32 SAMSS 011 - 02 18 2018 - Final PDF

Materials System Specification
32-SAMSS-011 18 February 2018

Manufacture of Air-Cooled Heat Exchangers
Document Responsibility: Heat Transfer Equipment Standards Committee
Contents
1 Scope ................................................................ 2
2 Normative References ...................................... 3
3 Terms and Definitions ....................................... 6
4 General ............................................................. 8
5 Proposals .......................................................... 9
6 Documentation ................................................ 10
7 Design ............................................................. 11
8 Materials ......................................................... 24
9 Fabrication of Tube Bundle ............................. 32
10 Inspection, Examination, and Testing ............. 39
11 Preparation for Shipment ................................ 48
12 Supplemental Requirements ........................... 51
Revision Summary .................................................. 51
Table 1 – Nondestructive Examination

Requirements ........................................ 52
Table 2 – Welds Encroachment Requirements ....... 53
Previous Issue: 30 June 2014 Next Planned Update: 2 July 2020

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Contact: Al-Otaibi, Dhawi A. (otiabida) on phone +966-13-8804877
©Saudi Aramco 2017. All rights reserved.

Document Responsibility: Heat Transfer Equipment Standards Committee 32-SAMSS-011
Issue Date: 18 February 2018
Next Planned Update: 2 July 2020 Manufacture of Air-Cooled Heat Exchangers
The following paragraph numbers refer to API STD 661, 7th Edition, July 2013, 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
1.1 This specification covers the minimum mandatory requirements for the
manufacture of air-cooled heat exchangers (hereinafter referred to as
exchangers) and new components.
1.2 This specification does not cover the followings:

a) In-service exchangers.
b) Exchangers used as part of heating, ventilation, and air conditioning
(HVAC) systems.
c) Skid mounted exchangers.
1.3 Exchangers that do not meet either partially or completely the requirements
of API STD 661 standards shall be evaluated for acceptance by Saudi
Aramco Engineer based on the following:
a) Full design details, specifying changes from API requirements.
b) LSTK and process licensors shall guarantee the thermal performance
and mechanical integrity, supported by detailed calculations.
1.4 Low alloy steels used for exchanger intended for services within the scope of
API RP 934-A, API RP 934-C or API RP 934-E, shall meet all requirements
of the respective document of the aforementioned documents and this
specification.
1.5 1 Cr- ½ Mo and 1 ¼ Cr- ½ Mo steels used for exchangers that are not in
hydrogen service with design temperature below 441°C (825°F), shall meet
all requirements of API RP 934-C and this specification.
1.6 Where a requirement of a licensor’s or a relevant industry standard/

specification is more stringent than that of this specification, the most
stringent requirement will govern.
1.7 Use of fitness-for-service assessment methodology to qualify exchangers

component(s) that do not satisfy any of the requirements of this specification
is prohibited.
Saudi Aramco: Company General Use

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1.8 Conflicting Requirements
1.8.1 Any conflicts between this specification and other Saudi Aramco Materials
System Specifications (SAMSSs), Industry codes and standards, and Forms
shall be resolved in writing by the Company or Buyer Representative
through the Saudi Aramco Engineer, Consulting Services Department of
Saudi Aramco, Dhahran.
1.8.2 Direct all requests to deviate from this specification in writing to the
Company or Buyer Representative, who shall follow internal company
procedure SAEP-302 and forward such requests to the Manager, Consulting
Services Department of Saudi Aramco, Dhahran.
2 Normative References
Unless otherwise noted in this specification, materials or equipment supplied to this

specification shall comply with the applicable edition of the references listed below.
The applicable edition of each reference is that in effect on the Project Proposal
approval date for Mandatory Saudi Aramco Engineering Requirements (MSAERs) and
the purchase order date for industry standards.
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 Materials Systems Specifications

01-SAMSS-016 Qualifications of Storage Tanks and Pressured
Equipment for Resistance to Hydrogen-Induced
Cracking
01-SAMSS-043 Carbon Steel Pipes for On-Plot Piping
01-SAMSS-046 Stainless Steel Pipe
02-SAMSS-005 Butt Welding Pipe Fittings
02-SAMSS-011 Forged Steel and Alloy Flanges
17-SAMSS-503 Severe Duty, Totally Enclosed, Squirrel Cage
Induction motors to 250 HP
32-SAMSS-013 Lubrication, Shaft Sealing, and Control Oil Systems
32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

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Saudi Aramco Engineering Standards

SAES-A-007 Hydrostatic Testing Fluids
SAES-A-105 Noise Control
SAES-A-112 Meteorological and Seismic Design Data
SAES-A-206 Positive Materials Identification
SAES-B-006 Fireproofing for Plants
SAES-E-101 Regulated Vendors List for Heat Transfer
Equipment
SAES-H-001 Selection Requirements for Industrial Coatings
SAES-L-133 Corrosion Protection Requirements for Pipelines,
Piping, and Process Equipment
SAES-M-001 Structural Design Criteria for Non-Building
Structures
SAES-P-111 Grounding
SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-014 Weld Overlays and Welding of Clad Materials
SAES-W-016 Welding of Special Corrosion-Resistant Materials
Saudi Aramco Inspection Requirements

Form 175-323600 Manufacture of Air-Cooled Heat Exchangers
Saudi Aramco Forms and Data Sheets

Form SA-7305 Equipment Noise Data Sheet
Form SA-2716 Air-Cooled Heat Exchanger Data Sheet (herein
referred to as data sheet)
Form SA-7922-2 Nonmaterial Requirements for Air-Cooled Heat
Exchangers
2.2 Industry Codes and Standards
American Petroleum Institute

API STD 661 Air-Cooled Heat Exchangers for General Refinery
Services
API RP 520 Part I - Sizing, Selection, and Installation of
Pressure Relieving Devices in Refineries

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API RP 934-A Materials and Fabrication of 2 ¼Cr-1Mo, 2 ¼Cr-

1Mo-¼V, 3Cr-1Mo, and 3Cr-1Mo- ¼V Steel
Heavy Wall Pressure Vessels for High-
temperature, High-pressure Hydrogen Service
API RP 934-C Materials and Fabrication of 1 ¼ Cr-½ Mo Steel
Heavy Wall Pressure Vessels for High-pressure
Hydrogen Service Operating at or Below 825°F
(441°C)
API RP 934-E Recommended Practice for Materials and
Fabrication of 1 ¼ Cr-½ Mo Steel Pressure
Vessels for Service above 825°F (441°C)
API RP 941 Steels for Hydrogen Service at Elevated
Temperatures and Pressures in Petroleum and
Petrochemical Plants
API RP 945 Avoiding Environmental Cracking in Amine Units
American Society of Civil Engineers

ASCE 7- 2005 Ed. Minimum Design Loads for Buildings and Other
Structures
American Society of Mechanical Engineers (Boiler and Pressure Vessel Codes)

ASME SEC II Materials
ASME SEC V Nondestructive Examination
ASME SEC VIII D1 Rules for Construction of Pressure Vessels
ASME SEC VIII D2 Rules for Construction of Pressure Vessels,
Alternative Rules
ASME B2.1 National Pipe Threads
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.11 Forged Fittings, Socket-Welding and Threaded
ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring-Joint,
Spiral-Wound, and Jacketed
ASME B16.21 Non-Metallic Gaskets for Pipe Flanges
ASME B16.25 Buttwelding Ends
ASME B16.47 Large Diameter Steel Flanges NPS 26 through
NPS 60
ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange
Joint Assembly
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American Society for Non-destructive Testing

ASNT CP-189 Standard for Qualification and Certification of
Nondestructive Testing Personnel
American Society for Testing and Materials

ASTM A380 Practice of Cleaning, Discleaning, and Passivation
of Stainless Steel Part Equipment and System
ASTM E381 Standard Method of Macrotech Testing Steel Bars,
Billets, Blooms, and Forgings
International Standards Organization

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-
Materials for use in H2S-Containing
Environments in Oil and Gas Production
National Association of Corrosion Engineers
NACE SP0472 Methods and Control to Prevent In-Service
Environmental Cracking of Carbon Steel
Weldments in Corrosive Petroleum Refining
Environments
Process Industry Practices

PIP VEFV1100 Vessel/S&T Heat Exchanger Standard Details
Tubular Exchanger Manufacturers Association (TEMA)
Welding Research Council

WRC 297 Local Stresses in Cylindrical Shells Due to External
Loadings on Nozzles
WRC 537 Local Stresses in Spherical and Cylindrical Shells
Due to External Loadings
3 Terms and Definitions
3.5 (Exception) Cyclic Service: Services that require fatigue analysis

according to screening criteria per 5.5.2 of ASME SEC VIII D2.
This applies to Division 1 and Division 2 of ASME SEC VIII.
3.11 (Exception) Hydrogen Service: Process streams containing hydrogen with

an absolute partial pressure of 350 kPa (50 psia) and higher.

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3.19 (Exception) MDMT: Minimum design metal temperature, determined by

the Design Engineer.
3.21 (Exception) Pressure Design Code: ASME SEC VIII.
3.34 AARH: Average arithmetic roughness height, which is a measure of surface

texture.
3.35 Amine Services: All amine solutions including MEA, DGA and ADIP.
3.36 Critical Installations: Installations where unplanned shutdown of the fin

fan could cause substantial loss of production.
3.37 Design Engineer: The Engineering Company responsible for specifying on

the data sheet the hydraulic, thermal and mechanical design requirements for
exchangers.
3.38 Exchanger Manufacturer: Company responsible for the manufacture of

exchangers.
3.39 Exchanger Unit: One or more tube bundles in one or more bays for an
individual service.
3.40 High - Alloy Steels: Steels with a total alloying content more than 5%.
3.41 Hydrogen Induced Cracking (HIC) Environment: Process streams that

introduce HIC according to SAES-L-133.
3.42 Lethal Service: 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 project design may also be designated as
lethal services.
3.43 Low - Alloy Steels: Steels with a total alloying content of less than 5% but
more than specified for carbon steels.
3.44 Minimum Thickness: Thickness required for withstanding all primary

loads, excluding allowance for corrosion.
3.45 Nominal Thickness: Thickness selected as commercially available, and

supplied to the Manufacturer. For plate material, the nominal thickness is
the measured thickness of the plate at the joint or location under
consideration after forming.
3.46 Saudi Aramco Buyer: The person or company authorized by Saudi

Aramco to procure heat exchanger to the requirements of this specification.

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3.47 Saudi Aramco Engineer: The Chairman of the Heat Transfer Equipment
Standards Committee.
3.48 Saudi Aramco Inspector: The person or company authorized by the Saudi
Aramco Inspection Department to inspect exchangers to the requirements of
this specification.
3.49 Sulfide Stress Cracking (SSC) Environment: Process streams that

introduce SSC according to SAES-L-133.
3.50 Thick Wall Exchanger: An exchanger with header plates greater than
50 mm nominal thickness.
3.51 Non-Critical Installations: Installations which are not defined as critical.
3.52 Utility Services: Water, air, and nitrogen services.
4 General
4.1 All exchangers shall be designed in accordance with the rules of the
Boiler and Pressure Vessel Codes, ASME SEC VIII D1 or ASME SEC
VIII D2 (hereinafter referred to as the Codes), and the requirements of
this specification.
4.4 (Exception) The Exchanger Manufacturer shall comply with applicable

local, state, and national codes, and insurance requirements.
4.8 Exchangers shall be designed to minimize field assembly.
4.9 Individual exchanger within a group of exchangers shall be designed for

maximum practical inter-changeability of components.
4.10 Stress analyses according to the Code rules shall be executed by the
manufacturer. A third party under full control and responsibility of the
manufacturer may execute only finite element analysis.
4.11 Proof testing is prohibited.
4.12 No credit shall be given to thickness of integrally-bonded or weld metal

overlay cladding in calculating material thickness, required to sustain all
primary loads.
4.13 Application of ASME Code Cases to the manufacture of exchangers

requires approval of the Saudi Aramco Engineer.

