32 Samss 007

Materials System Specification
32-SAMSS-007 26 June 2017

Manufacture of Shell and Tube Heat Exchangers
Document Responsibility: Heat Transfer Equipment Standards Committee
Contents
1 Scope ............................................................. 2
2 Normative References.................................... 3
3 Terms and Definitions .................................... 7
4 General .......................................................... 8
5 Proposal Information Required ....................... 9
6 Drawings and Other Required Data ............. 10
7 Design .......................................................... 11
8 Materials ....................................................... 26
9 Fabrication ................................................... 35
10 Inspection and Testing ................................. 44
11 Preparation for Shipment ............................. 54
12 Supplemental Requirements ........................ 57
Revision Summary ............................................... 57
Table 1 - Nondestructive Examination

Requirements ....................................... 58
Table 2 - Welds Encroachment Requirements ..... 59
Previous Issue: 1 December 2013 Next Planned Update: 26 June 2020

Page 1 of 59
Contact: Al-Otaibi, Dhawi A. (otiabida) on phone +966-13-8808477
©Saudi Aramco 2017. All rights reserved.

Document Responsibility: Heat Transfer Equipment Standards Committee 32-SAMSS-007
Issue Date: 26 June 2017
Next Planned Update: 26 June 2020 Manufacture of Shell and Tube Heat Exchangers
The following paragraph numbers refer to API STD 660, Ninth Edition, March 2015, 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 (hereinafter referred to as
exchangers) and new components.
1.2 This specification does not cover the following:

a) “UM” stamped exchangers per ASME SEC VIII D1.
b) In-service exchangers.
c) Exchangers used as part of heating, ventilation, and air conditioning
(HVAC) systems.
d) Exchangers used as integral radiators.
e) Sulfur Recovery Unit (SRU) steam drums.
1.3 Exchangers that do not meet either partially or completely the requirements
of API STD 660 or TEMA standards shall be evaluated for acceptance by
Saudi Aramco Engineer based on the following:
a) Full design details, specifying changes from API STD 660 or TEMA
requirements.
b) LSTK and process licensors shall guarantee the thermal performance
and mechanical integrity, supported by detailed calculations.
1.4 Sulfur Recovery Unit (SRU) waste heat boilers and condensers shall be
designed and fabricated in accordance with the design rules of ASME SEC
VIII D1 in addition to the requirements specified in this specification.
1.5 The design and fabrication of high pressure and special (non-conventional
types such as SRU waste heat boilers, condensers, etc.) heat exchangers shall
be done by licensed manufacturers who have previous experiences.
The details of licensing agreement shall be reviewed by Saudi Aramco
Engineer.
1.6 Low alloy steels for exchangers 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 59
1.7 1 Cr- ½ Mo and 1 ¼ Cr- ½ Mo steels used for exchangers that are not in
hydrogen service with design temperature below 441°C (825°F), shall meet
all requirements of API RP 934-C and this specification.
1.8 Where a requirement of a licensor’s or a relevant industry standard/

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

component(s) that do not satisfy any of the requirements of this specification
is prohibited.
1.10 Conflicting Requirements
1.10.1 Any conflicts between this specification and other Saudi Aramco Materials
System Specifications (SAMSSs), Industry codes and standards, and Forms
shall be resolved in writing by the Company or Buyer Representative
through the Saudi Aramco Engineer, Consulting Services Department of
Saudi Aramco, Dhahran.
1.10.2 Direct all requests to deviate from this specification in writing to the
Company or Buyer Representative, who shall follow internal company
procedure SAEP-302 and forward such requests to the Manager, Consulting
Services Department of Saudi Aramco, Dhahran.
2 Normative References
Unless otherwise noted in this specification, materials or equipment supplied to this

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

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
Saudi Aramco Engineering Standards

SAES-A-007 Hydrostatic Testing Fluids
SAES-A-206 Positive Materials Identification
SAES-A-112 Meteorological and Seismic Design Data
Page 3 of 59
SAES-H-001 Coating Selection and Application Requirements for

Industrial Plants and Equipment
SAES-L-133 Corrosion Protection Requirements for Pipelines,
Piping, and Process Equipment
SAES-M-001 Structural Design Criteria for Non-Building
Structures
SAES-N-001 Basic Criteria, Industrial Insulation
SAES-P-111 Grounding
SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-014 Weld Overlays and Welding of Clad Materials
SAES-W-016 Welding of Special Corrosion-Resistant Materials
Saudi Aramco Materials System Specifications

01-SAMSS-016 Qualification of Pipeline and Pressure Vessel Steels
for Resistance to Hydrogen-Induced Cracking
01-SAMSS-043 Carbon Steel Pipes for On-Plot Piping
01-SAMSS-046 Stainless Steel Pipe
02-SAMSS-005 Butt Welding Pipe Fittings
02-SAMSS-011 Forged Steel and Alloy Flanges
32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers
Saudi Aramco Standard Drawings

AA-036322 Anchor Bolt Details – Inch and Metric Sizes
AE-036250 Ferrules for ¾ Inch Tubes (Sheets 1 & 2)
Saudi Aramco Inspection Requirements

Form 175-323100 Manufacture of Shell and Tube Heat Exchangers
Form 175-323500 Floating Heads or Tube Bundles
Saudi Aramco Forms and Data Sheets

