Engineering Encyclopedia: Fabrication, Inspection, and Testing of Heat Exchangers

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Fabrication, Inspection,
and Testing of Heat Exchangers
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s
employees. Any material contained in this document which is not already
in the public domain may not be copied, reproduced, sold, given, or
disclosed to third parties, or otherwise used in whole, or in part, without
the written permission of the Vice President, Engineering Services, Saudi
Aramco.
Chapter : Vessels For additional information on this subject, contact

File Reference: MEX21004 J.H. Thomas on 875-2230
Engineering Encyclopedia Vessels
Fabrication, Inspection, and Testing of Heat Exchangers
CONTENT PAGE
INTRODUCTION .... .......................................................................................................... 1
EVALUATING VENDOR FABRICATION DRAWINGS FOR

SUITABILITY ......... .......................................................................................................... 2
Saudi Aramco and Industry Fabrication Details.................................................................. 2

32-SAMSS-007 ............................................................................................ 2
API-660 ........................................................................................................ 3
TEMA........................................................................................................... 4
32-SAMSS-011 ............................................................................................ 5
API-661 ........................................................................................................ 6
Tube-to-Tubesheet Joints .................................................................................................... 7

Rolled ......................................................................................................... 10
Welded ....................................................................................................... 11
TEMA......................................................................................................... 11
Dimensional Tolerances .................................................................................................... 12

TEMA......................................................................................................... 12
API-660 ...................................................................................................... 13
API-661 ...................................................................................................... 13
INSPECTION AND TESTING REQUIREMENTS.......................................................... 15
Type and Extent of Required Inspection ........................................................................... 15

32-SAMSS-007 .......................................................................................... 17
Saudi Aramco Form 175 ............................................................................ 17
API-660 ...................................................................................................... 17
TEMA......................................................................................................... 18
32-SAMSS-011 .......................................................................................... 19
API-661 ...................................................................................................... 19

Pressure Testing Requirements.......................................................................................... 20

32-SAMSS-007 .......................................................................................... 20
API-660 ...................................................................................................... 21
TEMA......................................................................................................... 21
32-SAMSS-011 .......................................................................................... 22
API-661 ...................................................................................................... 22
Saudi Aramco Form 175 ............................................................................ 22
WORK AID 1: PROCEDURE FOR EVALUATING VENDOR

FABRICATION DRAWINGS FOR SUITABILITY ...................................................... 23
GLOSSARY ........... ........................................................................................................ 27

INTRODUCTION
This module prepares the Participant to evaluate whether heat exchanger fabrication drawings
that are provided by a vendor meet the applicable fabrication, inspection, and testing
requirements that are specified in Saudi Aramco and industry specifications and standards.
The Participant is provided guidelines and procedures to use in the evaluation process.
Saudi Aramco DeskTop Standards 1

EVALUATING VENDOR FABRICATION DRAWINGS FOR SUITABILITY
All fabrication details for shell-and-tube and air-cooled heat exchangers must comply with the
ASME Code.
Specific additional requirements that apply to shell-and-tube heat exchangers are contained
in:
• 32-SAMSS-007
• API-660
• TEMA
As noted in prior modules, the sections in 32-SAMSS-007 correspond to and modify the
corresponding sections that are in API-660.
Specific additional requirements that apply to air-cooled heat exchangers are contained in:
• 32-SAMSS-011
• API-661
The sections in 32-SAMSS-011 correspond to and modify the corresponding sections that are
in API-661.
The industry codes and standards are contained in Course Handout 1. The Saudi Aramco
SAESs and SAMSSs are in Course Handout 2. Work Aid 1 provides a procedure that may be
used to evaluate vendor fabrication drawings.
Saudi Aramco and Industry Fabrication Details
32-SAMSS-007
Section 13 of 32-SAMSS-007 presents fabrication requirements for shell-and-tube heat

exchangers that modify API-660. This section covers fabrication tolerances, forming and
assembly, and welding.
For the precise wording set forth in the Standard for the fabrication requirements, refer to the
SAMSS document. Key elements of this document are summarized below.

Fabrication Tolerances - Some thinning will occur when a flat plate is formed into a head. Para.
13.1 requires that the flat plate be thick enough such that the thickness of the head is sufficient
for the design conditions throughout the head.
Forming and Assembly - Paragraph 13.2 specifies requirements for forming and assembly of
heat exchanger components. Several of these requirements are highlighted below:
• Any laminations that are found in plate edges by magnetic particle

examinations must be completely removed and repaired. If plates were welded
together with unrepaired laminations, weld shrinkage could cause the
laminations to open wider and initiate cracks in the plate.
• All rerolling or forming of shell sections must be completed prior to

