ENGINEERING SPECIFICATION

SSD0519EMP-IND

Specification for Design Criteria of air cooled heat

exchangers

REV. : 00
DATE : 2014.09.11

SAMSUNG ENGINEERING INDIA

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TABLE OF CONTENTS

1 Scope............................................................. 3
2 Normative References................................... 5
3 Terms and Definitions.................................... 6
4 General.......................................................... 9
5 Proposals....................................................... 9
6 Documentation............................................... 9
7 Design............................................................ 10
8 Materials....................................................... 16
9 Fabrication of the Tube Bundle.................... 18
10 Inspection, Examination, and Testing.......... 20
11 Preparation for Shipment............................. 23
12 Supplemental Requirements........................ 24

Table 1 - Acceptable Materials

for Carbon and Low Alloy Steels.......... 25
Table 2 - Charpy-V Impact Test Requirements.... 26
Table 3 - Material Classes.................................... 26

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th
The following paragraph numbers refer to API STD 661, 5 Edition, March 2002,
which is part of this specification. The text in each paragraph below is an
addition, exception, modification, or deletion to API STD 661 as noted. Paragraph
numbers not appearing in API STD 661 are new paragraphs to be inserted in
numerical order.

1 Scope
This specification covers the minimum mandatory requirements for the manufacture of
new air-cooled heat exchangers (herein referred to as exchangers). It does not cover
exchangers that undergo repairs or alterations.

This specification does not cover skid mounted exchangers, or exchangers that are
part of air conditioning equipment or exchangers that do not fall in the general
exchanger types covered in API STD 661.

1.1 General

1.1.1 The Design Engineer is responsible for specifying the process

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

1.1.2 Exchangers shall be designed to minimize field assembly.

1.1.3 Individual exchanger within a group of exchangers shall be designed

for maximum practical inter-changeability of components.

1.1.4 When specified, compliance with the latest edition of ASME SEC VIII D2,
Pressure Vessels, Alternative Code Rules is mandatory.

1.1.5 Should the Exchanger Manufacturer have any part of a stress analysis
executed by a third party, the Exchanger Manufacturer shall advise the
Saudi Aramco Engineer.

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

Saudi Aramco Engineer

1.1.7 Application of ASME Code Cases to the manufacture of exchangers

requires approval of the Saudi Aramco Engineer.

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

the requirements of this specification.

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

1.1.10 Exchangers in lube and seal oil services shall also conform to in addition
to the requirements of this specification.

1.1.11 The Exchanger Manufacturer is responsible for the thermal design

(rating) and verification of the Design Engineer's thermal design, if
applicable. The Exchanger Manufacturer is also responsible for the
manufacture of exchanger, which includes the complete mechanical
design, Code and structural calculations, supply of all materials,
fabrication, nondestructive examination, inspection, testing, surface
preparation, and preparation for shipment, in accordance with the
completed data sheet and the requirements of this specification.

1.1.12 The edition of the Code to be used for the manufacture of exchangers
shall be the edition in effect at time of purchase.

1.1.13 Where a licensor's specification requirement is more stringent than

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

1.2 Conflicting Requirements

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

vendor shall obtain written approval from the purchaser before
proceeding with the work affected by a conflict between the proposal
and the order.

1.2.2 Any conflicts between this specification and other Saudi Aramco
Materials System Specifications (SAMSSs), Saudi Aramco
Engineering Standards (SAESs), Industry codes and standards, and
Saudi Aramco Standard Drawings (SASDs) and Forms shall be
resolved in writing by the Company or Buyer Representative through
the Manager, Consulting Services Department of Saudi Aramco,
Dhahran.

1.2.3 Direct all requests to deviate from this specification in writing to the
Company or Buyer Representative, who shall follow internal company
procedure SAEP-302 and forward such requests to the Manager,
Consulting Services Department of Saudi Aramco, Dhahran.

2 Normative References
Materials or equipment supplied to this specification shall comply with the latest edition
in effect at time of purchase of the references listed below, unless otherwise noted.
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Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of Mandatory
Saudi Aramco Engineering requirement.

Saudi Aramco Materials Systems Specifications

01-SAMSS-016
Qualifications of Pipeline and Pressure Vessel Steels for Resistance to
Hydrogen-Induced Cracking
17-SAMSS-503
Severe Duty, Totally Enclosed, Squirrel Cage
Induction motors to 250 HP
32-SAMSS-013
Lubrication, Shaft Sealing and Control Oil
Systems
32-SAMSS-031
Manufacture of Clad Vessels and Heat
Exchangers

Saudi Aramco Engineering Standards

SAES-A-105 Noise Control
SAES-A-112 Meteorological and Seismic Design Data
SAES-A-206 Positive Materials Identification
SAES-H-001 Selection Requirements for Industrial Coatings
SAES-W-010 Welding Requirements for Pressure Vessels

Saudi Aramco Inspection Requirements

Form 175-323600 Manufacture of Air-Cooled Heat Exchangers

Saudi Aramco Forms and Data Sheets

Form 7305-ENG Equipment Noise Data Sheet
Form NMR-7922-2 Nonmaterial Requirements for Air-Cooled Heat
Exchangers