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4.14 The Exchanger Manufacturer is responsible for the thermal/hydraulic

design (rating) and verification of the Design Engineer's thermal /
hydraulic design, if applicable.
4.15 The Exchanger Manufacturer is responsible for the manufacture of

exchanger, which includes 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 datasheet and the requirements of this specification.
4.16 All welded joints of category A, B, C, and D shall be complete fusion

full penetration welds, except for joint welds of slip-on flanges specified
per paragraph 7.1.9.23 of this specification.
4.17 The Exchanger Manufacturer shall neither prepare nor certify a User’s
Design Specification.
4.18 Clad exchangers shall conform to 32-SAMSS-031 in addition to the

requirements of this specification.
4.19 ASME SEC VIII D2 shall be specified when economically justified.
5 Proposals
5.11 The proposal shall include a detailed description of any exception to the
5.12 The Exchanger Manufacturer may offer an alternative design, but must
also quote on the base inquiry documents.
5.13 The number of copies of drawings, datasheets, specifications, data reports,

operating manuals, installation instructions, and spare part lists shall be in
accordance with Form SA-7922-2, Nonmaterial Requirements.
5.14 The following shall be guaranteed for the length of the warranty period
specified in the purchase order or contract documents:
1) Exchangers shall meet thermal/hydraulic performance requirements
under continuous operation at design conditions specified on the
datasheets. Thermal, hydraulic, and mechanical guarantee shall be
in accordance with TEMA SEC 3, (paragraph G 5).
2) Exchangers shall perform the required design heat duty without
exceeding design air flow rates and/or maximum allowable
pressure drop.
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3) Sound levels at all specified operating conditions based on the

procedures of SAES-A-105.
4) Vibration limits of the complete assembly in accordance with the
requirements specified in this specification.
5.15 The Exchanger Manufacturer shall consider both normal and “fans off”
operating modes when assessing temperature exposure of materials and
parts.
5.16 Proposal shall identify all louver materials, louver manufacturers, louver
blade type (parallel or opposed) and confirm suitability of louver
materials at applicable design temperatures.
5.17 For strength welded tube-to-tubesheet joints, the proposed method of

fabrication, including complete sequential joint preparation, overlay
(when required), cleaning, assembly, welding, tube expansion, testing
and other inspection procedures, together with a representative mock-up
sample of the tube-to-tubesheet weld shall be submitted for review prior
to the start of fabrication.
6 Documentation
6.1 Approval Information
6.1.4 (Exception) The Exchanger Manufacturer shall prepare and submit for
approval all proposed welding maps, welding procedures, and welding
procedure qualifications including tube-to-tubesheet welding procedures
and qualifications (including impact test results, if applicable) prior to
start of fabrication.
6.1.6 (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 SA-7922-2, Nonmaterial Requirements.
6.2 Final Records
(Exception) The Exchanger Manufacturer shall prepare drawings,

calculations and data in accordance with SA-7922-2, Nonmaterial
Requirements, in addition to API STD 661 requirements. Calculations
shall include, but not limited to:
a. ASME Code Section VIII calculations.
b. Wind and earthquake calculations, as applicable.

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c. Support calculations.
d. Calculations associated with lifting and erecting the exchanger.
e. Nozzle load analysis for local and gross effect, when required.
f. Design of internal and external attachments.
g. Design loads and load combinations.
h. Thermal calculations and heat released curves.
i. Air approach velocity calculations.
k. Fan performance characteristic curves with the design point
marked on the curve, including fan critical speeds for use with
variable-frequency drives.
6.3 The Exchanger Manufacturer shall submit vibration analysis.
6.4 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.
6.5 The Exchanger Manufacturer shall prepare drawings, which indicate the
ultrasonic readings thickness of the exchanger headers and nozzles.
An adequate number of readings shall be taken to represent the actual
thickness of the components.
6.6 All approved datasheets, drawings and forms are to be submitted to

EK&RD/Drawing Management Unit (DMU) for inclusion into
Corporate Drawings Management System.
7 Design
7.1 Tube Bundle Design
7.1.1 General
7.1.1.11 Design requirements for steam-out conditions shall be as specified on the

data sheet.
7.1.1.13 Each tube bundle shall have one header free to move with thermal
expansion of the tubes and shall have sliding plates at the moving end
both on structure and on bundle.
7.1.3 Design Temperature
7.1.3.1 The value of design temperature(s) shall be as specified on the data sheet.

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7.1.3.2 The value of fin design temperature shall be as specified on the data sheet.
7.1.3.3 The value of the minimum design metal temperature (MDMT) shall be
as specified on the data sheet.
7.1.3.4 The MDMT shall be used to determine the requirements for impact
testing in accordance with the Code and this specification.
7.1.4 Design Pressure
7.1.4.1 The value of design pressure shall be as specified on the data sheet.
7.1.4.2 The Exchanger Manufacturer shall calculate the maximum allowable

working pressure (MAWP) acting in the hot and corroded condition in
accordance with the Code.
7.1.4.3 The MAWP of an exchanger shall not be limited by components such as

flanges, fittings, reinforcing pads, etc.
7.1.6 Headers
7.1.6.1 General
7.1.6.1.1 (Exception) The Exchanger Manufacturer shall investigate all

temperature conditions, temperature differentials, temperature shocks,
start-up, shutdown, and cyclic conditions as specified on the data sheet to
determine that the design of headers is adequate.
7.1.6.1.9 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 review by the Saudi
Aramco Engineer.
7.1.6.1.10 Headers handling two phase mixtures shall be designed for good flow
distribution over tubes and passes.
7.1.6.1.11 Effect of phase separation in condenser turnaround headers shall be

considered to ensure that it does not negatively affect heat exchanger
performance.
7.1.6.2 Removable Cover Plate and Removable Bonnet Headers
7.1.6.2.3 (Exception) Removable cover plate and removable bonnet designs shall
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be through-bolt designs using stud bolts and nuts on both sides.
7.1.6.2.12 Cover plate headers shall not be used in hydrogen, sour or lethal service.
7.1.6.2.13 Design pressure of cover plate headers shall not exceed 2,100 kPa gauge
(300 psig).
7.1.8 Gaskets
7.1.8.10 Cover plate and bonnet joints shall be designed with confined or semi-
confined gaskets.
7.1.8.11 The manufacturer shall supply the following:

1. Minimum two sets of spare gaskets with blind flanges.
2. All bolting with minimum 10% spare bolting (3 minimum for each
size) per exchanger.
7.1.8.12 The materials of construction for spiral wound gaskets shall be as

follows with flexible filler suitable for the intended service:
Service Winding Filler Guiding Ring(s)

Design Temperature Type 304 or 316 Solid outer; Type
Graphite
from -100°C to 0°C Stainless Steel (SS) 304 or 316 (SS)
Design Temperature Solid outer; Carbon
Type 304 or 316 SS Graphite
above 0°C to 425°C Steel (CS)
Solid inner and
Design Temperature
Type 321 or 347 SS Vermiculite outer; Type 304
above 425°C
or 316 SS
Per Temperature Per Temperature Solid inner; Type
Vacuum
Range Range 304 or 316 SS
7.1.9 Nozzles and other Connections
7.1.9.1 (Exception) Flanges shall be in accordance with ASME B16.5 pressure

rating.
7.1.9.8 (Exception) Flanged connections shall be one of the following types:

a) Forged steel long welding neck flange.
b) Forged steel welding neck flange. Such type of flange is welded to
seamless pipe, rolled plate with 100% radiography or an integrally
reinforced contour shaped forged nozzle. The bore of flange shall
match the bore of nozzle.

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c) Proprietary designs may be offered as alternatives provided their

design is in accordance with the applicable Code and approved by
the Saudi Aramco Engineer.
7.1.9.11 (Exception) 1½ NPS and smaller drains, vents and instrument connections
can be used and shall be attached to a blind flange on a flanged nozzle in
other than the following design conditions and services:
a) Lethal service
b) Hydrogen service
c) Caustic service
d) Cyclic service
e) Pressure-retaining parts thicker than 50 mm
Attachment welds of such connections to the blind flange shall be treated

as Category-D weld joint. Accordingly, attachment details and NDE
requirements shall be similar to those required for the exchanger per this
specification.
7.1.9.22 The ends of butt-welded connections shall be in accordance with

ASME B16.25.
7.1.9.23 Slip-on type flange with seamless pipe nozzle necks or rolled plate with
100% radiography is permissible for exchangers, in only non-cyclic air
and water services with design temperature and design pressure not
exceeding 400°C (750°F) and 2.1 MPA (300 psi), respectively. Slip-on
flange shall be welded on the front or face and at the back of the hub per
ASME SEC VIII D1, Figure UW-21, detail (1), (2) or (3).
7.1.9.24 Unless otherwise specified on the data sheet, the minimum projections
for nozzle necks, as measured from the outside surface of the header to
the face of a flange, shall meet the following requirements:
a) 6 in. for NPS 6 nozzles and smaller.
b) 8 in. for NPS 8 nozzles and larger.
c) For insulated exchangers, projection shall be sufficient to allow
bolting of studs without interference with the insulation.
d) For exchangers drain connections and other connections, where a
process stream is likely to be stagnant, the projection shall not
exceed three times the connection nominal diameter.

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7.1.9.25 The quantities, sizes, ratings, (ASME pressure classes), facings,

elevations, and orientations of nozzles shall be as specified on the data
sheet.
7.1.9.26 Flange bolt holes shall straddle the normal horizontal and vertical
centerlines of the exchanger.
7.1.9.27 Threaded connections shall conform to ASME B2.1.
7.1.9.28 Outlet nozzles for total condensers shall be sized for free draining such
that flooding does not occur in the bottom tube rows.
7.1.9.29 Nozzles shall be flush with the inside of the header box. Nozzles shall
be designed to avoid impingement on tube ends, flow restriction, and
uneven flow distribution.
7.1.9.30 Nozzles less than 2-inch NPS are not permissible.
7.1.9.31 Only flanged nozzles shall be used.
7.1.9.32 Exchangers in services other than air and water shall be provided with a
minimum 2-inch NPS flanged steam-out connection.
7.1.9.33 Flange Ratings (ASME Pressure Classes) and Facings
7.1.9.33.1 The ASME pressure classes and facings shall be as specified on the data
sheet.
7.1.9.33.2 Bolted joints specified with non-ASME flanges shall be designed to meet
all anticipated loading conditions of the exchanger.
7.1.9.33.3 Pressure ratings for standard flanges shall be in accordance with the
following:
a) ASME B16.5 for flanges NPS 24 and smaller.
b) ASME B16.47, Series A for flanges larger than NPS 24.
7.1.9.34 Attachment Details for Headers, Nozzles, and their Connections
7.1.9.34.1 All headers and nozzles necks shall be attached by welding completely
through the total thickness.
7.1.9.34.2 Permissible types of headers, nozzles and their connections shall be

according to the table below.

