Understanding Heat Exchanger Reading 03- Part 2 of 2 The ARAMCO Std.

My Reading on Heat Exchanger 

Reading 03- The ARAMCO Std. 

Part 2 of 2 

for my Aramco AOC’s QM31 Exam Preparations 

31 st May 2018 

Charlie Chong/ Fion Zhang


Charlie Chong/ Fion Zhang 

Fion Zhang at Shanghai 

Damuqiao 大木桥路 

31 st May 2018


http://greekhouseoffonts.com/

The Magical Book of Heat Exchanger Reading 




有 

书 

真 

幸 

福 

无事小神仙

Parts: 

1. API660/ ISO 16812:2007 

Shell-and-tube Heat Exchangers 

2. Materials System Specification 

32-SAMSS-007 

Manufacture of Shell and Tube Heat Exchangers 

3. Inspection & Testing Requirements SAUDI ARAMCO FORM-175 CODE 

NUMBER: IR323100 SCOPE: Heat Exchangers: Shell and Tubes. 



American Petroleum Institute API 600 Std.

Part 1: 

Shell-and-tube Heat Exchangers 

ANSI/API STANDARD 660 

EIGHTH EDITION, AUGUST 2007 

ISO 16812:2007 (Identical), Petroleum, petrochemical 

and natural gas industries-Shell-and-tube Heat 

Exchangers 


Contents 

1. Scope 

2. Normative references 

3. Terms and definitions 

4. General 

5. Proposals 

6. Drawings and other required 

7. Design 

8. Materials 

9. Fabrication 

10. Inspection and testing 

11. Preparation for shipment 

12. Supplemental requirements 

Annex A (informative) Recommended practices 

Annex B (informative) Shell-and-tube heat exchanger checklist 

Annex C (informative) Shell-and-tube heat exchanger data sheets 

Annex 0 (informative) Responsibility data sheet 


8 Materials 

8.1 General 

• 8.1.1 The purchaser shall specify if the service is sour (i.e. if sulfide stress 

cracking is possible) in accordance with: 

• ISO 15156 (all parts) for oil and gas production facilities and natural gas 

sweetening plants, or 

• in accordance with NACE MR0103 for other applications (e.g. oil 

refineries, LNG plants and chemical plants), 

in which case all materials in contact with the process fluid shall meet the 

requirements of that standard. 

NOTE For the purpose of this provision NACE MR0175 is equivalent to ISO 

15156. 


8.1.2 Castings shall not be used unless approved by the purchaser. 

8.1.3 Material for external parts that are welded directly to the heat exchanger, 

such as pads, brackets and lugs, shall be of the same nominal composition 

as the material to which they are welded. 

8.1.4 Alloy cladding shall be weld-overlay, integrally clad or explosion-bonded. 

Loose liners or sleeves shall not be used without the approval of the 

purchaser. 


8.2 Gaskets 

8.2.1 Gaskets shall not contain asbestos. 

8.2.2 Material for metal-jacketed, serrated-metal or solid-metal gaskets shall 

have a corrosion resistance at least equal to that of the gasket contact 

surface material. 

8.2.3 Metal windings of spiral-wound gaskets shall be of austenitic stainless 

steel unless otherwise specified or approved by the purchaser. 

8.2.4 Serrated- or solid-metal gaskets, including welds, shall be softer than 

the gasket contact surface. 

8.2.5 Gasket material, including filler material, shall be selected to withstand 

the maximum design temperature. 

8.3 Tubes 

8.3.1 Integrally finned tubes of copper alloy shall be furnished in the 

annealed-temper condition, such as described in ASTM B 359/B 359M. 

8.3.2 All welded tubes shall be eddy-current tested in the finished condition 

over their full length. 


8.3 Tubes 

8.3.1 Integrally finned tubes of copper alloy shall be furnished in the 

annealed-temper condition, such as described in ASTM B 359/B 359M. 

8.3.2 All welded tubes shall be eddy-current tested in the finished condition 



Tubes 

All welded tubes shall be eddy-current tested in the 

finished condition over their full length. 


http://www.pardtube.com/technicals/non-destructive-tests-for-welded-tube/

Tubes 

All welded tubes shall be eddy-current tested in the finished condition over 

their full length. 


Tubes 

All welded tubes 

shall be eddycurrent 

tested in 

the finished 

condition over 

their full length. 


Tubes- All welded tubes shall be eddy-current tested in the finished condition 









9 Fabrication 

9.1 Shells 

9.1.1 All longitudinal and circumferential welds of shells for other than kettletype 

heat exchangers shall be finished flush with the inner contour for ease of 

tube-bundle insertion and withdrawal. For kettle-type heat exchangers, this 

requirement shall not apply to welds in the enlarged section if they are not in 

the bottom quadrant of the shell. 


Bottom 

Quadrant

Kettle-type Heat Exchangers 


Kettle-type Heat Exchangers 


9.1.2 For removable-bundle heat exchangers, the permissible out-ofroundness 

of a completed shell, after all welding and heat treatment, shall 

allow a metal template to pass through the entire shell length without binding. 

The template shall consist of two rigid disks (each with a diameter equal to 

the diameter of the transverse baffle or support plate), rigidly mounted 

perpendicularly on a shaft and spaced not less than 300 mm (12 in) apart. 

9.1.3 Transverse baffle-to-shell clearances greater than those indicated in 

TEMA (8th edition), Table RCB-4.3, shall not be used unless approved by the 

purchaser. 

baffle-to-shell 

clearances 


Transverse baffle-to-shell 

baffle-to-shell 

clearances 


TEMA (8th edition), TABLE RCB-4.3 

Standard Cross Baffle and Support Plate Clearances 

Dimensions In Inches (mm) 

Nominal Shell ID 

6-17 (152-432) 

18-39 (457-991) 

40-54 (1016-1372) 

55-69 (1397-1753) 

70-84 (1n8-2134) 

85-100 (2159-2540) 

Design ID of Shell Minus 

Baffle OD 

1/8 (3.2) 

3/16 (4.8) 

1/4 (6.4) 

5/16 {7.9) 

3/8 {9.5) 

7/16 (11.1) 


9.2 Pass-partition plates 

Pass-partition plates for forged or welded channels and floating heads shall 

be welded full length, either from both sides or with full-penetration welds, 

except for special designs approved by the purchaser. If welded from both 

sides, the first 50 mm (2 in) from the gasket face shall be full-penetration 

welds. 

9.3 Connection junctions 

Nozzles and couplings shall not protrude beyond the inside surface of the 

shell, channel or head to which they are attached. 

9.4 Tubes 

All tubes including U-tubes shall be formed from a single length and shall 

have no circumferential welds. 


Tubes 

All tubes including 

U-tubes shall be 

formed from a single 

length and shall 

have no 

circumferential welds. 


9.5 Welding 

9.5.1 Welds may be made using any welding process other than 

oxyacetylene gas welding. 

9.5.2 Category A welded joints and category B welded joints shall be fullpenetration 

welds. 

9.5.3 All welds attaching connections to cylinders or to heads shall fully 

penetrate the total thickness of the component wall or the connection wall 

forming the attachment. 

9.5.4 If connections abut a component fabricated from plate (e.g. in the case 

of a set-on nozzle), the edge of the hole in the plate to which the connections 

are attached shall be examined for laminations by means of the magneticparticle 

or liquid-penetrant method. Subject to agreement with the purchaser, 

indications found shall be cleared to sound metal and then repair-welded. 

9.5.5 · Backing strips that remain in place on the inside of a component after 

welding is completed shall not be used unless approved by the purchaser. 


• 9.5.6 Tubes shall be welded to tubesheets if specified by the purchaser (e.g. 

for certain process conditions). The welding and testing procedures in these 

instances shall be mutually agreed upon by the purchaser and the vendor. 

9.5.7 It is not necessary that the welds attaching insulation support rings be 

continuous. 

9.5.8 Welds attaching other non-pressure attachments (such as lugs or 

structural steel supports) shall be continuous. 

9.5.9 Repair-associated welding procedures shall be submitted to the 

purchaser for review before the start of repair. 

9.5.10 Full-penetration welds shall be used for all internal attachments to the 

pressure boundary components that are exposed to hydrogen service. 

Geometric Gaps or void in base 

metal, continuous with the pressure 

boundary in hydrogen service may 

trap atomic Hydrogen forming → H 2 

gas at voids or crevices. 


9.6 Heat treatment 

9.6.1 Machined contact surfaces, including any threaded connections, shall 

be suitably protected to prevent scaling or loss of finish during heat treatment. 

• 9.6.2 Requirements and procedures for heat treatment after bending the U- 

tubes shall be specified by the purchaser. If the purchaser specifies heat 

treatment of U-bends of austenitic stainless steel, the procedure shall be as 

described in the pressure design code or shall be agreed between purchaser 

and vendor. 

The U-bends of copper and copper alloy tubes, including copper-nickel alloys, 

shall be heat-treated as required by the pressure design code or shall be 

agreed between purchaser and vendor. 


9.6.3 The heat-treated portion of the U-bend shall extend at least 150 mm (6 

in) beyond the tangent point. 


9.6.4 Post-weld heat treatment of fabricated carbon steel and low-alloy (max. 

9% chromium) steel channels and bonnets shall be performed for the 

following: 

a) channels and bonnets with six or more tube passes: 

b) channels and bonnets whose nozzle-to-cylinder internal diameter ratios 

are 0,5 or greater, except where a conical reducer is used in place of the 

channel or bonnet. 


Post-weld Heat Treatment 

of fabricated carbon steel and low-alloy (max. 9% chromium) steel channels 

and bonnets 


• 9.6.5 The purchaser shall specify if post-weld heat treatment is required for 

weld-overlaid channels and bonnets. 

9.6.6 Post-weld heat treatment shall be performed for all carbon steel and 

low-alloy (max. 9 % chromium) steel floating-head covers that are fabricated 

by welding a dished-only head into a ring flange. 

• 9.6.7 The purchaser shall specify if heat treatment is required for process 

reasons. 


Heating Cycle 

ASME A335 Cr-Mo P92 Steel Pipe 

http://www.nickelalloys.com.br/Metrode%20CD%202011/Technical%20Literature/CrMo%20-%20P92/P92%20paper-IIW%20Conference-Graz.pdf 


http://pressurevesseltech.asmedigitalcollection.asme.org/article.aspx?articleid=1761867

Post-weld Heat Treatment 

- on site Stress Relieve of Heat Exchanger 


http://airfurnace.us/the-miracle-of-pwht-furnace/

9. 7 Dimensional tolerances 

9.7.1 Manufacturing tolerances shall be such that nominally identical parts 

are interchangeable. 

9.7.2 Heat exchangers that are to be stacked in service shall be stacked in 

the shop to check connection alignment. 

9.7.3 For stacked heat exchangers, mating nozzle flanges shall not be out of 

parallel with each other by more than 0,8 mm (1/32 in), measured across any 

diameter. Separation of mating nozzle flanges shall not exceed 3 mm (1/.8 in) 

after installation of the gasket. Bolts shall be capable of being inserted and 

removed freely without binding. 

Shims shall be installed as required between the supports and shall be tackwelded 

in place. 


Gap: 3 mm max 

Dimensional tolerances 

For stacked heat exchangers, 

mating nozzle flanges shall not 

be out of parallel with each other 

by more than 0,8 mm (1/32 in), 

measured across any diameter. 

Separation of mating nozzle 

flanges shall not exceed 3 mm 

(1/.8 in) after installation of the 

gasket. Bolts shall be capable of 

being inserted and removed 

freely without binding. 

Shims shall be installed as 

required between the supports 

and shall be tack-welded in place. 

0,8 mm max 


http://underfill.blogspot.com/2010/11/pipe-fabrication-tolerances-courtesy.html

Piping Fabrication Dimensional tolerances 

A - Variations in the indicated dimensions for 

Center to Face. Location of attachments etc, 

shall not exceed 3 mm. (Tolerance shall be 

cumulative) 

B - For Piping Bends having a radius equal to 

SIX times the diameter or larger variations in the 

finished pipe caused by bending including any 

folds and bulges shall not exceed ± 3% x 

Nominal Ø of the Pipe. 

C - Lateral translation of flanges in any direction 

from the indicated position shall not exceed 1.5 

mm. 

D - Rotation of flanges from the indicated 

position as shown shall not exceed 1.5 mm. 

E - Alignment of flanges shall not deviate from 

the indicated position measured across any 

diameter more than 0.75 mm. 

Gap: 3 mm max 

0,8 mm max 


http://www.wermac.org/documents/tol_pipefabrication.html

9.8 Gasket contact surfaces other than nozzle-flange facings 

9.8.1 Gasket contact surfaces shall have finishes as given in Table 2. 

Table 2-Gasket contact surface finishes 

Dimensions in micrometers (micro-inches) 

Type 

Solid flat metal gaskets 

Surface roughness 

Ra a 

1,6 (63) maximum 

Double-jacketed gaskets 1,6 to 3,2 (63 to 125) 

Spiral-wound gaskets 3,2 to 6,3 (125 to 250) 

Serrated gaskets or corrugated-metal 

gaskets with soft gasket-seal facing 

a 

Ra is roughness average. 

3,2 to 6,3 (125 to 250) 


Ra value 

The roughness of a surface has most commonly been measured by an instrument in which a 

stylus travels across the surface, the movement of the stylus is amplified and the signal recorded. 

The result is generally expressed as Ra or average roughness and is the arithmetic average 

value of the deviation of the trace above and below the centre line. The value of Ra is normally 

measured in micromeres. ISO standards use the term CLA (Centre Line Average). Both are 

interpreted identically 

Figure 1. The principle of measuring average roughness (Ra) 


http://www.worldstainless.org/Files/issf/non-image-files/PDF/Euro_Inox/RoughnessMeasurement_EN.pdf

Roughness Parameters (EN ISO 4287) Ra 

– arithmetical mean roughness value: The arithmetical mean of the absolute 

values of the profile deviations (Z i ) from the mean line of the roughness 

profile (Figure 6). 

Figure 6: Arithmetical mean roughness value Ra 

Mean line of the 

roughness profile 

arithmetical mean of 

the absolute values 

of the profile 

deviations (Z i ) 


https://www.mitutoyo.com/wp-content/uploads/2012/11/1984_Surf_Roughness_PG.pdf

Elcometer 7062 MarSurf PS10 Surface Roughness Tester 

https://www.elcometer.com/en/coating-inspection/surface-cleanliness-surface-profile/surface-roughness/elcometer-7062-marsurf-ps10-surface-roughness-tester.html 


9.8.2 The flatness tolerance (maximum deviation from a plane) on peripheral 

gasket contact surfaces shall be 0,8 mm (1/32 in). 

• 9.8.3 The purchaser shall specify if there is a special application such as 

high-pressure service, high temperature service or hydrogen service. In such 

cases, the flatness tolerances on peripheral gasket contact surfaces shall be 

as given in Table 3. 

Table 3-Flatness tolerance on peripheral gasket contact surfaces 

Dimensions in millimeters (inches) 

Heat exchanger nominal diameter 

Tolerance 

≤ 375 (15) ± 0,08 (0,003) 

> 375 to ≤ 750 (15 to 30) ± 0,15 (0,006) 

> 750 to ≤ 1 125 (31 to 45) ± 0,20 (0,008) 

> 1125 (45) ± 0,20 (0,008) 


9.8.4 The flatness tolerance on pass-partition grooves and mating pass 

partition plate edges shall be 0,8 mm (1/32 in). 

9.8.5 The flatness of gasket contact surfaces shall be measured with a dial 

gauge. However, the flatness of the pass partition grooves and mating pass 

partition plate edges may be measured with a straight edge. 

9.8.6 Flange flatness tolerance and surface finish shall be measured after the 

flange has been attached to the component cylinder or the cover, and after 

any post-weld heat treatment. 

9.8.7 The flatness of tubesheet gasket contact surfaces shall be measured 

after the tube-to-tubesheet joints have been completed. 