 Industry Codes and Standards

American Petroleum Institute

API STD 661

Air-Cooled Heat Exchangers for General Refinery

Services
API PUBL 941

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Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum

and Petrochemical Plants
API RP 945

Avoiding Environmental Cracking in Amine Units

American Society of Civil Engineers

ASCE 7
Minimum Design Loads for Buildings and Other
Structures

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

ASME SEC V Nondestructive Examination

ASME SEC VIII D1 Rules for Construction of Pressure Vessels
ASME SEC VIII D2 Rules for Construction of Pressure Vessels, Alternative
Rules
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME SA-20

Specification for General Requirements for Steel

Plates for Pressure Vessels
ASME SA-435

Specification for Straight-Beam Ultrasonic

Examination of Steel Plates

National Association of Corrosion Engineers

NACE RP0472

Methods and Controls to Prevent In-Service Environmental Cracking in Carbon

Steel Weldments in Corrosive Petroleum Refining Environments

NACE MR0175/
Petroleum and Natural Gas Industries-
ISO 15156
Materials for use in H2S-Containing Environments in Oil and Gas Production

Tubular Exchanger Manufacturers Association

TEMA

Standards of the Tubular Exchanger

Manufacturers Association

3 Terms and Definitions

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

texture.

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

3.13 Cyclic Service: Services that require fatigue analysis per AD-160 of ASME SEC
VIII D2. This applies to Division 1 and Division 2 of ASME
SEC VIII.

3.14 Design Engineer: The Engineering Company responsible for specifying on the
data sheet the hydraulic, thermal and mechanical design
requirements for exchangers.
3.15 Exchanger Manufacturer: The company responsible for the manufacture of
exchangers.

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

3.17 Hydrogen Service: Process streams containing relatively pure hydrogen and
component streams containing hydrogen with a partial
pressure of 350 kPa (50 psia) or higher.

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

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

3.19 Low Alloy Steels: Steels with nominal chromium content up to 5% chrome and/or
nominal nickel content up to 3%.

3.20 Minimum Thickness: Thickness required for withstanding all primary loads,
excluding allowance for corrosion.

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

3.22 Nominal Thickness: Thickness required for withstanding all primary loads,
including allowance for corrosion.

3.23 Saudi Aramco Engineer: The Standards Committee Chairman.

3.24 Saudi Aramco Inspector: The person or company authorized by the Saudi
Aramco Inspection Department to inspect
exchangers to the requirements of this
specification.

3.25 Thick Wall Exchanger: An exchanger with header plates greater the 50 mm
nominal thickness.

3.26 Critical Installations: Installations where unplanned shutdown of the fin fan
could cause substantial loss of production.

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

3.28 Utility Services: Water, air and nitrogen services.

3.29 Wet Sour Service: Following process streams containing water and
hydrogen sulfide:

1 Sour water service with a hydrogen sulfide (H2S) concentration above 2 mg/L (2 ppm) and a
total pressure of 450 KPa absolute (65 psi) or greater.
2 Hydrocarbon services meeting the definition of sour environments in NACE MR0175/ISO
15156, where the H2S concentration of 2 mg/L (2 ppm) or more in the water phase is
equivalent to H2S partial pressure of 0.05 psia. Sour crude systems upstream of a
stabilization facility and sour gas upstream of a sweetening or dehydration plant are
examples of such environments.

3.30

Wet Sour HIC Services: Hydrogen Induced Cracking (HIC) resistant steel qualified in
accordance with 01-SAMSS-016 shall be specified for the
following environments with normal operating temperatures
between 0°C (32°F) and 150°C (302°F):

1. Sour water service with a hydrogen sulfide (H2S) concentration above 2 mg/L (2 ppm) and
a total pressure of 450 KPa absolute (65 psia) or greater.
2. Hydrocarbon services meeting the definition of sour environments in NACE MR0175/ISO
15156, where the H2S concentration of 2 mg/L (2 ppm) or more in the water phase is
equivalent to H2S partial pressure of 0.05 psia.
3. A hydrocarbon system exposed to an environment with a H2S concentration above 50
mg/L (50 ppm) in the water phase, regardless of H2S partial pressure.

Commentary Note:

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

4 General
5 Proposals
5.12 The Exchanger Manufacturer may offer an alternative design, but must also quote
on the base inquiry documents.

5.13 The number of copies of drawings, data sheets, specifications, data reports, operating
manuals, installation instructions, and spare part lists shall be in accordance with Form
NMR-7922-2, Nonmaterial Requirements.
5.14 The following shall be guaranteed for the length of the warranty period specified in
the purchase order or contract documents:
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1) Exchangers shall perform under continuous operation at design conditions specified on

the data sheets. Thermal guarantee shall be in accordance with TEMA SEC 3,
(paragraph G 5).
2) Exchangers shall perform the required design heat duty without exceeding design air flow
rates and/or maximum allowable pressure drop.
3) Sound levels at all specified operating conditions based on the procedures of
SAES-A-105.
4) Vibration limits of the complete assembly in accordance with the requirements
specified in this specification.
6 Documentation
6.1 Approval Information

6.1.4 (Exception) The Exchanger Manufacturer shall prepare and submit for
approval all proposed welding maps, welding procedures, and welding
procedure qualifications prior to start of fabrication.

