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Materials System Specification

32-SAMSS-011 Manufacture of Air-Cooled 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 Scope............................................................. 2 Normative References................................... 3 Terms and Definitions.................................... 5 General.......................................................... 7 Proposals....................................................... 7 Documentation............................................... 8 Design............................................................ 8 Materials....................................................... 15 Fabrication of the Tube Bundle.................... 17 Inspection, Examination, and Testing.......... 20 Preparation for Shipment............................. 24 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

Previous Issue: 5 April 2008 Next Planned Update: 22 January 2013 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: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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 1.1.1 GENERAL The Design Engineer is responsible for specifying the process data, the mechanical design requirements, and completing the API exchanger data sheet. Exchangers shall be designed to minimize field assembly. Individual exchanger within a group of exchangers shall be designed for maximum practical inter-changeability of components. When specified, compliance with the latest edition of ASME SEC VIII D2, Pressure Vessels, Alternative Code Rules is mandatory. 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. Clad exchangers shall also conform to 32-SAMSS-031 in addition to the requirements of this specification. Exchangers in lube and seal oil services shall also conform to 32-SAMSS-013.

1.1.2 1.1.3 1.1.4 1.1.5

1.1.6 1.1.7 1.1.8 1.1.9

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

1.1.9 1.1.10

Exchangers in lube and seal oil services shall also conform to in addition to the requirements of this specification. 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. The edition of the Code to be used for the manufacture of exchangers shall be the edition in effect at time of purchase. Where a licensor's specification requirement is more stringent than that of this specification, this licensor's specific requirement shall govern. CONFLICTING REQUIREMENTS 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. 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. 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.

1.1.11 1.1.12 1.2 1.2.1

1.2.2

1.2.3

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
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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

Mandatory Saudi Aramco Engineering Requirement Saudi Aramco Materials Systems Specifications 01-SAMSS-016 Qualifications of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking Severe Duty, Totally Enclosed, Squirrel Cage Induction motors to 250 HP Lubrication, Shaft Sealing and Control Oil Systems Manufacture of Clad Vessels and Heat Exchangers

17-SAMSS-503 32-SAMSS-013 32-SAMSS-031

Saudi Aramco Engineering Standards SAES-A-105 SAES-A-112 SAES-A-206 SAES-H-001 SAES-W-010 Noise Control Meteorological and Seismic Design Data Positive Materials Identification Selection Requirements for Industrial Coatings 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 Form NMR-7922-2 Equipment Noise Data Sheet Nonmaterial Requirements for Air-Cooled Heat Exchangers

Industry Codes and Standards American Petroleum Institute API STD 661 API PUBL 941 Air-Cooled Heat Exchangers for General Refinery Services Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum and Petrochemical Plants Avoiding Environmental Cracking in Amine Units
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API RP 945

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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 SEC V ASME SEC VIII D1 ASME SEC VIII D2 ASME B16.5 ASME SA-20 ASME SA-435 Nondestructive Examination Rules for Construction of Pressure Vessels Rules for Construction of Pressure Vessels, Alternative Rules Pipe Flanges and Flanged Fittings Specification for General Requirements for Steel Plates for Pressure Vessels 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 Petroleum and Natural Gas IndustriesMaterials for use in H2S-Containing Environments in Oil and Gas Production

NACE MR0175/ ISO 15156

Tubular Exchanger Manufacturers Association TEMA Standards of the Tubular Exchanger Manufacturers Association

Terms and Definitions 3.11 3.12 3.13 AARH: Average arithmetic roughness height, which is a measure of surface texture. Amine Services: All amine solutions including MEA, DGA and ADIP. 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
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3.14