radiography. In this way, any weld damage that might be caused by the
rerolling or forming will be found by the radiographic subsequent inspection.
• The layout of shell plates must be done in a manner that nozzles and their
reinforced plates are not within 50 mm (2 in.) of any weld seam. This plate
layout avoids the potential for the nozzle or reinforcement welds to have a
detrimental effect on the shell welds.
• All internal and external nonpressure welded attachments must be fully seal
welded and have their corners radiused. Seal welding prevents corrodants from
accumulating between the attachment and the shell. The use of rounded
corners reduces the local stress concentrations at these locations.
Welding - Para. 13.3.1 requires that all welding must be done in accordance with
SAES-W-010.
API-660
Section 7 of API-660 presents the requirements for fabrication details for shell-and-tube heat
exchangers. For the precise wording of the fabrication detail requirements, refer to API-660.
The key elements of Section 7 are summarized in the sections below.
Shell - Paragraph 7.1.1 stipulates that all welds must be flush with the inner contour of the
shell so that the tube bundle can be easily inserted and removed. Paragraph 7.1.2 provides
limits for out-of-roundness for the shell of removable bundle heat exchangers. Out-of-
roundness limits are also intended to permit easy bundle insertion and removal. Paragraph
7.1.3 refers to TEMA Table R-4.3 for maximum allowable baffle-to-shell clearances.
Adequate clearances must be provided to permit bundle insertion and removal, but excessive
clearances would permit flow bypassing which would reduce heat exchanger performance.
Pass Partition Plates - Paragraph 7.2 specifies that continuous welding from both sides, or full-
penetration welding, is required for pass partition plates. This extent of welding is necessary
to provide adequate strength and to ensure that fluid does not leak across the partition plates.

Connection Junctions - Paragraphs 7.3.1 and 7.3.2 indicate that protrusion of nozzles and
couplings beyond the inside surface of the cylinder is prohibited. Protrusions would interfere
with bundle insertion and removal.
U-Tubes - Paragraph 7.4 presents the requirement that U-tubes be constructed in one piece (i.e.,
no circumferential joints) in order to maximize their reliability.
Welding - Paragraph 7.5 covers welding requirements. Paragraph 7.5.1 prohibits the use of
oxyacetylene welding. The ASME Code is referred to in Paragraph 7.5.2, which requires
single or double butt welds for longitudinal and circumferential seams.
Paragraph 7.5.3 requires that full-penetration welds be used to attach connections to shells or
heads In order to achieve the full strength of the attachment.
Paragraph 7.5.4 sets forth the extra inspection requirements for set-on nozzle details. Backing
strips may be used only with the approval of the purchaser, as stated in Paragraph 7.5.5.
Paragraph 7.5.6 allows the purchaser to require seal-welding of tubes to tubesheets, and for
the purchaser and vendor to agree mutually upon welding and testing procedure. Seal-
welding is sometimes used for applications where greater assurance of tube-to-tubesheet joint
integrity is required.
Paragraphs 7.5.7 and 7.5.8 present the conditions for continuous and noncontinuous welds.
Paragraph 7.5.9 stipulates that procedures for the repair of weld defects be reviewed by the
purchaser before repair.
Heat Treatment - Paragraphs 7.6.1 through 7.6.6 present postweld heat treatment requirements
that exceed the ASME Code and focus on items that are specific to shell-and-tube exchangers.
For example, requirements are specified for U-tubes, floating heads, and channels.
Assembly - Paragraph 7.10.1 specifies the mating parts that must be doweled in order to
prevent misassembly. Paragraph 7.10.2 mandates the use of a thread lubricant for all external
studs and nuts. Thread lubricant reduces the friction between the stud and nut and increases
the boltup torque that is actually applied to tightening the stud rather than to overcoming
friction.
TEMA
Section 5 specifies additional fabrication requirements for shell-and-tube heat exchangers.

The fabrication requirements are included within the same sections as the design
requirements. These requirements cover U-bends, standard tube patterns, baffles and support
plates, channels, covers, bonnets, nozzle construction, flanges, and bolting. For the precise
wording for these requirements, see the TEMA Standard. Several of these requirements are
summarized below.

U-Tube Bend Requirements - RCB-2.31 presents a formula to determine the minimum wall
thickness at the outer radius of a tube after forming a U-bend. The requirements for
acceptable thinning will be discussed under Dimensional Tolerances later in this module.
Bend Spacing - RCB-2.321 stipulates that the center-to-center spacing between parallel legs of
a U-bend must allow the tubes to be inserted into the baffle without causing damage to the
tubes. RCB-2.322 prohibits metal-to-metal contact in the bends in the same plane of the
assembly.
Heat Treatment - RCB-2.33 specifies conditions under which the purchaser may wish to require
heat treatment of U-bends, such as in sour wet service. The formation of
U-bends using cold work may cause embrittlement or a tendency to corrode.
End Flanges and Bolting - RCB-11 sets forth the requirements for bolt size, layout, and spacing.
R-11.1 stipulates a minimum allowable bolt diameter of 19 mm (3/4 in.), and refers to the
dimensional standards in Section 9, Table D-5. RCB-11.24 specifies the required bolt
orientation and spacing. Bolts must be spaced evenly and straddle the horizontal and vertical
centerlines of the exchanger.
32-SAMSS-011
Section 13 of 32-SAMSS-011 presents the fabrication requirements for air-cooled heat

exchangers that modify API-661. This section covers forming and assembly, and welding.
For the precise wording set forth in the Standard for the fabrication requirements, refer to the
SAMSS document. Key elements of this document are summarized in the sections that
follow.