6.1.5 (Exception) The Exchanger Manufacturer shall prepare and submit for
review and approval the additional engineering information required for
installation, operation, maintenance, and inspection in accordance with
Form NMR-7922-2, Nonmaterial Requirements.

6.2 Final Records

(Exception) The Exchanger Manufacturer shall prepare and submit final

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

Requirements.

7 Design

7.1 Tube Bundle Design

7.1.1 General

7.1.1.14 Each tube bundle shall have one header free to move with thermal expansion of
the tubes and shall have sliding plates at the moving end both
on structure and on bundle.

7.1.3 Tube Bundle Design Temperature

7.1.3.4 The MDMT shall be used to determine the requirements for impact testing
in accordance with Section 8 of this specification.

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7.1.4 Tube Bundle Design Pressure

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

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 applicable Code.
The calculations shall be based on as-built thicknesses excluding
thicknesses required for corrosion. The MAWP of an exchanger
shall not be limited by flange rating.

7.1.6 Headers

7.1.6.1 General

7.1.6.1.1 (Exception) The Exchanger Manufacturer shall investigate all

temperature conditions, temperature differentials, temperature
shocks, start-up, shutdown, and cyclic conditions specified on the
data sheet to determine that the design of headers is adequate.

7.1.6.1.2 Selection of header type shall be as fo asfollows: Headers shall generally be of plug

type design.

For vacuum services such as steam turbine surface condensers and for
design pressures in excess of 14000 kPa (2000 psi), pipe manifold or
other suitable header type may be proposed for approval by the Saudi
Aramco Engineer.

7.1.6.2 Removable Cover Plate and Removable Bonnet Headers

7.1.6.2.3 (Exception) Removable cover plate and removable bonnet

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

7.1.8 Gaskets

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

7.1.8.11 The manufacturer shall supply the following:

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

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

7.1.9 Nozzles and other Connections

7.1.9.1 (Exceptions) through

7.1.9.2 Flanged connections shall be one of the following types:

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1) Forged steel long welding neck

2) Forged steel welding neck flange with seamless pipe, or
rolled plate with 100% radiography. Nozzle flange bore shall
match the nozzle neck bore.
3) Proprietary designs may be offered as alternatives
provided their designs are in accordance with the Code and
with prior approval of the Saudi Aramco Engineer.
However, for utility services up to and including 120°C (250°F)
design temperature and 1.4 MPa ga (200 psig) design pressure,
nozzles may be slip-on type flanges with seamless pipe nozzle
necks or rolled plate with 100% radiography.

7.1.9.11 Threaded or socket-welded connections are prohibited in

hydrogen, lethal, wet sour and caustic services. However, for
other services, threaded or socket-welded connections with
6000-lb. rating conforming to ASME B16.11 may be used for
smaller than NPS 1½ vents, drains and instrument connections.

Commentary Note:

This requirement is intended for vents, drains and instrument connections

that may be attached to header or nozzles.

7.1.9.23 For exchanger drain connections and other connections,

where a process stream is likely to be stagnant, the
projection shall be limited to 2.5 times the connection
nominal diameter for vertical connections and to 3.5 times
the connection nominal diameter for horizontal
connections.

7.1.9.24 Integrally reinforced openings (with no reinforcing pads) shall

be provided for all services and design conditions.

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

welds.

7.1.9.27 Ends of butt-welded connections shall be in accordance with

ASME B16.25.

7.1.10 Maximum Allowable Moments and Forces for Nozzles and

Headers

7.1.10.4 The Design Engineer shall calculate the forces and moments
acting on inlet and outlet connections based on allowable
bundle movements and frictional forces advised by the
Exchanger Manufacturer. The Design Engineer shall also
take into account the moments and forces acting on the
headers due to piping loads.

7.1.11 Tubes
7.1.11.2 (Exception) Unless otherwise approved by the Saudi Aramco
Engineer, the maximum tube length shall be 15,000 mm.

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

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

of up to and including 300°C.
2) Mechanically embedded fins may be used for a process fluid inlet
temperature of up to 400°C.
3) Welded fins, carbon steel on carbon steel, may be specified for a
process fluid inlet temperature of up to 450°C.
4) Embedded fins shall be used for cyclic service.
5) Fins, which are bonded to the outside surface of the tubes by hot-
dip galvanizing or brazing, shall not be used.
6) Other types of fins shall require approval by the Saudi Aramco
Engineer.

7.1.11.4 Design and selection of fins shall be such that fins will not
suffer any distortion when subjected to the design
requirements with fans out of service.

7.1.11.5 Tube sizes and spacing shall be uniform throughout bundles in

the same Unit.

7.2 Air-side Design

7.2.1 General

7.2.1.1 The Design Engineer shall specify all meteorological data, and
location of exchanger with respect to other buildings and equipment on the
data sheet.