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Figure Reference from Indicated

ASME Code Section VIII
Design Conditions / Services Group Attachment
Division 1 Division 2
Exchangers Exchangers
Group I
Figure UW-13.3, Table 4.2.7, details:
 Headers
a. Pressure-retaining exchanger’s component details: (a) or (b) (1) or (2)
with design thickness greater than 50 mm.
 All nozzle sizes

b. Lethal, hydrogen and cyclic services. Figure UW-16.1, Table 4.2.10, details:
 Connections
details: (c) (3)
attached to
c. Low alloy steel exchangers with design nozzles
thickness greater than 25 mm.
Figure UW-13.2, Table 4.2.6, details:
 Headers
details: (a), (b) or (c) (1) or (2)
Group II
 All nozzle sizes
Design conditions and service other than Figure UW-16.1, Table 4.2.10, details:
those in Group I of this table.  Connections details: (a) or (c) (1) or (3)
attached to
nozzles
7.1.9.35 All nozzles shall be attached to the header by full penetration welds.
7.1.10 Maximum Allowable Moments and Forces for Nozzles and Headers
7.1.10.5 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.
7.1.11 Tubes
7.1.11.2 (Exception) The maximum tube length shall be 15,000 mm.
7.1.11.7 (Exception) The finned tubes shall be either extruded or embedded type
per API STD 661 A.3.3 guidelines. Embedded fins shall be used for
cyclic services.
7.1.11.13 (Exception) Elliptical tubes could be used only with the A-Frame
condensers as alternative to the cylindrical type. The proposal shall be
reviewed by the Saudi Aramco Engineer.
7.1.11.14 Design and selection of fins shall be such that fins will not suffer any
distortion when subjected to the design requirements with fans out of
service.

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7.1.11.15 Tube sizes and spacing shall be uniform throughout bundles in the same
unit. Using different tube sizes in the same unit for condensers type
require approval by the Saudi Aramco Engineer.
7.2 Air-side Design
7.2.1 General
7.2.1.1 The Design Engineer shall specify all meteorological data, and location
of exchanger with respect to other buildings and equipment on the data
sheet.
7.2.1.8 The Design Engineer shall estimate the design exposure temperatures for
mechanical components using conventional heat transfer analyses and
shall submit the estimate to the Saudi Aramco Engineer for review.
7.2.1.9 Hot-air re-circulation units shall be designed so that the motors and the
drivers are not exposed to heated re-circulated air temperature higher
than their design temperature.
7.2.1.10 Gear- box vents, oil filters, sight glasses, and lubrication connections
shall be located outside the plenums.
7.2.1.11 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.
7.2.1.12 Air cooled heat exchanger components that may be exposed to high
temperatures shall be capable of withstanding the following maximum
inlet temperatures with fans out of service over prolonged period of time
(at least 48 hours).
a. Maximum process inlet temperature shown on individual item data
sheet less 28°C (50°F) (power failure).
b. Steamout service with fans not running.
7.2.1.13 Air seals shall be provided between bays to minimize air recirculation.
7.2.1.14 Fan blades shall be made from an Ultraviolet resistant material.
7.2.2 Noise Control
7.2.2.4 (Exception) Design Engineer shall specify limits for the sound pressure
levels (SPL) per fan at the designated locations, on Form SA-7305.
The Exchanger Manufacturer shall complete Form SA-7305 and ensure

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

supplying test results of a representative bay.
7.2.2.5 Sound pressure level shall be limited to 85 dBA maximum at 1 m (3 ft)

below the bundle.
7.2.3 Fans and Fan Hubs
7.2.3.14 (Exception) To avoid damage to fan blades due to vibration, the blade
pass frequency shall not fall within 80 to 120% of the fan blade assembly
fundamental operating natural frequency.
7.2.3.17 Actuators for auto-variable pitch fans must be provided with maximum
pitch stops. The maximum design blade setting shall be marked on the
hub nameplate.
7.2.3.18 Induced draft fans shall have all mounting and bearing arrangements
designed to allow removal and installation of fans and hubs without
damaging the bundles.
7.2.3.19 Fan hub seal disc shall be provided to prevent reverse airflow.
7.2.4 Fan Shafts and Bearings
7.2.4.7 Exchangers with enclosed plenums with hot air re-circulation shall be
equipped with fan shaft bearing vibration transducers to permit
monitoring of bearings from outside the enclosure.
7.2.4.8 Thrust bearings shall be mounted so as to allow removal without

dismantling shaft or fan hub and located at the lower end of shafts.
7.2.4.9 Bearings shall be of a re-greasable type. Grease supply tubing shall be

installed and brought to an accessible location. Bearing housing shall be
dust and drip proof.
7.2.6 Fan Guards
7.2.6.1 (Exception) Removable fan guards shall be provided for both the forced
and the induced draft exchangers.
7.2.7 Drivers
7.2.7.1 General
7.2.7.1.3 All drives shall be mounted beneath the tube bundles, except for
situations where the moisture content of the inlet air is artificially
increased for performance improvement purposes.
Page 18 of 53
7.2.7.2 Electric Motor Drivers
7.2.7.2.9 A self-actuating braking device shall be installed to prevent reverse

rotation of an idle fan.
7.2.7.2.10 Electric motors shall be manufactured in accordance with 17-SAMSS-503.
7.2.7.2.11 Motors shall be designed for variable frequency drive (VFD) application.
7.2.8.2 Belt Drives
7.2.8.2.1 (Exception) Belt drives shall be of the synchronous high torque (toothed)
type.
7.2.8.2.14 Belt tensioning adjustment shall be possible without removal of fan

guards.
7.2.9 Vibration Cut-out Switches
7.2.9.1 (Exception) Vibration switches shall be provided for each fan and
shutdown protection device shall be activated by an electric signal from
a seismic vibration.
7.2.10 Louvers
7.2.10.19 (Exception) Design Engineer shall specify louver position at loss of

control-air pressure, and design motive air pressure for louver actuation.
Unless specified otherwise, louvers shall fully open upon loss of control
air.
7.2.10.26 All control louvers shall be provided with side mounted hand handles.
7.3 Structural Design
7.3.1 General
7.3.1.7 The Exchanger Manufacturer shall supply all required structural steel
including platforms, walkways, hand-railing, and ladders, as specified by
the Design Engineer in accordance with this specification.
7.3.1.8 For grade mounted units, the minimum headroom clearance shall not be
less than 2.13 m (7 ft) measured from the fan guard or tube bundle and
grade.
7.3.1.9 For pipe-rack mounted units, the supporting of drivers shall be as follows:
a. For units with bottom mounted drivers, minimum vertical clear

Page 19 of 53
distance of 2.13 m (7 ft) shall be maintained between bottom of fan

guard or tube bundle and walking platforms.
b. The Exchanger Manufacturer shall supply supporting columns and
beams including motor access platforms, hand-railing, and ladders.
7.3.1.10 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. Fire proofing shall be
in accordance with SAES-B-006.
7.3.1.11 Each bay shall be provided with a grounding lug connection welded to
the support column.
7.3.1.12 Natural frequencies of structural members shall not be within 10% of the
fundamental excitation frequencies resulting from the fan speed and
motor speed. This applies to both shop-tested and field-tested structure.
7.3.2 Vibration Testing
7.3.2.2 (Exception) The Exchanger Manufacturer shall verify compliance with

the structural vibration requirements of this specification by shop testing
and during commissioning. On multi-bay identical exchanger units, a
minimum of one bay shall be shop tested.
7.3.2.4 Vibration in any axis on all bearings shall be less than 4 mm/sec RMS,
and 10 m/sec. sec. (1 g) RMS in the frequency range of 0-5 kHz.
7.3.2.5 Structural members shall be designed such that vibration is less than
6 mm/sec root mean square (RMS) and 150 micrometers peak to peak
unfiltered.
7.3.2.6 For multi-bay exchangers, the differences in driver speeds shall be a

maximum of 7-8% from one unit to another at maximum fan speeds.
7.3.3 Structural Design Loads and Forces
7.3.3.5 Thermal Loads
Thermal loads are loads caused by thermal transients and restraining

thermal expansion/ interaction of the exchanger and/ or its support(s).
7.3.3.7-8 Wind and Earthquake Loads

a) The Exchanger Manufacturer shall calculate the static effects of
loads due to wind and the effects due to earthquake loads acting on

Page 20 of 53
the exchanger in the operating position in accordance with

b) Wind and earthquake loads shall be calculated for the exchanger in
accordance with ASCE 7 (2005 Edition), using Occupancy
Category IV and based on design data corresponding to the site
location per SAES-A-112.
c) 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 as specified on the datasheet.
d) Earthquake loads shall include due allowances for platforms,
ladders, piping, insulation, and equipment supported from the
exchanger as specified on the data sheet.
7.3.3.9 Piping, Equipment, and External Loads

a) The Exchanger Manufacturer shall ensure that local stresses
imposed on an exchanger due to piping (other than the dead load),
equipment, lifting, supports and other external loads do not exceed
the allowable limits in accordance with the applicable Code.
b) Refer to the data sheet for piping and equipment loads imposed on
an exchanger.
7.3.3.13 Load Combinations
7.3.3.13.1 All components of an exchanger, including its support(s), shall be

designed to withstand stresses resulting from load combinations in
accordance with, but not be limited to, those shown in Table 4.1.2 of
ASME SEC VIII D2.
7.3.3.13.2 Anchor bolts shall be designed for load combinations, based on the
allowable stress design method (Service Loads) in accordance with
SAES-M-001.
7.3.3.13.3 All components of an exchanger shall be designed to withstand the

intended test pressure (full hydrostatic, or pneumatic) in the erected
position. Hydrostatic test pressure shall include the higher value of the
following:
a) Maximum operating liquid static head.
b) Test water static head in the erected position

Page 21 of 53
7.3.3.13.4 Combined stresses due to test pressure, including static head, and
minimum of 50% of wind load shall be within the following allowable
limits, based on the lowest Specified Minimum Yield Strength (SMYS)
of the materials of construction at test temperature:
1) ASME SEC VIII D2, paragraph 4.1.6.2(a) for full hydrostatic test.
2) ASME SEC VIII D2, paragraph 4.1.6.2(b) for pneumatic test.
7.3.3.13.5 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.
7.3.3.13.6 Loads (moments or forces) acting on an exchanger due to external piping

that will affect the overall integrity of the exchanger shall be added to
moments and forces due to other external primary loads (weight, wind or
earthquake loads). Addition of piping loads shall be based on
performing stress analysis.
7.3.3.14 Stress Analysis
7.3.3.14.1 Where applicable, the requirements for thermal stress and fatigue stress
analyses shall be as specified on the data sheet. Analysis methods and
stress combination limits presented in Division 2, Section 5, shall be
used for exchangers under scope of Division 1 and Division 2.
However, allowable stresses shall be taken from the respective tables of
ASME SEC II for each division for the corresponding material and
temperature.
7.3.3.14.2 The Design Engineer is responsible for specifying the heat transfer
coefficients to be used for all thermal stress analysis.
7.3.3.14.3 Fatigue Analysis

1) Scope of the required stress analysis shall be as specified on the
data sheet, in accordance with the rules of Division 2, by the
Design Engineer.
2) As a minimum, the scope of the stress analysis shall include the
following junctures, as applicable:
- Nozzle-to-header
- Header corner joints
- Header box