Form SA-2714 Shell and Tube Exchanger Data Sheet
(herein referred to as data sheet)
Form SA-7922-1 Non-material Requirements for Shell and Tube and
Double-Pipe Heat Exchangers
Page 4 of 59
2.2 Industry Codes and Standards
American Concrete Institute

ACI 318 Building Code Requirements for Structural Concrete
American Petroleum Institute

API STD 660 Shell-and-tube Heat Exchangers for General
Refinery Services
API RP 934A Materials and Fabrication Requirements for
2¼Cr-1 Mo & 3Mo Steel Heavy Wall Pressure
Vessels for High Temperature, High Pressure
Hydrogen Service
API RP 934C Materials and Fabrication of 1¼Cr-½Mo Steel
Heavy Wall Pressure Vessels for High-pressure
Hydrogen Service Operating at or below 825°F
(441°C)
API RP 934E Recommended Practice for Materials and
Fabrication of 1¼CR-½Mo Steel Pressure
Vessels for Service above 825°F (441°C)
API RP 941 Steels for Hydrogen Service at Elevated
Temperatures and Pressures in Petroleum and
Petrochemical Plants
API RP 945 Avoiding Environmental Cracking in Amine Units
American Society of Civil Engineers

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

ASME SA-20 Specification for General Requirements for Steel
Plates for Pressure Vessels
ASME SA-388 Ultrasonic Examination of Heavy Steel Forgings
ASME SA-435 Straight Beam Ultrasonic Examination of Steel Plates
ASME SA-450 Specification for General Requirements for Carbon,
Ferritic Alloy, and Austenitic Alloy Steel Tubes
ASME SA-688 Specification for Welded Austenitic Stainless Steel
Feedwater Heater Tubes
ASME SEC II Materials
Page 5 of 59
ASME SEC V Nondestructive Examination

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

ASTM A380 Practice of Cleaning, Discleaning, and Passivation
of Stainless Steel Part Equipment and System
ASTM E381 Standard Method of Macrotech Testing Steel Bars,
Billets, Blooms, and Forgings American Society
for Nondestructive Testing
American Society for Nondestructive Testing

ASNT CP-189 Standard for Qualification and Certification of
Nondestructive Testing Personnel
International Standards Organization

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-
Materials for use in H2S-Containing
Environments in Oil and Gas Production
National Association of Corrosion Engineers
NACE SP0472 Methods and Control to Prevent In-Service
Environmental Cracking of Carbon Steel
Weldments in Corrosive Petroleum Refining
Environments
Page 6 of 59
NACE SP0590 Prevention, Detection, and Correction of Deaerator

Cracking
Tubular Exchanger Manufacturers Association (TEMA)
Process Industry Practices

PIP VEFV1100 Vessel/S&T Heat Exchanger Standard Details
Welding Research Council

WRC 297 Local Stresses in Cylindrical Shells Due to External
Loadings on Nozzles
WRC 537 Local Stresses in Spherical and Cylindrical Shells
Due to External Loadings
3 Terms and Definitions
3.5 (Exception) Cyclic 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.
3.9 (Exception) Hydrogen Service: Process streams containing hydrogen with

an absolute partial pressure of 350 kPa (50 psi) and higher.
3.11 (Exception) MDMT: Minimum Design Metal Temperature determined by

the Design Engineer and specified in the data sheet.
3.13 (Exception) Pressure Design Code: ASME SEC VIII.
3.16 AARH: Average arithmetic roughness height, which is a measure of surface

texture.
3.17 Design Engineer: The Engineering Company responsible for specifying on

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

of exchangers.
3.19 High - Alloy Steels: Steels with a total alloying content more than 5%.
3.20 Hot Forming: Forming operations carried out at an elevated temperature

such that re-crystallization occurs simultaneously with deformation.
3.21 Hydrogen Induced Cracking (HIC) Environment: Process streams that

introduce HIC according to SAES-L-133.
Page 7 of 59
3.22 Lethal Services: Process streams containing a concentration of hydrogen

sulfide in excess of 20% by volume shall be considered as lethal service.
Other services as determined by the project design may also be designated as
lethal services.
3.23 Low-Alloy Steels: Steels with a total alloying content of less than 5% but
more than specified for carbon steels.
3.24 Minimum Thickness: Thickness required for withstanding all primary

loads, excluding allowance for corrosion.
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 exchanger to the requirements of this specification.
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 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 comply with applicable

local, state, and national codes, and insurance requirements.
4.13 Stress analyses according to the Code rules shall be executed by the
manufacturer. A third party under full control and responsibility of the
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manufacturer may execute only finite element analysis.
4.14 No proof testing shall be permitted unless specifically approved by the Saudi
Aramco Engineer.
4.15 No credit shall be given to thickness of integrally-bonded or weld metal

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

requires approval of the Saudi Aramco Engineer.
4.17 The Exchanger Manufacturer is responsible for the thermal/hydraulic design