Forming and Assembly - Most of the additional requirements for the forming and assembly of
air-cooled heat exchangers are identical to those that are specified for shell-and-tube heat
exchangers in 32-SAMSS-007. The following additional requirements are specific to air-
cooled heat exchangers:
• Flanges for removable cover plates and bonnet flanges must be attached to the
header with full penetration welds if the exchanger is in specified services.
These services are hydrogen, hydrocarbon, caustic, sour, wet-sour, and amine.
• Special close-fit tube-hole diameter tolerance in accordance with Table 5 of

API-661 must be used for specified tube materials or for specified services.
The closer tolerances make the tubes less prone to vibration and wear at the
supports. The closer tolerance is required for:
- Stainless steel, Monel, and nonferrous tubes
- All exchangers in hydrogen, cyclic, and lethal services
Welding - Para. 13.2 requires that all welding must be done in accordance with
SAES-W-010.
API-661
Section 7 of API-661 presents the fabrication requirements for air-cooled heat exchangers.
For the precise wording set forward in the Standard for the fabrication detail requirements,
refer to the API. The key elements of this document are summarized in the sections below.
Welding - Welding is covered in Paragraph 7.1. Paragraphs 7.1.1.1 and 7.1.1.2 refer to the
ASME Code for welding procedures, specifications, and welder qualifications. Paragraph
7.1.1.3 specifies that all header welds must be full-penetration and full-fusion. Paragraph
7.1.1.4 sets forth specifications for single-welded joints, which must use MIG, TIG, or
shielded metal arc for the root pass. Special provisions for plug-type headers are covered in
Paragraph 7.1.2. Partition plates for plug-type headers must be seal-welded from both sides.
Removable-cover plate and removable bonnet-type headers must meet the special provisions
presented in Paragraph 7.1.3.
Postweld Heat Treatment - Paragraphs 7.2.1 and 7.2.2 mandate postweld heat treatment for all
headers that are made from carbon steel and low-alloy steel.

Tube-to-Tubesheet Joints - Paragraph 7.3 provides the requirements for tube-to-tubesheet joints,
including diameters and tolerances for tube holes, tube hole grooving, expanded tube-to-
tubesheet joints, and welded tube-to-tubesheet joints.
Tube Hole Grooving - Paragraph 7.3.2 specifies dimensions and the required location for tube
hole grooves for tubesheet holes. The tube hole grooves must be square-edged, concentric,
and free of burrs.
Expanded Tube-to-Tubesheet Joints - Paragraph 7.3.3 stipulates that tube expansion into the
tubesheet must be accomplished by a procedure that results in uniform expansion. Paragraph
7.3.3 also sets forth the minimum and maximum dimensions of the expanded portion.
Welded Tube-to-Tubesheet Joints - Paragraph 7.3.4 allows the welding of tube-to-tubesheet joints
when all materials are suitable, and when welding is approved by the purchaser. The welded
joints are subject to the requirements of Paragraphs 7.3.1 through 7.3.3, except for the special
circumstances that are set forth in Paragraph 7.3.4.3.
Gasket Contact Surfaces - Paragraph 7.4 requires that all gasket contact surfaces be machined
and without surface scale. Any special surface finish requirements must be specified by the
purchaser.
Thread Lubrication - Paragraph 7.5 specifies that tube access plug threads must be coated with
a colloidal-metal type thread lubricant, and that header flange bolting must use a thread
lubricant that is suited to the operating temperature.
Tube-to-Tubesheet Joints
The most common types of tube-to-tubesheet joints that are used in refinery service are rolled
(i.e., expanded into the tube hole), welded, or a combination of the two. The joint efficiency
factor of a tube-to-tubesheet joint is a measure of its strength. Joint efficiency factors for the
different types of tube joints are presented in the ASME Code Section VIII, Division 1,
nonmandatory Appendix A. The ASME Code is included in Course Handout 1. Figure 1
illustrates several typical types of tube-to-tubesheet joints. Note that the dimensions "a" and
"t" that are shown in Figure 1 are parameters that are used to determine joint efficiency.

Standard TEMA Groved Joint
Standard Welded Joints
Typical Tube-to-Tubesheet Joints
Figure 1

The joint efficiency factor depends on the following factors:
• Whether the tubes are just rolled, rolled into a groove or grooves, seal-welded,
or strength-welded.
• The weld detail that is used.
• The size of the weld.
• Whether the joint is tested.
Equations are presented in the ASME Code, Section A-2, for calculation of the maximum
permitted axial load on a tube-to-tubesheet joint. The maximum permitted load on tube-to-
tubesheet joints is a function of:
• The cross-sectional area of the tube wall.
• The allowable stress of the tube.
• Several factors that account for the efficiency of the attachment, including:
- A factor for the length of the expanded portion of the tube, and whether
the tube holes are grooved.
- A factor for whether or not a qualification test has been done, and the
results of such a test.
- A factor for the allowable stress of the tube and tubesheet joint.
Refer to the ASME Code for the specific details of calculating the maximum permitted load
based on these factors.
Table A-2 in the ASME Code provides a table of efficiencies for tube-to-tubesheet joints.
Note the following general principles for the joint efficiency:
• Efficiency values are higher if qualification testing is done, as opposed to no

testing.
• If the weld thickness is less than 1.4 times the nominal thickness of the tube
wall, the efficiency is lower.
• In general, a greater number of grooves results in a higher efficiency.

A portion of Table A-2 is shown in Figure 2.
Joint Efficiency
Joint Description With Test No Test
Welded only, a ≥1.4t 1.00 0.80
Welded only, t ≤ a < 1.4t 0.70 0.55
Welded, a ≥1.4t, expanded 1.00 0.80
Welded, a < 1.4 t, and expanded, two or more grooves

Welded, a < 1.4 t, and expanded, single groove 0.95 0.75
Welded, a < 1.4 t, and expanded, no grooves 0.85 0.65
Expanded, two or more grooves 0.70 0.50
Expanded, single groove 0.90 0.70
Expanded, no grooves 0.80 0.65

0.60 0.50
Tube-to-Tubesheet Joint Efficiencies
Figure 2
Rolled
Rolled or expanded tube joints are generally used only for low-pressure applications. For
moderate to high pressures, the tubesheet is grooved with one or more grooves, and the tube
is expanded into the grooves. The grooves improve the mechanical strength and tightness of
the joint, and thereby deter leakage. A grooved tube-to-tubesheet joint is the most common
design.
Several methods can be used to expand the tube into the tubesheet. The most common
method is to roll the tube into the tubesheet hole with an expanding mandrel. Tubes may also
be expanded into the tubesheet by means of an explosive charge, or by the use of very high
hydraulic pressures within the confines of the tubesheet. Other than rolling, many of the
methods that are used to expand the tubes are proprietary methods of a given heat exchanger
manufacturer, and are outside the scope of this course.