9.9 Tube holes 

9.9.1 Tube-hole grooves shall be square-edged, concentric and free from 

burrs. 

9.9.2 If austenitic stainless steel, duplex stainless steel, titanium, cupro-nickel 

or nickel-alloy tubes are specified, the tube holes shall be machined in 

accordance with TEMA (8th edition), Table RCB-7.41, column (b) (Special 

Close Fit). 

RCB-7.2 TUBE HOLES IN TUBESHEETS 

RCB-7.21 TUBE HOLE DIAMETERS AND TOLERANCES 

Tube holes in tubesheets shall be finished to the diameters and 

tolerances shown in Tables RCB-7.21 and RCB-7.21 M, column (a). 

To minimize work hardening, a closer fit between tube OD and tube 

ID as shown in column (b) may be provided when specified by the 

purchaser. 

Tube Hole 

Square-edged 


9.10 Tube-to-tubesheet joints 

9.10.1 If roller-expanded joints are utilized, the tube wall thickness reduction 

shall be in accordance with Table 4. 

Table 4- Maximum allowable tube wall thickness reduction for rollerexpanded 

tube-to-tubesheet joints 

Material 

Carbon steel and low-alloy (max. 9% chromium) 

steel 

Stainless and high-alloy steel 

Titanium and work-hardening non-ferrous 

Maximum tube wall thickness 

reduction % 

8 a 

6 a 

5 a 

Non-ferrous non-work-hardening (e.g. admiralty 

brass) 

a 

These may be increased by a further 2 % if approved by the purchaser. 

8 a 


Experimental Investigation 

of Friction Stir Seal Welding 

of Tube–Tubesheet Joints 


http://pressurevesseltech.asmedigitalcollection.asme.org/article.aspx?articleid=1879821

Tube Expander 


https://krais.com/correct-tubes-expansion/

9.10.2 If welded-and-expanded joints are specified, tube-wall thickness 

reduction should begin at least 6 mm (1/4 in) away from welds. 

9.10.3 In no case shall the expansion encroach within 3 mm (1/8 in) of the 

shell side face of the tubesheet. 

9.10.4 For shell-side-clad tubesheets, the tube shall be expanded to seal 

against the cladding material for a minimum distance of 6 mm (1/4 in). 


Tube Expansion 

1. If welded-and-expanded joints are specified, tube-wall thickness 

reduction should begin at least 6 mm (1/4 in) away from welds. 

2. In no case shall the expansion encroach within 3 mm (1/8 in) of the shell 

side face of the tubesheet. 

3. For shell-side-clad tubesheets, the tube shall be expanded to seal against 

the cladding material for a minimum distance of 6 mm (1/4 in). 

1/2/3 

Weld 

6mm min 


9.11 Assembly 

9.11.1 Match marks or dowels ( 木钉 , 销子 ) shall be provided to prevent misassembly 

of the following bolted joints: 

a) floating-head cover to tubesheet; 

b) channel to tubesheet; 

c) grooved channel cover to channel; 

d) stationary tubesheet to shell. 

9.11.2 The threads of external studs and nuts shall be coated with a suitable 

anti seize compound to prevent galling. 


Dinner Time 

20180601- 1817hrs 儿童节快乐在上海 . 

儿童节快乐 


10 Inspection and testing 

10.1 Quality assurance 

• 10.1.1 If specified by the purchaser, materials, fabrication, conformance with 

mechanical design and testing of heat exchangers shall be subject to 

inspection by the purchaser, a designated representative or both. The 

purchaser shall specify the required degree of involvement. Examples of this 

are as follows: 

a) verification that qualified welding procedures and qualified welders and 

welding operators are being used by the manufacturer; 

b) verification that the construction complies with the applicable drawings 

and with this International Standard; 

c) review and/or examination of the results of any specified non-destructive 

examination; 

d) witnessing of hydrostatic testing and any additional testing specified by 

the purchaser; 

e) examination of required material certificates and the manufacturer's data 

reports. 


Quality assurance 

verification that the construction complies with the applicable drawings and 

with this International Standard; 



witnessing of hydrostatic testing and any additional testing specified by the 

purchaser; 



verification that qualified welding 

procedures and qualified welders and 

welding operators are being used by 

the manufacturer; 



verification that qualified welding 

procedures and qualified welders and 

welding operators are being used by 

the manufacturer; 



review and/or examination of the results 

of any specified non-destructive 

examination; 



review and/or examination of the 

results of any specified nondestructive 

examination; 


10.1.2 No tubes or tube holes shall be plugged without notifying the 

purchaser. The method and procedure of plugging shall be subject to the 

approval of the purchaser. 


10.2 Quality control 

10.2.1 Radiography shall be performed in accordance with the pressure 

design code; however, the minimum shall be as follows. 

a) At least one spot radiograph shall be made of each category A welded joint 

and category B welded joint. Nozzle welds are exempt from this requirement. 

b) Spot radiographs shall include each start and stop of welds made by the 

automatic submerged-arc welding process. 

c) Spot radiographs shall be at least 250 mm (10 in) long or shall be full 

length if the weld is less than 250 mm (10 in) long. 

d) Weld porosity limits for spot radiographs shall be as stated in the pressure 

design code for fully radiographed joints. 

10.2.2 The magnetic particle examination method, extent and acceptance 

criteria shall comply with the pressure design code. 



UW-11 RADIOGRAPHIC AND ULTRASONIC 

EXAMINATION 

(a) Full Radiography. The following welded 

joints shall be examined radiographically 

for their full length in the manner 

prescribed in UW-51: 

UW-11 RADIOGRAPHIC AND ULTRASONIC 

EXAMINATION 

(b) Spot Radiography. Except when spot 

radiography is required for Category B or C 

butt welds by (a)(5)(-b) above, butt welded 

joints made in accordance with Type No. (1) or 

(2) of Table UW-12 which are not required to be 

fully radiographed by (a) above, may be 

examined by spot radiography. Spot 

radiography shall be in accordance with UW-52. 


10.2.3 For non-magnetic materials, a liquid penetrant examination shall be 

used in place of any required magnetic-particle examination. 

10.2.4 The liquid-penetrant examination method, extent and acceptance 

criteria shall comply with the pressure design code. 


10.2.5 Weld-hardness testing shall be in accordance with the pressure design 

code or the following requirements, whichever is the more stringent. 

a) The weld metal and heat affected zone of pressure retaining welds in 

components shall be tested. 

b) Examination shall be made after any required post-weld heat treatment. 

c) Brinell hardness limits shall be in accordance with Table 5. 

d) Hardness shall be determined using a 10 mm diameter ball unless 

otherwise specified or approved by the purchaser. 

e) One longitudinal weld, one circumferential weld and, if the connection is 

DN 50 (NPS 2) or larger, each connection-to-component weld shall be 

tested. 

f) If more than one welding procedure is used to fabricate longitudinal or 

circumferential welds, hardness readings shall be made of welds 

deposited by each procedure. 


Table 5-Hardness limits 

Material 

Maximum Brinell hardness HBW 

Carbon steel 225 

Low-alloy steel (2 %Cr max.) 225 

Low-alloy steel (> 2 %Cr to 9 %Cr) 240 

High-alloy martensitic steels 240 

High-alloy ferritic steels 240 


Table 5-Hardness limits 

Material 

Maximum Brinell hardness HBW 

Carbon steel 225 

Low-alloy steel (2 %Cr max.) 225 

Low-alloy steel (> 2 %Cr to 9 %Cr) 240 

High-alloy martensitic steels 240 

High-alloy ferritic steels 240 

10.2.5 Weld-hardness testing 

shall be in accordance with the 

pressure design code or the 

following requirements, whichever 

is the more stringent. 


Brinell hardness 

Hardness shall be determined using a 10 mm diameter ball 

NACE 

MR0175? 


Brinell Hardness 

Testing 


Brinell Hardness 

Testing 


10.2.6 At welded joints in alloy-clad construction, the weld in the base metal 

and in the area adjacent to the weld where the cladding has been stripped 

back shall be examined by magnetic-particle inspection before weld overlay 

of the joint. 

10.2.7 All finished welds in ferromagnetic steel shall be examined after postweld 

heat treatment (unless the pressure design code specifies examination 

after hydrostatic testing) by the magnetic-particle method. 

1 0.2.8 Final welds in all non-magnetic materials, whether of solid alloy or 

alloy-clad plate, shall be examined by the liquid-penetrant method after any 

required post-weld heat treatment. 

10.2.9 Final visual weld inspection shall be performed after post-weld heat 

treatment. 

10.2.10 After cladding, but prior to fabrication, integrally clad material shall be 

subjected to an ultrasonic examination from the clad side in accordance with 

the pressure design code. 

10.2.11 Overlay weldments, back-cladding and attachment welds to overlay 

weldments shall be liquid-penetrant examined after post-weld heat treatment. 


Overlay weldments 

shall be liquid-penetrant 

examined after post-weld 

heat treatment. 

(Stellite-Monel-overlay) 



shall be liquid-penetrant examined after post-weld heat treatment. 




(UV Penetrant Testing) 










Picasso 


Picasso 


Picasso 


1 0.3 Pressure testing 

10.3.1 In the case of welded-and-expanded tube-to-tubesheet joints, the tubeweld 

integrity shall be verified before final expansion of the tubes by a 

pneumatic test from the shell side at a gauge pressure between 50 kPa 

(7,5 psi) and 100 kPa (15 psi), using a soap-water solution to reveal leaks. 

10.3.2 Except for differential-pressure designs, an independent hydrostatic 

test of the shell side and the tube side shall be performed. The minimum fluid 

temperature for hydrostatic testing shall be as required by the pressure 

design code. 

10.3.3 The water used for hydrostatic testing shall be potable and the test 

pressure shall be maintained for at least 1 h. 

10.3.4 The chloride content of the test water used for equipment with 

austenitic stainless steel materials that are exposed to the test fluid shall not 

exceed 50 mg/kg (50 parts per million by mass). Upon completion of the 

hydrostatic test, the equipment shall be promptly drained and cleared of 

residual test fluid. 


Pressure testing 

Welded-and-expanded tube-to-tubesheet joints, the tube-weld integrity shall 

be verified before final expansion of the tubes by a pneumatic test from the 

shell side at a gauge pressure between 50 kPa~ 100 kPa (15 psi), using a 

soap-water solution to reveal leaks. 

Tubesheet 

welding 

Pneumatic 

Testing at 

0.5~1.0 bar 

Final Tube 

Expansion 


Pressure Testing 













The minimum fluid temperature for hydrostatic testing shall be as required by 

the pressure design code. 



The water used for hydrostatic testing shall be potable and the test pressure 

shall be maintained for at least 1 h. 











The water used for hydrostatic testing shall be potable 

and the test pressure shall be maintained for at least 1 h. 



The chloride content of the test water used for equipment with austenitic 

stainless steel materials that are exposed to the test fluid shall not exceed ≤ 

50ppm 

Vent 

Pressure 

Gauge 

Pressure 

Recorder 

PSV 

Pressure 

Gauge 

Vent 

3-ways 

Valve 

To Pressure 

Recorder 

Nitrogen 

Test Manifold 

Temperature Probe 

Air 

Compressor 

for Pretest 

Drain 




Pressure testing 



Chart- Recorder 


• 10.3.5 Any additional requirements for equipment drying or preservation 

shall be specified by the purchaser. 

10.3.6 The shell side hydrostatic test shall be conducted with the bonnet or 

channel cover removed. 

10.3.7 Nozzle reinforcement pads shall be pneumatically tested at 170 kPa 

(25 psi) gauge. 

10.3.8 For safety considerations, any supplementary pneumatic test shall be 

performed at a nominal pressure of 170 kPa (25 psi) gauge. 

10.3.9 Flanged joints that have been taken apart after a hydrostatic test shall 

be reassembled with unused gaskets and re-hydrotested. 

10.3.10 Paint or other external coatings shall not be applied over welds 

before the final hydrostatic test. 

10.3.11 Heat exchangers that are stacked in service shall be hydrotested 

stacked. 


Re-Hydrotesting 

Flanged joints that have been taken apart after a hydrostatic test shall be 

reassembled with unused gaskets and re-hydrotested. 





Never 

Ending Story 





Never 

Ending Story 


10.4 Nameplates and stampings 

1 0.4.1 A stainless steel nameplate shall be permanently attached to the heat 

exchanger in such a manner that it is visible after insulation has been 

installed. 

1 0.4.2 The nameplate shall be located on the shell near the channel end. 

1 0.4.3 The following parts shall be stamped with the manufacturer's serial 

number: 

a) shell flange; 

b) shell cover flange; 

c) Channel or bonnet flange; 

d) channel cover; 

e) stationary tubesheet; 

f) floating tubesheet; 

g) floating-head cover flange; 

h) floating-head backing device; 

i) test ring flange and gland. 


Break 

擂茶 

配料编辑 

擂茶的配料多种多样 , 可以因 

寒暑不同或荤素各异加不同的 

佐料和药物 , 但制作过程基本 

是一样的。春夏湿热 , 常用新 

鲜艾叶、薄荷叶 ; 秋天风燥 , 

多选金盏菊或白菊花、金银花 ; 

冬天寒冷 , 便用桂皮、肉柱子、 

川芎等。据中医验证 , 从茶具 

有生津止渴、防风祛寒、开胃 

健脾、清热解毒、清肝明目、 

润肤美容、延年益寿之功效。 

在客家祖地石壁 , 每户每天都 

制作普通擂茶一钵 , 劳作后回 

来喝上几碗 , 一天的辛苦便烟 

消云散。客人远道而来 , 喝上 

一碗 , 便可提神醒脑 , 充饥益 

体。荤、素擂茶是石壁擂茶的 

特有品种。荤擂茶用冬季腌藏 

的生猪大油 , 拌佐料 , 加炒好 

的肉丝或小肠、煎豆腐、粉干、 

香葱等 , 泡入擂茶中 ; 素的则 

用净茶油拌佐料 , 然后加熟花 

生米、绿豆、糯米饭、地瓜粉 

条、粉干等。 

20180601-2343hrs 

Shanghai 大木桥路 


11 Preparation for shipment 

11.1 Protection 

11.1.1 All liquids used for cleaning or testing shall be drained from heat 

exchangers before shipment. 

11.1.2 Heat exchangers shall be free of foreign matter prior to shipment. 

11.1.3 All openings in heat exchangers shall be suitably protected to prevent 

damage and possible entry of water or other foreign material. 

11.1.4 All flange-gasket surfaces shall be coated with an easily removable 

rust preventative and shall be protected by suitably attached durable covers 

of such material as wood, plastic or gasketed steel. 


11.1.5 All threaded connections shall be protected by metal plugs or caps of 

compatible material. 

11.1.6 Connections that are bevelled for welding shall be suitably covered to 

protect the bevel from damage. 

• 11.1. 7 The purchaser shall specify if there are additional requirements for 

surface preparation and protection (e.g. painting). 

11.1.8 Exposed threads of bolts shall be protected with an easily removable 

rust preventative to prevent corrosion during testing, shipping and storage. 

Tapped holes shall be plugged with grease. 

11.1.9 Tie-rods or tie-bars installed on shell expansion joints for protection 

during shipping shall be painted in a contrasting colour and clearly tagged to 

specify their removal before commissioning. 


11.2 Identification 

11.2.1 The item number, shipping mass and purchaser's order number shall 

be painted on the heat exchanger. 

11.2.2 All boxes, crates or packages shall be identified with the purchaser's 

order number and the item number. 

11.2.3 The words "DO NOT WELD" shall be stenciled (in at least two places 

180° apart) on the side of equipment that has been post-weld heat-treated. 


12 Supplemental requirements 

12.1 General 

• This clause includes additional requirements for design, fabrication and 

examination that apply to one or both sides of the heat exchanger if specified 

by the purchaser. In general, these supplemental requirements should be 

considered: 

• if the cylinder thickness of a heat exchanger component exceeds 50 mm 

(2 in) or 

• if a heat exchanger will be placed in a critical service. 