(rating) and verification of the Design Engineer's thermal/hydraulic design,
if applicable.
4.18 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.
4.19 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 7.6.5 of this specification.
4.20 The exchanger manufacturer shall neither prepare nor certify a User’s
Design Specification.
5 Proposal Information Required
5.3 The proposal shall include a detailed description of any exception to the
requirements of this specification.
5.6 The Exchanger Manufacturer may offer an alternative design, but must
quote on the base inquiry documents.
5.7 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
Page 9 of 59
sheets. Thermal, hydraulic, and mechanical guarantee shall be in

accordance with TEMA paragraph G-5.
2) Exchangers shall be free from damaging flow induced vibration and
acoustic vibration.
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 SA-7922-1, Nonmaterial
Requirements, in addition to API STD 660 requirements. Calculations shall
include, but not limited to:
a. ASME SEC VIII calculations.
b. Wind and earthquake calculations, as applicable.
c. Support calculations.
d. Calculations associated with lifting and erecting the exchanger.
e. Nozzle load analysis for local and gross effect, when required.
f. Design of internal and external attachments.
g. Design loads and load combinations.
h. Thermal calculations and heat released curves.
6.1.2 The Exchanger Manufacturer shall submit flow-induced vibration analysis.
6.1.4 Drawings and calculations that are approved by the Design Engineer shall
not relieve the Exchanger Manufacturer from the responsibility to comply
with the Codes and this specification.
6.1.5 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.
6.1.6 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)
(f) Thermal, flow induced and acoustic vibration analysis.
Page 10 of 59
6.3 Reports and Records
The Exchanger Manufacturer shall furnish reports and records in accordance

with SA-7922-1, Nonmaterial Requirements.
7 Design
7.1 Design Temperature
7.1.3 The value(s) of design temperature(s) shall be as specified on the data sheet.
7.1.4 The value of the minimum design metal temperature (MDMT) shall be as
specified on the data sheet.
7.1.5 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.
7.3.8 The allowable concrete bearing stress to be used for the design of baseplates
shall be 10,340 kPa (1,400 psi).
7.3.9 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.
7.3.10 The sliding saddle height shall take into account the thickness of low friction
sheet assembly under the sliding saddle. The low friction sheet assembly
shall be provided by the Exchanger Manufacturer.
7.3.11 Anchor Bolts
7.3.11.1 The Exchanger Manufacturer shall determine the size and number of anchor
Page 11 of 59
bolts required.
7.3.11.2 Anchor bolts shall be in compliance with Standard Drawing AA-036322

Sht. 001 (Rev. 07 or later).
7.3.11.3 Anchor bolts shall not be less than ¾” (M20) minimum nominal diameter.
7.3.11.4 The design of anchor bolts shall be in accordance with the requirements of
Appendix D of ACI 318.
7.3.11.5 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.
7.3.11.6 Exchangers supported on saddles shall be provided with an even number of

anchor bolts with a minimum of two anchor bolts per saddle.
7.3.11.7 Anchor bolts shall be designed for load combinations, based on the allowable
stress design method (Service Loads) in accordance with SAES-M-001.
7.3.11.8 Anchor bolts shall straddle exchanger centerlines on the north-south,

east-west axes.
7.3.11.9 Design of anchor bolts shall be based on the following allowable stresses:
a) 0.264 of Ultimate Tensile Strength (tension).
b) 0.176 of Ultimate Tensile Strength (shear).
7.3.11.10 Exchangers supported on lugs shall be provided with minimum one anchor
bolt per support.
7.4 Stationary and Floating Heads
7.4.11 API STD 660 requirements for gasket contact seating surfaces shall be met.
7.4.12 Floating head covers shall be attached to the backing device or to the
floating tubesheet with through bolting.
7.5 Tube Bundle
7.5.1 Tubes
7.5.1.8 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.
Page 12 of 59
7.5.1.9 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.
7.5.1.10 For exchangers with tube-side design pressures 13.8 MPa (2,000 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.
7.5.1.11 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.
7.5.1.12 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 shall be
reviewed by Saudi Aramco Engineer.
Commentary Note:
This is to prevent any unexpected catastrophic failure in case of tube leak in

exchangers.
7.5.2 Tubesheets
7.5.2.5 API STD 660 requirements for gasket contact seating surfaces for both sides
shall be met.
7.5.2.6 Vertical exchangers with fixed tubesheets shall be provided with flanged
vents and drains through the tubesheets.
7.5.2.7 All stationary tubesheets with through bolting design shall have non-
threaded bolt holes.
7.5.3 Baffles and Support Plates
7.5.3.1 (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.
7.5.3.4 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.
Commentary Note:
Typically, this distance is approximately 150 mm (6 in.).
Page 13 of 59
7.5.3.5 '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.
Commentary Note:
Typically, support plates are 50 mm (2 in.) away from the tangent line.
7.5.4 Impingement Protection
7.5.4.7 (g) 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.
Commentary Note:
Typically, two rows of rods on a triangular layout are used as an impingement

protection.
7.5.4.8 The use of distribution belts shall be considered when shell-side nozzles are
large resulting in long inlet and/or outlet unsupported tube lengths.
Commentary Note:
A properly designed belt should result in more effective use of the heat
transfer area and a more rigid bundle with better tube support.
7.5.5 Bypass Sealing Devices
7.5.5.4 (Exception) The location of the sealing devices shall not interfere with the
continuous tube cleaning lanes for square and rotated square layouts.
7.6 Nozzles and Other Connections
7.6.1 (Exception) Flanges shall be in accordance with ASME B16.5 pressure

rating.
7.6.2 (Exception) The ends of butt-welded connections shall be in accordance with

