32 Samss 007

Materials System Specification
32-SAMSS-007 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
15 August 2009
Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 Scope............................................................. 2 Normative References.................................... 2 Terms and Definitions.................................... 5 General........................................................... 7 Proposals....................................................... 7 Drawings and Other Required Data............... 8 Design............................................................ 8 Materials....................................................... 18 Fabrication.................................................... 20 Inspection and Testing................................. 24 Preparation for Shipment............................. 31 Supplemental Requirements........................ 34 Drawings, Calculations and Data................. 34 35 37 37 38
Table 1 - Acceptable Materials for Carbon and Low - Alloy Steels.......................... Table 2 - Charpy-V Impact Test Requirements.. Table 3 - Material Classes.................................. Table 4 - Radiography Requirements for Heat Exchangers.............................
Previous Issue: 5 April 2008 Next Planned Update: 19 November 2012 Revised paragraphs are indicated in the right margin Primary contact: Anizi, Salamah Salem on 966-3-8746139
CopyrightSaudi Aramco 2009. All rights reserved.
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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 19 November 2012
32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers
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. 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. Conflicting Requirements 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. 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.
1.2
1.3 1.3.1
1.3.2
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 SAES-A-206 Hydrostatic Testing Fluids Positive Materials Identification
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SAES-A-112 SAES-H-101 SAES-H-101V SAES-N-001 SAES-P-111 SAES-W-010 SAES-W-014
Meteorological and Seismic Design Data Approved Protective Coating Systems Approved Saudi Aramco Data Sheets - Paints and Coatings Basic Criteria, Industrial Insulation Grounding Welding Requirements for Pressure Vessels 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 Manufacture of Clad Vessels and Heat Exchangers
32-SAMSS-031
Saudi Aramco Standard Drawings AA-036322 AE-036250 Anchor Bolt Details Inch and Metric Sizes Ferrules for Inch Tubes (Sheets 1 & 2)
Saudi Aramco Inspection Requirements Form 175-323100 Form 175-323500 Manufacture of Shell and Tube Heat Exchangers Floating Heads or Tube Bundles
Saudi Aramco Forms and Data Sheets Form 2714-ENG Form NMR-7922-1 2.1 Industry Codes and Standards American Concrete Institute ACI 318 Building Code Requirements for Structural Concrete Shell and Tube Exchanger Data Sheet (herein referred to as data sheet) Non-material Requirements for Shell and Tube and Double-Pipe Heat Exchangers
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American Petroleum Institute API STD 660 API RP 934 Shell-and-tube Heat Exchangers for General Refinery Services Materials and Fabrication Requirements for 2Cr-1 Mo & 3Mo Steel Heavy Wall Pressure Vessels for High Temperature, High Pressure Hydrogen Service Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum and Petrochemical Plants Avoiding Environmental Cracking in Amine Units
API PUBL 941
API RP 945
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 ASME SA-388 ASME SA-435 ASME SA-450 Specification for General Requirements for Steel Plates for Pressure Vessels Ultrasonic Examination of Heavy Steel Forgings Straight Beam Ultrasonic Examination of Steel Plates Specification for General Requirements for Carbon, Ferritic Alloy, and Austenitic Alloy Steel Tubes Specification for Welded Austenitic Stainless Steel Feedwater Heater Tubes Specifications for Welding Rods, Electrodes, and Filler Metals Nondestructive Examination Rules for Construction of Pressure Vessels Rules for Construction of Pressure Vessels, Alternative Rules National Pipe Threads Pipe Flanges and Flanged Fittings Forged Fittings, Socket-Welding and Threaded
ASME SA-688 ASME SEC IIC ASME SEC V ASME SEC VIII D1 ASME SEC VIII D2 ASME B2.1 ASME B16.5 ASME B16.11
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ASME B16.20 ASME B16.21 ASME B16.25 ASME B16.47
Metallic Gaskets for Pipe Flanges - Ring-Joint, Spiral-Wound, and Jacketed Non-Metallic Gaskets for Pipe Flanges Buttwelding Ends 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 Welding Research Council WRC 107 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 recrystallization occurs simultaneously with deformation.
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Vessel/S&T Heat Exchanger Standard Details
Welding Research Council Bulletin
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) 2) 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. Hydrocarbon services meeting the definition of sour environments in NACE MR0175/ISO 15156 as shown below: a) b) Dissolved H2S in free water (liquid) with a concentration of >50 mg/L (50 ppmw) or, H2S in gas with a gas phase with 0.05 psia or greater partial pressure.
Commentary Note: Page 6 of 38
HIC resistant steel is not required in caustic services, lean amine systems and rich amine DGA systems.
General 4.1 4.6 (Exception) Pressure design code shall be ASME Boiler and pressure vessel code, Section VIII. 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. No proof testing shall be permitted unless specifically approved by the Saudi Aramco Engineer. Application of ASME Code Cases to the manufacture of exchangers requires approval of the Saudi Aramco Engineer. Exchangers having partial or complete cladding shall also conform to 32-SAMSS-031 in addition to the requirements of this specification. 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.
4.7 4.8 4.9 4.10