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

and the drivers are not exposed to heated re-circulated air temperature
higher than their design temperature.

7.2.1.6 Gear- box vents, oil filters, sight glasses and lubrication
connections shall be located outside the plenums.

7.2.1.7 When requested, Exchanger Manufacturer shall quote for the

supply of a centralized lubrication grease system. The grease pump shall
be designed for an automatic operation.

7.2.2 Noise Control

7.2.2.1 (Exception) Design Engineer shall specify limits for the sound
pressure levels (SPL) per fan at the designated locations, on Form 7305-
ENG. The Exchanger Manufacturer shall complete Form 7305-ENG and
ensure that the required limits as specified for SPL can be achieved by
supplying test results of a representative bay.

7.2.3 Fans and Fan Hubs

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

the blade passing frequency shall not fall within 80 to 120% of fan blade
assembly fundamental operating natural frequency.

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

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

7.2.3.19 Induced draft fans shall have all mounting and bearing
arrangements designed to allow removal and installation of fans and
hubs without damaging the bundles.

7.2.4 Fan Shafts and Bearings

7.2.4.7 Exchangers with enclosed plenums with hot air re-circulation

shall be equipped with fan shaft bearing vibration transducers to permit
monitoring of bearings from outside the enclosure.

7.2.4.8 Thrust bearings shall be mounted so as to allow

removal without dismantling shaft or hub and located at the lower
end of shafts.

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

tubing shall be installed and brought to an accessible location. Bearing
housing shall be dust and drip proof.

7.2.6 Fan Guards

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

the forced and the induced draft exchangers.

7.2.7 Drivers

7.2.7.1 General

7.2.7.1.3 All drives shall be mounted beneath the tube bundles.

7.2.7.2 Electric Motor Drivers

7.2.7.2.10 Electric motors shall be manufactured in accordance with 17-

SAMSS-503.

7.2.8.2 Belt Drives

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

(toothed) type.

7.2.8.2.14 Belt tensioning adjustment shall be possible without removal of

fan guards.

7.2.9 Vibration Cut-out Switches

7.2.9.1 (Exception) Shutdown protection device shall be activated by

an electric signal from a seismic vibration.

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7.2.10 Louvers

7.2.10.18 (Exception) Design Engineer shall specify louver position at

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

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

7.3 Structural design

7.3.1 General

7.3.1.7 Exchanger Manufacturer shall supply all structural steel

including platforms, hand-railing, and ladders, as specified by the Design
Engineer in accordance with this specification.

7.3.1.9 For grade mounted exchangers, headroom clearance below unit,

excluding driver arrangement, shall not be less than 2150 mm between fan
ring and grade for forced draft units and between tube bundle and grade for
induced draft units.

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

shall be as follows:

For bottom supported drivers, the Exchanger Manufacturer shall supply

supporting columns and beams, including motor access platforms,
handrailing, and ladders with a minimum headroom of 2150 mm for support
of
fan and driver.

7.3.1.12 The Exchanger Manufacturer shall supply and install 12 mm

minimum hexagonal nuts welded on edge on 250 mm random pattern to
structural steel members that are specified to be fireproofed.

7.3.1.13 Each tube bank shall be provided with a grounding lug

connection welded to the support of each unit.

7.3.1.15 Natural frequencies of structural members shall not be within

10% of the fundamental excitation frequencies resulting from the fan speed
and motor speed. This applies to both shop-tested and field-tested
structure.

7.3.2 Vibration Testing

7.3.2.2 (Exception) The Exchanger Manufacturer shall verify compliance

with the structural vibration requirements of this specification by shop
testing and during commissioning. On multi-bay identical exchanger units,
a minimum of one bay shall be shop tested.

7.3.2.4 Vibration in any axis on all bearings shall be less than 4 mm/sec,
and 10 m/sec. sec. (1 g) RMS in the frequency range of 0-5 kHz.

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7.3.2.5 Structural members shall be designed such that vibration is less

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

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

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

7.3.3 Structural Design Loads and Forces

7.3.3.1 (Exceptions) Exchangers shall be designed for wind and

earthquake loads in accordance with ASCE 7.

The design engineer shall determine the basic wind speed corresponding to
the Saudi Aramco in accordance to SAES-A-112. The basic wind speed
shall be specified on the data sheet.

7.3.5 Mechanical Access Facilities

7.3.5.9 Maintenance platforms shall be provided if the bottom

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

7.3.5.10 A 1070 mm wide platform shall be provided for each header for the
length of each header. Crosswalks 760 mm wide shall connect
header access platforms at the ends of each bank. An
intermediate walkways intervals shall be provided when the bank
length exceeded 40 m. Interconnections between maintenance and
header walkways shall not be used to satisfy the intermediate
connection requirements.

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 one
in length 60 m or moreshall be provided at each end of each bank.
stairway

7.3.5.12 Pipe- rack -mounted banks 60 m and shorter shall be provided with
one at one end and ladder at the other. Banks greater than 60 m
stairway
shall
have intermediate ladders to grade on each side and spaced not more
30 than
m with access to both maintenance and header walkways.
Auxiliary
stairs shall be used at changes in walkway elevations and offsets
around
obstructions.