ASME B16.25.
7.6.3 (Exception) 1½ NPS and smaller drains, vents and instrument connections
can be used and shall be attached to a blind flange on a flanged nozzle or
manway in other than the following design conditions and services:
a) Lethal service
b) Hydrogen service
c) Caustic service
d) Cyclic service
Page 14 of 59
e) Pressure-retaining parts thicker than 50mm

f) Unfired steam boilers with design pressure exceeding 50 psi.
Attachment welds of such connections to the blind flange shall be treated as

category-D weld joint. Accordingly, attachment details and NDE
requirements shall be similar to those required for the exchanger per this
specification.
7.6.4 (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 applicable Code and
approved by the Saudi Aramco Engineer.
7.6.5 (Exception) Slip-on type flange with seamless pipe nozzle necks or rolled
plate with 100% radiography is permissible for exchangers, in only non-
cyclic air and water services with design temperature and design pressure
not exceeding 400°C (750°F) and 2.1 MPA (300 psi), respectively. Slip-on
flange shall be welded on the front or face and at the back of the hub per
ASME SEC VIII D1, Figure UW-21, detail (1), (2) or (3).
7.6.6 (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.
7.6.13 The quantities, sizes, ratings, (ASME pressure classes), facings, elevations,
and orientations of nozzles and manways shall be as specified on the data
sheet.
Page 15 of 59
7.6.14 Flange bolt holes shall straddle the normal horizontal and vertical centerlines
of the exchanger.
7.6.15 Threaded connections shall conform to ASME B2.1.
7.6.16 Reinforcement of Openings
7.6.16.1 Reinforcement of exchanger openings shall be in accordance with the

applicable Code and this specification.
7.6.16.2 Thickness of reinforcing pads shall not exceed that of the exchanger where
the pad is located.
7.6.16.3 Use of internal reinforcing pad and internal nozzle projection is not permitted.
7.6.17 Minimum inside corner radius of integrally reinforced contour nozzles and
manways shall be 13 mm.
7.6.18 Attachment Details for Nozzles, Manways and their Connections
7.6.18.1 All nozzles and manway necks shall be attached by welding completely
through the total thickness of the exchanger shell, head or nozzle wall,
including any reinforcement. Backing rings used in attaching nozzles and
manways to exchanger shall be removed after welding.
7.6.18.2 Permissible types of nozzles, manways, and their connections shall be

according to the table below.
Figure Reference from indicated

Design Conditions / ASME SEC VIII
Attachment
Services Group Division 1 Division 2
Exchangers Exchangers
Group I
a. Pressure-retaining exchanger’s component (shell,
head, nozzle or manway) with design thickness
greater than 50 mm  All nozzle sizes
and manway
b. Unfired steam boilers with design pressure
necks
exceeding 50 psi Figure UW-16.1,
Table 4.2.13,
details:
c. Lethal, hydrogen and cyclic services details: (1), (2),
(f-1), (f-2), (f-3) or
 Connections (3), (4), (5) or (6)
d. Openings larger than 900 mm (Note 1) (f-4)
attached to
nozzles and
e. Design temperature greater than 400°C (Note 1)
manways
f. Low alloy steel exchangers with design thickness
greater than 25 mm (Note 1)
g. Exchangers that will undergo PWHT (Note 1)
Page 16 of 59
Figure Reference from indicated

Design Conditions / ASME SEC VIII
Attachment
Services Group Division 1 Division 2
Exchangers Exchangers
- Table 4.2.10,
details: (1), (2),
(3), (4), (6), (7) or
Figure UW-16.1, (8)
details: (a), (a-1),
NPS 4 and smaller
(b), (c), (d), (e), (f- - Table 4.2.11,
nozzles
1), (f-2), (f-3), (f-4) detail (2)
or (g).
- Table 4.2.13,
details: (1), (2),
(3), (4), (5) or (6)
- Table 4.2.10,
Figure UW-16.1, details: (1), (2),
Group II details: (a), (b), (3), (4), (6), (7) or
Connections to
(c), (d), (e), (f-1), (8)
Design conditions and services other than those in NPS 4 and smaller
(f-2), (f-3), (f-4) or
group I of this table nozzles
(g). - Table 4.2.13,
(Note 2) details: (1), (2),
(3), (4), (5) or (6)
Figure UW-16.1, - Table 4.2.10,
Nozzles larger than
details: (c), (d), details: (3), (4),
NPS 4 and
(e), (f-1), (f-2), (f- (6), (7) or (8)
manway necks
3), (f-4) or (g)
Figure UW-16.1, - Table 4.2.11,
Connections details: (c), (d), detail (2)
attached to nozzles (e), (f-1), (f-2), (f-
larger than NPS 4 3), (f-4) or (g) - Table 4.2.13,
and manways details: (1), (2),
(Note 3) (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.
Note 2: Figure UW-16.1, details: (a), (b), (c), (d), and (e) shall be without reinforcement pad.
Note 3: Figure UW-16.1, details: (c), (d), and (e) shall be without reinforcement pad.
7.6.18.3 Integrally reinforced contour shaped attachments made partially or