Proposals 5.1 5.1.1 Purchaser's Responsibilities (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. The Design Engineer is responsible for specifying the requirements for Cyclic Services stress analysis. Vendor's Responsibilities The Exchanger Manufacturer may offer an alternative design, and may also quote on the base inquiry documents.
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5.1.2 5.2 5.2.8
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. Exchangers shall be free from damaging flow induced tube vibration and acoustic vibration.
2)
Drawings and Other Required Data 6.1 6.1.2 Outline Drawings 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. The Exchanger Manufacturer shall prepare drawings, calculations and data in accordance with Form NMR-7922-1, Nonmaterial Requirements. Information Required after Drawings are reviewed Flow induced and acoustic vibration analyses. Reports and Records The Exchanger Manufacturer shall furnish reports and records in accordance with Form NMR-7922-1, Nonmaterial Requirements.
6.1.3 6.2 6.2.4(d) 6.3
Design 7.1 7.1.3 7.1.4 7.1.5 Design Temperature (Exception) The value(s) of design temperature(s) shall be as specified on the data sheet. The value of the minimum design metal temperature (MDMT) shall be as specified on the data sheet. 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 7.3.2(f)
Shell Supports 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. 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. The allowable concrete bearing stress to be used for the design of base plates shall be 10340 kPa (1400 psi). 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. Anchor Bolts 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). Anchor bolts shall not be less than 20 mm minimum nominal diameter. The design of anchor bolts shall be in accordance with the requirements of Appendix D of ACI 318. 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. Saddles for horizontal exchangers shall be provided with an even number of anchor bolts with a minimum of two anchor bolts per saddle. Floating Head (Exception) Floating head covers shall be attached to the backing device or to the floating tubesheet with through bolting. Tube Bundle
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7.3.6
7.3.7 7.3.8
7.3.9 7.3.9.1
7.3.9.2 7.3.9.3 7.3.9.4
7.3.9.5 7.5 7.5.2 7.6
7.6.1 7.6.1.5
Tubes 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. 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. 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. 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. 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.
7.6.1.6
7.6.1.7
7.6.1.8
7.6.1.9
7.6.2 7.6.2.5 7.6.2.6 7.6.3 7.6.3.1 7.6.3.3
Tubesheets All stationary tubesheets with through bolting design shall have nonthreaded bolt holes. Vertical exchangers with fixed tubesheets shall be provided with flanged vents and drains through the tubesheets. Transverse Baffles and Support Plates (Exception) Minimum thickness of baffles and support plates shall be as per TEMA requirements. Support plates for floating heads shall be located as close to the tubesheet as the design and type of exchanger will permit. Support plate
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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 7.6.4.7
Impingement Protection 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 7.6.5.4 7.7 7.7.2 7.7.3
Bypass Sealing Devices (Exception) The location of the sealing devices shall not interfere with the continuous tube lanes for square and rotated square layouts. Nozzles and Other Connections (Exception) When butt welded connections are specified on the data sheet the ends shall be in accordance with ASME B16.25. (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
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conforming to ASME B16.11 may be used for NPS 1 and smaller vents, drains and instrument connections. 7.7.4 (Exception) Flanged connections shall be one of the following types: 1) 2) Forged steel long welding neck. 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. 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. 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 120C (250F).
3)
4)
7.7.5
(Exception) slip-on type flanges can only be used for utility services up to 400C (750F) design temperature and 2.1 MPa (300 psi) design pressure, with seamless pipe nozzle necks or rolled plate with 100% radiography. (Exception) Flanges shall be in accordance with ASME B16.5 pressure rating. The quantities, sizes, ratings (ASME pressure classes) and facings of exchanger nozzles shall be as specified on the data sheet. 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. Flange bolt holes shall straddle the normal horizontal and vertical centerlines of the exchanger. Threaded connections shall conform to ASME B2.1. 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).
7.7.6 7.7.11 7.7.12
7.7.13 7.7.14 7.7.15
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b) 7.7.16
For Division 2 exchangers: Figure AD-613.1: (a), (b), (c), (c-1) (d) or (e).
The calculated MAWP of an exchanger in the hot and corroded condition shall not be limited by the nozzle reinforcement or the flange rating. All nozzles in thick wall exchangers shall be weld neck, long weld neck or contour forged with inside corner radius of 13 mm minimum. Integrally reinforced openings (with no reinforcing pads) shall be provided under the following services and design conditions: 1) 2) 3) 4) 5) 6) Cyclic services Carbon steel with shell or channel thickness greater than 50 mm Low-chrome steels with shell or channel thickness 25 mm and greater Openings which are 900 mm and larger with design temperature 400C and greater Exchangers with design metal temperatures greater than 425C Hydrogen service
7.7.17 7.7.18
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. Permissible types of nozzle weld-attachments for exchangers with shell/channel cylinder nominal thickness equal to or less than 50 mm are: 1) 2) 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). 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.
7.7.20
7.7.21