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3) Analysis shall be based on the calculated number of cycles for a

minimum 20-year service life, as determined in accordance with
the rules of Division 2, paragraph 5.5.2.
4) The number of cycles shall include the number of start-ups, shut-
downs, emergency shut-downs, and upset conditions.
7.3.3.14.4 Local Stress Analysis
Stress analysis due to piping, equipment, lifting, supports and other

external loads shall be completed in accordance with the procedures as
detailed in WRC 537, WRC 297 or a finite element analysis.
7.3.3.15 Dead Weights of an Exchanger
Design of exchangers shall consider the following dead loads:

a) Weight of exchanger including internals and supports
(e.g., turbolators, lugs, etc.).
b) Weight of exchanger contents under operating and pressure testing
conditions.
c) Weight of insulation.
d) Weight of attached equipment such as valves, and piping.
7.3.5 Mechanical Access Facilities
7.3.5.9 Maintenance platforms shall be provided if the bottom elevation of the

inlet headers, return headers, or drive equipment is greater than 3,000 mm.
7.3.5.10 A 1,070 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.
7.3.5.11 One stairway from grade to both header walkway and maintenance
walkway shall be provided and one ladder at the other end. For banks
60 m or more in length one stairway shall be provided at each end of
each bank.
7.3.5.12 Pipe- rack -mounted banks 60 m and shorter shall be provided with one
stairway at one end and ladder at the other. Banks greater than 60 m
shall have intermediate ladders to grade on each side and spaced not
more than 30 m with access to both maintenance and header walkways.
Page 23 of 53
Auxiliary stairs shall be used at changes in walkway elevations and

offsets around obstructions.
7.3.5.13 Stairways shall be 915 mm wide minimum.
7.3.6 Lifting Devices
7.3.6.6 Structures shall be designed to permit use for the handling and rigging of
driver assemblies that are not accessible to mobile handling and lifting
equipment.
7.3.6.7 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
(1,000 lb.).
8 Materials
8.1 GENERAL
8.1.1 (Exception) All materials required for pressure and non-pressure

components shall be as specified on the data sheet.
8.1.2 (Exception) Cast iron pressure parts shall not be used for any service.
8.1.3 (Exception) Structural supports shall be coated in accordance with

SAES-H-001.
8.1.7 Prior approval by the Saudi Aramco Engineer is required for use of
alternative materials of construction. Alternative materials must comply
with all the requirements of the applicable Code and this specification.
8.1.8 All materials must be clearly identified and provided with legible
original or certified true copies of Mill Test Certificates. Lack of
adequate identification and certification shall be cause for rejection.
8.1.9 Material specifications and tests procedures for base metal and
weldments materials for 1 Cr- ½ Mo, 1 ¼ Cr- ½ Mo, 2 ¼ Cr-1 Mo,
2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V shall include all
applicable requirements of this specification for ordering the materials
from the mill.
8.1.10 1 Cr- ½ Mo and 1 ¼ Cr- ½ Mo steels can be used for components

(headers, nozzles, flanges, etc.) of exchangers with thickness not
exceeding 100 mm (4 in.).
8.1.11 Use of high alloy steels, including austenitic stainless steels, shall be on a
Page 24 of 53
case-by-case basis, with prior approval of the Saudi Aramco Engineer as

defined in this specification. Material selection shall be based on the
design temperature, minimum design metal temperature and intended
service.
8.1.12 All materials shall be alloy-verified by the Exchanger Manufacturer in

accordance with SAES-A-206 requirements.
8.1.13 Use of C-½ Mo steels in hydrogen services is prohibited.
8.1.14 Materials of construction (pressure-retaining parts of exchanger and non-

pressure retaining attachments) shall be tested to verify that their
mechanical properties (strength, toughness, creep-resistance, etc.) will be
retained, considering all of the following thermal treatments that could
affect the material:
a) All heat treatment cycles that will be required for the fabrication of
the exchanger, including as applicable: normalizing, normalizing
and tempering, quenching and tempering, intermediate stress relief
(ISR), and final postweld heat treatment (PWHT).
b) Two PWHT cycles to account for future repairs and/or alterations.
8.1.15 As an alternative to material qualification requirements per paragraph

8.1.14 of this specification for carbon steel nozzles and standard flanges
(according to ASME B16.5 and B16.47) and nozzle pipe that do not
require impact testing, materials of construction shall have minimum
70 MPa (10 ksi) over their specified minimum yield strength and
ultimate tensile strength values.
8.1.16 Forgings shall meet a material cleanliness C2/R2/S2 rating, as described

in ASTM E381.
8.1.17 Specimens for material testing shall be taken for the maximum heat-
treated thickness (T) per the following:
a) Plates
Specimens shall be taken from each plate transverse to the rolling
direction in accordance with SA-20 at the standard test locations
and at a depth of ½T location. If required, ½T specimens should be
used for hot tensile and step cooling tests.
b) Plate-like forgings (forged rings, tubesheets, blind flanges, etc.)
Specimens shall be taken from each heat transverse to the major
working direction in accordance with the material specification,
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and at a depth of ½T of a prolongation or of a representative

separate test block, as defined in API RP 934-A.
c) Standard flanges according to ASME B16.5 and B16.47.
1. For flanges with T equal to or less than 50 mm, specimens
shall be removed in accordance with the material
specification.
2. For flanges with T greater than 50 mm, specimens shall be
removed in accordance with the material specification from a
production forging or a representative separate test block that
are machined to essentially the finished product configuration
prior to heat treatment. The center axis of the specimen shall
be at a depth of ½T and the mid-length of the test specimen
shall be at a depth at least equal to T from any second heat-
treated surface.
d) Other forgings that are contour shaped or machined to essentially
the finished product configuration prior to heat treatment, test
specimens shall be removed in accordance with the material
specification from a production forging or a representative separate
test block.
(Exception: Test specimens for 2 ¼ Cr-1 Mo, 2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1
Mo and 3 Cr-1 Mo- ¼ V steels shall be removed from only a production
forging; samples shall not be taken from a representative test blocks.)
The center axis of the specimen for all materials taken shall be at a
depth of ½T and the mid-length of the test specimen shall be at a
depth at least equal to T from any second heat-treated surface.
e) Pipe
Specimens shall be taken from each heat and lot of pipe, transverse
to the major working direction in accordance with used material
specification except that test specimens should be taken from a
depth of ½T.
f) A separate test block, if used, should be made from the same heat
and should receive substantially the same reduction and type of hot
working as the production forgings that it represents. It should be
of the same nominal thickness as the production forgings and shall
be machined to essentially the finished product configuration prior
to heat treatment. The separate test forgings should be heat-treated
in the same furnace charge and under the same conditions as the
production forgings.

Page 26 of 53
8.1.18 Materials for exchangers exposed to SSC environments shall be in

accordance with the following:
a) Standard flanges and flanged fittings (i.e., flanges and flanged
fittings under the scope of ASME B16.5 and large diameter flanges
under the scope of ASME B16.47) are restricted to: SA-350 (Grade
LF1 or Grade LF2).
b) Special forgings (long weld neck flanges, non-standard forged
flanges, forged butt-welded fittings, etc.) are restricted to:
SA-266 (Grades 2 or 4), SA-350 (Grade LF1 or Grade LF2), and
SA-765 Grade II.
c) Studs are restricted to: SA-193 B7M or SA-320 L7M.
d) Nuts are restricted to: SA-194 Grade 2HM.
e) It shall satisfy the requirements of NACE MR0175/ISO 15156 and
NACE SP0472.
8.1.19 Low alloy steels shall not be mixed. For example, an exchanger
requiring 1 Cr-½ Mo materials shall have all components manufactured
from 1 Cr-½ Mo.
8.1.20 Low alloy steels shall be specified in the normalized and tempered
(N+T) or quenched and tempered (Q+T) conditions, based on the
required mechanical material’s properties (strength, toughness, creep-
resistance, etc.) and considering thermal treatments specified in
paragraph 8.1.14 of this specification.
8.1.21 Material for nameplate mounting brackets shall be of the same type and
material grade as the pressure retaining component to which it is attached.
8.1.22 Materials of lugs shall be same material as exchanger wall base material.
8.1.23 External attachments, other than those in paragraph 8.1.22 of this

specification, and internal attachments welded to the exchanger shall be
of the same material as the exchanger wall base material.
8.1.24 Internal attachments to clad exchangers shall be of the same material as

that of the cladding. SS 321 and SS 347 can be used interchangeably.
8.1.25 Material of construction for anchor bolts shall be ASTM A193 / A193M,
ASTM F1554 Grade 36 or ASTM F1554 Grade 105 with the
corresponding material of construction for nuts according to SASD
AA-036322.

Page 27 of 53
8.1.26 SA-105 shall not be used for applications requiring impact testing.
8.1.27 SA-266 (Grade 2 or Grade 4) may be used for applications requiring

impact testing, provided the energy values at the impact test temperature
per this specification are satisfied.
8.1.28 Materials for exchanger exposed to HIC environments with normal

operating temperature up to and including 150°C (300°F) shall be in
accordance with the following:
i) All components (headers, tube, partition plates, stays, nozzles
and covers, etc.) formed from plate shall be manufactured
from HIC resistant steels that meet the testing requirements
of 01-SAMSS-016.
ii) Piping components (such as nozzle necks, etc.) made from
rolled and welded plate used in the manufacture of a heat
exchanger within the scope of this specification shall be
manufactured from HIC resistant steels that meet the testing
requirements of 01-SAMSS-016. Wrought piping components
shall meet the requirements of 02-SAMSS-005. Forged piping
components do not require HIC testing. Welded pipes shall meet
the requirements of 01-SAMSS-043.
8.1.29 All components (headers, tubes, partition plates, stays, nozzles, covers,
rings, standard flanges, special forgings, forged rings, attachments, etc.)
shall be fabricated and machined by Saudi Aramco approved heat
exchanger manufacturers.
8.1.30 All raw materials used for exchanger components (headers, tubes,
partition plates, stays, nozzles, covers, rings, standard flanges, special
forgings, forged rings, plugs, attachments, etc.) shall be procured from
approved Saudi Aramco suppliers per applicable commodities included
in SAES-L-101.
8.1.31 All heat exchanger flanges shall be procured in accordance with

02-SAMSS-011 requirements from approved Saudi Aramco suppliers.
8.1.32 All heat exchanger nozzles “made from pipes” shall be procured in
accordance with 01-SAMSS-043 and 01-SAMSS-046 requirements from
approved Saudi Aramco suppliers.
8.1.33 All heat exchanger forged and wrought fittings shall be procured in
accordance with 02-SAMSS-005 requirements from approved Saudi
Aramco suppliers.