completely of weld build up are prohibited.
7.6.19 Design of flanged connections with stud bolts of diameter 1½ inch and
above shall be such as to provide clearance to permit use of a stud and bolt-
tensioning device.
7.6.20 A body flange shall be constructed of a single-piece forging.
7.6.21 Nozzles less than 2-inch NPS are not permissible.
7.6.22 Only flanged nozzles and manways shall be used.
7.6.23 Exchangers in services other than air and water shall be provided with a
minimum 2-inch NPS flanged steam-out connection.
Page 17 of 59
7.6.24 Flange Ratings (ASME Pressure Classes) and Facings
7.6.24.1 The ASME pressure classes and facings shall be as specified on the data sheet.
7.6.24.2 Bolted joints specified with non-ASME flanges shall be designed to meet all
anticipated loading conditions of the exchanger.
7.6.24.3 Pressure ratings for standard flanges shall be in accordance with the
following:
a) ASME B16.5 for flanges NPS 24 and smaller.
b) ASME B16.47, Series A for flanges larger than NPS 24.
7.6.25 Gasket seating surfaces shall comply with the following:

a) For spiral wound gaskets, 125 to 250 AARH, in all services, except
hydrogen.
b) For spiral wound gaskets in hydrogen service, 125 to 150 AARH.
c) The sidewalls of rings joint flanges in all services, 63 AARH.
d) For Nonmetallic gaskets, 250 to 500 AARH.
7.6.26 Machined surfaces other than gasket contact faces shall not exceed 500 AARH.
7.6.27 Flatness of gasket contact surfaces shall be measured after completion of all
welding and any required PWHT.
7.6.28 Manways
7.6.28.1 The number, nominal inside diameter and locations of manways shall be as
7.6.28.2 All manways shall be circular. The manway covers shall be hinged or
provided with handling davits as specified on the data sheet, according to
PIP VEFV1100.
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.
Page 18 of 59
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.
7.14 Design Pressure
7.14.1 The value(s) of design pressure(s) shall be as specified on 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 components such as

flanges, fittings, reinforcing pads, etc.
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 requirements of
this specification.
b) Wind and earthquake loads shall be calculated for the exchanger
in accordance with ASCE 7 (2005 Edition), using Occupancy
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Category IV and based on design data corresponding to the site

location per SAES-A-112.
c) Wind pressures shall be assumed to act on the projected surface area of
the exchanger and shall include due allowances for any platforms,
ladders, piping, insulation, and equipment supported from the
exchanger as specified on the datasheet.
d) Earthquake loads shall include due allowances for platforms, ladders,
piping, insulation, and equipment supported from the exchanger as
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 (e.g., lugs,
saddles, etc.).
b) Weight of exchanger contents under operating and pressure testing
conditions.
c) Weight of refractory linings and insulation.
d) Weight of attached equipment such as valves, other exchangers, and
piping.
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.
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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 components of an exchanger shall be designed to withstand the intended

test pressure (full hydrostatic, pneumatic or hydrostatic-pneumatic) in the
erected position. Hydrostatic and hydrostatic-pneumatic test pressures shall
include the higher value of the following:
a) Maximum operating liquid static head, including flooded condition.
b) Test water static head in the erected position
7.18.4 Combined stresses due to test pressure, including static head, and minimum
of 50% of wind load shall be within the following allowable limits, based on
the lowest Specified Minimum Yield Strength (SMYS) of the materials of
construction at test temperature:
1) ASME SEC VIII D2, paragraph 4.1.6.2(a) for full hydrostatic test.
2) ASME SEC VIII D2, paragraph 4.1.6.2(b) for pneumatic test and
hydrostatic-pneumatic test.
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
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 on the data sheet. Analysis methods and stress
combination limits presented in Division 2, Section 5, shall be used for
exchangers under scope of Division 1 and Division 2. However, allowable
stresses shall be taken from the respective tables of ASME SEC II for each
division for the corresponding material and temperature.
7.18.7.2 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
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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
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.
7.18.7.4 Fatigue Analysis

1) Scope of the required stress analysis shall be as specified on the data
sheet, in accordance with the rules of Division 2, by the Design
Engineer.
2) As a minimum, the scope of the stress analysis shall include the
following junctures, as applicable:
- Head-to-shell
- Support-to-exchanger
- Nozzle-to-shell, considering external piping loads
3) Analysis shall be based on the calculated number of cycles for a
minimum 20-year service life, as determined in accordance with the
rules of Division 2, paragraph 5.5.2.
4) The number of cycles shall include the number of start-ups, shut-
downs, emergency shut-downs, and upset conditions.
7.18.7.5 Local Stress Analysis
Stress analysis due to piping, equipment, lifting, supports, and other external
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loads shall be completed in accordance with the procedures as detailed in

WRC 537, WRC 297 or a finite element analysis.
7.19 Shell and Channel Covers
7.19.1 The type of heads to be used shall be ASME 2:1-ellipsoidal or ASME

hemispherical, unless as allowed in 7.19.2 of this specification.
7.19.2 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).
7.19.3 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 multi-segment
construction head:
a) Layout of head
b) Nondestructive examination
c) Heat treatment procedure, as applicable.
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.
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7.19.7 Shell-to-internal head joint shall be only any of the following details:
a) Forged junction ring according to ASME SEC VIII D2, Table 4.2.5 -
Detail 7.
b) Weld build-up construction connecting shell to internal head. This is
not applicable to exchangers in cyclic service.
7.19.8 Joint details in paragraph 7.19.7 shall provide a smooth transition,