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

on the data sheet the hydraulic, thermal and mechanical design requirements for exchangers. 3.15 3.16 3.17 Exchanger Manufacturer: The company responsible for the manufacture of exchangers. Exchanger Unit: One or more tube bundles in one or more bays for an individual service. Hydrogen Service: Process streams containing relatively pure hydrogen and component streams containing hydrogen with a partial pressure of 350 kPa (50 psia) or higher. Lethal Services: Process streams containing a concentration of hydrogen sulfide in excess of 20% by volume shall be considered as lethal service. Low Alloy Steels: Steels with nominal chromium content up to 5% chrome 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 exchangers to the requirements of this specification. Thick Wall Exchanger: An exchanger with header plates greater than 50 mm nominal thickness. Critical Installations: Installations where unplanned shutdown of the fin fan could cause substantial loss of production. Non-Critical Installations: Installations which are not defined as critical. Utility Services: Water, air and nitrogen services. Wet Sour Service: Following process streams containing water and hydrogen sulfide:

3.18 3.19 3.20 3.21 3.22 3.23 3.24

3.25 3.26 3.27 3.28 3.29

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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. 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. Sour crude systems upstream of a stabilization facility and sour gas upstream of a sweetening or dehydration plant are examples of such environments.

2.

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 0C (32F) and 150C (302F): 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. 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. 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.

2.

3.

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

4 5

General Proposals 5.12 5.13 The Exchanger Manufacturer may offer an alternative design, but must also quote on the base inquiry documents. 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. The following shall be guaranteed for the length of the warranty period specified in the purchase order or contract documents:
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5.14

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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). Exchangers shall perform the required design heat duty without exceeding design air flow rates and/or maximum allowable pressure drop. Sound levels at all specified operating conditions based on the procedures of SAES-A-105. Vibration limits of the complete assembly in accordance with the requirements specified in this specification.

2)

3) 4)

Documentation 6.1 6.1.4 Approval information (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. (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. Final records (Exception) The Exchanger Manufacturer shall prepare and submit final records in accordance with Form NMR-7922-2, Nonmaterial Requirements.

6.1.5

6.2

Design 7.1 7.1.1 7.1.1.14 Tube Bundle Design General 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. Tube bundle design temperature The MDMT shall be used to determine the requirements for impact testing in accordance with Section 8 of this specification.
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7.1.3 7.1.3.4

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

7.1.4 7.1.4.2

Tube Bundle Design Pressure For exchangers subjected to steam out, the Design Engineer shall specify on the data sheet the external design pressure and corresponding temperature. 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.

7.1.4.3

7.1.6 7.1.6.1 7.1.6.1.1

Headers General (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. 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.

7.1.6.1.10

7.1.6.2 7.1.6.2.3 7.1.8 7.1.8.10 7.1.8.11

Removable cover plate and removable bonnet headers (Exception) Removable cover plate and removable bonnet designs shall be through-bolt designs using stud bolts and nuts on both sides. Gaskets Cover plate and bonnet joints shall be designed with confined or semiconfined gaskets. The manufacturer shall supply the following: 1. Minimum two sets of spare gaskets with blind flanges.

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

3. 7.1.9 7.1.9.4 through 7.1.9.10

All bolting with minimum 10% spare bolting (3 minimum for each size) per exchanger.

Nozzles and other connections (Exceptions) 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. Nozzle flange bore shall match the nozzle neck bore. 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 120C (250F) 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.

3)

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 1 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. Integrally reinforced openings (with no reinforcing pads) shall be provided for all services and design conditions. All nozzles shall be attached to the header by full penetration welds. Ends of butt-welded connections shall be in accordance with ASME B16.25. Maximum allowable moments and forces for nozzles and headers
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7.1.9.24 7.1.9.25 7.1.9.27 7.1.10

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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 Engineer shall also take into account the moments and forces acting on the headers due to piping loads. Tubes (Exception) Unless otherwise approved by the Saudi Aramco Engineer, the maximum tube length shall be 15,000 mm. (Exception) The fin type selection shall be as follows: 1) 2) 3) 4) 5) 6) Fins shall be extruded (integral) type for process inlet temperature of up to and including 300C. Mechanically embedded fins may be used for a process fluid inlet temperature of up to 400C. Welded fins, carbon steel on carbon steel, may be specified for a process fluid inlet temperature of up to 450C. Embedded fins shall be used for cyclic service. Fins, which are bonded to the outside surface of the tubes by hot-dip galvanizing or brazing, shall not be used. Other types of fins shall require approval by the Saudi Aramco Engineer.