Permissible types of nozzle weld-attachments for thick wall exchangers are: 1) 2) For Division 1 exchangers: Figure UW-16.1 (f-1), (f-2), (f-3) or (f-4). For Division 2 exchangers: Figure AD-613.1: (a), (b), (c), (c-1), (d) or (e), backing rings are to be removed.
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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) 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).
2) 7.7.23 7.11 7.11.5
Use of internal reinforcing elements is not permitted. Handling Devices 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. 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. Protective plugs shall be fully engaged. 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. 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.
7.11.6
7.11.7 7.11.8
7.12
7.13
Kettle Reboilers Kettle type reboilers shall conform to the following: 1) 2) 3) The distance between the top of weir and top of tubes shall be a minimum of 75 mm. The distance from the weir to adjacent tangent line of the head shall not be less than 900 mm. Weirs shall be provided with a 50 mm semi-circular drain hole.
7.14
Design Pressure
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7.14.1 7.14.2
The value(s) of design pressure(s) shall be in accordance with the data sheet. For exchangers subjected to steam out, the Design Engineer shall specify on the data sheet the external design pressure and corresponding temperature. Maximum Allowable Working Pressure 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. The MAWP of an exchanger shall not be limited by flange ratings. Joint Efficiency A joint efficiency of 85% or higher shall be used for the design of all pressure containing components of ASME SEC VIII D1 exchangers. Loads 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. 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. 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.
7.15 7.15.1
7.15.2 7.16 7.16.1 7.17 7.17.1
2)
3)
7.17.2
Piping, Equipment and External Loads 1) 2) The design engineer shall provide piping and equipment loads imposed on the exchanger. 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.
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7.18 7.18.1
Load Combinations All components of an exchanger, including supports, shall be designed to withstand the combined stresses resulting from the following: 1) 2) 3) Internal and/or external design pressures. All other loads exerted on the component and specified in section 7.17. 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 7.19.1 7.19.2 Shell and Channel Covers ASME flanged and dished heads (torispherical) may be used for utility services up to a design pressure of 690 kPa (100 psi). 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. 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. Dished heads in thick wall exchangers shall be specified as hemispherical unless 2:1 ellipsoidal heads are deemed economical. 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
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7.19.3
7.19.4 7.19.5
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. 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.
c)
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. Longitudinal Baffles (TEMA 'F' shells) 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. Clips and Attachments For insulation support attachment, refer to exchanger data sheet for the extent and thickness of external insulation. The Exchanger Manufacturer shall supply and install all clips and attachments as specified by the Design Engineer. 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. All exchangers shall be provided with a grounding lug connection welded to the fixed exchanger support. The Exchanger Manufacturer shall supply and install supports required for fireproofing materials. Vertical exchangers, which are externally insulated, shall be provided with insulation supports in accordance with SAES-N-001. Coatings and Painting 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.
7.20 7.20.1 7.21 7.21.1 7.21.2 7.21.3
7.21.4 7.21.5 7.21.6 7.22 7.22.1
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7.22.2 7.23 7.23.1
Gasket contact surfaces shall not be painted. General 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. Where more than one exchanger of identical design, pressure rating and materials is required for the same service, the tube bundles shall be interchangeable. 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. For tube bundles that can be rotated 180 degrees, additional impingement plate, bundle runners etc. shall be provided. 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.
7.23.2
7.23.3
7.23.4 7.23.5
Materials 8.1 8.1.1 General (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. (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. (Exception) Materials other than those listed in Table 1 of this specification shall not be permitted without the prior approval of the Saudi Aramco Engineer.
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8.1.2
8.1.3
8.1.5 8.1.6
Material test report is requested to be certified as per 175-323100. Suitability of low chrome alloy steels for use for exchangers in hydrogen services above 205C (400F) 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. All materials, except carbon steels, shall be alloy verified by the Exchanger Manufacturer in accordance with SAES-A-206. The use of C- Mo steels in hydrogen services is prohibited. 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. HIC Resistant Materials For exchangers designated for wet sour HIC (hydrogen induced cracking) services as defined in Section 3 of this specification with normal operating temperatures between 0C and 150C, 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. Gaskets (Exception) The materials of construction for spiral wound gaskets shall be as follows: 1) For exchangers with design temperatures from -100C to 0C: 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 1C to 425C: Type 304 or 316 SS windings with solid carbon steel outer centering rings. 3) For exchangers with design temperatures above 425C:
8.1.7 8.1.8 8.1.9
8.1.10 8.1.10.1
8.2 8.2.3
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Type 321 or 347 SS windings with solid; Type 304 or 316 outer centering rings. 4) 8.4 8.4.1 For exchangers in vacuum service, inner ring shall be either Type 304 or 316 SS.
Impact Testing 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. Baffle plates, sealing strips, tie-rods, sliding bars, tubes, spacers, and support plates are exempt from impact testing requirements. Impact testing requirements for materials not listed in Table 1, shall be obtained from the Saudi Aramco Engineer. 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. 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.
8.4.2 8.4.3 8.4.4
8.4.5
Fabrication 9.1 9.1.4 Shells 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. All re-rolling or forming of the shell sections is to be completed prior to radiography. 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. Plate edge laminations revealed by magnetic particle examination shall be completely removed and repaired per SAES-W-010.
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9.1.5 9.1.6
9.1.7
9.1.8
External welded attachment pads shall have their corners rounded to a minimum radius of the length or width of the pad whichever is less with a maximum of 50 mm and shall be fully seal welded. External attachment pads shall be vented through a " NPT telltale hole. Vent holes shall be plugged with grease, wooden plugs or other nonpressure retaining material to prevent moisture from entering. 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. Tapped tell-tale holes "NPT shall be provided in reinforcing pads as follows: 1) 2) One hole in single piece reinforcing pad. Where a pad is split, each segment shall have at least one tapped hole.
9.1.9
9.1.10
9.1.11
9.2
Pass Partition Plates Pass partition plate shall be provided with a 6 mm (") 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 9.5.11
(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. 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. 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.
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9.5.12
9.6 9.6.2
Heat Treatment (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. Monel, brass and all chrome alloy tubes in all services.
b) 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. 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.
b)
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. PWHT shall be done when required by the applicable Code or when required by SAES-W-010. 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 650C maximum for carbon steel, 690C maximum for C-0.5 Mo and 700C for low alloy steels. Final PWHT shall follow all welding and repairs but shall be performed prior to any hydrotest or other load test. 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".
9.6.8 9.6.9
9.6.10 9.6.11
9.6.12 9.8
PWHT shall be in accordance with the requirements of SAES-W-010. Gasket Contact Surfaces other than Nozzle Flange Facings
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9.8.6
Gasket seating surfaces shall comply with the following: 1) 2) 3) 4) For spiral wound gaskets, 125 to 250 AARH, in all services, except hydrogen. For spiral wound gaskets in hydrogen service, 125 to 150 AARH. The side-walls of ring joint flanges in all services, 63 AARH. 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 9.9.4 Tube-Hole Grooves Tubesheet tube hole diameters and tolerances shall be special close fit when tube bundle vibration is suspected or when exchanger is in cyclic service. Tube expanding procedures shall incorporate stops to prevent tube expansion past tubesheet faces. 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. 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. Forming and Heat Treatment 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.
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9.9.5 9.9.6
9.9.7
9.12 9.12.1
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 10.1.7 Quality Assurance The responsibility for quality assurance rests with the Exchanger Manufacturer in accordance with the applicable Code and the requirements of this specification. 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. 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. 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. Magnetic-particle, liquid-penetrant, ultrasonic and radiographic examinations on exchangers to be postweld heat-treated shall be made after completion of final heat treatment. 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.
10.1.8
10.1.9
10.1.10
10.1.11
10.1.12
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10.1.13
Additional examination of any weld joint at any stage of the fabrication may be requested by the Saudi Aramco Inspector, including reexamination 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. All necessary safety precautions shall be taken for each examination method. Surface irregularities, including weld reinforcement, inhibiting accurate interpretation of the specified method of examination shall be ground smooth. Examination of all welds shall include a band of base metal at least one inch wide on each side of the weld. 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. 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. 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. 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. The Exchanger Manufacturer shall provide the Saudi Aramco Inspector all reasonable facilities to satisfy him that the work is being performed as specified. 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.
10.1.14 10.1.15
10.1.16 10.1.17 101.1.18
10.1.19
10.1.20
10.1.21
10.1.22
10.1.23
