of four bolts equally spaced. For ocean

shipment, flanged connections shall also be covered with heavy duty

plastic bags securely taped to the nozzles.

11.6 Prior to shipping, exchangers are to be completely dried and then cleaned

from all loose scales, weld slags, dirt and debris to the satisfaction of the

Saudi Aramco Inspector.

11.7 Exchangers shall be protected from salt water and salt water spray during

shipment.





Page 25 of 27

12 Supplemental Requirements

12.1 General

The requirements of API STD 661 section 12 shall be applied for the

conditions outlined in API STD 661 paragraph 12.1 if specified by the

Design Engineer.

12.3 Examination

12.3.14 For ferromagnetic material, all welds on plate 50 mm and thicker including

temporary welds are to be wet fluorescent magnetic particle tested after final

heat treatment. For non-ferromagnetic material, all welds on plate 50 mm

and thicker including temporary welds are to be wet fluorescent liquid

penetrant tested after final heat treatment.

Revision Summary

19 February 2013 Revised the “Next Planned Update.” Reaffirmed the content of the document, and reissued with editorial revision to change the primary contact person.




Page 26 of 27

Table 1 – Acceptable Materials for Carbon and Low Alloy Steels

Design Metal Temperature

Exchanger Component -46 to 0°C 1 to 425°C 351 to 645°C

Header plates, pass partition plates and stiffener plates

SA-516 Grade 60N SA-516 Grade 70N, or SA-537 Class 1

SA-516 Grade 60 SA-516 Grade 70, or SA-537 Class 1 or SA-285 Grade C

(1)

SA-387 Grades 11, 12, or 22

Nozzle necks SA-333 Grade 6 SA-106 Grade B SA-53 Grade B

(1)

SA-335 P11, 12, or 22

Tubes (2)

SA-334 or SA-249 Type 304

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

Forged flanges, forged fittings, and plugs

SA-350 LF2 SA-105 SA-182 F11, 12, or 22

Wrought fittings SA-420 WPL6 SA-234 WPB SA-234 WP 11, 12, or 22

Studs/nuts for pressure connections

SA-320 L7 w/ SA-194 Grade 4

SA-193B7/ SA-194 Grade 2H

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

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 212°F (100°C), 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, Grade 4, S2, or S9. Flanges above 24-inch diameter shall be SA-266, Grade 4, S2, or S9.

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

(3) Satisfy the requirements of NACE MR0175/ISO 15156 and NACE RP0472.

(D) Low alloy materials shall not be mixed, i.e., an exchanger requiring 1 1/4 Cr-1/2 Mo materials for pressure components shall have all pressure parts (with the exception of tubes) manufactured from 1 1/4 Cr-1/2 Mo.

(E) All chrome alloy material shall be specified in the normalized and tempered heat-treated condition.

(F) The material for nameplate mounting brackets shall be of the same type and material grade as the header.

Specific Notes:

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

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








Page 27 of 27

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 < 1/2 1/2 < 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 Gr. 1

2c SA 266 Gr. 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. WPL3 and WPL6

2c SA 234 Gr. WPB

2c SA 234 Gr. WP11, WP12 and WP22

Documents

32-SAMSS-011-2013_HE