minimizing peak stress concentration effects. The inner radius of the weld
build-up and forged detail shall be minimum 1 inch. Backing strips used in
fabricating the junction shall be removed after completion of welding. All
welds shall be ground smooth flush contour of the joined parts.
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 Non- Pressure Retaining 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.
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.
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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-retaining parts, shall be fully seal welded, except for blank square
nuts used for external insulation where tack welding is allowed.
7.22 Coatings and Painting Systems
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.
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 inter-
changeable.
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.
Commentary Note:
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.
Page 25 of 59
7.24 Nominal Thickness
7.24.1 Nominal thickness of shells and heads shall not be less than the following:
a) Carbon steels, 6 mm.
b) Low chrome alloy steels, 5 mm.
7.24.2 Maximum thickness for plates used for construction of shell or channel
under the scope of API RP 934-A shall be limited to 150 mm (6 in.).
For exchangers requiring thickness higher than 6”, forged ring construction
shall be used.
8 Materials
8.1 General
8.1.6 All materials required for pressure and non-pressure components shall be as
8.1.7 Prior approval by the Saudi Aramco Engineer is required for use of
alternative materials of construction. Alternative materials must comply
with all the requirements of the applicable Code and this specification.
8.1.8 Material specifications and tests procedures for base metal and weldments
materials for 1 Cr- ½ Mo, 1 ¼ Cr- ½ Mo, 2 ¼ Cr-1 Mo, 2 ¼ Cr-1 Mo- ¼ V,
3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V shall include all applicable requirements of
this specification for ordering the materials from the mill.
8.1.9 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.
8.1.10 Material test report is requested to be certified as per 175-323100.
8.1.11 1 Cr- ½ Mo and 1 ¼ Cr- ½ Mo steels can be used for shells and heads of
exchangers with thickness not exceeding 100 mm (4 in.). These alloys can
also be used for forged components (e.g. integrally reinforced nozzles,
flanges, etc.) of exchangers with a thickness exceeding 100 mm (4 in.)
within the scope of API RP 934-C, API RP 934-E and paragraph 1.7 of this
specification, provided that fracture toughness requirements specified in
these documents and this standard are met.
8.1.12 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
Page 26 of 59
defined in this specification. Material selection shall be based on the design

temperature, minimum design metal temperature and intended service.
8.1.13 All materials shall be alloy-verified by the Exchanger Manufacturer in

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

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

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

ASTM E381.
8.1.18 Specimens for material testing shall be taken for the maximum heat-treated
thickness (T) per the following:
a) Plates
Specimens shall be taken from each plate transverse to the rolling
direction in accordance with SA-20 at the standard test locations and at
a depth of ½T location. If required, ½T specimens should be used for
hot tensile and step cooling tests.
b) Plate-like forgings (forged rings, tubesheets, blind flanges, etc.)
Specimens shall be taken from each heat transverse to the major
working direction in accordance with the material specification, and at
a depth of ½T of a prolongation or of a representative separate test
block, as defined in API RP 934-A.
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c) Standard flanges according to ASME B16.5 and B16.47.

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

NACE SP0590.
Page 28 of 59
8.1.21 Materials for exchangers exposed to SSC environments shall be in

accordance with the following:
a) Standard flanges and flanged fittings (i.e., flanges and flanged fittings
under the scope of ASME B16.5 and large diameter flanges under the
scope of ASME B16.47) are restricted to: SA-350 (Grade LF1 or
Grade LF2).
b) Special forgings (long weld neck flanges, non-standard forged flanges,
integrally reinforced nozzles and manways, forged Y-rings, complex
forgings that are contour shaped or machined to essentially the finished
product configuration prior to heat treatment, forged butt-welded
fittings, etc.) are restricted to: SA-266 (Grades 2 or 4), SA-350
(Grade LF1 or Grade LF2) and SA-765 Grade II.
c) Studs are restricted to: SA-193 B7M or SA-320 L7M.
d) Nuts are restricted to: SA-194 Grade 2HM.
e) It shall satisfy the requirements of NACE MR0175/ISO 15156 and
NACE SP0472.
8.1.22 Low alloy steels shall not be mixed. For example, an exchanger requiring
1 Cr-½ Mo materials shall have all components manufactured from
1 Cr-½ Mo.
8.1.23 Low alloy steels shall be specified in the normalized and tempered (N+T) or
quenched and tempered (Q+T) conditions, based on the required mechanical
material’s properties (strength, toughness, creep-resistance, etc.) and
considering thermal treatments specified in paragraph 8.1.15 of this
specification.
8.1.24 Material for nameplate mounting brackets shall be of the same type and
material grade as the pressure retaining component to which it is attached.
8.1.25 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.
8.1.26 Materials of supports shall be as follows:

1) Lugs: same material as exchanger wall base material. Supports of
exchangers described in paragraph 8.1.25 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.
Page 29 of 59
8.1.27 External attachments, other than those in paragraph 8.1.26 of this

specification, and internal attachments welded to the exchanger shall be of
the same material as the exchanger 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 exchangers in environments not containing wet H2S.
8.1.28 Internal attachments to clad exchangers shall be of the same material as that
of the cladding. SS 321 and SS 347 can be used interchangeably.
8.1.29 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 SA-105 shall not be used for applications requiring impact testing.
8.1.31 SA-266 (Grade 2 or Grade 4) may be used for applications requiring impact
testing, provided the energy values at the impact test temperature per this
specification are satisfied.
8.1.32 Materials for exchanger exposed to HIC environments with normal