Welded
Welded tube joints are generally used for higher pressure applications, or in cases where
leakage of the tube-to-tubesheet joints could have serious consequences. Welded joints are
usually categorized as either strength-welded or seal-welded.
In a strength-welded joint, the tube is first rolled into the tube hole to ensure a good fit. The
tube is then welded with a weld whose size is equal to or greater than 1.4 times the minimum
tube wall thickness. This size weld will be at least as strong as the cross section of the tube.
See Figure 1 for illustrations of several acceptable types of tube-to-tubesheet welds, and see
Figure 2 for the corresponding joint efficiencies.
In a seal-welded joint, the tube is generally rolled to develop its full strength in the tubesheet,
and then welded to the tubesheet with a weld that is smaller than 1.4 times the minimum tube
wall thickness. Seal-welded tube-to-tubesheet joints are often used in conjunction with
grooved tubesheets. See the ASME Code in Course Handout 1 and Figure 2 for the
appropriate efficiencies.
TEMA
The TEMA requirements for tube-to-tubesheet joints are presented in RCB-7.43 through 7.53.
RCB-7.43 states that the tube holes must be free of burrs and have a workmanlike finish on
internal surfaces.
RCB-7.51 covers rolled (i.e., expanded) tube-to-tubesheet joints. The limits of the length of
expansion into the tubesheet are presented. Uniform expansion throughout the tube is
mandated, and the tubes must be flush with the face of the tubesheet, or extend by no more
than one-half of the tube's diameter.
RCB-7.52 presents requirements for welded tube-to-tubesheet joints. When only a seal weld
is provided for additional leak tightness, the requirements of RCB-7.4 through RCB-7.51
apply, and the tube loads are carried by the expanded joint. When the welded tube joints
carry longitudinal tube loads, a strength weld is required and the other joint requirements may
be modified.
RCB-7.53 states that explosive bonding may also be used for tube-to-tubesheet joints, if
appropriate.

Dimensional Tolerances
TEMA
Fabrication tolerances for heat exchangers are covered in TEMA Section 2, Part F. See the
following drawings in the TEMA Standard in Course Handout 1:
• F-1: External Dimensions, Nozzle and Support Locations
• F-2: Recommended Fabrication Tolerances
• F-3: Tubesheets, Partitions, Covers and Flanges
U-Bend Requirements - Paragraph RCB-2.31 presents requirements for minimum thickness of

the unbent tubing, and maximum flattening of the tube when U-bends are formed. The
thickness of the tube wall before bending must be greater than the minimum required
thickness of the tube, in order for the tube to still be thick enough after bending. The
minimum original tube wall thickness, to , is a function of:
• The Code minimum required tube wall thickness for a straight tube, t1
• The outside tube diameter, do
• The mean radius of the bend, R
Note that tubes may be purchased to a nominal wall thickness. In this case, the
manufacturer's stated tolerance must be subtracted from the nominal wall thickness before the
calculation is made.
Flattening at the bend may not be greater than 10% of the tube outside diameter.
Tube Hole Clearances - Requirements for tube hole clearances are presented in RCB-4.2.
Clearances depend upon the length and diameter of the tube.
• Clearances are to be 0.8 mm (1/32 in.) over the outside diameter of the tubes
where:
- Tube length is 900 mm (36 in.) or less, or
- Outside diameter is greater than 32 mm (1-1/4 in.)

• Clearances are to be 1.5 mm (1/16 in.) over the outside diameter of the tubes
where:
- Tube length is greater than 900 mm (36 in.), or
- Outside diameter is 32 mm (1-1/4 in.) or less.
Transverse Baffle Clearances - RCB-4.3 provides a table for the allowable difference between the
shell inside diameter and the baffle outside diameter.
Tube Hole Diameters and Tolerances - Table RCB 7.41 presents tube hole diameters and
tolerances for a selection of tube outside diameters. Note that two tolerances are listed.
Standard-fit tolerance is to be used when tubes are rolled; special-close-fit tolerance is to be
used when tubes are to be welded, or are to be expanded with very thin tubes.
Tube Hole Finish - Inside edges of tube holes must be free of burrs and have a workmanlike
finish, in accordance with RCB-7.43.
Tube Hole Grooving - RB-7.44 mandates that tube holes for expanded joints be machined with
at least two grooves to provide greater load resistance, and specifies the dimensions of the
grooves, which must be 3 mm (1/8 in.) wide by 0.4 mm (1/64 in.) deep.
API-660
Gasket Contact Surface - Paragraphs 7.8.1 through 7.8.5 provide the requirements for flatness of
gasket contact surfaces other than nozzle flange facings. These tolerances are important
factors that influence the ability of the girth flanges to remain leak-tight. In most applications,
the tolerance, or maximum deviation from a plane, is 0.8 mm
(1/32 in.). More stringent tolerances may be specified for special applications, such as high-
pressure, high-temperature, or hydrogen services.
Tube Hole Grooves - Paragraph 7.9 requires that all tube hole grooves be square-edged,
concentric, and free from burrs.
API-661
Tube Access Plugs - For air-cooled heat exchangers, Paragraph 5.1.8.6 specifies that tube access
plugs must be long enough to fill the plug sheet threads. According to Paragraph 5.1.8.7,
threads must be Unified Fine Thread (ANSI B1.1) for plugs with diameters 42 mm (1-1/2 in.
or less).