The purchaser shall specify if these supplemental requirements shall be 

applied. 


Thick Walled Shell Construction 


http://www.fdflanges.com/en/show1.asp?id=269

12.2 Design 

12.2.1 The attachment of welded nozzles and other connections to 

components shall have integral reinforcement The nozzles or other 

connections shall be attached using a full-penetration groove weld with 

additional fillet or butt welds. They may be set-on, set-in or integrally 

reinforced forging-type inserts. 

Set-on type connections shall not be welded to a plate that contains 

laminations or other defects and shall only be used if the component is 

forged or if the component plates are ultrasonically examined in the area of 

attachment. In this case, the examination for laminations and other defects 

shall be carried out for a radial distance of at least twice the thickness of the 

component. 

12.2.2 Tubesheet attachment welds to shell or channel cylinders shall be butt 

welds. 


Design…. 

Set-on type connections shall not be welded to a plate that contains 

laminations or other defects and shall only be used if the component is 

forged or if the component plates are ultrasonically examined in the area of 

attachment. In this case, the examination for laminations and other defects 

shall be carried out for a radial distance of at least twice the thickness of the 

component. 

Examination for laminations 

and other defects shall be 

carried out for a radial 

distance of at least twice the 

thickness of the component. 


Set-On Connection 

Examination for 

laminations and other 

defects shall be carried out 

for a radial distance of at 

least twice the thickness of 

the component. 


Plate Sub-Surface Defects 


https://www.ndt.net/forum/thread.php?admin=&forenID=0&msgID=46331&rootID=46278

12.3 Examination 

12.3.1 All material for formed heads or cylinders exceeding 50 mm (2 in) in 

thickness shall be ultrasonically examined. Non-destructive examination and 

acceptance criteria shall comply with the pressure design code. 

12.3.2 All forgings, except standard flanges designed as described in 7.7, 

shall be ultrasonically examined in accordance with the pressure design code. 

The criteria for acceptance shall be agreed upon by the purchaser and 

the vendor. 


Examination 

12.3.1 All material for formed heads or cylinders exceeding 50 mm (2 in) in thickness shall be ultrasonically examined. Nondestructive 

examination and acceptance criteria shall comply with the pressure design code. 

12.3.2 All forgings, except standard flanges designed as described in 7.7, shall be ultrasonically examined in accordance with the 

pressure design code. The criteria for acceptance shall be agreed upon by the purchaser and the vendor. Examination 

Tabulated 

Part Description NDT Coverage Clause 

All formed 

heads 

Preformed head material; 

material thickness >50mm 

UT 

lamination 

100% 12.3.1 

All forging Except standard flanges UT 100% 12.3.2 

Whole Vessel All pressure-retaining welds MPI 100% 12.3.5 

12.3.6 

Temporary lugs Removal MPI 100% 12.3.7 

Whole Vessel 

All external pressure-retaining welds and all 

internal nozzle welds where accessible 

MPI 100% 12.3.8 

Weld Weld inaccessible to mandatory RT MPI 100% 12.3.9 

Weld Back gouged root pass MPI 100% 12.3.9 


Plate Ultrasonic Testing (Pre-formed?) 

All material for formed heads or cylinders exceeding 50 mm (2 in) in thickness 

shall be ultrasonically examined. Non-destructive examination and 


All Cat A Joint 

Type 

















Ultrasonic Examination of Forging 

All forgings, except standard flanges designed as described in 7.7, shall be 

ultrasonically examined in accordance with the pressure design code. The 

criteria for acceptance shall be agreed upon by the purchaser and 

the vendor. 






the vendor. 






the vendor. 






the vendor. 






the vendor. 


Hot Forging 


Hot Forging 


Hot Forging 


Hot Forging Head 


http://www.glmhead.com/

Cold Forming 


Cold Forming 


Hot Forming 

https://www.youtube.com/watch?v=OniopadJNDY 


Cold Forming 

https://www.youtube.com/watch?v=UFzxgSD4DRE 


Cold Forming 


12.3.3 For ultrasonic examination of welds and forgings, the purchaser shall 

be supplied with a report providing diagrams of the surfaces scanned and 

indications obtained, the areas repaired, the nature of defects repaired and 

the repair procedures used. The following information shall also be provided: 

a) pulse-echo instrument manufacturer's name and model and the damping 

control setting; 

b) search-unit manufacturer, model, dimensions and the substance (such as 

oil or water) that is used to couple the transducer with the material being 

inspected; 

c) frequency used and the test angle to the component surface; 

d) wedge medium for angle-beam examination. 

12.3.4 Magnetic-particle examination shall be performed on all plate edges 

and openings before welding. Any defects found shall be removed and any 

necessary repairs performed. 


MPI 

Magnetic-particle examination shall be performed on all plate edges and 

openings before welding. Any defects found shall be removed and any 


Soft iron 

laminated core 

Adjustable 

legs 

All plate edges and 

opening 


MPI 

Magnetic-particle examination shall be performed on all plate edges and 

openings before welding. Any defects found shall be removed and any 



12.3.5 Magnetic-particle examination shall be performed on all pressureretaining 

welds. If accessible, the back side of the root pass shall be 

examined after being prepared for final welding. Both sides of accessible 

completed welds shall be examined. 

12.3.6 Magnetic-particle examination shall be performed on all pressureboundary 

attachment welds. 

12.3.7 Magnetic-particle examination shall be performed on areas where 

temporary lugs have been removed. These areas shall be prepared by 

grinding them before the examination. 

12.3.8 After the hydrostatic test, a magnetic-particle examination shall be 

performed on all external pressure-retaining welds and all internal nozzle 

welds that are accessible without disassembling the heat exchanger. 


12.3.9 On components subject to full radiography, nozzle-attachment welds 

that cannot be radiographed shall be examined for the presence of cracks by 

the magnetic-particle method or by the liquid-penetrant method. Examination 

shall apply to the root pass after back-chipping or after flame-gouging, if 

applicable, and to the completed weld. Any defects revealed shall be 

removed before the weld is finished. For liquid-penetrant examination of 

austenitic stainless steel, neither the penetrant nor the developer shall 

contain any chlorides. 


MPI- Magnetic Particle Testing 


http://www.applus.com/en/ServiceSheet/magnetic_particle_(mt)-1340261535436

MPI- Magnetic Particle Testing 


http://www.applus.com/en/ServiceSheet/magnetic_particle_(mt)-1340261535436

Tabulated 


All formed 

heads 

Preformed head material; 

material thickness >50mm 

UT 

lamination 

100% 12.3.1 

All forging Except standard flanges UT 100% 12.3.2 


12.3.6 


Whole Vessel 

Weld 

All external pressure-retaining 

welds and all internal nozzle 

welds where accessible 

Weld inaccessible to mandatory 

RT 

MPI 100% 12.3.8 

MPI 100% 12.3.9 



12.3.10 A full radiographic examination shall be performed on all pressureretaining 

butt welds. 

12.3.11 An ultrasonic examination shall be performed on all pressureretaining 

butt welds after post-weld heat treatment. Ultrasonic examination 

shall comply with the pressure design code. The entire volume of deposited 

weld metal shall be examined from two directions. Before the welds are 

examined, the adjacent base material shall be examined by means of a 

longitudinal beam with a 100% scan for a distance of twice the plate 

thickness back from the weld. A diagram shall be prepared indicating all areas 

larger than 12 mm (1/2 in) in diameter that show a loss of back-reflection of 

50 % or more. The acceptance criteria shall be agreed upon by the purchaser 

and the vendor. 



All formed heads 

Preformed head material; material 

thickness >50mm 

UT 

lamination 

All forging Except standard flanges Volumetric 

UT 

100% 12.3.1 

100% 12.3.2 


12.3.6 


Whole Vessel 

All external pressure-retaining welds 

and all internal nozzle welds where 

accessible 

MPI 100% 12.3.8 

Weld Weld inaccessible to mandatory RT MPI 100% 12.3.9 


Whole Vessel All pressure-retaining butt welds. RT 100% 12.3.10 

Whole Vessel 

All pressure-retaining butt welds 

after post-weld heat treatment. 

Volumetric 

UT 

100% 12.3.11 


Tabulated

Annex A 

(informative) 

Recommended practices 

A.1 Introduction 

ANSI/API Standard 660/ISO 16812 

AnnexA 

(informative) 

Recommended practices 

This annex has been prepared to give advice to the designer in particular 

areas outside the scope of this 

International Standard. The advice is not mandatory and is offered for 

guidance only. 

A.2 Design 

A.2.1 Tube failure in high-pressure units - Guidance to Clause 7 

The effects of potential overpressure caused by tube rupture should be 

considered. 

NOTE 1 For further information, see ISO 23251. 

NOTE 2 For the purpose of this provision API 521 is equivalent to ISO 23251. 


A.2.2 Tube bundle and tubes- Guidance to 7.6.1 

A.2.2.1 For U-tube type bundles, if the mean bend radius is less than three 

times the tube outside diameter, the tube wall thickness should be increased 

to compensate for thinning in the bends. Such thinning can be as much as 

17%. 

A.2.2.2 In calculating the effective surface, the purchaser and vendor should 

agree as to whether the "U" bend region should be included. · 

A.2.3 Transverse baffles and support plates- Guidance to 7.6.3 

Segmental baffles are conventional in shell-and-tube heat exchangers, as 

described in 7.6.3. Other designs such as rod-baffles, helical baffles, 

expanded-metal baffles and twisted tube designs may be permitted if agreed 

with the purchaser. 


U-Bend 

Thinning 

For U-tube type 

bundles, if the 

mean bend 

radius is less 

than three times 

the tube outside 

diameter, the 

tube wall 

thickness should 

be increased to 

compensate for 

thinning in the 

bends. Such 

thinning can be 

as much as 17%. 

RCB-2.31 U-BEND 

REQUIREMENTS 

When U-bends are formed, it is 

normal for the tube wall at the outer 

radius to thin. The 

minimum tube wall thickness in the 

bent portion before bending shall be: 

t o = t 1 [1+d o /4R] 


Helical Baffles 


Twisted Tube Design 


Twisted Tube Design 


A.2.4 Tube bundle skid bars- Guidance to 7.6.6 

A.2.4.1 For bundles with mass and dimensions outside the range of 

conventional bundle-pulling devices, alternative means of bundle removal 

should be considered. For example, if the bundle mass exceeds 18 150 kg 

(40 000 lb), the diameter exceeds 1 220 mm (48 in), or the length exceeds 

7,3 m (24ft), the following options may be considered: 

a) bundle rollers; 

b) skid bars on a rail; 

c) removable shell. 

A.2.4.2 Skid bars should not obstruct tube lanes or pass-partition lanes if 45° 

or 90° tube layouts are used. 


A.2.5 Tube to tubesheet joint- Guidance to 7.6.7 

A.2.5.1 To minimize crevice corrosion on the shell side, tubes should be 

contact-expanded into the tubesheet for a length of tubesheet thickness 

minus 3 mm (1/8 in). 

A.2.5.2 For heat exchangers operating at a pressure above 7 000 kPa (1 000 

psi) gauge, tube-to-tubesheet joints should be strength-welded. In addition, 

expansion of the tubes should be considered. 

A.2.5.3 For heat exchangers in hydrogen service, tube-to-tubesheet joints 

should be strength-welded and expanded. 

Hydrogen service ≠ 

Sour service 


A.3 Fabrication 

A.3.1 Shell - Guidance to 9.1 

Openings and attachments (including reinforcing pads and support pads) 

should clear weld seams by at least 50 mm (2 in). If this construction is not 

possible, the seam weld should be ground flush and radiographed for a 

distance of 100 mm (4 in) on either side of the opening or for the full length 

covered by an attachment plus 100 mm (4 in) on either side prior to welding 

the nozzle or attachment to the heat exchanger. 

A.3.2 Tube-to-tubesheet joints - Guidance to 9.10 

A.3.2.1 For welded-and-expanded tube-to-tubesheet joints requiring postweld 

heat treatment, the tubes should be expanded after post-weld heat 

treatment. 

A.3.2.2 If welded tube-to-tubesheet joints are specified for dissimilar tubes 

and tubesheet material, weld overlay or cladding should be provided on the 

tubesheet to eliminate bimetallic welds. The overlay or cladding should have 

the same metallurgy as the tubes. 

A.3.2.3 If using titanium tubes, tube-to-tubesheet joints should be welded and 

expanded (if the tubes extend through the tubesheet). 


A.4 Preparation for shipment protection - Guidance to 11.1 

A.4.1 If water residues cannot be tolerated, equipment should be dried by one 

of the following methods: 

a) blowing dry air or nitrogen, of relative humidity less than 15% (usually 

dehumidified), through the heat exchanger and monitoring the outlet air 

until the relative humidity falls below 30 %; 

b) evacuating the heat exchanger with a vacuum pump to an absolute 

pressure of between 0,4 kPa (0,06 psi) and 0,5 kPa (0,075 psi). 

A.4.2 After draining and drying, internal surfaces may be protected against 

corrosion by the addition of a desiccant (e.g. silica gel), by the addition of a 

volatile corrosion inhibitor or by blanketing with an inert gas such as nitrogen 

[typically at gauge pressures up to 100 kPa (15 psi)]. 


Annex B 

(informative) 

Shell-and-tube heat exchanger checklist 


ISO 16812:2002(E) 

API Standard 660 / ISO 16812:2002 (E) 

Annex B 

(informative) 

Shell-and-tube heat exchanger checklist 

This checklist summarizes the bulleted subclauses in this International Standard, i.e. the subclauses in which a 

decision is required by the purchaser. 

Subclause Item Requirement 

4.1 Pressure design code to be used? 

4.3 Applicable local regulations: 

6.2.2 Welding procedures and qualifications to be submitted for 

review? 

6.2.5 Design calculations for lifting/pulling devices to be 

submitted for review? 

Yes 

Yes 

No 

No 

Vibration analysis to be submitted for review? Yes No 

6.3 Number of copies of reports and records required: 

7.1.1 Maximum design temperature: 

(annex A, line 41) 

Minimum design metal temperature (MDMT): 

(annex A, line 41) 

7.1.3 Expansion joint conditions: 

(annex A) 

7.7.7 Insulation thickness 

Shell: 

Channel: 

7.7.9 Chemical cleaning connections required? Yes No 

7.7.10 Loads and moments on connections? 

7.8.7 Bolt tightening devices required? Yes No 

7.12 Is heat exchanger exposed to hydrogen at partial pressure 

exceeding 690 kPa (6,9 bar) (100 psi) absolute? 

Which side of heat exchanger is in hydrogen service? 

Yes 

No 

Shell side Yes No 

Tube side Yes No 

8.1.1 Sour service (as defined by NACE MR0175)? Yes No 

8.1.4 Alloy linings? Yes No 

34 

34 © ISO 2002 – All rights reserved


ISO 16812:2002(E) 

Subclause Item Requirement 

9.5.6 Welded tube-to-tubesheet joints required? Yes No 

9.6.2 Heat treatment requirements and procedures for U-tube 

bend sections: 

9.6.5 Postweld heat treatment of weld-overlaid carbon steel 

channels and bonnets? 

9.6.7 Postweld heat treatment for process reasons? 

Yes 

No 



9.8.3 Special flatness tolerance on gasket contact surfaces? Yes No 

10.1.1 Purchaser's inspection? Yes No 

10.1.5 Extent of purchaser's inspection: 

10.1.5 d) Additional testing: 

10.3.5 Removal of bonnet or channel cover for shell-side 

hydrostatic test? 