operating temperature up to and including 150°C (300°F) shall be in
accordance with the following:
i) All components (tubesheet, tube, shell, channel, baffle, nozzle, head,
cover and ring, etc.) formed from plate shall be manufactured from HIC
resistant steels that meet the testing requirements of 01-SAMSS-016.
ii) Piping components (such as nozzle/manway necks, elbow, etc.) made
from rolled and welded plate used in the manufacture of a heat
exchanger within the scope of this specification shall be manufactured
from HIC resistant steels that meet the testing requirements of
01-SAMSS-016. Wrought piping components shall meet the
requirements of 02-SAMSS-005. Forged piping components do not
require HIC testing. Welded pipes shall meet the requirements of
01-SAMSS-043.
8.1.33 All components (tubesheets, tubes, shells, channels, baffles, nozzles, heads,
covers, rings, standard flanges, special forgings, forged rings, attachments,
etc.) shall be fabricated and machined by Saudi Aramco approved heat
exchanger manufacturers.
8.1.34 All raw materials used for exchanger components (tubesheets, tubes, shells,
channels, baffles, nozzles, heads, covers, rings, standard flanges, special
forgings, forged rings, attachments, etc.) shall be procured from approved
Saudi Aramco suppliers per applicable commodities included in SAES-L-101.
Page 30 of 59
8.1.35 All heat exchanger flanges shall be procured in accordance with

02-SAMSS-011 requirements from approved Saudi Aramco suppliers.
8.1.36 All heat exchanger nozzles “made from pipes” shall be procured in
accordance with 01-SAMSS-043 and 01-SAMSS-046 requirements from
approved Saudi Aramco suppliers.
8.1.37 All heat exchanger forged and wrought fittings shall be procured in
accordance with 02-SAMSS-005 requirements from approved Saudi Aramco
suppliers.
8.1.38 HIC Resistant Materials
Hydrogen Induced Cracking (HIC) resistant steel shall be qualified in

accordance with 01-SAMSS-016. HIC resistant steel shall be procured from
Saudi Aramco approved manufacturers.
8.3 Gaskets
8.3.3 (Exception) The materials of construction for spiral wound gaskets shall be
as follows with flexible filler suitable for the intended service:
Service Winding Filler Guiding Ring(s)

Type 304 or 316 Solid outer;
Design Temperature
Stainless Steel Graphite Type 304 or
from -100°C to 0°C
(SS) 316 (SS)
Design Temperature Type 304 or Solid outer;
Graphite
above 0°C to 425°C 316 SS Carbon Steel (CS)
Solid inner and
Design Temperature Type 321 or
Vermiculite outer; Type 304
above 425°C 347 SS
or 316 SS
Per Per Solid inner;
Vacuum Temperature Temperature Type 304 or
Range Range 316 SS
8.4 Tubes
8.4.3 Bare tubes shall be procured from approved Saudi Aramco suppliers per
applicable tubes' commodities included in SAES-L-101.
8.5 Impact Testing
8.5.1 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.
Page 31 of 59
8.5.2 Impact test temperature for a component of an exchanger shall be as

8.5.3 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
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.
8.5.4 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.
8.5.5 Impact testing is required, with no exception, for exchangers made of low
alloy steels.
8.5.6 Impact testing of materials and welding procedures are required when test
temperature is lower than -28°C.
8.5.7 Baffle plates, sealing strips, tie-rods, sliding bars, tubes, spacers, and support
plates are exempt from impact testing requirements.
8.6 All forgings shall be forged as close as practicable to finished shape and size
to develop metal flow in a direction most favorable for resisting the stresses
encountered in service.
8.7 Elevated temperature tensile test shall be performed for 2 ¼ Cr-1 Mo,
2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V steels at the design
temperature. Test specimens should be in the maximum PWHT condition,
considering thermal treatments specified in paragraph 8.1.15 of this
Page 32 of 59
specification. Acceptance value is 90 % of values listed in ASME SEC IID,

Table - U for the test temperature.
8.8 Special Testing for Steels under Scope of API RP 934-A
8.8.1 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
exchanger components.
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.
8.8.2 Hardness Testing

a) Two hardness readings shall be taken on each exchanger component,
which includes each forged ring, shell plate, nozzle, pipe, fitting, and
flange.
b) Test method and acceptance criteria shall follow API RP 934-A
(Second Edition, Addendum 2, March 2012), Paragraph 7.4.2.
8.8.3 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 441°C (825°F) for 2 ¼ Cr-1 Mo and 3 Cr-1 Mo steels.
2) Above 468°C (875°F) for 2 ¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V
steels.
b) Test specimens shall be according to the following:
1) The specimen diameter within the gage length shall be 13 mm
(½ in.) or greater. The specimen centerline shall be located at the
0.25-t thickness location (or closer to the center) for material
19 mm (¾ in.) and greater in thickness.
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2) The gage length for the transverse specimen shall include the weld
and at least 19 mm (¾ in.) of base metal adjacent to the fusion line.
3) The test material shall be postweld heat treated to the maximum
PWHT condition.
c) Acceptance Criteria
1) For 2 ¼ Cr-1Mo and 3 Cr-1Mo steels, the condition of the stress-
rupture test shall be 210 MPa (30 ksi) at 510°C (950°F). The time
of failure shall exceed 650 hours.
2) For 2 ¼ Cr-1Mo-¼ V and 3 Cr-1Mo-¼ V steels, the condition of
the stress-rupture test shall be 210 MPa (30 ksi) at 540°C
(1,000°F). The time of failure shall exceed 900 hours.
8.8.4 Reheat Transverse Cracking Susceptibility Qualification
Each combination of heat-of-filler wire and batch-of-flux for submerged arc