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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. 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. Quality Control Radiographic testing shall be performed as follows: 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. Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as individual rounded indications. Clustered or aligned tungsten inclusions shall be removed and repaired. Radiography requirements for heat exchangers are outlined in table 4 of this specification. 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. 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. Where a reinforcing pad is required, the butt weld shall be ground flush and radiographed, prior to the installation of the reinforcing pad.
10.1.25
10.2 10.2.1 10.2.1.1
10.2.1.2
10.2.1.3 10.2.1.4
10.2.1.4.1
2)
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.
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2) 10.2.12 10.2.13 10.2.13.1 10.2.13.1.1
Perform magnetic particle examination on the exchanger side of the joint attaching the reinforcing pad or structural component.
Weld hardness testing shall be in accordance with the requirements of SAES-W-010. Ultrasonic Examination For thick wall exchangers Ultrasonic Examination of Plates and Welds a) b) c) All plates, including plate-like forgings, such as shell rings shall be ultrasonically examined in accordance with ASME SA-435. All category A and B welds are to be 100% ultrasonically examined in accordance with the applicable Code in all services. All category C and D welds shall be ultrasonically examined in cyclic, hydrogen or lethal services in accordance with the applicable Code. 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. All pressure retaining welds and exchanger support attachment full penetration welds shall be 100% ultrasonically examined after final heat treatment.
d)
f)
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 10.2.14.1 10.2.14.2
Magnetic Particle Examination Permanent magnetic yokes are not permitted. 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. Magnetic particle examination or liquid penetrant examination shall be performed on the surfaces of hot formed and reheat treated as per the applicable Code.
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10.2.14.3
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. 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. Exchanger support attachment welds.
2)
3) 10.2.14.5 10.2.14.6 10.2.14.6.1 10.2.14.6.2
Final acceptance of the exchanger shall be based on completion of all required NDE after the final postweld heat treatment. For thick wall exchangers: All edges prepared for welding and all openings shall be magnetic particle examined in accordance with the applicable Code. 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. All ferro-magnetic welds are to be wet fluorescent magnetic particle examined after final heat treatment. Pressure Testing 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.
10.2.14.6.3 10.3 10.3.1
10.3.2
(Exception) An independent hydrostatic test of shell-side and tube-side shall be performed. The temperature of the water during hydrostatic
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testing shall be maintained at not less than 17C 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. Water used for pressure testing shall be potable. 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. No preliminary pressure testing shall be made prior to postweld heat treatment. 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. The Exchanger Manufacturer shall furnish all test materials and facilities, including blinds, bolting, and gaskets. 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. The manufacturer shall supply the following: 1) 2) 3) 10.3.17 10.3.18 Minimum two sets of spare gaskets with a blind flange for all nozzles. Minimum one set of service gaskets and two sets of spare gaskets for each nozzle with companion flanges in the exchanger. All bolting with minimum 10% spare bolting (3 minimum for each size) per exchanger.
10.3.4 10.3.11
10.3.12 10.3.13
10.3.14 10.3.15
10.3.16
After testing, the exchanger shall be completely drained and thoroughly dried including around the internals. For other than differential-pressure design exchangers, test pressure for the shell side and the tube side shall be as per the applicable code
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10.3.19 10.3.20
For differential-pressure design exchangers, test pressure shall be as per the applicable code. 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. 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. 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. Nameplates and Stampings (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. 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. Exchangers shall be Code stamped for all services, in accordance with the applicable Code. 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. Repairs during Fabrication 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
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10.3.21
10.3.22
10.4 10.4.1
10.4.4
10.4.5 10.4.6
10.5 10.5.1
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) b) Heat treat the repaired section if it has been heat-treated prior to the repairs. All nondestructive examinations performed on the repaired section prior to the repairs.
11
Preparation for Shipment 11.1 11.1.1 Protection 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. Prior to shipping, exchangers are to be completely dried. 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. 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. 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. Tell-tale holes in reinforcing pads shall be protected with wooden plugs or packed with rust preventative grease such as Denso paste. 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.
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11.1.2 11.1.3 11.1.4
11.1.5
11.1.6 11.1.7
11.1.8 11.1.9
Export packing, marking, and shipping shall be in accordance with the purchase order. 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. Internal & External Protection 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/m. 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/m. 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. 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. 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. 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