7.3.5.13 Stairways shall be 915 mm wide minimum.

7.3.6 Lifting Devices

7.3.6.7 Structures shall be designed to permit use for the handling and rigging
of assemblies that are not accessible to mobile handling and lifting
driver
equipment.

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

which may be lifted with a 25% impact allowance, but not less
thanlb.).
(1000 460 kg

8
Materials

8.1 GENERAL

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

components shall be specified on the data sheet in accordance with
Table 1, Materials for Carbon and Low Alloy Steels.
Acceptable

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

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

through SAES-H-001.

8.1.4 The Exchanger Manufacturer may propose alternative materials at the

time
of proposal, but the alternative materials must comply with all the

8.1.5 All materials for pressure retaining parts must be clearly identified
and provided with Mill Test Certificates. Lack of adequate
identification and certification shall be cause for rejection.

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

theExchanger Manufacturer in accordance with SAES-A-206.

8.1.10 Suitability of low chrome alloy steels for use for exchangers in
hydrogen services above 205°C (400°F) shall be qualified through chemical
analysis, mechanical testing including but not limited to tensile, hardness, micro
hardness, temper embrittlement tests and nondestructive examinations
(ultrasonic, wet fluorescent magnetic particle, etc.). Materials specifications and
tests procedures for base and weldments materials shall be submitted to Saudi
Aramco Engineer for review and approval prior to ordering the materials.

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

8.1.12 Materials with properties enhanced by heat treatment cycles such

as tempering, intermediate stress relief (ISR) and the final post weld heat
treatment shall be tested to verify that their mechanical properties have been
retained after all heat treatment cycles. These tests shall also include two
additional postweld heat treatment cycles to account for future repairs or
alteration.

8.1.13 Resistant Materials

8.1.13.1 For exchangers designated for wet sour HIC (hydrogen induced
cracking) services as defined in this specification with normal operating design

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temperatures between 0°C (32°F) and 150°C (212°F), all plates for headers
shall be made of HIC resistant steel qualified in accordance with
01-SAMSS-016.

8.1.14 All the components (header, plain tube, fin tube, nozzle, blade,
shaft, fan ring, plenum, motor and plug) shall be fabricated by Saudi Aramco
approved exchanger manufacturer.

8.2 Headers

8.3 Other Components

8.3.1

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

blades and fan components shall not be used when the air outlet
temperature for induced draft fans exceeds 107°C with fans switched-off.

8.3.2
Steel used for slide plates shall be type 316 stainless steel. Carbon steel
slide plates shall not be used.

8.3.3
The materials of construction for spiral wound gaskets shall be as follows:

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

Type 304 or 316 stainless steel windings with solid Type 304 or 316 stainless
steel outer centering rings.

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

304 or 316 stainless steel windings with solid carbon steel outer
centering rings.

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

Type 321 or 347 stainless steel windings with solid Type 304 or 316 outer
centering rings.

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

same material as the windings corresponding to the design metal temperature.

8.4 Impact testing

8.4.1 The Exchanger Manufacturer shall determine impact testing

requirements of materials based on the values of the minimum design metal
temperature (MDMT), unless lower test temperature is specified on the data
sheet.

8.4.2 Impact testing requirements for materials not listed in Table 1,

shall be obtained from the Saudi Aramco Engineer.

8.4.3 The minimum acceptable Charpy impact energy values for

steels listed in Table 3 shall be per Table 2 unless larger values are specified

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on the data sheet. Materials that are not listed in Table 3 shall be referred to
Saudi Aramco Engineer for classification

8.4.4 For Div. 1 exchangers the impact testing exemptions of UG-20 (f),
UCS-
66 (b)(1) and (3), UCS-68(c), UG-84 (b)(2) and by reference to Table UG-
84.4 are not permitted. For Div. 2 exchangers the exemptions of AM-
213.1 and AM-218.2 are not permitted.

9 Fabrication of the Tube Bundle

9.1 Welding

9.1.1 General

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

requirements through of SAES-W-010.

9.1.1.5 Corner weld joints in box headers shall be in accordance

with ASME SEC VIII D1.

9.1.1.6 The beveled edges of carbon steel plates with thickness 25

mm and thicker and all ferrous alloy plates shall be magnetic particle
or liquid penetrant examined, after cutting, for linear discontinuities.
Defects shall not exceed limits as per ASME SA-20.

9.1.1.7 Plate edge laminations revealed by magnetic particle

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

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

headers with a smooth inner edge radius.

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

attachments.

9.1.1.10 All external non-pressure welded attachments shall

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

9.2 Postweld Heat Treatment

9.2.1 Code exemptions for PWHT of P4 and P5 materials are not
permitted for applications involving either wet sour service or
hydrogen or materials exceeding 1.5% nominal chromium content.

9.2.2 The maximum PWHT soaking temperature for quenched

and tempered carbon steel and C-0.5 Mo materials shall not
exceed the temperature at which the test pieces were heat treated

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as shown on the Mill Test Certificates or 650°C maximum for
carbon steel, 690°C maximum for
C-0.5 Mo and 700°C for low alloy steels.