7.1.11 7.1.11.2 7.1.11.7

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. Tube sizes and spacing shall be uniform throughout bundles in the same Unit. Air-side design General The Design Engineer shall specify all meteorological data, and location of exchanger with respect to other buildings and equipment on the data sheet. 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.

7.1.11.15 7.2 7.2.1 7.2.1.1 7.2.1.5

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

7.2.1.6 7.2.1.7

Gear- box vents, oil filters, sight glasses and lubrication connections shall be located outside the plenums. 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. Noise Control (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. Fans and Fan Hubs (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. 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. Induced draft fans shall have all mounting and bearing arrangements designed to allow removal and installation of fans and hubs without damaging the bundles. Fan shafts and bearings 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. Thrust bearings shall be mounted so as to allow removal without dismantling shaft or hub and located at the lower end of shafts. 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. Fan Guards (Exception) Removable fan guards shall be provided for both the forced and the induced draft exchangers.
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7.2.2 7.2.2.1

7.2.3 7.2.3.14

7.2.3.18

7.2.3.19

7.2.4 7.2.4.7

7.2.4.8 7.2.4.9

7.2.6 7.2.6.1

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

7.2.7 7.2.7.1 7.2.7.1.3 7.2.7.2 7.2.7.2.10 7.2.8.2 7.2.8.2.1 7.2.8.2.14 7.2.9 7.2.9.1 7.2.10 7.2.10.18 7.2.10.26 7.3 7.3.1 7.3.1.7

Drivers General All drives shall be mounted beneath the tube bundles. Electric motor drivers Electric motors shall be manufactured in accordance with 17-SAMSS-503. Belt Drives (Exception) Belt drives shall be of the synchronous high torque (toothed) type. Belt tensioning adjustment shall be possible without removal of fan guards. Vibration Cut-out Switches (Exception) Shutdown protection device shall be activated by an electric signal from a seismic vibration. Louvers (Exception) Design Engineer shall specify louver position at loss of control-air pressure, and design motive air pressure for louver actuation. All control louvers shall be provided with side mounted hand handles. Structural design General Exchanger Manufacturer shall supply all structural steel including platforms, hand-railing, and ladders, as specified by the Design Engineer in accordance with this specification. 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. For pipe-rack supported exchangers, the supporting of drivers shall be as follows:

7.3.1.9

7.3.1.10

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

For bottom supported drivers, the Exchanger Manufacturer shall supply supporting columns and beams, including motor access platforms, handrailing, 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. Each tube bank shall be provided with a grounding lug connection welded to the support of each unit. 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. Vibration Testing (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. 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. 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. 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. Structural design loads and forces (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 7.3.5.9 Mechanical access facilities Maintenance platforms shall be provided if the bottom elevation of the inlet headers, return headers, or drive equipment is greater than 3000 mm.
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7.3.1.13 7.3.1.15

7.3.2 7.3.2.2

7.3.2.4 7.3.2.5

7.3.2.6 7.3.3 7.3.3.1

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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. 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. 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. Stairways shall be 915 mm wide minimum. Lifting devices 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. 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.).

7.3.5.11

7.3.5.12

7.3.5.13 7.3.6 7.3.6.7

7.3.6.8

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) Cast iron pressure parts shall not be used for any service. (Exception) Structural supports shall be coated in accordance with SAES-H-001. The Exchanger Manufacturer may propose alternative materials at the time of proposal, but the alternative materials must comply with all the
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8.1.2 8.1.3 through 8.1.5 8.1.7

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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. All materials, except carbon steels, shall be alloy verified by the Exchanger Manufacturer in accordance with SAES-A-206. 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, 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. Use of C-1/2 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. Resistant Materials For exchangers designated for wet sour HIC (hydrogen induced cracking) services as defined in this specification with normal operating design temperatures between 0C (32F) and 150C (212F), all plates for headers shall be made of HIC resistant steel qualified in accordance with 01-SAMSS-016. Headers Other components (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 107C with fans switched-off.