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11.1.10 11.1.10.1
11.1.10.2
11.1.10.3
11.1.10.4
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. 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) 2) 3) 11.1.13 During transportation (Ocean and Land). At fabrication shop/site after completion of its fabrication. At construction site from its arrival until its commissioning.
11.1.12
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. 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. For exchangers which have permanent internal coatings, the Exchanger Manufacturer shall contact the Saudi Aramco Engineer for any corrosion protection required. 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. 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.
11.1.14
11.1.15
11.1.16
11.1.17
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11.1.18 11.1.19 11.2 11.2.4
Bolt heads shall also be protected with a rust preventative compound to prevent corrosion during shipment, storage and construction. Spare bolts shall be protected with a rust preventative compound to prevent corrosion during shipment, storage and construction. Identification 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. Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, or other halogens.
11.2.5
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 13.2 The Exchanger Manufacturer shall prepare drawings, calculations, and data in accordance with NMR-7922-1, Nonmaterial Requirements. 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. 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. 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 Major revision. Editorial revision. Editorial revision to replace cancelled SAES-A-301 with NACE MR0175/ISO 15156.
13.3
13.4
20 November 2007 5 April 2008 15 August 2009
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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] De si gn T e mp er atu r e Exchanger Component Shells, channels, dished heads, tubesheets, rolled nozzle necks, covers, and reinforcing pads Pipe, nozzle necks Tubes
(2)
-100C to -47C SA-203 Grade D or E
-46C to 0C SA-516 Grade 70N, or SA-537 Class 1
1C to 425C SA-516 Grade 70, or SA-537 Class 1 or (1) SA-285 Grade C (6) SA-387 Grade 5 SA-106 Grade B (1) SA-53 Grade B (6) SA-335 Grade P5 SA-179 or SA-214 (6) SA-213 Grade T5 SA-105 (6) SA-182 Grade F5 SA-234 WPB SA-234 Grade (6) WP5 SA-193 B7/SA-194 Grade 2H SA-516 Grade 70, or SA-537 Class 1, or SA-285 (1) Grade C SA-516 Grade 70, or SA-537 Class 1, or SA-285 Grade C, (1) or SA-36 SA-516 Grade 70, or SA-285 Grade C, (1) or SA-36
351C to 645C SA-387 Grades 11, 12 or 22
SA-333 Grade 3 SA-249 Type 304 SA-350 LF3 SA-420 WPL3 SA-320 L43/ SA-194 Grades 4 or 7 SA-203 Grades D or E SA-203 Grades D or E SA-203 Grades D or E
SA-333 Grade 6 SA-334 or SA-249 Type 304 SA-350 LF2 SA-420 WPL6 SA-320 L7/SA-194 Grade 2H SA-516 Grade 70N, or SA-537 Class 1 SA-516 Grade 70N, or SA-537 Class 1 SA-516 Grade 70N, or SA-537 Class 1 or SA-285 Grade C SA-307 Grade B
Forged flanges Wought fittings Studs/nuts for pressure connections Internal attachment (4) clips External attachment (4) clips Saddle Supports and Lugs
(3)
SA-335 Grades P11, 12 or 22 SA-179 or SA-214 or SA-213 Type 304 SA-182, Grades F11, 12 or 22 SA-234, Grades WP11, 12 or 22 SA-193 B5, or B16/ SA-194 Grade 3 SA-387 Grades 11, 12 or 22 SA-387 Grades 11, 12 or 22 SA-387 Grades 11, 12 or 22
Anchor bolts
SA-307 Grade B
SA-307 Grade B
SA-307 Grade B
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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 30C above the design temperature. Materials for exchangers in amine service shall be selected in accordance with Table 1 and API RP 945. Materials for exchangers in wet sour service, with design temperature up to 100C (212F), shall be in accordance with Table 1, with the following revisions: 1) 2) 3) 4) D) 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. Studs and nuts are restricted to: SA-193 B7M or L7M and SA-194 Grade 2HM. It shall satisfy the requirements of NACE MR0175/ISO 15156 and NACE RP0472. 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.
B) C)
Materials for pressure components in sea water service shall be in accordance with Table 1 with the following revisions: 1) 2) Carbon steel pressure components in contact with seawater shall be clad or weld overlayed with Monel in accordance with 32-SAMSS-031. Tube material shall be either Cu/Ni SB-111 (Alloy Number C71500) or Titanium SB-338 Grade 2.
E) F) G) H) I)
Low alloy steels shall not be mixed, i.e. an exchanger requiring 1 Cr- Mo materials shall have all components manufactured from 1 Cr- Mo. Low alloy steels shall be specified in the normalized and tempered heat treated condition. The material for nameplate mounting brackets shall be of the same type and material grade as the shell material. Impact testing of materials and welding procedures are required when MDMT is lower than -28C. Impact testing of materials is only required when MDMT is -27 to -18C. 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 -46C or lower.
Specific Notes: 1) 2) 3) 4) 5) SA-36, SA-53, SA-283, and SA-285 materials shall only be used for utility services. Tubes in hydrogen, wet sour, amine and caustic services shall be seamless. Saddle support wear plates shall be of the same ASME material as the shell material. All internal and external clips and attachments on exchangers shall be of the same ASME material as the attached pressure component. 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. For hydrocarbon services containing hydrogen sulfide or organic sulfides at temperatures exceeding 550F.
6)
Page 36 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 1a 1b 2a 2b 2c 3
Notes: 1) 2) 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. See Table 3 for material specification.
t< 34/27 34/27 34/27 34/27 34/27 34/27
<t<1 34/27 34/27 34/27 34/27 34/27 34/27
1<t<2 34/27 34/27 34/27 34/27 47/38 34/27
t>2 34/27 34/27 34/27 47/38 61/48 34/27
Table 3 Material Classes