9.2.3 Final PWHT shall follow all welding and repairs but shall
be performed prior to any hydrotest or other load test.

9.2.4 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"

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

9.3 Tube-to-tubesheet joints

9.3.1.2

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

for exchangers with stainless steel, monel, and non-ferrous tubes, and for
exchangers classified in hydrogen, cyclic, or lethal services.

9.3.4.4

Welded tube to tube sheet joint shall not be used for services that require
postweld heat treatment for resistance due to the service such as caustic or
amine.

9.4 Gasket contact surfaces

9.4.4
(Exception) Nozzle gasket seating surfaces shall comply with the
following:

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

except hydrogen.
2) For spiral wound gaskets in hydrogen service, 125 to 150 AARH.
3) The sidewalls of rings joint flanges, in all services, 63 AARH.
9.5 Thread lubrication

9.8 Heat Treatment of Tubes

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

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

from the tangent line of all carbon steel tubes for exchangers in
caustic, wet sour and amine services
2) Monel, brass and all chrome alloy tubes in all services

The following tubes shall be solution annealed:

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1) Entire tubes manufactured of unstabilized stainless steels or

non low carbon or Nickel base alloys in accordance with ASME SA-
688.
2) U bends, including 150 mm of straight portions measured from
the tangent lines of all stabilized stainless steels and low carbon
stainless steels or Nickel base alloys.
9.9 Hot Forming

9.9.1

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

operation (hot or cold) for components made of P-No. 3, 4, 5, 8, 9A or 9B
materials.The heat treatment shall be annealing, normalizing, normalizing
and tempering, or quench and tempering, as required.
9.9.2

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

Saudi Aramco Engineer for approval prior to commencement of any
fabrication requiring hot forming. The procedure shall describe all
heat treatment operations and tests to be performed. The tests
shall include, but not limited to, all of the mechanical tests required
by the original material specification.
10 Inspection, Examination, and Testing
10.1 General

10.1.3 (Exception) Exchangers manufactured in accordance

with this specification are subject to verification by the Saudi Aramco
Inspector in accordance with Saudi Aramco Inspection Requirements
Form 175-323600.

10.1.5 Examination procedures shall be established in

accordance with ASME SEC V. A written procedure for each
examination method and technique, including acceptance criteria to
be used, shall be submitted to the Saudi Aramco Inspector for
approval. Qualification of the Exchanger Manufacturer's procedure
may be required, as determined by the Saudi Aramco Inspector.

10.1.6 Written reports and evaluations of all examinations

performed by the Exchanger Manufacturer shall be made and
submitted to the Saudi Aramco Inspector, at a frequency to be
determined by the Saudi Aramco Inspector.

10.1.7 Additional examination of any weld joint at any stage of

the fabrication may be requested by the Saudi Aramco Inspector,
including re- examination of previously examined joints. The Saudi
Aramco Inspector also has the right to request or conduct
independent NDE of any joint. If such examination should disclose
non-conformance to the requirements of the applicable Code or this
specification, all repair and NDE costs shall be done at the
Exchanger Manufacturer's expense.

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10.1.8 Surface irregularities, including weld reinforcement,

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

10.1.9
Examination of all welds shall include a band of base metal at least
one inch wide on each side of the weld.

10.1.10
The Saudi Aramco Inspector shall have free access to the work at all
times.
Saudi Aramco shall have the right to inspect the fabrication at any
stage and to reject material or workmanship, which does not
conform to the specified requirements. All of the rights of Saudi
Aramco and their designated representatives for access,
documentation, inspection, and rejection shall include any work
done by sub-contractors or sub-vendors.

10.1.11
Saudi Aramco reserves the right to inspect, photograph, and/or videotape
all material, fabrication, coating, and workmanship and any materials or
equipment used or to be used for any part of the work to be performed.

10.1.12
Saudi Aramco may reject the use of any materials, equipment, or tools that
do not conform to the specification requirements, jeopardize safety of
personnel, or impose hazard of damage to Saudi Aramco property.

10.1.13
The Exchanger Manufacturer shall provide the Saudi Aramco Inspector all
reasonable facilities to satisfy him that the work is being performed as
specified.

10.1.14
The Exchanger Manufacturer shall furnish, install, and maintain in a safe
operating condition all necessary scaffolding, ladders, walkways, and
lighting for a safe and thorough inspection.

10.1.15
Prior to final inspection and pressure testing, the inside and outside of the
exchanger shall be thoroughly cleaned of all slag, scale, dirt, grit, weld
spatter, paint, oil, etc.

10.1.16
Inspection at the mill, shop, or fabrication yard shall not release the
Exchanger Manufacturer from responsibility for repairing or replacing any
defective material or workmanship that may be subsequently discovered in
the field.

10.2 Quality Control

10.2.1 Radiographic testing shall be performed as follows:

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

lead foil screens shall be permitted unless otherwise approved by the Saudi
Aramco Inspection Department.