Expanded Tube-to-Tubesheet Joints - Paragraph 7.3.3.3 presents requirements for the limits of
the extension of the ends of the tube beyond the tubesheet; the extension must be between 1.5
and 9.5 mm (1/16 and 3/8 in.).
Alignment and Tolerances - Paragraph 7.6 refers to the dimensional tolerances of air-cooled heat
exchangers and nozzle locations.

INSPECTION AND TESTING REQUIREMENTS
This section presents inspection and testing requirements for heat exchangers that are set forth
in Saudi Aramco SAMSSs and industry standards.
Type and Extent of Required Inspection
The ASME Code, Section VIII, Division 1, presents the basic testing requirements and
describes testing methods for tube-to-tubesheet joints.
This section does not describe in detail the inspection methods, which have already been
covered in other courses. The following paragraphs and table are intended as a brief review
of the inspection methods. Refer to MEX 202.04 for a more detailed discussion of the
methods of weld examination.
The five primary nondestructive examination (NDE) techniques that are used for welds are as
follows:
• Visual inspection (VT)
• Liquid penetrant examination (PT)
• Magnetic particle test (MT)
• Radiographic examination (RT)
• Ultrasonic examination (UT)
• Hardness testing (HT)
The decision as to which examination method, or combination of methods, to use depends

upon the weld quality required of the joint, the position of the weld, the material to be joined,
and the specific defects that are expected.
Figure 3 summarizes the types of nondestructive examinations, the defects that are typically
found by each, and the advantages and limitations of each inspection method.

NDE TYPE DEFECTS ADVANTAGES LIMITATIONS

DETECTED
Visual Inspection Porosity holes, slag Helps pinpoint areas Can only detect what
(VT) inclusions, weld for additional NDE. is clearly visible.
undercuts, overlapping
Liquid Penetrant Weld surface-type Used for ferrous and Can only detect
Examination (PT) defects: cracks, nonferrous materials. surface imperfections.
seams, porosity, folds, Simple and less
pits, inclusions, expensive than RT,
shrinkage MT, or UT.
Magnetic Particle Cracks, porosity, lack Flaws up to 6 mm (1/4 Cannot be used on

Test (MT) of fusion in.) beneath surface nonferrous materials.
can be detected.
Radiographic Gas pockets, slag Produces permanent Expensive.

Examination (RT) inclusions, incomplete record. Not practical for
penetration, cracks Detects small flaws. complex shapes.
Most effective for
butt-welded joints.
Ultrasonic Subsurface flaws: Can be used for thick Equipment must be

Examination (UT) laminations, slag plates, welds, castings, constantly calibrated.
inclusions forgings.
May be used for welds
where RT is not
practical.
Hardness Testing Excessive hardness of Indicates whether the Used primarily for
(HT) the weld, heat-affected component has had ferritic materials.
zone (HAZ), and base proper PWHT.
metal
NDE Types, Defects Detected, Advantages, and Limitations
Figure 3

32-SAMSS-007
Section 14 and Section 16 of 32-SAMSS-007 presents additional Saudi Aramco inspection

requirements for shell-and-tube heat exchangers. Section 16 also presents Saudi Aramco
pressure test requirements. Paragraph 16.1.2 states that inspection requirements must be in
accordance with Form 175 and the Purchase Order.
Several of the additional inspection requirements are as follows:
• All Category A and B single-sided welds must be visually inspected and 100%
radiographed for all services.
• Magnetic particle testing must be done on all structural attachment welds on

pressurized components of ferro-magnetic materials that are attached after
hydrotesting.
• Wet fluorescent magnetic particle testing (WFMT) is required for all internal
welds for certain services (e.g., wet sour, caustic, amine, hydrogen,
hydrocarbon). WFMT is also required for all welds made using the SMAW
process if the pressurized component is over 25 mm (1 in.) thick.
• Additional inspection requirements are specified in Addendum A for clad

exchangers and in Addendum B for exchangers that are over 50 mm
(2 in.) thick.
Saudi Aramco Form 175
Saudi Aramco Form 175 summarizes the examinations, tests, and standard inspections that
are required for heat exchangers. Form 175 may be specialized for shell-and-tube heat
exchangers, air-cooled heat exchangers, and plate-type heat exchangers. Form 175 specifies
whether the specified inspections themselves must be witnessed, whether just the inspection
records must be reviewed, or whether the vendor must just provide inspection data. A copy
of Form 175 that is specialized for shell-and-tube heat exchangers is contained in Course
Handout 3.
API-660
Section 8 of API-660 presents inspection and testing requirements for shell-and-tube heat
exchangers.
For the precise wording set forth in the Standard for the inspection and testing requirements,
refer to API-660. Several key elements of this document are summarized in the sections
below.