Yes 

No 

11.1.7 Additional painting requirements: Yes No 

Details: 

12.1 Supplemental requirements apply to: 



Details: 

35 

© ISO 2002 – All rights reserved 35

Annex C 

(informative) 

Shell-and-tube heat exchanger data sheets 


ISO 16812:2002(E) 


A.2 Specification sheet (SI units) 

1 Client Location Page 1 of 

2 Process unit Item No. Document No. 

3 Job No. Fabricator 

4 Service of unit No. of units 

5 Size TEMA Type Connected in: Parallel Series 

6 Effective surface per unit m 2 Shells/unit Effective surface per shell m 2 

7 PERFORMANCE OF ONE UNIT 

8 Inlet SHELL SIDE Outlet Inlet TUBE SIDE Outlet 

9 Fluid name 

10 Fluid quantity, total kg/h 

11 Vapour (relative molecular mass) kg/h 

12 Liquid kg/h 

13 Steam kg/h 

14 Water kg/h 

15 Non-condensable / relative molecular mass kg/h 

16 Temperature °C / / 

17 Density (vapour/liquid) kg/m 3 

18 Viscosity (vapour/liquid) mPa·s 

19 Specific heat (vapour/liquid) kJ/(kg·K) 

20 Thermal conductivity (vapour/liquid) W/(m·K) 

21 Specific latent heat kJ/kg @ °C @ @ 

22 Inlet pressure kPa (ga) 

23 Velocity m/s 

24 Pressure drop (allowable/calculated) kPa 

25 Fouling resistance m 2·K /W 

26 Average film coefficient W/(m 2·K) 

27 Heat exchanged kW Mean temp. diff., MTD (corrected) (weighted) °C 

28 Heat transfer rate (required/fouled/clean) W/(m 2·K) 

29 ρV 2 [kg/(m·s 2 )]: Inlet nozzle Bundle entrance Bundle exit 

30 CONSTRUCTION PER SHELL 

31 Tube No. OD mm NOZZLES – No., Size and Rating 

32 Thickness mm (min./average) SHELL SIDE TUBE SIDE 

33 Pitch mm Tube pattern Inlet 

34 Length m Type Outlet 

35 Tube-tubesheet joint Intermediate 

36 Shell diameter (ID/OD) / mm Vent 

37 Cross-baffle type Drain 

38 Spacing: c/c mm No. of cross passes Press. relief 

39 % Cut Design pressure kPa (ga) 

40 Tube support type Vacuum kPa (abs) 

41 Long baffle seal type Design temp. (Max/MDMT) °C / / 

42 Bypass seal type No. of passes per shell 

43 Impingement Protection (Y/N) Corrosion allowance mm 

44 MATERIALS OF CONSTRUCTION 

45 Shell Tubes Gaskets: 

46 Shell cover Shell side 

47 Channel or bonnet Tube side 

48 Channel cover Floating head 

49 Floating head cover/bolts Spare sets req'd 

50 Tubesheet Stat. Floating Test ring req'd (Y/N) 

51 Baffles: Cross Long Insulation: shell 

52 Tube support material Channel inlet/exit 

53 Expansion joint type Expansion joint material 

54 Pressure design code Stamp Calc. MAWP (Y/N) TEMA Class 

55 REMARKS: 

56 

57 

58 

59 Originator/Check: / Approved Issue date: Issue No. 

24 



ISO 16812:2002(E) 

Job No. Page 2 of 

Client 

Location 

Item No. 

Document No. 

Issue No. 

1 CONNECTION SCHEDULE (Optional) THERMAL EXPANSION DESIGN INFORMATION (Optional) 

2 Mark No. Size Rating Facing Description Shell Shell Tubesheet Tube Tube 

3 req'd mean metal press. mean metal mean metal press. 

4 Temp. °C kPa (ga) Temp. °C Temp. °C kPa(ga) 

5 Design 

6 Normal 

7 Starting 

8 Shutdown 

9 Upset #1 

10 Upset #2 

11 Steam out 

12 Expansion joint design life cycles 

13 

14 MATERIALS OF CONSTRUCTION (Optional) Corr. allow. 

15 Shell: mm 

16 Head: mm 

17 Pipe/stub ends: mm 

18 Nozzle necks: mm 

19 Nozzle flanges: mm 

20 Body flanges: mm 

21 Expansion joint: mm 

22 Support mm 

23 Bolting (internal): mm 

24 Bolting (external): mm 

25 Nozzle reinforcement: mm 

26 Tubes: mm 

27 Tubesheets: mm 

28 Bonnet/channel: mm 

29 Bonnet head(s) mm 

30 Channel cover(s): mm 

31 Body flanges: mm 

32 Pipe/stub ends: mm 

33 Bolting (internal): mm 

34 Bolting (external): mm 

35 Nozzle reinforcement mm 

36 Nozzle necks: mm 

37 Nozzle flanges: mm 

38 Baffles, spacers, tie rods: mm 

39 

40 

41 

42 

43 

44 

45 

46 

47 

48 

49 GASKETS (Optional) MECHANICAL DATA (Optional) 

50 Shell side: Thickness: mm MAWP (hot and corroded): kPa (ga) 

51 y = Pa m = MAP (new and cold): kPa (ga) 

52 Tube side: Thickness: mm Hydrotest pressure: 

53 y = Pa m = Field: kPa (ga) Shop: kPa (ga) 

54 Floating head Thickness: mm Masses: Empty: kg Bundle: kg 

55 y = Pa m = Full of water: kg 

25 


ISO 16812:2002(E) 



Client 

Location 

Item No. 

Document No. 

Issue No. 

ADDITIONAL REMARKS, SKETCHES, ETC. (Optional) 

26 



ISO 16812:2002(E) 

• 


Client 

Location 

Item No. 

Document No. 

Issue No. 

Fluid Name: Ref. Pressure 1: bar (abs) 

Pressure 

bar (abs) 

Temp 

°C 

Enthalpy 

kJ/kg 

Vapour 

Mass 

Fraction 

Enthalpy (kJ/kg) 

Vapour mass fraction 

Density 

Vapour 

Density 

Liquid 

Viscosity 

Vapour 

Viscosity 

Liquid 

Thermal 

Cond. Vap 


Cond. Liq 

Sp. Heat 

Vapour 


Liquid 

Surface 

Tension 

Liquid 

Critical 

Press. 

Liq Crit 

Temp. 

kg/m 3 kg/m 3 mPa . s mPa . s W/m . K W/m . K kJ/(kg . K) kJ/(kg . K) N/m bar (abs) °C 

Fluid Name: Ref. Pressure 2: bar (abs) 

Pressure 

bar (abs) 

Temp 

°C 

Enthalpy 

kJ/kg 

Vapour 

Mass 

Fraction 

Enthalpy (kJ/kg) 

Vapour mass fraction 

Density 

Vapour 

Density 

Liquid 

Viscosity 

Vapour 

Viscosity 

Liquid 


Cond. Vap 


Cond. Liq 


Vapour 


Liquid 

Surface 

Tension 

Liquid 

Critical 

Press. 

Liq Crit 

Temp. 

kg/m 3 kg/m 3 mPa . s mPa . s W/m . K W/m . K kJ/(kg . K) kJ/(kg . K) N/m bar (abs) °C 

27 2 


ISO 16812:2002(E) 



Client 

Location 

Item No. 

Document No. 

Issue No. 

DESIGN CONDITIONS FOR EXPANSION JOINT (Optional) 

Case a 

SHELL SIDE 

Flow Fluid temperature Pressure d Mean metal 

condition b temperature e 

TUBE SIDE 

Flow Fluid temperature Pressure d Mean metal 

condition b temperature e 

Inlet Outlet c Inlet Outlet c 

°C °C kPa (ga) °C °C °C kPa (ga) °C 

Determine the mean shell and tube metal temperatures at the following operating conditions. Evaluate the need for an expansion joint based on the metal 

temperatures at these conditions with either or both sides clean or with specified fouling. 

Unless otherwise specified, operation in accordance with the recommendations of the TEMA Standards, paragraph E3.2, “Operating Procedures”, is assumed. 

a 

b 

c 

d 

e 

Case = e.g. steam out, upset, etc., which may affect design. 

F = Flowing (specify flowrate), S = Stagnant, E = Empty. 

Outlet temperature = (if known), thermal designer determines for other conditions. 

Pressure = Specify design pressure for operating conditions. Use maximum actual pressure at other conditions. 

Mean metal temperature = To be provided by the thermal designer. 

28 


Annex D 

(informative) 

Responsibility data sheet 


ISO 16812:2002(E) 


Annex C 

(informative) 

Responsibility specification sheet 

1 Client P Location P Page 1 of 

2 Process unit P Item No. P Document No. P 

3 Job No. P Fabricator P 

4 Service of unit P No. of units: P 

5 Size D TEMA Type P Connected in D Parallel D Series 

6 Surface/unit (eff.) D Shells/unit D Surface/shell (eff.) D 

7 PERFORMANCE OF ONE UNIT 

8 Fluid allocation (Inlet) SHELL SIDE (Outlet) (Inlet) TUBE SIDE (Outlet) 

9 Fluid name P P 

10 Fluid quantity, total P P 

11 Vapour (relative molecular mass) P P P P P P P P 

12 Liquid P P P P 

13 Steam P P P P 

14 Water P P P P 

15 Noncondensable / relative molecular mass P / P P / P 

16 Temperature P P P P 

17 Density (vapour/liquid) P P P P P P P P 

18 Viscosity (vapour/liquid) P P P P P P P P 

19 Specific heat (vapour/liquid) P P P P P P P P 

20 Thermal conductivity (vapour/liquid) P P P P P P P P 

21 Latent heat P @ P P @ P 

22 Inlet pressure P P 

23 Velocity D D 

24 Pressure drop (allowable/calculated) P D P D 

25 Fouling resistance P P 

26 Average film coefficient D D 

27 Heat exchanged P MTD (corrected) (weighted) D 

28 Transfer rate (required/fouled/clean) D D D 

29 ρV 2 Inlet nozzle D Bundle entrance D Bundle exit D 

30 CONSTRUCTION PER SHELL 

31 Tube No. D OD P NOZZLES – No., Size and Rating 

32 Thickness P (Min./Avg). P SHELL SIDE TUBE SIDE 

33 Pitch P Tube pattern P Inlet P P 

34 Length P Type P Outlet P P 

35 Tube-tubesheet joint P Intermediate D D 

36 Shell diameter (ID/OD) D / D Vent P P 

37 Cross baffle type D Drain P P 

38 Spacing: D No. of crosspasses D 

39 % Cut D Design pressure P P 

40 Tube support type D Vacuum pressure P P 

41 Long baffle seal type D Design temp. (Max./MDMT) P / P P / P 

42 Bypass seal type D No. of passes per shell D D 

43 Impingement Protection (Y/N) D Corrosion Allowance P P 

44 MATERIALS OF CONSTRUCTION 

45 Shell P Tubes P Gaskets: 

46 Shell cover P Shell side P 

47 Channel or bonnet P Tube side P 

48 Channel cover P Floating head P 

49 Floating head cover/bolts P Spare sets req'd P 

50 Tubesheet Stat. P Floating P Test ring req'd (Y/N) P 

51 Baffles: Cross P Long P Insulation: shell P 

52 Tube support material P Channel inlet/exit P 

53 Expansion joint type P Expansion joint material P, D 

54 Pressure design code P Stamp P Calc. MAWP (Y/N) P TEMA Class P 

55 REMARKS : P, D 

56 P = Purchaser 

57 D = Designer 

58 

59 Originator/check: / Approved Issue Date: Issue No. 

36 



Materials System Specification 

32-SAMSS-0071December2013 



Materials System Specification 

32-SAMSS-007 1 December 2013 


Document Responsibility: Heat Transfer Equipment Standards Committee 

Saudi Aramco DeskTop Standards 

Table of Contents 

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

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

3 Terms and Definitions.................................... 6 

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

5 Proposals....................................................... 8 

6 Drawings and Other Required Data.............. 9 

7 Design........................................................... 9 

8 Materials....................................................... 22 

9 Fabrication.................................................... 30 

10 Inspection and Testing................................. 36 

11 Preparation for Shipment............................. 44 

12 Supplemental Requirements........................ 47 

Table 1 - Nondestructive Examination 

Requirements...................................... 48 

Previous Issue: 19 February 2013 Next Planned Update: 1 December 2018 

Revised paragraphs are indicated in the right margin Page 1 of 49 

Primary contact: Al-Mansour, Khalid Mohammad on +966-13-8809575 

Copyright©Saudi Aramco 2013. All rights reserved.


32-SAMSS-007 

Draft Date: 1 December 2013 

Next Planned Update: 1 December 2018 


The following paragraph numbers refer to API STD 660, Eighth Edition, August 2007, 

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

exception, modification, or deletion to API STD 660 as noted. Paragraph numbers not 

appearing in API STD 660 are new paragraphs to be inserted in numerical order. 

1 Scope 

1.1 This specification covers the minimum mandatory requirements for the 

manufacture of shell and tube heat exchangers and new components 

(hereinafter referred to as exchangers). It does not cover exchangers that 

undergo repairs or alterations. 

1.2 This specification does not cover the design of non-TEMA exchangers. 

Commentary Note: 

such as sometimes used for lube and seal oil cooling duties for 

packaged equipment like compressors, pumps and turbines. 

1.3 Sulfur Recovery Unit (SRU) waste heat boilers, steam drums and 

condensers shall be designed and fabricated in accordance with the 

design rules of ASME Section VIII Division 1 in addition to the 

requirements specified in this specification. 

1.4 The design and fabrication of high pressure heat exchangers shall be 

done by licensed manufacturers. The details of licensing agreement shall 

be reviewed by Saudi Aramco engineer. 

1.5 Conflicting Requirements 

1.5.1 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 Standards Committee Chairman, 

Consulting Services Department of Saudi Aramco, Dhahran. 

1.5.2 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. 

1.6 Low alloy steels for vessels 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. 

Page 2 of 49


32-SAMSS-007 




2 Normative References 

Materials or equipment supplied to this specification shall comply with the latest edition 

of the references listed below, unless otherwise noted. 