8.1.9 8.1.10

8.1.11 8.1.12

8.1.13 8.1.13.1

8.2 8.4 8.4.2

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

8.4.7 8.4.8

Steel used for slide plates shall be type 316 stainless steel. Carbon steel slide plates shall not be used. The materials of construction for spiral wound gaskets shall be as follows: 1) For exchangers with design metal temperatures from -100C to 0C: 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 1C to 425C: 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 8.5.1

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. 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), UCS66 (b)(1) and (3), UCS-68(c), UG-84 (b)(2) and by reference to Table UG84.4 are not permitted. For Div. 2 exchangers the exemptions of AM213.1 and AM-218.2 are not permitted.

8.5.2 8.5.3

8.5.4

Fabrication of the Tube Bundle 9.1 Welding

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

9.1.1 9.1.1.1 through 9.1.1.4 9.1.1.5 9.1.1.6

General (Exception) All welding shall be in accordance with the requirements of SAES-W-010. Corner weld joints in box headers shall be in accordance with ASME SEC VIII D1. 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. Plate edge laminations revealed by magnetic particle testing shall be completely removed and repaired per SAES-W-010. Set-in nozzles shall be ground flush to the inside of the headers with a smooth inner edge radius. Vent holes shall be provided in external non-pressure welded attachments. All external non-pressure welded attachments shall have their corners rounded to a minimum radius of 20 mm and shall be fully seal welded. Postweld heat treatment 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. 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 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"

9.1.1.7 9.1.1.8 9.1.1.9 9.1.1.10 9.2 9.2.5

9.2.6

9.2.7 9.2.8

9.2.9

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


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9.3 9.3.1.2

Tube-to-tubesheet joints (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. 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. Gasket contact surfaces (Exception) Nozzle gasket seating surfaces shall comply with the following: 1) 2) 3) 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 sidewalls of rings joint flanges, in all services, 63 AARH.

9.3.4.4

9.4 9.4.4

9.5 9.8

Thread lubrication 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 Monel, brass and all chrome alloy tubes in all services

2)

The following tubes shall be solution annealed: 1) 2) Entire tubes manufactured of unstabilized stainless steels or non low carbon 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 stainless steels and low carbon stainless steels or Nickel base alloys.

9.9 9.9.1

Hot Forming 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.
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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 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 10.1.3 General (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. 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. 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. 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 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. Surface irregularities, including weld reinforcement, preventing accurate interpretation of the specified method of NDE 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
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10.1.5

10.1.6

10.1.7

10.1.8 10.1.9 10.1.10

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

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. 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. 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. 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. 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 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. 100% radiography is required for category C joint for nozzle connections in exchangers for the following services and design conditions: 1) Lethal services
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10.1.12

10.1.13

10.1.14

10.1.15

10.1.16

10.2 10.2.1 10.2.1.1

10.2.1.2

10.2.1.3

Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

32-SAMSS-011 Manufacture of Air-Cooled Heat Exchangers

2) 3) 4) 5)

Hydrogen services Cyclic services Weld joints where any of the pressure retaining materials requires impact testing per the applicable Code or this specification. 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) 2) The corner weld shall be 100% ultrasonically tested after the installation of the nozzle. Magnetic particle examination shall be performed on the root pass and final pass of the weld joint attaching the nozzle.