10.2.1.2
Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as
individual rounded indications. Clustered or aligned tungsten inclusions
shall be removed and repaired.
10.2.1.3

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

1) Lethal services
2) Hydrogen services
3) Cyclic services
4) Weld joints where any of the pressure retaining materials
requires impact testing per the applicable Code or this
specification.
5) Exchanger weld joints requiring full radiography per the
applicable Code (see UW-11 for Division 1 exchangers and AF-220
for Division 2 exchangers).

10.2.1.4 Where nozzles are installed onto or encroaching on a

corner weld in the header, 100% ultrasonic testing shall be performed on
the corner weld prior to the installation of the nozzle.

1) The corner weld shall be 100% ultrasonically tested

after the installation of the nozzle.
2) Magnetic particle examination shall be performed on the root
pass and final pass of the weld joint attaching the nozzle.

10.2.1.5 Plates for exchangers in hydrogen and wet sour

services shall be ultrasonically tested in accordance with ASME
SA-435.

10.2.8 (Exception) Weld hardness testing shall be in

accordance with the requirements of SAES-W-010.

10.2.13 Radiographic film interpretation shall be done by personnel

certified in accordance with ASNT CP-189 to ASNT Level II Film
Interpreter or approved equivalent.

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

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

10.2.15
100% ultrasonic examination is required for corner joints in headers and
category D joint for nozzle connections in exchangers for the services and
design conditions stipulated in paragraph 10.2.1.3 of this specification.

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

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

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

wet sour, caustic, amine, hydrogen and hydrocarbon services

2) All internal and external welds for all services made using the
SMAW welding process when the nominal thickness of pressured
components is 25 mm and thicker

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

required NDE after the final postweld heat treatment.

10.3 Pressure Test

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

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

2) For exchangers with stainless steel, monel or non-ferrous
tubes, the water shall not contain more than 50 ppm chlorides.
3) For lube-oil and seal-oil exchangers the fluid to be used for
pressure testing shall be the system fluid.

10.3.4 (Exception) Pressure tests shall be performed after

completion of all external and internal welding and heat treatment , in
accordance with the Code and this specification.

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

10.3.9
After testing, exchangers shall be completely drained and thoroughly dried
with dry air.

10.3.10
For Division 1 exchangers: Test pressure shall be 1.3 times its calculated
MAWP in the hot and corroded condition multiplied by the lowest ratio (for
the materials of which the tube side is constructed) of the allowable stress
for the test temperature to the allowable stress for the design temperature.

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

MAWP in the hot and corroded condition multiplied by the lowest ratio
(for the materials of which the tube side is constructed) of the stress
intensity for the test temperature to the stress intensity for the design
temperature.

10.3.11 Temperature of water during hydrostatic testing shall be

maintained at not less than 17°C throughout the testing cycle.

10.5 Nameplates

10.5.1 The name plate should indicate the test pressure.

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10.5.4 All exchangers shall be Code stamped.

10.5.5

Nameplates and nameplate mounting brackets shall be located such that they are easily
readable from a platform. Brackets with continuous welding shall extend from the
outside of exchanger with sufficient access for surface preparation, and painting.

10.5.6

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

bracket.

10.5.7

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

11 Preparation for Shipment

11.2 Surfaces and Finishes

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

H-001. through
11.2.4

11.2.5 Prior to coating, the internal and external

surfaces shall be cleaned to remove all scale, rust, grease dirt,
weld spatter and foreign objects.

11.2.6 Gasket contact surfaces shall not be painted.

11.3 Identification, Conditioning and Notification

11.3.1 (Exception) Marking shall be done with water-

insoluble material that contains no harmful substances that would
attack or harmfully affect the material at ambient or elevated
temperatures. The marking material shall be free of lead, sulfur,
zinc, cadmium, mercury, chlorine, or other halogens.

11.4 The internals of exchangers shall be protected from

corrosion by use of a non-toxic vapor phase corrosion inhibitor
such as CORTEC VCI-309 or
307 or equivalent, applied at a rate of 0.3 kg/m³ fogged into the space.

The inhibitor selected must be appropriate for the metallurgy of the

exchanger. Exchangers must be sealed vapor tight for the inhibitor
to be effective. Corrosion inhibitors for use on exchangers with
stainless steel and Monel tubes must be chloride free, suitable for its
intended use and not result in crevice corrosion.
Alternatively, nitrogen blanketing at a pressure of 5 psig may be used.

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11.5
Flanged connections and all other machined surfaces shall be
protected by a suitable coating, which is easily removed in the field
and fitted with a steel or wood cover, 3 mm thick and neoprene
gaskets. Covers shall be securely attached by a minimum of four
bolts equally spaced. For ocean shipment, flanged connections shall
also be covered with heavy duty plastic bags securely taped to the
nozzles.

11.6

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

cleaned from all loose scales, weld slags, dirt and debris to the
satisfaction of the Saudi Aramco Inspector.