Page 28 of 53
8.1.34 All exchanger manufacturers shall have the required equipment for
header boxes fabrication, bundles assembly, and pressure testing either
in-house or in a wholly owned subsidiary approved by Saudi Aramco.
It is not acceptable to outsource any of the above operations.
8.1.35 Tubes finning shall be manufactured in-house or shall be procured from

approved Saudi Aramco suppliers per applicable commodities included
in SAES-E-101.
8.1.36 Bare tubes shall be procured from approved Saudi Aramco suppliers per
applicable tubes' commodities included in SAES-L-101.
8.1.37 Material test report is requested to be certified as per 175-323600.
8.1.38 HIC Resistant Materials
Hydrogen Induced Cracking (HIC) resistant steel shall be qualified in

accordance with 01-SAMSS-016. HIC resistant steel shall be procured
from Saudi Aramco approved manufacturers.
8.5 Other Components
8.5.7 Fiber-glass-reinforced plastic (phenolic or epoxy resins) fan blades and

fan components shall not be used when the air outlet temperature for
induced draft fans exceeds 107°C with fans switched-off.
8.5.8 Steel used for slide plates shall be Type 316 stainless steel. Carbon steel
slide plates shall not be used.
8.6 Impact testing
8.6.1 The Exchanger Manufacturer is responsible of determining the required

Charpy impact energy value(s) based on the impact test temperature
specified on the data sheet and the purchased exchanger’s component
thickness.
8.6.2 Impact test temperature for a component of an exchanger shall be as

specified on the data sheet.
8.6.3 Minimum acceptable Charpy impact energy values for all materials of
construction (base and weld metals) shall not be less than the highest of
the following applicable values:
1) 40/32 Joules for carbon steels thicker than 50 mm
2) As specified by ASME SEC VIII D2, but not less than 34/27 Joules

Page 29 of 53
3) As specified by the licensor’s specification, but not less than

34/27 Joules
4) 55/48 Joules for 1 Cr- ½ Mo, 1 ¼ Cr- ½ Mo, 2 ¼ Cr- 1 Mo,
2 ¼ Cr- 1 Mo- ¼ V, 3 Cr- 1 Mo and 3 Cr- 1 Mo- ¼ V steels.
Commentary Notes:
a) The first number of required energy values is the minimum average

energy of three specimens and the second number is the minimum for
one specimen of the impact test results.
b) Minimum acceptable Charpy impact energy values are applicable to

Div. 1 and Div.2 exchangers.
8.6.4 For Div. 1 exchangers the impact testing exemptions of UG-20 (f),
UCS-66 (b) (1) and (3), UCS-68(c), UG-84 (b) (2) and by reference to
Table UG-84.4 are not permitted. For Div. 2 exchangers the exemptions
of 3.11.2.3, 3.11.2.4, 3.11.2.5, 3.11.2.6, 3.11.2.8, 3.11.2.10, 3.11.3.1, and
3.11.4 are not permitted.
8.6.5 Impact testing is required, with no exception, for exchangers made of

low alloy steels.
8.6.6 Impact testing of materials and welding procedures are required when
test temperature is lower than -28°C.
8.7 All forgings shall be forged as close as practicable to finished shape and
size to develop metal flow in a direction most favorable for resisting the
stresses encountered in service.
8.8 Elevated temperature tensile test shall be performed for 2 ¼ Cr-1 Mo,
2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V steels at the design
temperature. Test specimens should be in the maximum PWHT
condition, considering thermal treatments specified in paragraph 8.1.14
of this specification. Acceptance value is 90% of values listed in
ASME SEC IID, Table - U for the test temperature.
8.9 Special Testing for Steels under Scope of API RP 934-A
8.9.1 Microstructure Testing

a) Two sets of microstructures shall be provided for each forged ring
or header plate. One set of microstructure shall be provided for
other exchanger components.
b) Each set of sample shall consist of both transverse and longitudinal
direction. The Transverse microstructure shall include ID, mid

Page 30 of 53
wall and OD microstructure at proper magnification to show grain

structure. The longitudinal microstructure shall include ID and OD
samples at proper magnification to show grain structures.
c) Microstructure sample shall include Charpy test specimen.
8.9.2 Hardness Testing

a) Two hardness readings shall be taken on each exchanger
component, which includes each forged ring, header plate, nozzle,
pipe, fitting, and flange.
b) Test method and acceptance criteria shall follow API RP 934-A
(SECOND EDITION, ADDENDUM 2, MARCH 2012),
Paragraph 7.4.2.
8.9.3 Stress Rupture Test

a) Each heat of filler wire and flux combination used in production for
all weld joint categories (A, B, C, and D) intended for the
following design temperatures shall be qualified by a weld metal
stress-rupture test on specimens machined parallel (all weld metal
specimens) and transverse to the weld axis (one specimen each):
1) Above 441°C (825°F) for 2 ¼ Cr-1 Mo and 3 Cr-1 Mo steels.
2) Above 468°C (875°F) for 2 ¼ Cr-1 Mo- ¼ V and 3 Cr-1
Mo- ¼ V steels.
b) Test specimens shall be according to the following:
1) The specimen diameter within the gage length shall be 13 mm
(½ in.) or greater. The specimen centerline shall be located at
the 0.25-t thickness location (or closer to the center) for
material 19 mm (¾ in.) and greater in thickness.
2) The gage length for the transverse specimen shall include the
weld and at least 19 mm (¾ in.) of base metal adjacent to the
fusion line.
3) The test material shall be postweld heat treated to the
maximum PWHT condition.
c) Acceptance criteria:
1) For 2 ¼ Cr-1Mo and 3 Cr-1Mo steels, the condition of the
stress-rupture test shall be 210 MPa (30 ksi) at 510°C
(950°F). The time of failure shall exceed 650 hours.

Page 31 of 53
2) For 2 ¼ Cr-1Mo-¼ V and 3 Cr-1Mo-¼ V steels, the condition

of the stress-rupture test shall be 210 MPa (30 ksi) at 540°C
(1,000°F). The time of failure shall exceed 900 hours.
8.9.4 Reheat Transverse Cracking Susceptibility Qualification
Each combination of heat-of-filler wire and batch-of-flux for submerged

arc welding (SAW) used in production of all weld joint categories (A, B,
C, and D) in 2 ¼ Cr-1Mo-¼ V steels shall be qualified for transverse
reheat cracking susceptibility as follows:
a) Performing Gleeble test. Procedure and acceptance criteria of test
shall be in accordance with API RP 934A, Annex B.
b) Chemical composition factor (K-factor = Pb+Bi+0.03Sb) of filler
wire shall not exceed 1.5 ppm, where units of Pb, Bi, and Sb are in
ppm. K-factor shall be determined utilizing the Inductively
Coupled Plasma Mass Spectrometry (ICP-MS) method according
to the relevant requirements of the US national Institute of
Standards and Technology (NIST), including but not limited to the
calibration of the ICP-MS instrument. ICP-MS shall be calibrated
with sample standards provided by NIST. Test results shall be
documented as a reference, including calibration curves for Pb, Bi,
and Sb.
8.9.5 Unless the Exchanger Manufacturer can provide supporting documents

to differentiate bonding strength resulting from different welding
procedures, all disbonding tests shall be according to Domain - A test
conditions and acceptance criteria of Table 3 in API RP 934-A.
8.9.6 Step cooling tests of the base metal are required for 2 ¼ Cr-1 Mo,
2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V steels, unless impact
testing at -80°F (-62°C) results in 40 ft-lb (55 Joules) average minimum
and no single value below 35 ft-lb (48 Joules).
8.10 The phosphorous content of 1 Cr- ½ Mo and 1 ¼ Cr-½ Mo steels shall

not exceed 0.007% in weight.
9 Fabrication of Tube Bundle
9.1 Welding
9.1.1 General
9.1.1.1 (Addition) All welding shall be in accordance with the requirements of

SAES-W-010 and SAES-W-016.
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9.1.1.6 Corner weld joints in header boxes shall be in accordance with

ASME SEC VIII D1.
9.1.1.7 The beveled edges of weld preparations for carbon steel plates with
thickness 25 mm and thicker and all ferrous alloy plates shall be
magnetic particle examined for linear discontinuities. Liquid Penetrant
examination shall be employed for non-ferrous steels. Defects shall not
exceed limits as per ASME SA-20.
9.1.1.8 Plate edge laminations revealed per examination method in paragraph

9.1.1.7 of this specification shall be completely removed and repaired.
9.1.1.9 Set-in nozzles shall be ground flush to the inside of the headers with a
smooth inner edge radius.
9.1.1.10 Vent holes shall be provided in external non-pressure welded

attachments.
9.1.1.11 Dissimilar metal welds (DMW) are not permitted in sulfide stress
cracking environment as defined in this specification.
9.1.1.12 Following maximum allowable carbon equivalent, based on thickness

before forming (t) shall be met for exchanger intended for sulfide stress
cracking environment.
Thickness (mm) Carbon Equivalent (%)

6 < t ≤ 60 0.43
60 < t ≤ 100 (0.00125*t – 0.075) + 0.43
t > 100 0.48
9.1.1.13 The method of weld overlay shall be such as to produce a minimum of

3.2 mm thickness meeting the specified chemical composition of the
specified weld overlay material.
9.1.1.14 Intermediate stress relief (ISR) shall be performed on all highly

restrained joints in exchangers under the scope of API RP 934-A, such as
nozzle welds in headers and for other joints which are highly stressed
during fabrication (e.g., grooves in RTJ). Dehydrogenation Heat
Treatment (DHT) shall not be used as an alternative to ISR for the
aforementioned joints.
9.1.1.15 Exchangers constructed of 1 Cr- ½ Mo, 1 ¼ Cr- ½ Mo, 2 ¼ Cr-1 Mo,

2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V steels with internal
weld overlay shall have two-layer (ER309L/ER347) overlay.
Page 33 of 53
9.1.1.16 Weld overlay per paragraph 9.1.1.15 shall have smooth contour finished
surfaces where there is change in geometry for highly stressed areas
(such as nozzle welds in headers and RTJ grooves).
9.1.1.17 Necessary logistic fabrication steps shall be taken to ensure that highly
restrained joints, such as nozzle welds in headers and RTJ grooves, in
exchangers constructed of 2 ¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V steels
are welded continuously throughout the welding process without any
stop, i.e., from start of the first welding pass to completion of welding
the joint.
9.1.1.18 No dissimilar metal weld is allowed for A, B, C and D weld joint

categories in exchangers fabricated according to API RP 934-A,
API RP 934-C or API RP 934-E, regardless of the presence of stainless
steel weld overlay.
9.1.1.19 For services requiring impact test, welding procedures shall be qualified
for at least 80% of the time for any heat treatment after welding required
per paragraphs 8.1.14 (a) and 8.1.14 (b) of this specification.
9.1.1.20 Production Test Coupons, if required as per Code, shall be subject after
welding to the production heat treatment time per paragraphs 8.1.14 (a)
and 8.1.14 (b) of this specification.
9.1.1.21 In addition to the requirement of paragraph 9.1.1.19 of this specification,

welding procedures and production test coupons (if required by code) for
exchangers in sour service shall be subject to additional supplementary
impact and hardness tests with one PWHT cycle. Hardness testing shall
comply with NACE MR0175/ISO 15156.
9.1.1.22 When production test coupons require multiple thermal heat treatment
cycles to be simulated, the multiple cycles shall not be combined into
one cycle.
9.1.1.23 Welding procedures shall be qualified considering all of the thermal

treatments that could affect the material plus two additional cycles to
account for future repairs and/or alterations (refer to paragraph 8.1.14 of
this specification).
9.1.1.24 All external non-pressure welded attachments shall have their corners
rounded to a minimum radius of 25 mm (1 in.) and shall be fully seal
welded.
9.2 Postweld Heat Treatment

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9.2.4 Postweld heat treatment (PWHT) shall be done when required by the
applicable Code or when specified on the data sheet.
9.2.5 Code exemptions for postweld heat treatment (PWHT) of ferritic

materials based on the use of austenitic or nickel-based electrodes are not
permitted for exchangers in sulfide stress cracking environments as
defined in this specification.
9.2.6 Code exemptions for postweld heat treatment of P4 and P5 materials are
not permitted for applications involving the following:
a) Environments containing wet H2S
b) Hydrogen services
c) Materials exceeding 2.5% nominal chromium content
9.2.7 The maximum post weld heat treating soaking temperature for quenched
and tempered carbon and low alloy steel materials shall not exceed either
the tempering temperature shown on the Mill Test Reports or the
following:
 650°C maximum for carbon steel
 700°C maximum for low alloy steels.
For Cr-Mo materials covered by API RP 934-A, alternative tempering

and PWHT temperatures are acceptable if qualified in accordance with
this specification.
9.2.8 Final postweld heat treatment (PWHT) shall follow all welding and
repairs but shall be performed prior to any hydrotest or other load test.
9.2.9 A sign shall be painted on a postweld heat treated exchanger and located
such that it is clearly visible from grade:
"Caution – Exchanger Has Been Postweld Heat Treated – Do Not Weld"
9.2.10 Postweld heat treatment (PWHT) shall be in accordance with the

requirements of SAES-W-010 and this specification.
9.2.11 The holding temperature for postweld heat treatment for carbon steel
exchangers shall be 620°C – 650°C (1,150°F – 1,200°F).
9.2.12 It is the responsibility of the Exchanger Manufacturer to ensure structural

stability of the exchanger that will undergo PWHT, considering but not
limited to the following:

Page 35 of 53
a) Dead weight at intended PWHT soaking temperature.

b) Temperature gradients in equipment wall due to the intended PWHT
procedure.
c) Mechanical restraints that may prevent the equipment from free
movement (expansion/ contraction) during PWHT.
9.3 Tube-to-tubesheet Joints
9.3.1.4 Special close-fit tube-hole diameter tolerances shall be used for

exchangers classified in hydrogen, cyclic, or lethal services.
9.3.1.5 Fabrication tolerances shall be in accordance with the more stringent of

the applicable Code, TEMA and PIP document VEFV1100.
9.3.1.6 Use of fitness-for-service assessment methodology to qualify the design

of components that do not satisfy the fabrication tolerances according to
this specification is prohibited.
9.3.1.7 Tubes are normally expanded into the tubesheet. However, for the
following conditions, the tubes shall be expanded and strength welded to
the tubesheet:
a) Design pressure is equal to or greater than 7,000 kPa (ga)
(1,000 psig).
b) Hydrogen, cyclic or lethal service.
c) Services with operating temperature exceeding 205°C (400°F).
d) Required by the Code or process licensor.
9.3.1.8 Tube expanding procedures shall incorporate stops to prevent tube

expansion past tubesheet faces.
9.3.1.9 Tube expansion and tube-end welding (where specified) procedures shall
be submitted to the Saudi Aramco Inspector for review and approval
before start of fabrication.
9.3.1.10 The Exchanger Manufacturer shall submit a mock-up sample of the tube
to tubesheet weld when tubes are strength welded to the tubesheet.
This sample shall contain a minimum of four tubes and shall be prepared
using the same materials and fabrication procedures (including heat
treatment) as are to be used in actual production. Approval from the
Saudi Aramco Inspector is required prior to start of production. No need
to repeat the test if similar joint design was done in the past 6-months.
9.4 Gasket Contact Surfaces

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9.4.4 Nozzle gasket seating surfaces shall comply with the following:
1) For spiral wound gaskets, 125 to 250 AARH, in all services, except
hydrogen.
2) For spiral wound gaskets in hydrogen service, 125 to 150 AARH.
3) The sidewalls of ring joint flanges, in all services, 63 AARH.
9.4.5 Flatness of gasket contact surfaces shall be measured after completion of

all welding and any required PWHT.
9.8 Heat Treatment of Tubes
The following tubes shall be stress relief heat treated after cold forming and
bending:
1) U bends, including 150 mm of straight portions measured from the
tangent line of all carbon steel tubes for exchangers in caustic, H2S
containing environments, and amine services
2) Monel, brass and all chrome alloy tubes in all services
The following tubes shall be solution annealed:

1) Entire tubes manufactured of unstabilized or non-low carbon stainless
steels or Nickel base alloys in accordance with ASME SA-688.
2) U bends, including 150 mm of straight portions measured from the
tangent lines of all stabilized or low carbon stainless steels or Nickel
base alloys.
9.9 Forming and Heat Treatment
9.9.1 General
a) Cold forming for carbon steels shall be performed at temperatures
within the range of above 20°C (68°F) and below 120°C (248°F).
b) Hot forming is any forming performed above the austenite phase
start temperature of 740°C (1364°F).
c) All tempering heat treatments for all carbon steels must be at least
25°C (45°F) above the nominal PWHT temperature as given in the
applicable ASME code for the respective material. The tempering
temperature must not exceed the temperature stated in the steel
manufacturers Material Test Certificate.

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d) There are no restrictions for tempering temperature of 1 Cr- ½ Mo,

1 ¼ Cr- ½ Mo, 2 ¼ Cr-1 Mo, 2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo, and
3 Cr-1 Mo- ¼ V steels, provided that the requirements of paragraph
8.1.14 are met.
9.10 Bolt tensioning device shall be used for bolting up flanged connections
with stud bolts of diameter 1-½ inch and above. Bolt up of flanges,
irrespective of bolt diameter shall be according to ASME PCC-1
requirements.
9.11 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.
9.12 Welds Encroachment
9.12.1 It is the responsibility of the Exchanger Manufacturer to ensure that the

outer edge of welds attaching nozzles and other structural attachments
(with and without reinforced pads), except those in paragraph 9.12.4, to
pressure-retaining components shall not be closer than 1 inch from the
adjacent edge of any other weld. It is the responsibility of the
manufacturer to ensure that requirements of paragraph 7.3.3.9 of this
specification are met in the vicinity of the welds.
Commentary Note:
Weld spacing requirements for nozzle welds in exchangers under the scope
of API RP 934-A constructed of 2 ¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V shall
be according to paragraph 9.12.4 of this specification.
9.12.2 NDE per paragraph 10.1.41 shall be performed, where the optimized
fabrication layout and/ or process design requirements do not absolutely
allow meeting the spacing requirement in paragraph 9.12.1 of this
specification.
9.12.3 It is prohibited to cover butt and corner welds in wall of exchangers that
will undergo PWHT by structural attachments (with or without
reinforcing pads).
9.12.4 Nozzle welds in exchangers under the scope of API RP 934-A

constructed of 2¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V steels shall be
located without intersecting any circumferential or longitudinal welds.
Adjacent edges of circumferential or longitudinal welds and welds

Page 38 of 53
attaching nozzles shall not be closer than the greater of 50 mm (2 in.)

and one thickness of header.
10 Inspection, Examination, and Testing
10.1 Quality Control
10.1.15 The responsibility for examination rests with the Exchangers

Manufacturer in accordance with the applicable Code and the
10.1.16 Exchangers manufactured in accordance with this specification are

subject to verification by the Saudi Aramco Inspector in accordance with
Saudi Aramco Inspection Requirements Form SA-175-323600.
10.1.17 All required Nondestructive Examination (NDE) shall be performed in

accordance with inspection procedures that are in complete compliance
with ASME SEC V and this specification. This written procedure shall
address each inspection method and technique used including acceptance
criteria. The procedure(s) shall be submitted to Saudi Aramco
Inspection Department for approval.
10.1.18 All Nondestructive Examination, including Magnetic Particle and Liquid

Penetrant examinations, shall be performed by personnel certified in
accordance with ASNT CP-189, or equivalent National Certification
Programs that has been approved by the Saudi Aramco Inspection
Department. Personnel responsible for interpretation of Nondestructive
Examination results shall be certified to a minimum of Level II.
10.1.19 All required NDE for final acceptance of the exchanger shall be
performed after the completion of all welding and repairs and prior to
pressure testing. In exchangers requiring PWHT, all NDE for final
acceptance shall be performed after the final PWHT.
10.1.20 Use of fitness-for-service assessment methodology to qualify exchanger

welding joints that do not satisfy the applicable construction code
acceptance criteria is prohibited.
10.1.21 Magnetic particle examination or liquid penetrant examination per the

applicable Code shall be performed on the surfaces of hot formed and
reheat treated parts.
10.1.22 All pressure and non-pressure welds in exchangers that are not required
to undergo PWHT shall be visually inspected where accessible.
All segments of longitudinal or circumferential pressure weld seams

Page 39 of 53
covered or rendered inaccessible by internals, lifting lugs or other

attachments shall be fully radiographed over the entire affected length
plus minimum 50 mm (2 in.) either side prior to installation of the
attachment.
10.1.23 Additional examination of any weld joint at any stage of the fabrication
may be requested by the Saudi Aramco Inspector, including re-
examination of previously examined joints. The Saudi Aramco Inspector
also has the right to request or conduct independent NDE of any joint.
If such examination should disclose nonconformance to the requirements
of the applicable Code or this specification, all repair and NDE costs
shall be done at the Exchanger Manufacturer's expense.
10.1.24 All necessary safety precautions shall be taken for each examination
method.
10.1.25 Surface irregularities, including weld reinforcement, inhibiting accurate

interpretation of the specified method of nondestructive examination
shall be ground smooth.
10.1.26 Examination of all welds shall include a band of base metal at least one
inch wide on each side of the weld.
10.1.27 The Saudi Aramco Inspector shall have free access to the work at all
times.
10.1.28 Saudi Aramco shall have the right to inspect the fabrication at any stage
and to reject material or workmanship, which does not conform to the
specified requirements.
10.1.29 Saudi Aramco reserves the right to inspect, photograph, and/or videotape
all material, fabrication, coating, and workmanship and any materials,
equipment, or tools used or to be used for any part of the work to be
performed.
10.1.30 Saudi Aramco may reject the use of any materials, equipment, or tools
that do not conform to the specification requirements, jeopardize safety
of personnel, or impose hazard of damage to Saudi Aramco property.
10.1.31 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.
10.1.32 The Exchanger Manufacturer shall provide the Saudi Aramco Inspector
all reasonable facilities to satisfy him that the work is being performed as
specified.
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10.1.33 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.
10.1.34 Prior to final inspection and pressure testing, the inside and outside of
the exchanger shall be thoroughly cleaned of all slag, scale, dirt, grit,
weld spatter, paint, oil, etc.
10.1.35 Inspection at the mill, shop, or fabrication yard shall not release the
Exchanger Manufacturer from responsibility for repairing or replacing
any defective material or workmanship that may be subsequently
discovered in the field.
10.1.36 Radiographic Examination
10.1.36.1 All radiography shall be performed with intensifying screens. Only lead
or lead foil (fluoro-metallic) screens shall be permitted unless otherwise
approved by the Saudi Aramco Inspection Department.
10.1.36.2 Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as

individual rounded indications. Clustered or aligned tungsten inclusions
shall be removed and repaired.
10.1.36.3 Radiography examination requirements for weld joints categories A, B,

C, and D shall be according to Table 1 of this specification.
10.1.37 Ultrasonic Examination
10.1.37.1 Ultrasonic examination requirements for weld joints categories A, B, C,

and D shall be according to Table 1 of this specification.
10.1.37.2 All plates with thickness more than and including 50 mm (2.0 in.) shall be
ultrasonically examined by the Exchanger Manufacturer in accordance
with ASTM SA578. Acceptance criteria shall be Level C of SA-578.
10.1.37.3 Plates with thickness more than 12.5 mm (0.5 in.) and less than 50 mm
(2.0 in.) shall be ultrasonically examined by the Exchanger Manufacturer
in accordance with ASME SA-435. Any area where one or more
discontinuities produce a continuous total loss of back reflection
accompanied by continuous indications on the same plane (within 5% of
plate thickness) that cannot be encompassed within a 25 mm (1 in.)
diameter circle is unacceptable.
10.1.37.4 100% Ultrasonic examination is required for the following weld joints:
a) Full-penetration welds in external attachments (brackets, lugs, etc.)