10.2.1.5 10.2.8 10.2.13

Plates for exchangers in hydrogen and wet sour services shall be ultrasonically tested in accordance with ASME SA-435. (Exception) Weld hardness testing shall be in accordance with the requirements of SAES-W-010. Radiographic film interpretation shall be done by personnel certified in accordance with ASNT CP-189 to ASNT Level II Film Interpreter or approved equivalent. Ultrasonic testing may be substituted for radiography if approved by the Saudi Aramco Inspector, unless radiography is required by the Code. 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. For ferro-magnetic materials, wet fluorescent magnetic particle testing, using an AC yoke is required for all accessible welds as follows: 1) 2) All internal welds, including temporary internal welds for exchangers in wet sour, caustic, amine, hydrogen and hydrocarbon services 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

10.2.14 10.2.15

10.2.16

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10.2.17 10.3 10.3.3

Final acceptance of the exchanger shall be based on completion of all required NDE after the final postweld heat treatment. Pressure test (Exception) Fluids used for pressure testing shall be as follows: 1) 2) 3) Clean potable water, treated for control of bacteria and corrosion For exchangers with stainless steel, monel or non-ferrous tubes, the water shall not contain more than 50 ppm chlorides. 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. Use of shellacs, glues, lead, etc., on gaskets during testing is prohibited. After testing, exchangers shall be completely drained and thoroughly dried with dry air. 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.

10.3.8 10.3.9 10.3.10

10.3.11 10.5 10.5.1 10.5.4 10.5.5

Temperature of water during hydrostatic testing shall be maintained at not less than 17C throughout the testing cycle. Nameplates The name plate should indicate the test pressure. All exchangers shall be Code stamped. Nameplates and nameplate mounting brackets shall be located such that they are easily readable from a platform. Brackets with continuous
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welding shall extend from the outside of exchanger with sufficient access for surface preparation, and painting. 10.5.6 10.5.7 Nameplates shall be 3 mm minimum thickness and welded or riveted to the mounting bracket. The empty and water flooded weights of bundles shall be marked on the nameplates.

11

Preparation for Shipment 11.2 11.2.1 through 11.2.4 11.2.5 11.2.6 11.3 11.3.1 Surfaces and Finishes Coating systems to be used shall be in accordance with SAES-H-001.

Prior to coating, the internal and external surfaces shall be cleaned to remove all scale, rust, grease dirt, weld spatter and foreign objects. Gasket contact surfaces shall not be painted. Identification, Conditioning and notification (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. 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/m 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.

11.4

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
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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

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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. Exchangers shall be protected from salt water and salt water spray during shipment.

11.7

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 12.3.14 Examination 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.

22 January 2008 5 April 2008 15 August 2009

Revision Summary Major revision. Editorial revision. Editorial revision to replace cancelled SAES-A-301 with NACE MR0175/ISO 15156.

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

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Table 1 Acceptable Materials for Carbon and Low Alloy Steels


Design Metal Temperature Exchanger Component Header plates, pass partition plates and stiffener plates Nozzle necks Tubes (2) Forged flanges, forged fittings, and plugs Wrought fittings Studs/nuts for pressure connections -46 to 0C SA-516 Grade 60N SA-516 Grade 70N, or SA-537 Class 1 SA-333 Grade 6 SA-334 or SA-249 Type 304 SA-350 LF2 SA-420 WPL6 SA-320 L7 w/ SA-194 Grade 4 1 to 425C SA-516 Grade 60 SA-516 Grade 70, or SA-537 Class 1 or SA-285 Grade C (1) SA-106 Grade B SA-53 Grade B (1) SA-179 or SA-214 SA-105 SA-234 WPB SA-193B7/ SA-194 Grade 2H 351 to 645C SA-387 Grades 11, 12, or 22 SA-335 P11, 12, or 22 SA-179 or SA-214 or SA-213 Type 304 SA-182 F11, 12, or 22 SA-234 WP 11, 12, or 22 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 30C 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 212F (100C), 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.

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Document Responsibility: Heat Transfer Equipment Issue Date: 15 August 2009 Next Planned Update: 22 January 2013

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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 t < 1/2 34/27 34/27 34/27 34/27 34/27 34/27 1/2 < 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

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 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 Gr. 1 Gr. 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. WPL3 and WPL6 Gr. WPB Gr. WP11, WP12 and WP22

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