Class 1a 2b 2a 2b 2c 3 2b 2b 2c 1a 3 2a 2b 2b 2c 2b 3 2b 2c 2a 2b 2c 2b 2c 2c 2c SA 53 SA 105 SA106 SA 182 SA 182 SA 203 SA 204 SA 266 SA 266 SA 333 SA 333 SA 333 SA 335 SA 336 SA 336 SA 350 SA 350 SA 387 SA 387 SA 442 SA 516 SA 533 SA 537 SA 420 SA 234 SA 234 Material Specification Gr. B Gr. B Gr. F11 and F12 Gr. F22 Gr. D and E Gr. A, B and C Cl. 1 Cl. 2 and 4 Gr. 1 Gr. 3 Gr. 6 Gr. P11, P12 and P22 Gr. F12 Gr. F11 and F22 Gr. LF2 Gr. LF3 Cl. 1, Gr. 11, 12 and 22; Cl. 2, Gr. 12 Cl. 2, Gr. 11 and 22 Gr. 55 and 60 Gr. 70 Cl. 1 Cl. 1 Gr. WPP3 and WPL6 Gr. WPB Gr. WP11, WP12 and WP22 Page 37 of 38
Table 4 Radiography Requirements for Heat Exchangers

Weld Joint Category A and B C D
Notes: 1. 100% RT is required in heat exchangers under any of the following services or design conditions: 2. 3. 4. 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.
Radiography (RT) Per Code Design Criteria (Spot or 100%) 100% 100%
Notes (1) and (4) (1), (3) and (4) (1), (2), (3), (4) and (5)
UT for Category-D weld joint in attachments with a reinforcing plate must be performed prior to installing reinforcing plate. UT from accessible side must be conducted after any heat treatment, if applicable. 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. 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. UT may be substituted for RT for NPS 4 and smaller connections to nozzles and manways. To facilitate 100% radiography of category-D weld joint, it shall be according to: a) b) For Division 1 exchangers: Figures UW-16.1: (f-1), (f-2) (f-3) or (f-4). For Division 2 exchangers: Figures AD-613.1: (a), (b) (c), (c-1) (d) or (e).
5.
6. 7.
Page 38 of 38