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to pressure retaining parts.
10.1.37.5 All forgings shall be 100% ultrasonically examined by the Exchanger

Manufacturer in accordance with ASME SA388. Acceptance criteria
shall be in accordance with ASME SEC VIII D2, paragraph 3.3.4.2.
Indications per ASME SEC VIII D2, paragraphs 3.3.4.3 and 3.3.4.4 are
not acceptable.
10.1.37.6 Detection method and acceptance criteria of reheat transverse cracking in

submerged arc welds in 2 ¼ Cr-1 Mo, 2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and
3 Cr-1 Mo- ¼ V steels shall be according to API RP 934-A, Annex A.
10.1.37.7 For UT methods that generate permanent records, the Exchanger

Manufacturer shall provide a calibration block according to requirements
of ASME SEC V, without reference reflectors, solely for Saudi
Aramco’s use. Reference reflectors shall be embedded in the block by
Saudi Aramco Inspection Department to verify capabilities of the
manufacturer’s equipment /technique /personnel for employing such
methods. Calibration blocks shall be submitted for evaluation by the
Inspection Department prior to commencement of any work.
10.1.38 Magnetic Particle Examination
10.1.38.1 Permanent magnetic yokes are not permitted.
10.1.38.2 Prods are not permitted for use on air-hardenable materials, materials
which require impact testing, and on the fluid side of pressured
components for exchangers in environments containing wet H2S.
10.1.38.3 Except for non-ferro magnetic materials, magnetic particle examination

using an AC yoke is required for the following welds:
a) Pressure containing weld joints categories A, B, C, and D per Table
1 of this specification.
b) Welds in exchanger support (lug, and leg).
c) Attachment welds to the exchanger.
d) Areas where temporary attachments have been removed.
e) Arc strike areas.
Internal welds shall be examined with Wet fluorescent MPI. External

welds shall be examined with wet visible MPI or Wet fluorescent MPI.
Notes: 1. If wet visible MPI is used, a white color contrast coating shall be
applied prior to the examination.

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2. Examination shall be performed at the root pass and final weld

surface for items a), b), and c).
10.1.38.4 All edges prepared for welding and all openings in ferromagnetic
exchangers shall be 100% magnetic particle examined in accordance
with the applicable Code.
10.1.38.5 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.
(Exception: Liquid penetrant examination is acceptable as an alternative
to magnetic particle examination for welding edges.)
10.1.39 Liquid Penetrant Examination
10.1.39.1 For non-Ferro magnetic materials, liquid penetrant examination shall be

used for the following welds:
a) Pressure containing weld joints categories A, B, C, and D per
Table 1 of this specification.
b) Welds in exchanger support (lug, and leg).
c) Attachment welds to the exchanger.
d) Areas where temporary attachments have been removed.
e) Arc strike areas.
Note: Examination shall be performed at the root pass and final weld surface
for items a), b) and c).
10.1.39.2 All edges prepared for welding and all openings in non-ferromagnetic
exchangers shall be 100% liquid penetrant examined in accordance with
the applicable Code.
10.1.40 Weld hardness testing shall be in accordance with the requirements of

SAES-W-010.
10.1.41 Welds Encroachment
Where the optimized fabrication layout and/ or process design

requirements do not absolutely allow meeting the spacing requirement in
paragraph 9.12.1 of this specification, NDE per Table 2 shall be
performed. This is only applicable for design conditions/ services
Group II.
Nozzles and structural attachments weld shall not cover the

longitudinal header seam weld for design conditions/ services Group I.
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The manufacturer shall design the headers to have enough space to

perform the required NDE per Table 1.
10.2 Pressure Test
10.2.3 (Exception) Water used for pressure testing shall be potable.

For exchangers manufactured from stainless steel, the water shall not
contain more than 50 ppm chlorides with pH value not exceeding 7 at the
time of filling the exchanger. The hydrostatic test pressure shall be held
for a minimum of one hour per 25 mm of exchanger header thickness
and in no case less than one hour.
10.2.7 Fluids used for pressure testing shall be as follows:

1) Clean potable water, treated for control of bacteria and corrosion
2) For exchangers with stainless steel, Monel or non-ferrous tubes, the
water shall not contain more than 50 ppm chlorides.
3) For lube-oil and seal-oil exchangers the fluid to be used for
pressure testing shall be the system fluid.
10.2.8 After completion of all external and internal welding, nondestructive

examination, repair and heat treatment, as applicable, and prior to
painting, exchangers shall be pressure tested using water as the testing
media in accordance with the applicable Code and this specification.
10.2.9 Pneumatic testing for exchangers to be pressure tested at final erection

site within Saudi Aramco facility requires the approval of Saudi Aramco
Inspection Department.
10.2.10 Pressure testing for acceptance of the exchanger shall not be made prior
to the final postweld heat treatment.
10.2.11 The use of shellacs, glues, lead, etc., on gaskets during testing is
prohibited. No paint or primer shall be applied to an exchanger prior to
hydrostatic testing.
10.2.12 The Exchanger Manufacturer shall furnish all test materials and
facilities, including blinds, bolting, and gaskets.
10.2.13 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.

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10.2.14 The manufacturer shall supply the following:

a) Minimum two sets of spare gaskets with a blind flange for each
blinded nozzle in the exchanger.
b) Minimum one set of service gasket set and two sets of spare
gaskets for each nozzle with companion flanges in the exchanger.
c) All bolting with minimum 10% spare bolting (3 minimum for each
size) per an exchanger.
d) All plugs and their associated gaskets with minimum 10% spare
plugs and gaskets per an exchanger.
10.2.15 After completion of exchanger testing, the exchanger shall be

completely drained and thoroughly dried including surfaces of internals.
For exchangers made completely of stainless steels and exchangers
internally cladded or weld-overlaid with these materials, pickling and
passivation shall be applied according to ASTM A380.
Notes: After complete draining of water used for hydrostatic test, the
exchangers shall be dried completely following API STD 661 Section
A.5 requirements in addition to drying the exchangers to a dew point
that will ensure a dew point of (-1°C) or less at the exit points.
The inspection representative must witness and verify the equipment

complete water draining and moisture draying.
10.2.16 All welded attachments provided with telltale holes shall be

pneumatically tested at minimum 100 kPa (15 psig) prior to heat
treatment and exchanger pressure testing. Telltale holes must not be
plugged during the exchanger pressure test.
10.2.17 Minimum test pressure of the exchanger shall be:
10.2.17.1 Hydrostatic Pressure Test

a) For Division 1 exchangers per paragraph UG-99(b):
PT=1.3 MAWP (ST /S)
b) For Division 2 exchangers per paragraph 8.2.1:
Greater of:
i) PT = 1.43 MAWP
ii) PT = 1.25 MAWP (ST/ S)
Where,

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PT is the minimum test pressure

S is the allowable stress at design temperature
ST is the allowable stress at test temperature
ST /S is the lowest ratio for the pressure boundary materials,
excluding bolting materials, of which the exchanger is
constructed.
10.2.17.2 Pneumatic Pressure Test

a) For Division 1 exchangers per paragraph UG-100(b):
PT = 1.1 MAWP (ST/ S)
b) For Division 2 exchangers per paragraph 8.3:
PT = 1.15 MAWP (ST/ S)
10.2.18 Testing Conditions

a) Metal temperature throughout an exchanger shall be maintained at
all times during pressure testing as follows:
1. At least 17ºC (30°F) above the warmest MDMT based on the
temperature values on the impact test exemption curves of the
applicable code, considering materials of construction for all
of the exchanger’s components.
2. Not below 15°C (59°F).
3. Not above 50°C (122°F), unless there is information on the
brittle characteristics of the equipment material indicating that
a higher test temperature is needed.
b) The temperature of the test water shall be maintained at least 15°C
(59°F) at all times during hydrostatic testing.
c) For pneumatic testing, medium test temperature shall be
maintained at least 11°C (20°F) above the dew point temperature
of the testing medium at all times during pneumatic testing.
When compressed air is used, testing shall be performed when the
dew point of air is between -20°C to -70°C (-4°F to -94°F).
d) The test pressure shall not be applied until the exchanger and the
test fluid are at about the same temperature.

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10.2.19 Exchangers shall be protected from being over pressured, while being
pressure tested, by use of pressure test relief valve(s) meeting the
following:
a) Relief valves shall prevent pressure from rising more than 3% or
5 psi, whichever is greater, above the test pressure, provided that
requirements of paragraph 7.3.3.13.4 of this specification are met.
b) Sizing of relief valve(s) shall be according to API RP520, Part I.
c) The relief valve(s) shall be tested, dated, and tagged within one
week prior to the pressure test.
d) The pressure test relief valve shall be accompanied with a
calibration certificate that includes the cold differential test
pressure (CDTP), test date and the spring range. The CDTP shall
be within the spring range.
10.5 Nameplates
10.5.4 Nameplates shall be 3 mm minimum thickness and manufactured from

Type 304 stainless steel or Monel and continuously welded to the
mounting bracket.
10.5.5 Each exchanger shall be identified by a nameplate and marked with the
information required by the applicable Code and the requirements of this
specification.
10.5.6 Nameplate and nameplate mounting brackets shall be located such that
the nameplate will not be covered by insulation and is easily readable
from grade or platform. 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 the
applicable Code shall be stamped or engraved such that the nameplate
material is permanently deformed with the symbols.
10.5.7 Exchangers shall be Code stamped for all services in accordance with the
applicable Code.
10.5.8 The mounting bracket shall be continuously seal-welded and positioned

such as not to allow for collection of moisture or rain.
10.5.9 Nameplate for internally coated exchangers shall show: the Saudi
Aramco Painting System Numbers, type of coating, brand name, and
date of application.

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10.6 Manufacturing Repairs
10.6.1 The Saudi Aramco Engineer must review and approve crack repair
procedures, required by the applicable Code, prior to commencement of
the repairs. It is the responsibility of the manufacturer to ensure that
repairs done by the mill of any material defects, per the applicable Code,
are documented.
10.6.2 After completion of repairs required by the applicable Code, the

following shall be repeated:
a) Heat treatment of the repaired section if it has been heat-treated
prior to the repairs.
b) All nondestructive examinations (radiography, magnetic particle,
dye-penetrant, etc.) performed on the repaired section prior to the
repairs.
c) A weld map of all repairs shall be made a part of the final
exchanger documentation. The weld map shall include the
nondestructive examination procedure and results, the welding
procedure specifications and stress relief charts.
11 Preparation for Shipment
11.1 General
11.1.6 Prior to shipping, exchangers are to be completely and thoroughly dried

and cleaned from all loose scales, weld slags, dirt, and debris to the
satisfaction of the Saudi Aramco Inspector.
11.1.7 All threaded connections shall be protected with threaded plugs of

compatible materials and by the use of an appropriate lubricant with rust
preventive compound such as Cortec VpCI-369 or equivalent.
11.1.8 The Exchanger Manufacture shall protect the equipment from

mechanical and corrosion damage in order to assure that the
equipment will be serviceable after shipping, storage, and construction.
The duration of these activities is assumed to be 24 months. If longer
period is specified, the required protection measures shall be determined
on a case-by-case basis.
11.1.9 Flanged connections and all other machined surfaces shall be protected
by a coating suitable for the metallurgy of the exchanger and can be
easily removed in the field. Connections shall be fitted with steel or
wood cover, 3 mm thick, and neoprene gaskets.
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11.1.10 Covers shall be securely attached by a minimum of four bolts equally

spaced. For ocean shipment, flanged connections shall also be covered
with heavy-duty plastic bags securely taped to the nozzles.
11.1.11 Flanges with permanent blind flanges or covers shall be secured with the
gaskets and bolting specified for service.
11.1.12 Tell-tale holes in reinforcing pads shall be protected with wooden plugs
or packed with rust preventative grease.
11.1.13 Markings shall be done with water-insoluble materials that contain no