2.1 Saudi Aramco References 

Saudi Aramco Engineering Procedure 

SAEP-302 

Saudi Aramco Engineering Standards 

SAES-A-007 

SAES-A-206 

SAES-A-112 

SAES-H-001 

SAES-N-001 

SAES-P-111 

SAES-W-010 

SAES-W-014 

Instructions for Obtaining a Waiver of a Mandatory 

Saudi Aramco Engineering Requirement 

Hydrostatic Testing Fluids 

Positive Materials Identification 

Saudi Aramco Materials System Specifications 

01-SAMSS-016 

02-SAMSS-011 

32-SAMSS-031 

Saudi Aramco Standard Drawings 

AA-036322 

Meteorological and Seismic Design Data 

Coating Selection and Application Requirements for 

Industrial Plants and Equipment 

Basic Criteria, Industrial Insulation 

Grounding 

Welding Requirements for Pressure Vessels 

Weld Overlays and Welding of Clad Materials 

Qualification of Pipeline and Pressure Vessel Steels 

for Resistance to Hydrogen-Induced Cracking 

Forged Steel and Alloy Flanges 

Manufacture of Clad Vessels and Heat Exchangers 

Anchor Bolt Details – Inch and Metric Sizes 

AE-036250 Ferrules for ¾ Inch Tubes (Sheets 1 & 2) 

Saudi Aramco Inspection Requirements 

Form 175-323100 

Form 175-323500 


Floating Heads or Tube Bundles 



32-SAMSS-007 




Saudi Aramco Forms and Data Sheets 

Form 2714-ENG 

Form NMR-7922-1 

Industry Codes and Standards 

American Concrete Institute 

ACI 318 

American Petroleum Institute 

API STD 660 

API RP 934 

API PUBL 941 

API RP 945 

American Society of Civil Engineers 

ASCE 7 

Shell and Tube Exchanger Data Sheet (herein 

referred to as data sheet) 

Non-material Requirements for Shell and Tube and 

Double-Pipe Heat Exchangers 

Building Code Requirements for Structural 

Concrete 

Shell-and-tube Heat Exchangers for General 

Refinery Services 

Materials and Fabrication Requirements for 2¼Cr- 

1 Mo & 3Mo Steel Heavy Wall Pressure Vessels 

for High Temperature, High Pressure Hydrogen 

Service 

Steels for Hydrogen Service at Elevated 

Temperatures and Pressures in Petroleum and 

Petrochemical Plants 

Avoiding Environmental Cracking in Amine Units 

Minimum Design Loads for Buildings and Other 

Structures 

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

ASME SA-20 

ASME SA-388 

ASME SA-435 

ASME SA-450 

ASME SA-688 

Specification for General Requirements for Steel 

Plates for Pressure Vessels 

Ultrasonic Examination of Heavy Steel Forgings 

Straight Beam Ultrasonic Examination of Steel 

Plates 

Specification for General Requirements for Carbon, 

Ferritic Alloy, and Austenitic Alloy Steel Tubes 

Specification for Welded Austenitic Stainless Steel 

Feedwater Heater Tubes 



32-SAMSS-007 




ASME SEC IIC 

ASME SEC V 

ASME SEC VIII D1 

ASME SEC VIII D2 

ASME B2.1 

ASME B16.5 

ASME B16.11 

ASME B16.20 

ASME B16.21 

ASME B16.25 

ASME B16.47 

Specifications for Welding Rods, Electrodes, and 

Filler Metals 

Nondestructive Examination 

Rules for Construction of Pressure Vessels 

Rules for Construction of Pressure Vessels, 

Alternative Rules 

National Pipe Threads 

Pipe Flanges and Flanged Fittings 

Forged Fittings, Socket-Welding and Threaded 

Metallic Gaskets for Pipe Flanges - Ring-Joint, 

Spiral-Wound, and Jacketed 

Non-Metallic Gaskets for Pipe Flanges 

Buttwelding Ends 

Large Diameter Steel Flanges NPS 26 through NPS 

60 

American Society for Nondestructive Testing 

ASNT CP-189 

National Association of Corrosion Engineers 

NACE RP0472 

Standard for Qualification and Certification of 

Nondestructive Testing Personnel 

Methods and Control to Prevent In-Service 

Environmental Cracking of Carbon Steel 

Weldments in Corrosive Petroleum Refining 

Environments 

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-Materials 

for use in H 2 S-Containing Environments in Oil 

and Gas Production 

Tubular Exchanger Manufacturers Association (TEMA) 

Process Industry Practices 

PIP VEFV1100 

Vessel/S&T Heat Exchanger Standard Details 

Welding Research Council 

WRC 107 

Welding Research Council Bulletin 



32-SAMSS-007 




3 Terms and Definitions 

3.8 (Exception) Hydrogen Service: Process streams containing relatively 

pure hydrogen and process streams containing hydrogen as a component 

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

3.11 Pressure Design Code: ASME SEC VIII. 

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

surface texture. 

3.15 Cyclic Services: 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. 

3.16 Design Engineer: The Engineering Company responsible for specifying 

on the data sheet the hydraulic, thermal and mechanical design 

requirements for exchangers. 

3.17 Exchanger Manufacturer: The Company responsible for the 

manufacture of exchangers. 

3.18 High - Alloy Steels: Steels with a total alloying content more than 5%. 

3.19 Hot Forming: Forming operations carried out at an elevated 

temperature such that re-crystallization occurs simultaneously with 

deformation. 

3.20 Hydrogen Induced Cracking (HIC) Environment: Process streams 

that introduce HIC according to SAES-L-133. 

3.21 Lethal Services: Process streams containing a concentration of 

hydrogen sulfide in excess of 20% volume per total volume of exchanger 

shall be considered as lethal service. Other services as determined by the 

project design may also be designated as lethal services. 

3.22 Low-Alloy Steels: Steels with a total alloying content of less than 5% 

but more than specified for carbon steels. 

3.23 Minimum Thickness: Thickness required for withstanding all primary 

loads, excluding allowance for corrosion. 

3.24 MDMT: Minimum Design Metal Temperature determined by the 

Design Engineer and specified in the data sheet. 



32-SAMSS-007 




3.25 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. 

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

Aramco to procure heat exchnager to the requirements of this 


3.27 Saudi Aramco Engineer: The chairman of the Heat Transfer 

Equipment Standards Committee. 

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

Saudi Aramco Inspection Department to inspect exchangers to the 

requirements of this specification. 

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

introduce SSC according to SAES-L-133. 

3.30 Thick Wall Exchanger: An exchanger or portion of it with nominal 

thickness greater than 50-mm. 

3.31 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. 

4.3 (Exception) The Exchanger Manufacturer shall advise the Saudi Aramco 

Engineer. 

4.8 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. 

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

Saudi Aramco Engineer. 

4.10 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. 



32-SAMSS-007 




4.11 Application of ASME Code Cases to the manufacturing of exchangers 

requires approval of the Saudi Aramco Engineer. 

4.13 1 Cr- ½ Mo and 1 ¼ Cr- ½ Mo steels used for vessels that are not in 

hydrogen service with design temperature below 440°C, shall meet all 

requirements of API RP 934-C and this specification. 

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 data sheet and the requirements of this specification. 

4.16 The edition of the Code to be used for the manufacture of exchangers 

shall be per the referenced code edition in effect at time of purchase. 

4.17 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. 

5 Proposals 

5.5 The proposal shall include a detailed description of any exception to the 


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

quote on the base inquiry documents. 

5.10 Performance Guarantees 

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

specified in the purchase order or contract documents: 

1) Exchangers shall meet thermal/hydraulic performance requirements 

under continuous operation at design conditions specified on the 

data sheets. Thermal/hydraulic guarantee shall be in accordance 

with TEMA paragraph G-5. 

2) Exchangers shall be free from damaging flow induced tube 

vibration and acoustic vibration. 



32-SAMSS-007 




6 Drawings and Other Required Data 

6.1 Outline Drawings and Other Supporting Data 

6.1.1 (Exception) The Exchanger Manufacturer shall prepare drawings, 

calculations and data in accordance with NMR-7922-1, Nonmaterial 

Requirements 

6.1.2 The Exchanger Manufacturer shall submit flow-induced vibration 

analysis. 

6.1.3 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. 

6.1.4 The Exchanger Manufacturer shall prepare drawings, which indicate the 

ultrasonic readings thickness of the exchanger shell, heads and nozzles. 

An adequate number of readings shall be taken to represent the actual 

thickness of the components. 

6.1.5 All approved data sheets, drawings and forms are to be submitted to 

EK&RD/Drawing Management Unit (DMU) for inclusion into 

Corporate Drawings Management System. 

6.2 Information Required After Outline Drawings are Reviewed 

6.2.4 (Addition) 

(e) Flow induced and acoustic vibration analysis. 

6.3 Reports and Records 

7 Design 

The Exchanger Manufacturer shall furnish reports and records in 

accordance with NMR-7922-1, Nonmaterial Requirements. 

7.1 Design Temperature 

7.1.4 The value(s) of design temperature(s) shall be as specified on the data 

sheet. 

7.1.5 The value of the minimum design metal temperature (MDMT) shall be 

as specified on the data sheet. 



32-SAMSS-007 




7.1.6 The MDMT shall be used to determine the requirements for impact 

testing in accordance with the Code and this specification. 

7.2 Cladding for Corrosion Allowance 

Exchangers having partial or complete cladding shall conform to 32- 

SAMSS-031 in addition to the requirements of this specification. 

7.3 Shell Supports 

7.3.2 (Addition) 

(f) The exchanger shall be fixed at one saddle support and free to slide 

at the other saddle. 

7.3.6 The shell shall be analyzed in accordance with the “L. P. Zick” method. 

Saddle supports and the exchanger shell shall be analyzed for operating 

and hydrotest loads including any piping, wind or other external loads. 

7.3.7 The allowable concrete bearing stress to be used for the design of 

baseplates shall be 10340 kPa (1400 psi). 

7.3.8 The outline drawing for horizontal exchangers shall specify locations of 

the fixed and sliding saddles and dimension from exchanger centerline to 

underside of saddle baseplate. 

7.3.9 Anchor Bolts 

7.3.9.1 The Exchanger Manufacturer shall determine the size and number of 

anchor bolts required. 

7.3.9.2 Anchor bolts shall be in compliance with Standard Drawing AA-036322 

Sht. 001 (Rev. 07 or later). 

7.3.9.3 Anchor bolts shall not be less than 19 mm minimum nominal diameter. 

7.3.9.4 The design of anchor bolts shall be in accordance with the requirements 

of Appendix D of ACI 318. 

7.3.9.5 Anchor bolts that are exposed to the weather in coastal areas, subjected 

to frequent wash downs, or subjected to firewater deluge testing shall 

have their diameters increased by 3 mm as a corrosion allowance. 

7.3.9.6 Exchangers supported on saddles shall be provided with an even number 

of anchor bolts with a minimum of two anchor bolts per saddle. 

7.5 Floating Head 



32-SAMSS-007 




7.5.6 Floating head covers shall be attached to the backing device or to the 

floating tubesheet with through bolting. 

7.6 Tube Bundle 

7.6.1 Tubes 

7.6.1.4 Wall thickness of integral low-fin tubes, if used, shall be measured from 

the inside diameter of the tube to the root of the fins. The specified wall 

thickness shall be nominal, except that the actual wall thickness shall not 

be less than 90% of that specified. 

7.6.1.5 For expanded joints, the tubes shall extend 3 mm beyond the face of 

tubesheets, except tubes shall be flush on the upper tubesheet of vertical 

exchangers. 

7.6.1.6 For exchangers with tube-side design pressures 13.8 MPa (2000 psi) and 

above, all tubes shall be hydrostatically tested at the mill at the tube-side 

design pressure and the variation from the tube outside diameter shall not 

exceed the values specified in Table 5 of ASME SA-450. 

7.6.1.7 For steam condensing services, when steam is in the 'U' tubes and the 

process is controlled by flow control of condensate, the design engineer 

shall consider wither the 'U' bends shall be in the horizontal or vertical 

plane. 

7.6.1.8 In exchangers with tube side as the high-pressure side, design pressure of 

the shell side should be at least two-thirds of the tube side design 

pressure if the shell side is not protected with a relief system. Other 

options require the approval of Saudi Aramco Engineer. 


7.6.2 Tubesheets 

This is to prevent any unexpected catastrophic failure in case of tube leak 

in exchangers. 

7.6.2.5 All stationary tubesheets with through bolting design shall have nonthreaded 

bolt holes. 

7.6.2.6 Vertical exchangers with fixed tubesheets shall be provided with flanged 

vents and drains through the tubesheets. 

7.6.3 Baffles and Support Plates 



32-SAMSS-007 




7.6.3.1 (Exception) Minimum thickness of baffles and support plates shall be as 

per TEMA requirements and in no case less than twice the specified shell 

side corrosion allowance. 

7.6.3.4 Support plates for floating heads shall be located as close to the 

tubesheet as the design and type of exchanger will permit. Support plate 

shall be cut at either top or bottom or in the center to minimize 

ineffective heat transfer surface at the floating head end. 


Typically, this distance is approximately 150 mm (6 inches). 

7.6.3.5 'U' tube bundles shall have a support plate close to the tangent line of 

tubes. The support plates shall be cut to allow some flow over 'U' bends, 

provided that all tubes are supported. 


7.6.4 Impingement Protection 

Typically, support plates are 50 mm (2 inches) away from the tangent line. 

7.6.4.7 Impingement rods, if used, shall be arranged in a pattern, which will 

minimize bypassing of the shell side fluid and avoid the flow hitting the 

tubes directly. 


Typically, two rows of rods on a triangular layout are used as an 

impingement protection. 

7.6.4.8 The use of distribution belts shall be considered when shell-side nozzles 

are large resulting in long inlet and/or outlet unsupported tube lengths. 


7.6.5 Bypass-Sealing Devices 

A properly designed belt should result in more effective use of the heat 

transfer area and a more rigid bundle with better tube support. 

7.6.5.4 (Exception) The location of the sealing devices shall not interfere with 

the continuous tube lanes for square and rotated square layouts. 

7.7 Nozzles and Other Connections 

7.7.2 (Exception) The ends of butt-welded connections shall be in accordance 

with ASME B16.25. 



32-SAMSS-007 




7.7.3 (Exception) Threaded or socket-welded connections are prohibited in 

hydrogen, lethal, wet sour and caustic services. However, for other 

services, threaded or socket-welded connections with 6000-lb. rating 

conforming to ASME B16.11 may be used for NPS 1½ and smaller 

vents, drains and instrument connections. 

7.7.4 (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. 

c) Studded nozzles and proprietary designs may be offered as 

alternatives provided their design is in accordance with the Code 

and approved by the Saudi Aramco Engineer. 

d) Lap-type joints with loose end flange can be used for utility 

services with pressure up to 1.4 MPa (200 psi) and a temperature of 

120°C (250°F). 

7.7.5 (Exception) Slip-on type flange with seamless pipe nozzle necks or 

rolled plate with 100% radiography is permissible for exchangers, in 

only non-cyclic utility 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). 

7.7.6 (Exception) Unless otherwise specified on the data sheet, the minimum 

projections for nozzle necks, as measured from the outside surface of the 

shell or head to the face of a flange, shall meet the following 

requirements: 

a) 6 inches for NPS 6 nozzles and smaller. 

b) 8 inches 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. 



32-SAMSS-007 




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

elevations, and orientations of nozzles and manways shall be as specified 

on the data sheet. 

7.7.11 Flanges shall be in accordance with ASME B16.5 pressure rating. 

7.7.12 Flange bolt holes shall straddle the normal horizontal and vertical 

centerlines of the exchanger. 

7.7.13 Threaded connections shall conform to ASME B2.1. 

7.7.14 Reinforcement of Openings 

7.7.14.1 Reinforcement of exchanger openings shall be in accordance with the 

applicable Code and this specification. 

7.7.14.2 The thickness of reinforcing pads shall not exceed the shell or head 

thickness of an exchanger. 

7.7.14.3 Use of internal reinforcing elements is not permitted. 

7.7.15 Minimum inside corner radius of integrally reinforced contour nozzles 

and manways shall be 13 mm. 

7.7.16 Permissible types of nozzles, manways and their connections shall be 

according to the table below. 

Design Conditions / Services Group 

Group I 

Attachment 

Figure Reference from Indicated 

ASME Code Section VIII 

Division 2 

Division 1 Exchangers 


a. Pressure-retaining exchanger’s 

component (shell, head, nozzle or 

manway) with design thickness greater 

than 50 mm 

b. Unfired steam boilers with design 

pressure exceeding 50 psi 

c. Lethal, hydrogen and cyclic services 

d. Openings larger than 900 mm (Note 1) 

e. Design temperature greater than 

400°C (Note 1) 

All nozzle 

sizes and 

manway 

necks 

Connections 

attached to 

nozzles and 

manways 

Figure UW-16.1, details: 

(f-1), (f-2), (f-3) or 

(f-4) 

Table 4.2.13, 

details: (1), (2), (3), 

(4), (5) or (6) 

f. Low alloy steel exchangers with design 

thickness greater than 25 mm (Note 1) 

g. Exchangers that will undergo PWHT 

(Note 1) 



32-SAMSS-007 




Design Conditions / Services Group 

Group II 

Design conditions and service other than 

those in Group I of this table 

Attachment 

NPS 4 and 

smaller nozzles 

Nozzles larger 

than NPS 4 and 

manway necks 

Connections 

attached to 

nozzles and 

manways 

Figure Reference from Indicated 

ASME Code Section VIII 

Division 2 

Division 1 Exchangers 



(a), (a-1), (b), (c), (d), (e), 

(f-1), (f-2), (f-3), (f-4) or 

(g). 


(c), (d), (e), (f-1), (f-2), 

(f-3), (f-4) or (g) 

- Table 4.2.10, 

details: (1), (2), (3), 

(4), (6), (7) or (8) 

- Table 4.2.11, 

detail (2) 

- Table 4.2.13, 

details: (1), (2), (3), 

(4), (5) or (6) 

Note 1: 

Alternatively, detail per Figure UW-16.1 (g) may be used for Division 1 exchangers provided that design conditions/ services per 

a, b and/or c of group I are not applicable. 