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Materials System Specification

Saudi Aramco DeskTop Standards

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

SAES-A-112 SAES-H-101 SAES-H-101V SAES-N-001 SAES-P-111 SAES-W-010 SAES-W-014

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

API PUBL 941

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

ASME B16.20 ASME B16.21 ASME B16.25 ASME B16.47

Vessel/S&T Heat Exchanger Standard Details

Welding Research Council Bulletin

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

Commentary Note: Page 6 of 38

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

4.7 4.8 4.9 4.10

5.1.2 5.2 5.2.8

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

6.1.3 6.2 6.2.4(d) 6.3

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.3.9.2 7.3.9.3 7.3.9.4

7.3.9.5 7.5 7.5.2 7.6

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.6.2 7.6.2.5 7.6.2.6 7.6.3 7.6.3.1 7.6.3.3

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.6.5 7.6.5.4 7.7 7.7.2 7.7.3

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.7.6 7.7.11 7.7.12

7.7.13 7.7.14 7.7.15

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

2) 7.7.23 7.11 7.11.5

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.15.2 7.16 7.16.1 7.17 7.17.1

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.20 7.20.1 7.21 7.21.1 7.21.2 7.21.3

7.21.4 7.21.5 7.21.6 7.22 7.22.1

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

7.22.2 7.23 7.23.1

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

8.1.7 8.1.8 8.1.9

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

8.4.2 8.4.3 8.4.4

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

10.1.16 10.1.17 101.1.18

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

10.2 10.2.1 10.2.1.1

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

2) 10.2.12 10.2.13 10.2.13.1 10.2.13.1.1

10.2.14 10.2.14.1 10.2.14.2

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

3) 10.2.14.5 10.2.14.6 10.2.14.6.1 10.2.14.6.2

10.2.14.6.3 10.3 10.3.1

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers

11.1.2 11.1.3 11.1.4

32-SAMSS-007 Manufacture of Shell and Tube Heat Exchangers