harmful substances that would attack or harmfully affect the exchanger
base metal or its coating at both ambient and design temperatures.
11.1.14 Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury,
chlorine, or any other halogens.
11.1.15 Export packaging marking and shipping shall be in accordance with the
purchase order.
11.1.16 The Exchanger Manufacturer is responsible for ensuring that the

exchangers and internals being shipped are adequately braced and shall
provide temporary supports where appropriate to ensure adequate
support of the exchanger during shipment.
11.1.17 Internal and External Protection
11.1.17.1 For carbon steel and stainless steel fully assembled heat exchangers,
spray interior surfaces with a vapor phase inhibitor such as Cortec
VpCI-307 or 309 or equivalent. Apply the Cortec product at a rate of
0.3 kg/m³. Other manufacturer's products should be applied at treatment
rates recommended by the manufacturer if greater than the specified
treatment rates of 0.3 kg/m³. If possible, vapor phase inhibitor powder
shall be sprayed directly into the tubes so that it can be easily detected
exiting from the opposite end of the tube. For copper alloy construction,
VpCI-307 or equivalent shall be specified. Exchangers must be sealed
vapor tight using metallic covers for the inhibitor to be effective.
11.1.17.2 The external surfaces shall be protected by preparing the surface and
fully coating the external surfaces using the specified Saudi Aramco
coating specification prior to shipment.
11.1.17.3 Solid stainless steel exchangers which are to be shipped by ocean freight
or are to be stored in a coastal or near coastal location but are not
specified to be coated in service shall be protected by the application of a
temporary soft external coating such as Cortec VpCI 368 or Daubert
Page 49 of 53
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, etc.
11.1.17.4 Components (such as headers, etc.) shipped separately must be

adequately protected and supported to prevent mechanical and corrosion
damage. Internals shall be protected using Cortec VpCI-307 or
VpCI-309 or equivalent as detailed in Paragraph 11.1.17.1, 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 where they might cause a contamination problem.
Alternatively, the complete component 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.
11.1.18 Use of Nitrogen blanketing with temporary rust preventive substance

such as Tectyl 846 or a vapor proof bag with moisture control is an
acceptable protection measure for carbon and low chrome alloy steels
without Austenitic Stainless Steels internally cladded or Austenitic
Stainless Steels weld over-layed exchangers.
11.1. 19 Nitrogen blanketing at a pressure of 35 kPa (5 psi) shall be provided for

Austenitic Stainless Steels or internally cladded or Austenitic Stainless
Steels weld over-layed exchangers in the following conditions:
1) During transportation (Ocean and Land).
2) At fabrication shop/site after completion of its fabrication.
3) At construction site from its arrival until its commissioning.
11.1.20 Nitrogen blanketing at a pressure of 35 kPa (5 psi) shall be provided for

components that cannot be protected properly by the use of vapor phase
inhibitor due to inaccessible difficulties such as header's internal surface.
11.1.21 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.

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11.1.22 For exchangers which have permanent internal coatings, the Exchanger
Manufacturer shall contact the Saudi Aramco Engineer for any corrosion
protection required.
11.1.23 Martensitic stainless steels such as Type 410 and Type 420 are
particularly prone to atmospheric corrosion especially when shipped by
sea. The Manufacturer shall prepare a preservation and shipping plan for
approval by CSD.
11.1.24 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.
11.1.25 Bolt and plug heads shall also be protected with a rust preventative
compound to prevent corrosion during shipment, storage and construction.
11.1.26 Spare bolts and plugs shall be protected with a rust preventative
compound to prevent corrosion during shipment, storage, and
construction.
11.2 Surfaces and Finishes
11.2.5 Type of coating and painting systems shall be as specified on the data
sheet.
11.2.6 Surfaces to be coated shall be cleaned and prepared prior to its coating in
accordance with SAES-H-001.
11.2.7 Gasket contact surfaces shall be properly protected from blasting and shall
not be coated or painted.
12 Supplemental Requirements
12.1 General
Exchangers with headers greater than 50 mm thick or design pressure

exceeds 2,000 psig shall be manufactured in accordance with this
specification in addition to API STD 661 requirements.
Revision Summary
2 July 2017 This major revision to the materials specification is to:
1- Overlay and align with API STD 661.
2- Re-affirm its contents against company needs.
3- Clarify some requirements in the document.

Page 51 of 53
Table 1 – Nondestructive Examination Requirements
Weld Joint Radiography Ultrasonic Liquid Penetrant (LP)

Category (RT) (UT) or Magnetic Particle (MP)
Per Design Code Criteria
A See Notes (2) & (3) 100%
(Spot or 100%) (1) & (3)
C 100% (3) See Notes (2) & (3) 100% (6)
D See Note (4) See Note (4) See Note (4)
Notes:
(1) 100% RT is required for exchangers under any of the following services or design conditions:
 Weld joints requiring full radiography per the applicable code.
 Lethal services.
 Hydrogen services.
 Cyclic services.
 Thick wall exchangers.
(2) 100% conventional UT is required.
(3) 100% UT, employing methods that generate permanent records may be used as a substitute for the
combination of 100% RT and 100% conventional UT specified for exchangers under common services and
design conditions per notes 1 and 2 of this table. Such UT methods must be approved by Inspection
Department prior to commencement of any work.
(4) Inspection for Category - D weld joint shall meet the following:
a) 100% UT employing methods that generate permanent records shall be used for design conditions/
services Group I per paragraph 7.1.9.34.2 of this specification. Such methods must be approved by the
Inspection Department prior to commencement of any work.
b) For design conditions/ services Group II per paragraph 7.1.9.34.2 of this specification, the whole joint shall
be either 100% magnetic particle (MP) or 100% liquid penetrant (LP) examined at the root pass, after each
6 mm depth of weld deposit and at the final weld surface and then 100% UT. Where PWHT is required,
final surfaces of weld joints shall be examined for acceptance after final PWHT.
c) For both Group I and Group II, 100% UT shall be performed on the weld joints prior to the cut and prior to
the installation of the nozzles.
(5) Inspection requirements for connections attached to nozzles per paragraph 7.1.9.34.2 shall be according to note
4 of this table.
(6) 100% MT or 100% LP shall be applied to the root pass and final surface of lap-welded Category - C weld joint.

Page 52 of 53
Table 2 – Welds Encroachment Requirements (Note 3)
Case PWHT is required (Notes 1, 2) PWHT is not required

RT of butt weld in exchanger for a
1. Nozzle installed onto a butt weld length equal to three times the
Same as when PWHT is required.
in exchanger wall. diameter of the opening with the
center of the opening at mid-length.
2. Nozzle encroaching on a butt length equal to three times the
weld in exchanger wall. diameter of the opening with the
center of the opening at mid-length.
3. Structural attachment (clips, lugs,
etc.):
(a) Structural attachment, length equal to the projection of the
without a reinforcing pad, attachment weld plus a minimum of
encroaching on a butt weld in 50 mm on either side. Minimum
exchanger wall. length of the radiographed weld is
12 in.
length equal to the projection of the
(b) Reinforced structural N/A reinforcing pad attachment weld
attachment, with the plus a minimum of 50 mm on either
reinforcing pad covering a (See prohibition in paragraph 9.12.3 side. Minimum length of the
butt weld in exchanger wall. of this specification) radiographed weld is 12 in.
The butt weld shall be ground flush
prior to installation of the pad.
(c) Structural attachment, N/A length equal to the projection of the
without a reinforcing pad, structural attachment weld plus a
covering a butt weld in (See prohibition in paragraph 9.12.3 minimum of 50 mm on either side.
exchanger wall. of this specification) Minimum length of the radiographed
weld is 12 in..
(d) Reinforced structural
length equal to the projection of the
attachment, with the
reinforcing pad attachment weld
reinforcing pad encroaching Same as when PWHT is required.
plus a minimum of 50 mm on either
on a butt weld in exchanger
side. Minimum length of the
wall.
radiographed weld is 12 in.
4. Structural attachment (with or
without reinforcing pads) MP or LP on the entire outermost
encroaching: fillet weld of each attachment on the
exchanger side per paragraph
(a) Another structural Same as when PWHT is required.
10.1.38 or 10.1.39, as applicable,
attachment (with or without
after completion of all welds in all
reinforcing pads).
attachments.
(B) Nozzle.
Note 1: NDE for final acceptance of the exchanger shall be performed after the final PWHT per paragraph 10.1.19 of this
specification.
Note 2: 100% UT, employing methods that generate permanent records, must be approved by Inspection Department prior to
commencement of any work.
Note 3: Table-2 is only applicable for design conditions/ services Group II.

Page 53 of 53

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Materials System Specification

32-SAMSS-011 18 February 2018

Table 1 – Nondestructive Examination

Previous Issue: 30 June 2014 Next Planned Update: 2 July 2020

©Saudi Aramco 2017. All rights reserved.

1.2 This specification does not cover the followings:

1.6 Where a requirement of a licensor’s or a relevant industry standard/

1.7 Use of fitness-for-service assessment methodology to qualify exchangers

Saudi Aramco: Company General Use

1.8 Conflicting Requirements

Unless otherwise noted in this specification, materials or equipment supplied to this

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

Saudi Aramco Materials Systems Specifications

Saudi Aramco: Company General Use

Saudi Aramco Engineering Standards

Saudi Aramco Inspection Requirements

Saudi Aramco Forms and Data Sheets

2.2 Industry Codes and Standards

American Petroleum Institute

Saudi Aramco: Company General Use

API RP 934-A Materials and Fabrication of 2 ¼Cr-1Mo, 2 ¼Cr-

American Society of Civil Engineers

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

American Society for Non-destructive Testing

American Society for Testing and Materials

International Standards Organization

Process Industry Practices

Tubular Exchanger Manufacturers Association (TEMA)

Welding Research Council

3 Terms and Definitions

3.5 (Exception) Cyclic Service: Services that require fatigue analysis

3.11 (Exception) Hydrogen Service: Process streams containing hydrogen with

Saudi Aramco: Company General Use

3.19 (Exception) MDMT: Minimum design metal temperature, determined by

3.21 (Exception) Pressure Design Code: ASME SEC VIII.

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

3.36 Critical Installations: Installations where unplanned shutdown of the fin

3.37 Design Engineer: The Engineering Company responsible for specifying on

3.38 Exchanger Manufacturer: Company responsible for the manufacture of

3.41 Hydrogen Induced Cracking (HIC) Environment: Process streams that

3.42 Lethal Service: Process streams containing a concentration of hydrogen

3.44 Minimum Thickness: Thickness required for withstanding all primary

3.45 Nominal Thickness: Thickness selected as commercially available, and

3.46 Saudi Aramco Buyer: The person or company authorized by Saudi

Saudi Aramco: Company General Use

3.49 Sulfide Stress Cracking (SSC) Environment: Process streams that

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

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

4.4 (Exception) The Exchanger Manufacturer shall comply with applicable

4.8 Exchangers shall be designed to minimize field assembly.

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

4.11 Proof testing is prohibited.

4.12 No credit shall be given to thickness of integrally-bonded or weld metal

4.13 Application of ASME Code Cases to the manufacture of exchangers

Saudi Aramco: Company General Use

4.14 The Exchanger Manufacturer is responsible for the thermal/hydraulic

4.15 The Exchanger Manufacturer is responsible for the manufacture of

4.16 All welded joints of category A, B, C, and D shall be complete fusion

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

4.19 ASME SEC VIII D2 shall be specified when economically justified.

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

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