7.7.17 Integrally reinforced contour shaped attachments made partially or 

completely of weld build up are prohibited. 

7.11 Handling Devices 

7.11.5 Exchangers with a component weighing up to and including 27 kg 

(60 lb.) shall be provided with at least one lifting lug per component. 

Two lifting lugs shall be provided for heavier weights. 

7.11.6 Shell lifting lugs shall be designed such that the lifted parts hang 

vertically when suspended from the lugs. Lugs on insulated exchangers 

shall be of sufficient standout to clear insulation. 

7.11.7 Protective plugs shall be fully engaged. 

7.11.8 Clad fixed tubesheets shall be drilled and tapped and provided with base 

plugs of the same material as the cladding. Base plugs shall be seal 

welded and ground flush with the tubesheet surface and re-drilled and 

tapped for pulling eyes. 

7.13 Kettle Reboilers 

Kettle type reboilers shall conform to the following: 

a) The distance between the top of weir and top of tubes shall be a 

minimum of 75 mm. 

b) The distance from the weir to adjacent tangent line of the head 

shall not be less than 900 mm. 

c) Weirs shall be provided with a 50 mm semi-circular drain hole. 



32-SAMSS-007 




7.14 Design Pressure 

7.14.1 The value(s) of design pressure(s) shall be in accordance with the data 

sheet. 

7.15 Maximum Allowable Working Pressure 

7.15.1 The Exchanger Manufacturer shall calculate the maximum allowable 

working pressure (MAWP) acting on both sides of the exchanger, in the 

hot and corroded condition in accordance with the Code. 

7.15.2 The MAWP of an exchanger shall not be limited by flange ratings. 

7.16 Joint Efficiency 

7.16.1 A joint efficiency of 85% or higher shall be specified for the design of all 

pressure containing components of ASME SEC VIII D1 exchangers. 

7.17 Loads 

7.17.1 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 

the exchanger in the operating position in accordance with 


b) Wind and seismic loads shall be calculated for the exchanger in 

accordance with ASCE 7, 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. 

d) Seismic loads shall include due allowances for platforms, ladders, 

piping, insulation, and equipment supported from the pressure 

exchanger as specified on the data sheet. 

7.17.2 Dead Weights of an Exchanger 

Design of exchangers shall consider the following dead loads: 

a) Weight of exchanger including internals and supports. 

b) Weight of exchanger contents under operating and testing 

conditions. 

c) Weight of refractory linings and insulation. 



32-SAMSS-007 




d) Weight of attached equipment. 

7.17.3 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. 

7.17.4 Thermal Loads 

Thermal Loads are loads caused by thermal transients and restraining 

thermal expansion/ interaction of the exchanger and/ or its support(s). 

7.18 Load Combinations 

7.18.1 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. 

7.18.2 Anchor bolts shall be designed for load combinations, based on the 

allowable stress design method (Service Loads) in accordance with 

SAES-M-001. 

7.18.3 All pressure exchanger components whether shop or field fabricated 

shall be designed to withstand a full hydrostatic test in the erected 

position. 

7.18.4 Combined stresses due to full hydrostatic test and the greater of wind and 

earthquake loads shall be within the allowable limits per ASME SEC 

VIII D2, paragraph 4.1.6.2, based on the lowest Specified Minimum 

Yield Strength (SMYS) of the materials of construction at test 

temperature. However, wind and earthquake design loads can be reduced 

to 50% of its values. 

7.18.5 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. 

7.18.6 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 



32-SAMSS-007 




earthquake loads). Addition of piping loads shall be based on performing 

stress analysis. 

7.18.7 Stress Analysis 

7.18.7.1 Where applicable, the requirements for thermal stress and fatigue stress 

analyses shall be as specified in 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. 

7.18.7.2 The Design Engineer is responsible for specifying the heat transfer 

coefficients to be used for all thermal stress analysis. 

7.18.7.3 Thermal Analysis 

1) A thermal stress analysis is required for a exchanger, if a thermal 

gradient (calculated under steady state operating conditions and, if 

applicable, transient operating conditions) across any exchanger 

section exceeds 65°C (150°F), in a distance equal to the square root 

of R times T, where: 

- R is the radius of the exchanger component under consideration 

and, 

- T is the thickness of the component under consideration 

- R and T have the same units. 

2) As a minimum, the scope of the stress analysis shall include the 

following junctures, as applicable: 

- Head-to-shell 

- Support-to-exchanger 

- Nozzle-to-shell, considering external piping loads 

- Tray supports to exchanger wall 

3) Thermal analysis shall be based on gradients under steady state 

design conditions and also, if applicable, transient design 

conditions. 

4) Thermal gradients may be reduced to within allowable limits with 

the provision of the thermal sleeves in pressure-retaining 

components 



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7.18.7.4 Fatigue Analysis 

1) Scope of the required stress analysis shall be as specified in 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: 

- Head-to-shell 

- Support-to-exchanger 

- Nozzle-to-shell, considering external piping loads 

- Tray supports to exchanger wall 

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, shutdowns, 

emergency shut-downs, and upset conditions. 

7.18.7.5 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 107, WRC 297 or a finite element analysis. 

7.19 Shell and Channel Covers 

7.19.1 ASME dished flat head (with knuckle) and ASME torispherical head 

shall not be used for other than air and water services with a design 

pressure of 690 kPa (100 psi). 

7.19.2 One-piece construction (made from one-piece or welded multi-piece 

blanks) shall be used for heads with nominal thickness greater than 50 

mm and exchangers in cyclic, hydrogen or lethal services. Other types of 

head construction shall require prior approval of Saudi Aramco Engineer 

as defined in this specification. 

Note: Following shall be submitted to support review of the proposed multisegment 

construction head: 

a) Layout of head. 

b) Nondestructive examination. 



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c) Forming procedure and, 

d) Heat treatment procedure, as applicable. 

7.19.3 Where a forged shell-and-head junction according to ASME SEC VIII 

D2, Figure AD-912-1(k) is used, one piece construction shall be used for 

the remaining portion of heads mentioned in paragraph 7.19.2 of this 

specification. Other types of head construction shall require prior 

approval of Saudi Aramco Engineer. 

7.19.4 Heads in exchangers with design thickness greater than 50 mm shall be 

hemispherical unless 2:1 ellipsoidal heads are deemed more economical. 

7.19.5 Minimum inside radius of knuckles for conical transition sections or 

torispherical heads shall be as follows: 

a) Not be less than 15% of the outside diameter of the adjoining 

cylindrical section with conical section of thickness more than 

2 inches. 

b) Not be less than 10% of the outside diameter of the adjoining 

cylindrical section with conical transition section or torispherical 

heads with thickness more than 0.75 inch and less than 2 inches. 

c) Not be less than 6% of the outside diameter of the adjoining 

cylindrical section with conical transition section or torispherical 

heads with thickness 0.75 inch and less. 

7.19.6 Reinforcing for conical transition sections in thick wall exchangers shall 

be provided by increased plate thickness. The use of reinforcing rings is 

prohibited. 

7.20 Longitudinal Baffles (TEMA 'F' shells) 

7.20.1 Baffles shall be designed for 1.5 times the shell-side allowable pressure 

drop and with a maximum deflection in the corroded condition of 6 mm. 

7.21 Clips and Attachments 

7.21.1 General 

The Exchanger Manufacturer shall supply and install all clips and 

attachments as specified on the data sheet. 

7.21.2 Insulation Support 

7.21.2.1 Support for insulation system shall be according to the data sheet. 



32-SAMSS-007 




7.21.2.2 The Exchanger Manufacturer shall supply and install supports required 

for insulation. 

7.21.3 Refractory Supporting System 

7.21.3.1 Anchoring system of refractory lining shall be according to the data 

sheet. 

7.21.3.2 The Exchanger Manufacturer shall supply and install anchoring system 

required for refractory. 

7.21.4 Fireproofing Supports 

7.21.4.1 Support for fireproofing system shall be according to the data sheet. 

7.21.4.2 The Exchanger Manufacturer shall supply and install supports required 

for fireproofing materials. 

7.21.5 Grounding Lugs 

All exchangers shall be provided with a grounding lug connection 

welded to the fixed exchanger support in accordance with PIP 

VEFV1100. 

7.21.6 All internal and external attachments, including clips, welded directly to 

pressure parts are to be attached by continuous welding except for blank 

nuts used for external insulation where tack welding is allowed. 

7.21.7 Vertical exchangers, which are externally insulated, shall be provided 

with insulation supports in accordance with SAES-N-001. 

7.22 Coatings and Painting 

7.22.1 Type of coating and painting systems shall be as specified on the data 

sheet. 

7.22.2 Surfaces to be coated shall be cleaned and prepared prior to its coating in 

accordance with SAES-H-001. 

7.22.3 Gasket contact surfaces shall be properly protected from blasting and shall 

not be coated or painted.. 

7.23 General 

7.23.1 Single tube pass TEMA rear end floating head type exchangers shall be 

designed with a removable shell cover to provide easy access to the 

expansion joint in the tube side nozzle. 



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7.23.2 Where more than one exchanger of identical design, pressure rating and 

materials is required for the same service, the tube bundles shall be interchangeable. 

7.23.3 Kettle type reboilers shall be provided with guide rails and a hold down 

angle located above the floating end, in order to keep the bundle in place 

during shipment. 

7.23.4 For tube bundles that can be rotated 180 degrees, additional 

impingement plate, bundle runners etc. shall be provided. 

7.23.5 Exchangers with sea water on the tube side shall be fitted with ferrules 

(tube end protectors) at the inlet end of tubes at each tube pass. For tube 

materials other than given in paragraph 8.4.4, the requirement for 

ferrules shall be confirmed with the Saudi Aramco Engineer. 


Saudi Aramco Standard Drawing AE-036250 gives ferrules details for 

0.75 inch outside diameter tubes. For larger tube diameters, Exchanger 

Manufacturer shall propose ferrule details for the consideration of the 

Saudi Aramco Engineer. 

7.23.6 Maximum thickness for plates used for construction of shell or channel 

under the scope of API RP 934-A and API RP 934-C shall be limited to 

6 inches (150 mm). For exchangers requiring thickness higher than 6”, 

forged ring construction shall be used. 

8 Materials 

8.1 General 

8.1.5 All materials required for pressure and non-pressure components shall be 

as specified on the data sheet. 

8.1.6 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. 

8.1.7 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 be submitted to 

Saudi Aramco Engineer for review and approval prior to ordering the 

materials from the mill. 



32-SAMSS-007 




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 test report is requested to be certified as per 175-323100. 

8.1.10 1 Cr- ½ Mo and 1 ¼ Cr- ½ Mo steels with thickness exceeding 100 mm 

can be used for components (shell, head, integrally reinforced nozzles, 

flanges, etc.) of exchangers within scope of API RP 934-C, API RP 934- 

E and paragraph 4.13 of this specification, provided that fracture 

toughness requirements of the respective document of the 

aforementioned documents and this specification can be met. 

8.1.11 Use of high alloy steels, including austenitic stainless steels, shall be on a 

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, except carbon steels, shall be alloy-verified by the 

Exchanger Manufacturer in accordance with SAES-A-206. 

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 nonpressure 

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 

12.1.14 of this specification for carbon steel nozzles and standard flanges 

according to ASME B16.5 and B16.47 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. 



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8.1.17 Specimens for material testing shall be taken 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 (T = maximum heat-treated thickness) 

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, 

and at a depth of ½T of a prolongation or of a representative 

separate test , 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 


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 heattreated 

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.) 

e) Pipe 

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. 



32-SAMSS-007 




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. 

8.1.18 Layered constructions are prohibited for all exchangers. 

8.1.19 Materials for exchangers in de-aeration service shall be in accordance 

with NACE RP0590. 

8.1.20 Materials for exchangers exposed to SSC environments shall be in 

accordance with the following: 

a) Forged flanges and forged fittings are restricted to: SA-350 (Grade 

LF1 or Grade LF2) or SA-765 Grade II. 

b) Studs are restricted to: SA-193 B7M or SA-320 L7M. 

c) Nuts are restricted to: SA-194 Grade 2HM. 

d) It shall satisfy the requirements of ISO 15156 and NACE RP0472. 

8.1.21 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. (Exception: Refer to paragraph 12.1.20 of this specification 

for requirements for skirts.) 

8.1.22 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, creepresistance, 

etc.) and considering thermal treatments specified in 

paragraph 8.1.14 of this specification. 

8.1.23 Material for nameplate mounting brackets shall be of the same type and 

material grade as the shell material. 



32-SAMSS-007 




8.1.24 SA-36 and SA-285 materials may be used only for pressure retaining 

components of exchangers in water and air services with plate thickness 

not exceeding 19 mm. 

8.1.25 Materials of supports shall be as follows: 

1) Legs and lugs: same material as exchanger wall base material. 

Supports of exchangers described in paragraph 8.1.24 of this 

specification may be of the same ASME material P No. as that of 

the exchanger wall base material. 

2) Saddles: same material as the exchanger wall base material. 

8.1.26 External attachments, other than those in paragraph 8.1.25 of this 

specification, and internal attachments welded to the exchnager shall be 

of the same material as the exchnager wall base material. With prior 

approval of Saudi Aramco Engineer as defined in this specification, 

Stainless Steel (SS) internal attachments can be welded to carbon steel 

pressure-retaining parts of exhcnagers in non-sour services. 

8.1.27 SA-266 (Grade 2 or Grade 4) or SA-105 shall be only used where impact 

testing is not required. 

8.1.28 Internal attachments to clad exchnagers shall be of the same material as 

that of the cladding. SS 321 and SS 347 can be used interchangeably. 

8.1.29 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. 

8.1.30 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 approved Saudi Aramco suppliers within a list available by the 

Saudi Aramco Buyer, as defined in this specification. F8.1.16 All the 

components (tubesheet, tube, shell, channel, baffle, nozzle, head, cover 

and ring) shall be fabricated by Saudi Aramco approved exchanger 

manufacturer. 

8.1.31 All heat exchanger flanges shall be procured in accordance with 02- 

SAMSS-011 requirements from approved Saudi Aramco suppliers. 

8.2 Gaskets 



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8.2.3 (Exception) The materials of construction for spiral wound gaskets shall 

be as follows: 

8.3 Tubes 

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

Type 304 or 316 stainless steel (SS) windings with solid Type 304 

or 316 stainless steel outer centering rings. 

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

Type 304 or 316 SS windings with solid carbon steel outer 

centering rings. 

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

Type 321 or 347 SS windings with solid; Type 304 or 316 outer 

centering rings. 

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

Type 304 or 316 SS. 

8.3.3 Bare tubes shall be procured from approved Saudi Aramco suppliers in 

accordance with SAES-L-101 requirements. 

8.4 Impact Testing 

8.4.1 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. 

8.4.2 Impact test temperature for a component of a exchanger shall be as 

specified on the data sheet. 

8.4.3 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 

3) As specified by the licensor’s specification, but not less than 34/27 

Joules 



32-SAMSS-007 




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. 

8.4.4 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 

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. 

8.4.5 Impact testing is required, with no exception, for pressure exchangers 

made of low alloy steels. 

8.4.6 Impact testing of materials and welding procedures are required when 

test temperature is lower than -28°C. 

8.4.7 Baffle plates, sealing strips, tie-rods, sliding bars, tubes, spacers, and 

support plates are exempt from impact testing requirements. 

8.5 Special Testing for Steels under Scope of API RP 934-A 

8.5.1 Microstructure Testing 

a) Two sets of microstructures shall be provided for each forged ring or 

shell plate. One set of microstructure shall be provided for other reactor 

b) Each set of sample shall consist of both transverse and longitudinal 

direction. The Transverse microstructure shall include ID, mid 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. 

8.5.2 Hardness Testing 

a) Two hardness readings shall be taken on each reactor component, 

which includes each forged ring, shell plate, nozzle, pipe, fitting, and 

flange. 