General Requirements - Paragraphs 8.1.1 through 8.1.3 require that the manufacturer notify the
purchaser prior to critical dates in the fabrication process, and provide the purchaser access to
the manufacturer's premises for inspection and testing.
The minimum inspection requirements are set forth in Paragraph 8.1.5. These requirements
consist of:
• Verifying that the manufacturer is using qualified welding procedures and

welders.
• Verifying compliance of the construction with applicable drawings and

standards.
• Reviewing NDE results.
• Witnessing required tests.
• Examining material test reports.
Quality Control - Paragraphs 8.2.1 through 8.2.12 provide detailed information concerning the
types of weld inspections that are required. Paragraph 8.2.1 stipulates that weld inspection
must be performed after postweld heat treatment. Paragraphs 8.2.2 through 8.2.5 cover the
requirements for full and spot radiographic examination, and the inspection alternatives for
welds that cannot be radiographed.
Paragraph 8.2.6 refers to the ASME Code for magnetic particle examination requirements.
Liquid penetrant examination for nonmagnetic materials according to the ASME Code is
mandated by Paragraphs 8.2.7 and 8.2.8.
Paragraphs 8.2.9.1 through 8.2.9.6 specify the requirements for the examination of weld
hardness. Paragraphs 8.2.10 through 8.2.12 stipulate the examination requirements for
finished welds.
TEMA
Paragraph G-2.1 indicates the manufacturer provides the necessary inspection and testing in
accordance with the ASME Code, unless otherwise specified by the purchaser. TEMA does
not specify any additional inspection. Paragraph G-2.2 allows the purchaser to make
inspections and witness any tests.

32-SAMSS-011
Section 14 and Section 16 of 32-SAMSS-011 presents additional Saudi Aramco inspection

requirements for air-cooled heat exchangers. Section 16 also presents Saudi Aramco pressure
test requirements.
Many of the additional inspection requirements are similar to those that are specified in 32-
SAMSS-007 for shell-and-tube heat exchangers. The following summarizes several of the
additional requirements:
• Welds must be 100% radiographed in specified cases that are based on

exchanger service or plate thickness.
• Ultrasonic examination is required for all plates that are 50 mm (2 in.) and
thicker and for all exchangers that are in hydrogen, sour, and wet-sour services.
• Welds must be ultrasonically inspected in specified cases that are based on

plate thickness, weld category, and design pressure.
API-661
Section 8 of API-661 covers inspection and testing requirements for air-cooled heat
exchangers.
For the precise wording set forth in the Standard for the inspection and testing requirements,
refer to API-661. Several key elements of this document are summarized in the sections
below.
General Requirements - Paragraphs 8.1.1 through 8.1.4 state that the manufacturer must notify
the purchaser prior to critical dates in the fabrication process. The manufacturer must also
provide the purchaser access to the manufacturer's premises for inspection and testing.
Quality Control - Paragraphs 8.2.1 through 8.2.16 provide information concerning the types of
weld inspections that are required. Paragraphs 8.2.1 through 8.2.6 provide specifications for
full and spot radiographic examination and the inspection alternatives for welds that cannot be
radiographed.

Paragraphs 8.2.7 and 8.2.8 specify magnetic particle testing for root welds, and magnetic
particle or ultrasonic testing for finished welds that are made in ferro-magnetic steels of P.
No. 3 or higher. The liquid penetrant method must be used in accordance with Paragraph
8.2.9. Paragraph 8.2.10 indicates that a magnetic particle or dye penetrant test must be used
to examine for laminations in the edges of plate where set-on connections are to be attached.
Paragraphs 8.2.11 and 8.2.12 refer to the ASME Code for examination and acceptance criteria
for magnetic-particle testing and liquid-penetrant testing.
Paragraph 8.2.13 presents the requirements for weld hardness testing in P-1, P-3, P-4, P-5, P-
6 or P-7 materials.
Paragraphs 8.2.14 and 8.2.15 cover inspection of tubes with circumferential welds. Paragraph
8.2.14 prohibits backing rings, and requires the manufacturer to demonstrate that weld root
reinforcement does not exceed 1.5 mm (1/16 in.). Paragraph 8.2.15 stipulates that at least
10% of circumferential welds must be randomly selected and examined, and that sampling
must be done throughout the fabrication process. Paragraph 8.2.16 refers to ASME SA-450
for tube eddy current test requirements.
Pressure Testing Requirements
The ASME Code requires that all pressure vessels, including heat exchangers, be pressure
tested. The SAMSSs, Form 175, TEMA, and the API Standards provide pressure-testing
requirements that supplement or modify the requirements in the ASME Code.
32-SAMSS-007
32-SAMSS-007 modifies the API-660 requirements for the pressure testing of shell-and-tube
heat exchangers. Paragraph 16.3.6 specifies dryness criteria that apply after the hydrostatic
test fluid has been drained from the exchanger. Paragraph 16.3.8 specifies the maximum
chloride ion content of hydrotest fluid for exchangers that are manufactured from stainless
steel. Paragraph 16.3.11 addresses special cases in which the use of water as the test fluid
may damage the equipment; in such cases, the system fluid must be used as the test fluid.
Paragraph 16.3.13 presents the test criteria for ensuring that reinforcing pad attachment welds
are free of leaks. The testing of stacked heat exchanger units as a single unit is required in
Paragraph 16.3.14.