11.7

Exchangers shall be protected from salt water and salt water spray
during shipment.
12 Supplemental Requirements
12.1 General
The requirements of API STD 661 section 12 shall be applied for the
conditions outlined in API STD 661 paragraph 12.1 if specified by the
Design Engineer.
12.3 Examination

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

thicker including temporary welds are to be wet fluorescent magnetic particle
tested after final heat treatment. For non ferromagnetic material, all welds
on plate 50 mm and thicker including temporary welds are to be wet
fluorescent liquid penetrant tested after final heat treatment.

Revision Summary

22 January 2008 Major revision.

5 April 2008 Editorial revision.
15 August 2009 Editorial revision to replace cancelled SAES-A-301 with NACE
MR0175/ISO 15156.
23 June 2010 Editorial revision to add paragraph 8.1.14.

Table 1 – Acceptable Materials for Carbon and Low Alloy Steels

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Design Metal Temperature

Exchanger Component -46 to 0°C 1 to 425°C 351 to 645°C
SA-516 Grade 60
Header plates, pass SA-516 Grade 60N
SA-516 Grade 70, or SA-387
partition plates and SA-516 Grade 70N, SA-537 Class 1 or
Grades 11, 12, or 22
stiffener plates or SA-537 Class 1 (1)
SA-285 Grade C
SA-106 Grade B
Nozzle necks SA-333 Grade 6 (1) SA-335 P11, 12, or 22
SA-53 Grade B
(2) SA-334 or SA-179 or SA-214 or
Tubes SA-179 or SA-214
SA-249 Type 304 SA-213 Type 304
Forged flanges, forged SA-182
SA-350 LF2 SA-105
fittings, and plugs F11, 12, or 22
Wrought fittings SA-420 WPL6 SA-234 WPB SA-234 WP 11, 12, or 22
Studs/nuts for SA-320 L7 w/ SA-193B7/ SA-193 B5, or B16 w/
pressure connections SA-194 Grade 4 SA-194 Grade 2H SA-194 Grade 3

General Notes:
(A) Materials for hydrogen service shall be selected in accordance with API PUBL 941 using a value
for the hydrogen partial pressure 10% above the design partial pressure and a temperature of 30°C
above the design temperature.
(B) Materials for exchangers in amine service shall be selected in accordance with Table 1
and API RP 945.
(C) Materials for exchangers in wet sour service, with design temperature up to 212°F
(100°C), shall be in accordance with Table 1, with the following revisions:
(1) Forged flanges and forged fittings are restricted to: SA-350 LF1 or LF2 or SA-266, Grade 4,
S2, or S9. Flanges above 24-inch diameter shall be SA-266, Grade 4, S2, or S9.
(2) Studs and nuts are restricted to: SA-193 B7M or L7M and SA-
194 Grade 2HM.
(3) Satisfy the requirements of NACE MR0175/ISO 15156 and
NACE RP0472.
(D) Low alloy materials shall not be mixed, i.e., an exchanger requiring 1 1/4 Cr-1/2 Mo
materials for pressure components shall have all pressure parts (with the exception of
tubes) manufactured from 1 1/4 Cr-1/2 Mo.
(E) All chrome alloy material shall be specified in the normalized and tempered heat-treated
condition.
(F) The material for nameplate mounting brackets shall be of the same type and material grade as
the header.

Specific Notes:
(1) SA-36, SA-53, SA-283, and SA-285 materials may be used for

utility services only.

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

seamless.

Table 2 – Charpy-V Impact Test Requirements

Minimum Required Impact Value for Full Size Specimen at MDMT,

Joules

Reference Thicknesst
inch

Material Class t < 1/2 1/2 < t < 1 1<t<2 t>2

1a 34/27 34/27 34/27 34/27
1b 34/27 34/27 34/27 34/27
2a 34/27 34/27 34/27 34/27
2b 34/27 34/27 34/27 47/38
2c 34/27 34/27 47/38 61/48
3 34/27 34/27 34/27 34/27
Notes:
(1) In the notation such as 34/27, the first number is the minimum average energy of
three specimens and the second number is the minimum for one specimen impact
test results.
(2) See Table 3 for material specification.

Table 3 – Material
Classes
Class Material Specification
1a SA 53 Gr. B
2b SA 105
2a SA106 Gr. B

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2b SA 182 Gr. F11 and F12

2c SA 182 Gr. F22
3 SA 203 Gr. D and E
2b SA 204 Gr. A, B and C
2b SA 266 Gr. 1
2c SA 266 Gr. 2 and 4
1a SA 333 Gr. 1
3 SA 333 Gr. 3
2a SA 333 Gr. 6
2b SA 335 Gr. P11, P12 and P22
2b SA 336 Gr. F12
2c SA 336 Gr. F11 and F22
2b SA 350 Gr. LF2
3 SA 350 Gr. LF3
2b SA 387 Cl. 1, Gr. 11, 12 and 22; Cl. 2, Gr. 12
2c SA 387 Cl. 2, Gr. 11 and 22
2a SA 442 Gr. 55 and 60
2b SA 516 Gr. 70
2c SA 533 Cl. 1
2b SA 537 Cl. 1
2c SA 420 Gr. WPL3 and WPL6
2c SA 234 Gr. WPB
2c SA 234 Gr. WP11, WP12 and WP22

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