32-SAMSS-007 




b) Test method and acceptance criteria shall follow API RP 934-A 

(SECOND EDITION, ADDENDUM 2, MARCH 2012), Paragraph 

7.4.2. 

8.5.3 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 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 440°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 Document 

stress-rupture test shall be 210 MPa (30 ksi) at 510°C (950°F). The time 

of failure shall exceed 650 hours. 

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 (1000°F). The time 

of failure shall exceed 900 hours. 

8.5.4 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: 



32-SAMSS-007 




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. 

8.5.5 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. 

8.5.6 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). 

9 Fabrication 

9.1 Shells 

9.1.4 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. 

9.1.5 Plate edge laminations revealed per examination method in paragraph 

9.1.6 of this specification shall be completely removed and repaired as 

per SAES-W-010. 

9.1.6 Each shell section shall be completely welded longitudinally and 

corrected for out of roundness and peaking of the weld seam prior to 

welding to the adjoining shell section or head. 

9.1.7 All re-rolling or forming of the shell sections is to be completed prior to 

radiography. 



32-SAMSS-007 




9.1.8 External welded attachment pads shall have their corners rounded to a 

minimum radius ¼ of the length or width of the pad whichever is less 

with a maximum of 50 mm and shall be fully seal welded. 

9.1.10 Attachment pad for supports, lifting lugs and other attachments shall be a 

minimum of 10 mm (3/8") thick or equal to the shell thickness, 

whichever is less. Attachment loads must comply with paragraph 7.17.3 

above and pads shall not cover pressure-retaining welds. 

9.1.11 Telltale Holes in Reinforcing Pads 

9.1.11.1 ¼ - inch telltale vent holes drilled and tapped for ⅛ -inch NPT shall be 

provided in reinforcing pads for welded attachments, including nozzles 

and manways, per the following: 

1) One hole in single piece reinforcing pad. 

2) Where a pad is split, each segment shall have at least one hole. 

9.1.11.2 Telltale holes shall be located at the lowest position accessible for 

inspection with center of the hole 25 mm from edge of the pad. This is 

applicable to each segment of a split-reinforcing pad. 


In case of reinforcing pads for attachments, other than nozzles and 

manways, center of telltale hole shall be 25 mm from the closest edge of 

the pad. 

9.1.11.3 Telltale holes in reinforcing pads for external welded attachments shall 

be plugged with grease or other materials adequate for the operating 

temperature but not capable of retaining pressure, to prevent moisture 

ingress between the pad and the exchanger pressure-retaining 

component. Telltale holes in internal attachment pads shall be seal 

welded. 

9.1.12 Segments of split reinforcing pad shall be welded together without using 

a backing strip. 

9.2 Pass Partition Plates 

Pass partition plate shall be provided with a 6 mm (¼") drain hole. 

9.3 Connection Junctions 

(Exception) All nozzles shall be ground flush to the inside curvature of 

the exchanger inside diameters with smooth inside corner radius equal to 

the nozzle wall thickness. 



32-SAMSS-007 




9.5 Welding 

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

SAES-W-010. 

9.5.2 (Exception) 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 7.7.5 of this specification. 

9.5.11 Welds attaching nozzles and their reinforcement pads and other 

attachments to pressure components shall not be closer than 20 mm from 

any pressure retaining welds. See also paragraph 10.2.1.4. 

9.5.12 Where a split-reinforcing pad is required, the weld joining the pad 

sections shall be oriented with the circumferential direction of the shell. 

Welding the pad sections together shall be done without using a backing 

strip. 

9.6 Heat Treatment 

9.6.2 (Exception) 

1) The following tubes shall be stress relief heat treated after cold 

forming and bending: 

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

from the tangent line of all carbon steel tubes for exchangers 

in caustic, wet sour and amine services. 

b) Monel, brass and all chrome alloy tubes in all services. 

2) The following tubes shall be solution annealed: 

a) Entire tubes manufactured of unstabilized or non low carbon 

stainless steels or Nickel base alloys in accordance with 

ASME SA-688. 

b) 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. 

9.6.8 Postweld heat treatment (PWHT) shall be done when required by the 

applicable Code or when specified on the data sheet. 

9.6.9 Code exemptions for postweld heat treatment (PWHT) of ferritic 

materials based on the use of austenitic or nickel-based electrodes are not 



32-SAMSS-007 




permitted for exchangers in sulfide stress cracking environments as 

defined in this specification. 

9.6.10 Code exemptions for postweld heat treatment (PWHT) of P4 and P5 

materials are not permitted for applications involving either wet sour or 

hydrogen services for materials exceeding 1.25% nominal chromium 

content. 

9.6.11 The maximum postweld heat treating soaking temperature for quenched 

and tempered carbon steel materials shall not exceed the temperature at 

which the test pieces were heat treated, as shown on the Mill Test 

Reports or 650°C maximum for carbon steel and 700°C for low chrome 

alloy steels. 

9.6.12 Time and temperature of postweld heat treatment (PWHT) for carbon 

steel exchanger with potential environmental cracking shall be in 

accordance with requirements of API RP582. 

9.6.13 Final postweld heat treatment (PWHT) shall follow all welding and 

repairs but shall be performed prior to any hydrotest or other load test. 

9.6.14 A sign shall be painted on a postweld heat treated exchanger and located 

such that it is clearly visible from grade: 

"Caution – Exchanger Has Been Postweld Heat Treated – Do Not Weld" 

9.6.15 Postweld heat treatment (PWHT) shall be in accordance with the 

requirements of SAES-W-010 and this specification. 

9.8 Gasket Contact Surfaces other than Nozzle Flange Facings 

9.8.1 (Exception) Gasket seating surfaces shall comply with the following: 

9.9 Tube Holes 

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 side-walls of ring joint flanges in all services, 63 AARH. 

4) For non-metallic gaskets, 250 to 500 AARH. 

The surface roughness of machined surfaces, other than gasket contact 

faces, shall not exceed 500 AARH. 



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9.9.3 Tubesheet tube hole diameters and tolerances shall be special close fit 

when tube bundle vibration is suspected or when exchanger is in cyclic 

service. 

9.9.4 Tube expanding procedures shall incorporate stops to prevent tube 

expansion past tubesheet faces. 

9.9.5 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. 

9.9.6 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. 

9.12 Forming and Heat Treatment 

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

forming operation (hot or cold) for any of the conditions listed below. 

The heat treatment shall be annealing, normalizing, normalizing and 

tempering, or quench and tempering, as required. 

Heads and other double-curvature components with nominal 

thickness exceeding 50 mm. 

Heads and other double-curvature components made of P-No. 3, 4, 5, 

9A or 9B materials. 

Any hot-formed component. 

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

Aramco Engineer for approval prior to commencement of any 

fabrication requiring hot forming. The procedure shall describe all heat 

treatment operations and tests to be performed. The tests shall include, 

but not limited to, all of the mechanical tests required by the original 

material specification. 

9.12.3 Cold Forming 

a) Heat treatment requirements for Carbon Steels (P-1) and Low Alloy 

Steels (P-3, 4, 5, 9A and 9B) that undergo cold forming (by pressing or 

cold spinning) shall be as follows: 



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Material Fiber Elongation Strain ε f (%) Heat Treatment Requirement 

Carbon Steels P-1 

Low Alloy Steels P-3, P-4, 

P-5, P-9A & P9B 

High Alloy Materials 

Non-ferrous Materials 

Less than or equal to 5 

Greater than 5 and 

equal to or less than 10 

Greater than 10 

Less than or equal to 3 

Greater than 3 and 

equal to or less than 10 

Greater than 10 

Table 6.2 of ASME Section VIII, 

Division 2 

Table 6.3 of ASME Section VIII, 

Division 2 

None 

(Exception: PWHT per the applicable Code 

shall be performed for cold spun heads) 

PWHT per the applicable Code 

Normalizing, Normalizing and tempering or 

quenching and tempering, as required to 

maintain original material properties. 

None 

(Exception: PWHT per the applicable Code 

shall be performed for cold spun heads) 

PWHT per the applicable Code 

Normalizing, normalizing and tempering or 

quenching and tempering, as required to 

maintain original material properties. 

Table 6.2 of ASME Section VIII, Division 2 

Table 6.3 of ASME Section VIII, Division 2 

b) Calculation of forming fiber elongation strain εf (%) shall be according to the 

following: 

Type of Part Being Formed Fiber Elongation Strain ε f (%) 

For double curvature heads that are formed from onepiece 

or welded multi-piece blanks by any process that 

includes dishing or cold spinning (e.g., dished heads or 

cold spun heads) 

For heads that are assembled from formed segments 

(e.g., spherical dished shell plates or dished segments 

of ellipsoidal or torispherical heads) 

ε f = 100 ln [D b /(D f -2t)] [1] 

ε f = 100 t / R fd [2] 

Cylinders and cones formed from plate ε f = (50 t / R fc ) [1-(R fc / R o )] [3] 

Where: 

ln 

D b 

D f 

is the natural logarithm 

is the diameter of unformed blank plate or diameter of intermediate product 

is the outside diameter of the finished product 



32-SAMSS-007 




R fd 

R fc 

R o 

t 

is the smallest mean radius of curvature of formed segment (mean radius of spherical 

segment, mean knuckle radius of knuckle segment of multi sectional semi-ellipsoidal or 

torispherical heads) 

is the mean radius of curvature of finished product (mean radius of cylinder, mean 

radius of the smaller diameter of cone) 

is the mean radius of initial product (flat plate) or the intermediate product (in case of 

unformed initial product equals to infinity) 

is the nominal thickness of the plate before forming or intermediate product 

Commentary Notes: 

i) Cold spun heads with nominal thickness exceeding 50 mm shall be heat treated by normalizing, 

normalizing and tempering or quenching and tempering, as required to maintain original material 

properties), irrespective of the calculated fiber elongation strain. 

ii) 

iii) 

iv) 

Need for heat treatment of all double curvature circular products (e.g., spherical crowns, semiellipsoidal 

and torispherical heads) formed from one-piece or welded multi-piece blank, shall be 

based on fiber elongation strain calculated using equation [1] of the above table. 

Separate calculation of extreme fiber elongation shall be made for each formed segment forming 

multi-sectional heads (torispherical or ellipsoidal) or spheres (excluding spherical crown). Need 

for heat treatment shall be determined for each segment individually using equation [2] of the 

above table based on the greatest measured thickness and smallest radius of curvature after 

forming. 

In case of different forming steps without intermediate heat treatment are employed, extreme 

fiber elongation is the total amount of elongation of the individual forming steps. In case of 

intermediate heat treatment, the deformation is that elongation achieved after the last previous 

heat treatment. This is applicable for all types of formed part. 

v) Filler metal used in items subjected to hot forming temperatures, or normalized, shall satisfy the 

weld joint design requirements after such heat treatment. This is considering that such welds will 

generally suffer significant strength reduction. 

10 Inspection and Testing 

10.1 Quality Assurance 

10.1.3 The responsibility for quality assurance rests with the Exchanger 

Manufacturer in accordance with the applicable Code and the 


10.1.4 Exchangers manufactured in accordance with this specification are 

subject to verification by the Saudi Aramco Inspector in accordance with 

Saudi Aramco Inspection Requirements Form 175-323100. 



32-SAMSS-007 




10.1.5 All required Nondestructive Examination shall be included in inspection 

procedures established according to ASME SEC V and this specification. 

A written procedure shall address each inspection method and technique 

used including acceptance criteria. When required by the purchase order 

the procedure(s) shall be submitted to Saudi Aramco Inspection 

Department for approval. 

10.1.6 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. 

10.1.7 Magnetic-particle, liquid-penetrant, ultrasonic and radiographic 

examinations on exchangers to be postweld heat-treated shall be made 

after completion of final heat treatment. 

10.1.8 All pressure and non-pressure welds shall be visually inspected where 

accessible. All segments of longitudinal, circumferential or built-up head 

pressure weld seams covered or rendered inaccessible by internals, lifting 

lugs or other attachments shall be fully radiographed the entire affected 

length plus 10 inches either side prior to installation of the attachment. 

10.1.9 Additional examination of any weld joint at any stage of the fabrication 

may be requested by the Saudi Aramco Inspector, including reexamination 

of previously examined joints. The Saudi Aramco Inspector 

also has the right to request or conduct independent NDE of any joint. If 

such examination should disclose gross non-conformance to the 

requirements of the applicable Code or this specification, all repair and 

NDE costs shall be done at the Exchanger Manufacturer's expense. 

10.1.10 All necessary safety precautions shall be taken for each examination 

method. 

10.1.11 Surface irregularities, including weld reinforcement, inhibiting accurate 

interpretation of the specified method of nondestructive examination 

shall be ground smooth. 

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

inch wide on each side of the weld. 

10.1.13 The Saudi Aramco Inspector shall have free access to the work at all 

times. 



32-SAMSS-007 




10.1.14 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. 

10.1.15 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. 

10.1.16 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. 

10.1.17 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. 

10.1.18 The Exchanger Manufacturer shall provide the Saudi Aramco Inspector 

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

specified. 

10.1.19 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. 

10.1.20 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. 

10.1.21 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 (Exception) Radiographic testing shall be performed as follows: 

10.2.1.1 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. 

10.2.1.2 Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as 

individual rounded indications. Clustered or aligned tungsten inclusions 

shall be removed and repaired. 



32-SAMSS-007 




10.2.1.3 Radiography examination requirements for weld joints categories A, B, 

C and D shall be according to Table 1 of this specification and the 

following: 

a) Butt welds connecting forged junction ring, conforming to ASME 

SEC VIII D2, Figure 4.2.4(e), to shell and head shall be 100% 

radiographed. Use of ultrasonic examination method that generates 

permanent records can be used as a substitute to radiography, as 

applicable (see relevant requirements per Note 3 of Table 1). 

b) Butt welds in multi-piece plate blanks to be formed into heads shall 

be 100% radiographed after forming. Use of ultrasonic examination 

method that generates permanent records can be used as a 

substitute to radiography (see relevant requirements per Note 3 of 

Table 1). 

10.2.1.4 100% radiography examination is required for butt welds connecting 

forged junction ring according to ASME SEC VIII D2, Table 4.2.5 - 

Detail 7 to shell and head. 

10.2.2 (Exception) Magnetic particle examination shall be performed as follows: 

10.2.2.1 Permanent magnetic yokes are not permitted. 

10.2.2.2 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 wet sour service. 

10.2.2.3 Magnetic particle examination or liquid penetrant examination shall be 

performed on the surfaces of hot formed and reheat treated as per the 

applicable Code. 

10.2.2.4 Except for non-ferromagnetic 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 (saddle, 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. 



32-SAMSS-007 




Note: 

If wet visible MPI is used, a white color contrast coating shall be applied 

prior to the examination. 

10.2.2.5 All edges prepared for welding and all openings in ferromagnetic 

exchangers shall be 100% magnetic particle examined in accordance 

with the applicable Code. 

10.2.2.6 Forgings shall be examined on all surfaces, utilizing wet fluorescent 

magnetic particle method after final machining. All defects shall be 

removed and repaired by welding in accordance with SAES-W-010. 

Except for welding edges, liquid penetrant examination is acceptable as 

an alternative to magnetic particle examination. 

10.2.2.7 All ferromagnetic welds are to be wet fluorescent magnetic particle 

examined after final heat treatment. 

10.2.4 (Exception) Liquid penetrant examination shall be performed as follows: 

10.2.4.1 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 (saddle, lug, and leg). 

c) Attachment welds to the exchanger. 

d) Areas where temporary attachments have been removed. 

e) Arc strike areas. 

10.2.4.2 All edges prepared for welding and all openings in non-ferromagnetic 

exchangers shall be 100% liquid penetrant examined in accordance with 

the applicable Code. 

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

requirements of SAES-W-010. 

10.2.12 Ultrasonic Examination 

10.2.12.1 Ultrasonic examination requirements for weld joints categories A, B, C and 

D shall be according to Table 1 of this specification. 