API-660
Paragraphs 8.3.1 through 8.3.8 provide additional pressure-testing requirements for shell-and-
tube heat exchangers. The paragraphs specify:
• A minimum time of one hour for hydrostatic pressure tests.
• A minimum fluid temperature of 16°C (60°F) for hydrostatic tests.
• The use of potable water with a low chloride ion content (less than
100 ppm) for hydrostatic testing of austenitic stainless steel materials.
• The shell-side test to be conducted with the bonnet or channel cover removed,
when specified by the purchaser.
• A nominal pressure of 170 kPa (25 psig) for supplementary air testing.
• After testing, the reassembly of flanged joints with new gaskets and a retest for
tightness.
• Painting or coating of welds after the final hydrostatic test.
TEMA
TEMA specifies pressure testing requirements in Paragraphs RCB-1.31 through

RCB-1.33.
• Paragraph RCB-1.31 requires that each side of the exchanger must be tested
separately in such a manner that leaks at the tube joints can be detected from at
least one side. The minimum hydrotest pressure for each side must be 1.5
times the design pressure, corrected for temperature, as required by the ASME
Code.
• Paragraph RCB-1.32 permits a pneumatic test in services where liquid cannot

be tolerated as the test medium. The pneumatic test pressure for each side is
1.25 times the design pressure, corrected for temperature.
• Paragraph RCB-1.33 requires that a supplementary air or gas test, if specified

by the purchaser, must be preceded by a hydrotest. Supplementary air or gas
tests may be specified for services where greater assurance is required that the
tube-to-tubesheet joints are tight.

32-SAMSS-011
32-SAMSS-011 modifies the API-661 requirements for pressure testing of air-cooled heat
exchangers. Paragraph 16.3.6 specifies dryness criteria. Paragraph 16.3.8 specifies the
maximum chloride ion content of hydrotest fluid for exchangers with stainless steel, Monel,
and nonferrous tubes. Paragraph 16.3.8 addresses special cases in which the use of water as
the test fluid may damage the equipment; in such cases, the system fluid must be used as the
test fluid.
API-661
Paragraphs 8.3.1 through 8.3.6 provide additional pressure-testing requirements for air-cooled
heat exchangers. The paragraphs specify:
• A minimum time of one hour for hydrostatic pressure tests.
• A minimum fluid temperature of 16°C (60°F) for hydrostatic tests of

exchangers made from ferritic materials.
• The use of potable water with a low chloride ion (less than 100 ppm) for
hydrostatic tests of exchangers that are fabricated of austenitic stainless steel
materials.
• A nominal pressure of 170 kPa (25 psig) for supplementary air testing.
• Painting or coating of welds after the final hydrostatic test.
• The purchaser may require other tests (e.g., halogen tests).
Saudi Aramco Form 175
All pressure tests, including supplementary air tests or sensitive leak tests, should be indicated
on Saudi Aramco Form 175. A copy of Form 175 that is specialized for shell-and-tube heat
exchangers is included in Course Handout 3.

WORK AID 1: PROCEDURE FOR EVALUATING VENDOR FABRICATION

DRAWINGS FOR SUITABILITY
Figure 4 summarizes the locations where heat exchanger fabrication requirements may be
found in the relevant SAMSSs, API, and TEMA standards. Use this summary as an aid to
review the fabrication drawings that are supplied by a heat exchanger manufacturer to
determine if these drawings are suitable. Copies of the SAMSSs are in Course Handout 2,
and copies of the API and TEMA standards are in Course Handout 1. These source
documents should be referred to for the complete requirements.
ATTRIBUTE 32-SAMSS 007 API-660 TEMA 32-SAMSS-011 API-661
Shell: 7.1.
Smooth weld finish
Pass partition plates: 7.2 7.1.2
Continuous weld
Full-penetration
Connection junctions: 7.3 RCB-

No nozzle protrusion 10.1
U-Tubes: 7.4
One-piece
construction
Minimum thickness RCB-

2.31
Heat Exchanger Fabrication Requirements
Figure 4

ATTRIBUTE 32-SAMSS 007 API-660 TEMA 32-SAMSS-011 API-661
Welding:
No oxyacetylene 7.5.1
welding
Welding processes
and design 13.3 13.2 7.1.1.4
Welded tube-to- 7.3.4

tubesheet joints 7.5.6
Full-penetration 7.1.1.3
welds 7.5.2, 7.5.3
Seal-welded
attachments 13.2.9 13.1.6
UT of plates or welds 14.3, 6.1 in 14.3.1, 14.3.2

Addendum A, 6
in Addendum B
MT 14.4
Heat Exchanger Fabrication Requirements, cont'd
Figure 4, cont'd

ATTRIBUTE 32-SAMSS-007 API-660 TEMA 32-SAMSS-011 API-661
100% Radiography 8.6.2, 14.2.2 14.2.3
Heat Treatment 7.6 RCB- 7.2

2.33
Tube Hole Grooves 7.9 7.3.2
Assembly: 13.2 7.10 13.1 7.6

Doweling 7.10.1
Thread lubricant 7.10.2 7.5
Nozzle Construction 13.2.5, 13.2.6, RCB- 13.1.3, 13.1.4,

13.2.7, 13.2.8 10.1 13.1.5
End Flanges & RCB-

Bolting 11
Tube-to-Tubesheet
Joints:
RCB- 7.3.3
Rolled 7.51
Welded RCB-
7.52 7.3.4
Figure 4, cont'd

ATTRIBUTE 32-SAMSS-007 API-660 TEMA 32-SAMSS-011 API-661
Dimensional
Tolerances:
7.4
Gasket contact
surface 7.8
U-bend requirements RCB-

2.31
Bend spacing
Tube hole clearances
RCB-
Transverse baffle 2.32
clearances
RCB-
Tube hole diameters 4.2
and tolerances
7.3.1
Tube hole finish
RCB-
Tube hole grooves 4.3
7.3.1.1
7.9 7.3.2
RCB-
7.41
RCB-
7.43
RCB-
7.44
Figure 4, cont'd

GLOSSARY
colloidal A metal-type thread lubricant, such as molybdenum disulfide

in a petroleum grease base.
full or 100% Radiography Full radiography usually implies 100% radiography of all
weld seams that are radiographable. The joint efficiency of
the shell allowed with this type of inspection is 1.0.
Gas Metal Arc Welding An arc-welding process that produces a coalescence of

(GMAW) metals by heating them with an arc between a continuous
filler metal and the work. Shielding is obtained by an
externally-supplied gas mixture. This process is sometimes
called MIG.
Gas Tungsten Arc Welding An arc-welding process that produces the coalescence of
(GTAW) metals by heating them with an arc between a single tungsten
(nonconsumable) electrode and the work. A shielding gas is
used. A filler metal may or may not be used. This process is
sometimes called TIG.
Oxyacetylene welding A welding process whereby coalescence of metal is obtained

by heating with an oxyacetylene welding torch. A filler may
or may not be used.
seal-welded tube joint A tube that is welded to the tubesheet with a weld that is less
than 1.4 times the minimum thickness of the tube.
Shielded Metal Arc An arc-welding process that produces coalescence of metals

Welding (SMAW) by heating them with an arc between a covered metal
electrode and the work. Shielding is obtained by
decomposition of the coating that is on the electrode.
Sometimes called stick welding.
sour wet service A service in which H2S and water are present.
spot radiography Spot radiography requires that at least one 150 mm

(6 in.) length of weld be radiographed for every 15 m
(50 ft.), or fraction thereof, of a given type of weld
performed by a given welder or welding machine operator.
The joint efficiency of the shell that is allowed with this type
of inspection is typically 0.85.

strength-welded tube joint A tube joint that is welded to the tubesheet with a weld
greater than or equal to 1.4 times the minimum thickness of
the tube.
Submerged Arc Welding An arc-welding process that produces a coalescence of

(SAW) metals by heating them with an arc between a bare metal
electrode and the work. Shielding is obtained by a blanket of
granular fusible material that is applied on the work
immediately after welding.
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Saudi Aramco DeskTop Standards

Chapter : Vessels For additional information on this subject, contact

INTRODUCTION .... .......................................................................................................... 1

EVALUATING VENDOR FABRICATION DRAWINGS FOR

Saudi Aramco and Industry Fabrication Details.................................................................. 2

Tube-to-Tubesheet Joints .................................................................................................... 7

Dimensional Tolerances .................................................................................................... 12

INSPECTION AND TESTING REQUIREMENTS.......................................................... 15

Type and Extent of Required Inspection ........................................................................... 15

Saudi Aramco DeskTop Standards

Pressure Testing Requirements.......................................................................................... 20

WORK AID 1: PROCEDURE FOR EVALUATING VENDOR

GLOSSARY ........... ........................................................................................................ 27

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards 1

EVALUATING VENDOR FABRICATION DRAWINGS FOR SUITABILITY

Saudi Aramco and Industry Fabrication Details

Section 13 of 32-SAMSS-007 presents fabrication requirements for shell-and-tube heat

Saudi Aramco DeskTop Standards 2

• Any laminations that are found in plate edges by magnetic particle

• All rerolling or forming of shell sections must be completed prior to

Saudi Aramco DeskTop Standards 3

Section 5 specifies additional fabrication requirements for shell-and-tube heat exchangers.

Saudi Aramco DeskTop Standards 4

Section 13 of 32-SAMSS-011 presents the fabrication requirements for air-cooled heat

Saudi Aramco DeskTop Standards 5

• Special close-fit tube-hole diameter tolerance in accordance with Table 5 of

- Stainless steel, Monel, and nonferrous tubes

- All exchangers in hydrogen, cyclic, and lethal services

Saudi Aramco DeskTop Standards 6

Saudi Aramco DeskTop Standards 7

Standard TEMA Groved Joint

Standard Welded Joints

Typical Tube-to-Tubesheet Joints

Saudi Aramco DeskTop Standards 8

The joint efficiency factor depends on the following factors:

• The weld detail that is used.

• The size of the weld.

• Whether the joint is tested.

• The cross-sectional area of the tube wall.

• The allowable stress of the tube.

• Efficiency values are higher if qualification testing is done, as opposed to no

• In general, a greater number of grooves results in a higher efficiency.

Saudi Aramco DeskTop Standards 9

A portion of Table A-2 is shown in Figure 2.

Welded, a ≥1.4t, expanded 1.00 0.80

Welded, a < 1.4 t, and expanded, two or more grooves

Welded, a < 1.4 t, and expanded, no grooves 0.85 0.65

Expanded, two or more grooves 0.70 0.50

Expanded, single groove 0.90 0.70

Expanded, no grooves 0.80 0.65

Tube-to-Tubesheet Joint Efficiencies

Saudi Aramco DeskTop Standards 10

Saudi Aramco DeskTop Standards 11

• F-1: External Dimensions, Nozzle and Support Locations

• F-2: Recommended Fabrication Tolerances

• F-3: Tubesheets, Partitions, Covers and Flanges

U-Bend Requirements - Paragraph RCB-2.31 presents requirements for minimum thickness of

• The outside tube diameter, do

• The mean radius of the bend, R

- Tube length is 900 mm (36 in.) or less, or