32-SAMSS-007 




10.2.12.2 All plates with thickness more than and including 50 mm (2.0 inches) 

shall be ultrasonically examined in accordance with ASTM SA578. 

Acceptance criteria shall be Level C of SA-578. 

10.2.12.3 Plates with thickness more than 12.5 mm (0.5 inch) and less than 50 mm 

(2.0 inches) shall be ultrasonically examined 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 inch) diameter circle is unacceptable. 

10.2.13.4 100% Ultrasonic examination is required for the following weld joints: 

a) Butt-welds in exchanger supports. 

b) Full-penetration welds in external attachments (supports, brackets, 

lugs, etc.) to pressure retaining parts. 

10.2.12.5 All forgings shall be 100% ultrasonically examined 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. 

10.2.12.6 100% conventional ultrasonic examination is required for all full 

penetration welds in exchnager supports. Alternatively, 100% 

radiography examination shall be used. 

10.2.12.7 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. 

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

required NDE after the final postweld heat treatment. 

10.3 Pressure Testing 

10.3.2 (Exception) An independent hydrostatic test of shell-side and tube-side 

shall be performed. The temperature of the water during hydrostatic 

testing shall be maintained at not less than 17°C throughout the testing 

cycle. 

10.3.3 (Exception) Water used for pressure testing shall be potable and the 

hydrostatic test pressure shall be held for a minimum of one hour per 25 

mm of exchanger shell/channel thickness and in no case less than one 

hour. 



32-SAMSS-007 




10.3.12 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. 

10.3.13 Pneumatic testing in lieu of hydrostatic testing requires the approval 

from Saudi Aramco Inspection Department. 

10.3.14 No preliminary pressure testing shall be made prior to postweld heat 

treatment. 

10.3.15 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. 

10.3.16 The Exchanger Manufacturer shall furnish all test materials and 

facilities, including blinds, bolting, and gaskets. 

10.3.17 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. 

10.3.18 The manufacturer shall supply the following: 

a) Minimum two sets of spare gaskets with a blind flange for each 

manway and 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 exchanger. 

10.3.19 After testing, the exchanger shall be completely drained and thoroughly 

dried including around the internals. 

10.3.20 For other than differential-pressure design exchangers, test pressure for 

the shell side and the tube side shall be as per the applicable code 

10.3.21 For differential-pressure design exchangers, test pressure shall be as per 

the applicable code. 

10.3.22 Vertical exchangers that are tested in the horizontal position shall be 

adequately supported such that the primary stresses in any part of the 

exchanger do not exceed 90% of the minimum specified yield strength of 

the exchanger material. 



32-SAMSS-007 




10.3.23 Horizontal exchangers are to be tested while resting on their permanent 

support saddles, without additional supports or cribbing. Primary 

stresses in any part of the exchanger for this case shall not exceed 90% 

of the minimum specified yield strength of the exchanger material. 

10.3.24 All welded attachments provided with tell-tale holes shall be 

pneumatically tested at minimum 35 kPa (5 psi) prior to heat treatment 

and exchanger pressure testing. Tell-tale holes must not be plugged 

during the exchanger pressure test. 

10.3.25 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. 

10.4 Nameplates and Stampings 

10.4.1 Nameplates shall be 3 mm minimum thickness and manufactured from 

type 304 stainless steel or Monel and welded to the mounting bracket 

according to PIP VEFV1100. 

10.4.4 Each exchanger shall be identified by a nameplate and marked with the 

information required by the applicable Code and the requirements of this 


10.4.5 The nameplate and its mounting bracket 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. 

10.4.6 Exchangers shall be Code stamped for all services, in accordance with 

the applicable Code. 



32-SAMSS-007 




10.4.7 The mounting bracket material shall conform to Table 1 and it shall be 

continuously seal-welded and positioned such as not to allow for 

collection of moisture or rain. 

10.4.8 Nameplate for internally coated exchangers shall show: the Saudi 

Aramco Painting System Numbers, type of coating, brand name, and 

date of application. 

10.5 Repairs during Fabrication 

10.5.1 The Saudi Aramco Engineer must review and approve crack repair 

procedures, required by the applicable Code, prior to commencement of 

the repair work. It is the responsibility of the manufacturer to ensure that 

repairs done by the mill of any material defects, per the applicable Code, 

are documented. 

10.5.2 After completion of repairs required by the applicable Code, the 

following shall be repeated: 

11 Preparation for Shipment 

11.1 Protection 

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. 

11.1.2 (Exception) Exchangers is to be cleaned from all loose scales, weld 

slags, dirt and debris to the satisfaction of the Saudi Aramco Inspector. 

11.1.10 The Manufacture shall protect the equipment from mechanical and 

corrosion damage in order to assure that the equipment will be serviceable 

after shipping, storage, and construction. The duration of these activities 

is assumed to be 24 months. If longer period is specified, the required 

protection measures shall be determined on a case-by-case basis. 

11.1.11 Prior to shipping, exchangers are to be completely dried. 



32-SAMSS-007 




11.1.12 Temporary covers, 3 mm thick steel or wood cover with neoprene 

gasket, for flanges shall be bolted in place with a minimum of 4 bolts 

equally spaced and sufficient to contain the protective media inside the 

exchanger. Bolts shall be protected from external corrosion by a rust 

preventive grease or equivalent substance liberally applied over the bolt 

surface. Flanges with permanent blind flanges shall be secured with the 

gaskets and bolting specified for service. 

11.1.13 Threaded nozzle connections shall be protected with threaded plugs and 

by the use of an appropriate lubricant with rust preventive compound 

such as Cortec VpCI-369 or equivalent. 

11.1.14 Tell-tale holes in reinforcing pads shall be protected with wooden plugs 

or packed with rust preventative grease such as Denso paste. 

11.1.15 Flanged connections and all other machined surfaces not described 

elsewhere in this section shall be protected by use of an appropriate 

lubricant with rust preventive compound such as Cortec VpCI-369 or 

equivalent. 

11.1.16 Export packing, marking, and shipping shall be in accordance with the 

purchase order. 

11.1.17 The exchanger manufacturer is responsible for ensuring that the 

exchangers being shipped are adequately braced and shall provide 

temporary supports where appropriate to ensure adequate support of the 

exchanger during shipment. 

11.1.19 Internal & External Protection 

11.1.19.1 For carbon steel and stainless steel fully assembled heat exchangers, 

spray interior surfaces (both shell and tube side) with a vapor phase 

inhibitor such as Cortec VpCI-307 or 309 or equivalent. Apply the 

Cortec product at a rate of 0.3 kg/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. 19.2 The shell and external surfaces shall be protected by preparing the 

surface and fully coating the external surfaces using the specified Saudi 

Aramco coating specification prior to shipment. 



32-SAMSS-007 




11.1.19.3 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 

Chemical's Tectyl 506 or equivalent. Coating shall be removed prior to 

service using a non-caustic steam wash. Alternatively, solid stainless 

steel exchangers shall be 100% wrapped and sealed in a 4-mil thick 

anticorrosion polyethylene film containing vapor phase corrosion 

inhibitor such as Cortec VpCI 126 Blue or equivalent. Equipment that is 

an emergency spare for long term storage shall be wrapped in Cortec's 

10-mil thick MillCorr film or equivalent. Stainless steel exchangers 

shipped by ocean freight must be protected from sea spray, rain, etcetera. 

11.1.19.4 Tube bundles shipped separately from shells must be adequately 

protected and supported to prevent mechanical and corrosion damage. 

Tube internals shall be protected using Cortec VpCI-307 or VpCI-309 or 

equivalent as detailed in Paragraph 11.1.19.1, 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 tube bundle shall be 100% wrapped and sealed in a 4-mil thick 

anticorrosion polyethylene film containing vapor phase corrosion 

inhibitor such as Cortec VpCI 126 Blue or equivalent. Equipment that is 

an emergency spare for long term storage shall be wrapped in Cortec's 

10-mil thick MillCorr film or equivalent. 

11.1.20 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. 21 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. 

11.1.22 Nitrogen blanketing at a pressure of 35 kPa (5 psi) shall be provided for 

components that can not be protected properly by the use of vapor phase 

inhibitor due to inaccessible difficulties such as shell's internal surface 

for fixed tubesheet heat exchangers. 



32-SAMSS-007 




11.1.23 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. 

11.1.24 For exchangers which have permanent internal coatings, the Exchanger 

Manufacturer shall contact the Saudi Aramco Engineer for any corrosion 

protection required. 

11.1.25 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. 

11.1.26 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. 

11.1.27 Bolt heads shall also be protected with a rust preventative compound to 

prevent corrosion during shipment, storage and construction. 

11.1.28 Spare bolts shall be protected with a rust preventative compound to 

prevent corrosion during shipment, storage and construction. 

12 Supplemental Requirements 

12.1 General 

(Exception) Exchangers with cylindrical pressure components greater 

than 50 mm thick shall be manufactured in accordance with Section 9 

and the requirements for thick wall exchangers as detailed in this 


Revision Summary 

20 November 2007 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 8.1.11. 

1 December 2013 Major revision. 



32-SAMSS-007 




Table 1 – Nondestructive Examination Requirements 

Weld Joint 

Category 

A and B 

Radiography 

(RT) 

Per Design 

Code 

Criteria 

(Spot or 

100%) (1) & 

(3) 

Ultrasonic 

(UT) 

See 

Notes (2) & 

(3) 

Liquid 

Penetrant (LP) 

or Magnetic 

Particle (MP) 

100% 

Notes: 

C 100% (3) 100% (3) 100% (6) 

D See Note (4) See Note 

(4) See Note (4) 

(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. 

Unfired steam boilers with design pressure exceeding 50 psi. 

Thick wall exchangers. 

(2) 100% conventional UT is required for only exchangers under any of the services or design conditions per note 

1 of this table. 

(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% RT and 100% Conventional UT on joints for design conditions/ services Group I per paragraph 8.5.2 

of this specification. Alternatively, 100% UT employing methods that generate permanent records can be 

used and must be approved by the Inspection Department prior to commencement of any work. 

b) Following design details shall be used where RT is required for Category - D weld joint: 

i. For Division 1 exchangers: Figures UW-16.1: (f-1), (f-2), (f-3) or (f-4). 

ii. For Division 2 exchangers: Figures 4.2.13: (1), (2), (3), (4), (5) or (6). 

c) 100% UT shall be performed from an accessible side, where RT cannot be utilized due to only geometry, 

on joints for design conditions/ services Group II per paragraph 8.5.2 of this specification. If conventional 

UT method cannot be utilized, other UT methods shall be used and must be approved by Inspection 

Department prior to commencement of any work. 

d) Following examinations shall be performed, where RT and UT cannot be utilized due to only geometry, on 

joints used for design conditions/ services Group II per paragraph 8.5.2 of this specification: 

i. For attachments without a reinforcing pad, 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. Where PWHT is required, final surfaces of weld joints shall be examined for 

acceptance after final PWHT. 



32-SAMSS-007 




ii. 

For attachments with a reinforcing plate, similar examination as in (i) above shall be performed at the 

nozzle. 100% MT or 100% LP shall be also performed on the final surface of the fillet welds attaching 

the reinforcing pad to exchanger and nozzle. 

(5) Inspection requirements for connections attached to nozzles and manways per paragraph 8.5.2 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. 



Inspection & Testing Requirements 

Saudi Aramco Form-175 

CODE NUMBER: 

IR323100 

SCOPE: HEAT EXCHANGERS: Shell and Tubes. 

TEST AND INSPECTION PER: 32-SAMSS-007and 

Specifications As Noted Below. 


INSPECTION & TESTING REQUIREMENTS 

SAUDI ARAMCO FORM-175 

REVISION: 06/22/2011 

REPLACES: 06/21/2010 

CODE NUMBER: 

IR323100 

PAGE: 

1 of 3 

SCOPE: HEAT EXCHANGERS: Shell and Tubes. 

TEST AND INSPECTION PER: 32-SAMSS-007and Specifications As Noted Below. 

0010 

(1) VISUAL INSPECTION WITNESSING BY INSPECTOR (Note 1) 

(2) CERTIFICATES / RECORDS TO BE CHECKED BY INSPECTOR 

(3) CERTIFICATES / DATA TO BE PROVIDED BY VENDOR / SUPPLIER / MANUFACTURER 

* * * 

Pre-Fabrication/Production Requirements Specification Details / Notes: 

0010 X X Pre Inspection meeting Verify Company approval of manufacturer Inspection and test 

plan. 

0020 X Material Test Reports MTRs shall be submitted for all pressure retaining materials & 

highly stressed components, including chemical composition of 

cladding, overlay on clad or weld overlaid exchangers. 

0030 X NDT Procedures and Personnel Check for valid personnel certification and procedures. 

0040 X Procedure Qualification Records ,Welding Procedure 

Specifications (PQR & WPS)and Weld Map 

Per SAES-W-010 and ASME IX. Company approval required. 

0050 X Welder Qualification Records Per SAES-W-010 and ASME IX. 

0020 

* * * 

In process inspection & test requirement Specification Details / Notes: 

0010 X Workmanship, Components and Dimensions Extent of witness is as per approved ITP 

0020 X X PMI Per SAES-A-206 

0030 X HIC Test Per 01-SAMSS-016 

0040 Nondestructive Testing (NDT): 

0050 X X a) Radiography of Butt Welds & Major Repairs of Pressure 

retaining Parts 

Per 32-SAMSS-007. 

0060 X b) Ultrasonic Testing of Welds in Lieu of Radiography ASME VIII, Div. 1. Applicable where joint details not allow 

radiography. 

0070 X c) Ultrasonic Testing of Plate ASME VIII, Div. 1. Only on plates of thickness more than or 

equals to 50mm & on cladding. 

0090 X d) Magnetic Particle Testing Per 32-SAMMS-007. 

0100 X e) Liquid Penetrant Testing ASME VIII, Div. 1. Only for overlaid heat exchangers. 

IR323100 Continued...



REVISION: 06/22/2011 

REPLACES: 06/21/2010 

CODE NUMBER: 

IR323100 

PAGE: 





0110 X f) Liquid Penetrant Testing of tube to tube sheet welds ASME VIII, Div. 1. Only for Wet Sour Service. 

0120 Workmanship, Components and Dimensions: 

0130 X a) Visual Inspection of internal Pressure & Non-pressure Welds Per 32-SAMSS-007, SAES-W-010 & ASME Section V Article 9. 

0140 X b) Heat Treatment Procedures and Charts Per 32-SAMSS-007, SAES-W-010 & applicable code. 

0150 X c) Impact Test Per 32-SAMSS-007. 

0160 X d) Hardness Test of Wetted Parts SAES-W-010 only for wet sour service. 

0030 

* * * 

Final inspection & test requirements Specification Details / Notes: 

0010 X Visual and Dimensional Inspection Per 32-SAMSS-007 

0020 X Hydrostatic Test Test pressure is based on ASME VIII div. 1. See 

32-SAMSS-007 for details. 

0022 X Dry out Heat Exchangers shall be dried completely and immediately 

after the hydro test. 

0030 X Corrosion Inhibitor Refer 32-SAMSS-04 

0040 X Grounding and lifting lugs Per approved drawing 

0050 X Air Test On reinforcing pad welds, at 35 to 50Kpa (5 to 7.5psig) 

0060 X Painting / Coating Per SAES-H-100. 

0070 X Marking, Code Stamping & Preparation for shipment Per 32-SAMSS-007. 

Notes: 

(1) May only be waived by the responsible Saudi Aramco, ASC, or AOC Inspection Offices. 

(2) See form SA175 - 000003 for instructions on using this form. 

(3) Extent of witness shall be determined in the pre-Inspection Meeting. 

IR323100 Continued...



REVISION: 06/22/2011 

REPLACES: 06/21/2010 

CODE NUMBER: 

IR323100 

PAGE: 





End of IR323100


Charlie Chong/ Fion Fion Zhang Zhang

Understanding Heat Exchanger Reading 03- Part 2 of 2 The ARAMCO Std.

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