welding (SAW) used in production of all weld joint categories (A, B, C, and
D) in 2 ¼ Cr-1Mo-¼ V steels shall be qualified for transverse reheat
cracking susceptibility as follows:
a) Performing Gleeble test. Procedure and acceptance criteria of test shall
be in accordance with API RP 934A, Annex B.
b) Chemical composition factor (K-factor = Pb+Bi+0.03Sb) of filler wire
shall not exceed 1.5 ppm, where units of Pb, Bi, and Sb are in ppm.
K-factor shall be determined utilizing the Inductively Coupled Plasma
Mass Spectrometry (ICP-MS) method according to the relevant
requirements of the US national Institute of Standards and Technology
(NIST), including but not limited to the calibration of the ICP-MS
instrument. ICP-MS shall be calibrated with sample standards
provided by NIST. Test results shall be documented as a reference,
including calibration curves for Pb, Bi, and Sb.
8.8.5 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.
8.8.6 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).
Page 34 of 59
8.9 The phosphorous content of 1 Cr- ½ Mo and 1 ¼ Cr-½ Mo steels shall not
exceed 0.007% in weight.
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 9.1.4
of this specification shall be completely removed and repaired.
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.
9.1.8 Reinforcing/Wear Pads
9.1.8.1 Reinforcing / wear pads for internal and external welded attachments shall
be sized to meet requirements of paragraph 7.17.3 of this specification. Pads
shall be a minimum of 10 mm (⅜") thick, but shall not exceed the shell
thickness; with all of their corners rounded to a minimum radius of 50 mm.
Distance from any edge of the attachment to the closest edge of the
reinforcing pad shall not be less than 50 mm.
9.1.8.2 Where no reinforcing pad is required, internal and external welded

attachments shall be welded directly onto pressure boundary of exchanger
surfaces with a smooth transition, minimizing peak stress concentration
effects and facilitating nondestructive examination. Where this construction
detail cannot be met (due to only exchanger geometry) for exchanger with
design thickness greater than 50 mm (2 in.), exchangers in hydrogen or
lethal services, wear pads per paragraph 9.1.8.1 of this specification shall be
provided.
9.1.8.3 For exchangers in cyclic service no reinforcing / wear pads are allowed.
Attachments shall be welded using full penetration groove welds and smooth
contour fillet welds.
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9.1.9 Telltale Holes in Reinforcing Pads
9.1.9.1 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.
9.1.9.2 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 also applicable
to each segment of a split-reinforcing pad.
Commentary Note:
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.
9.1.9.3 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. Telltale holes in internal
attachment pads shall be seal welded.
9.1.10 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.
9.5 Welding
9.5.1 (Exception) All welding shall be in accordance with the requirements of

SAES-W-010 and SAES-W-016.
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 7.6.5 of this specification.
9.5.13 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
Page 36 of 59
pad sections together shall be done without using a backing strip.
9.5.14 Dissimilar metal welds (DMW) are not permitted in sulfide stress cracking
environment as defined in this specification.
9.5.15 Following maximum allowable carbon equivalent, based on thickness before

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

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

3.2 mm thickness meeting the specified chemical composition of the
specified weld overlay material.
9.5.17 Intermediate stress relief (ISR) shall performed on all highly restrained joints
in exchangers under the scope of API RP 934-A, such as nozzle/ manway
welds in shells or heads and for other joints which are highly stressed during
fabrication (e.g., grooves in RTJ). Dehydrogenation Heat Treatment (DHT)
shall not be used as an alternative to ISR for the aforementioned joints.
9.5.18 Welding procedures shall be qualified considering all of the thermal

treatments that could affect the material plus two additional cycles to
account for future repairs and/or alterations (refer to paragraph 8.1.15 of this
specification).
9.5.19 Exchangers constructed of 1 Cr- ½ Mo, 1 ¼ Cr- ½ Mo, 2 ¼ Cr-1 Mo,

2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V steels with internal weld
overlay shall have two-layer (ER309L/ER347) overlay.
9.5.20 Weld overlay per paragraph 9.5.19 shall have smooth contour finished
surfaces where there is change in geometry for highly stressed areas (such as
nozzle/manway welds in shells or heads and RTJ grooves).
9.5.21 Necessary logistic fabrication steps shall be taken to ensure that highly
restrained joints, such as nozzle/manway welds in shells or heads and RTJ
grooves, in exchangers constructed of 2 ¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V
steels are welded continuously throughout the welding process without any
stop, i.e., from start of the first welding pass to completion of welding the
joint.
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9.5.22 No dissimilar metal weld is allowed for A, B, C, and D weld joint categories
in exchangers fabricated according to API RP 934-A, API RP 934-C or
API RP 934-E, regardless of the presence of stainless steel weld overlay.
9.5.23 For services requiring impact test, welding procedures shall be qualified for
at least 80% of the time for any heat treatment after welding required per
paragraphs 8.1.15 (a) and 8.1.15 (b) of this specification.
9.5.24 Production Test Coupons, if required as per Code, shall be subject after
welding to the production heat treatment time per paragraphs 8.1.15 (a) and
8.1.15 (b) of this specification.
9.5.25 Production test coupons are required for hot forming. The coupons shall
simulate all heat treatment cycles expected during and after forming, and any
post weld heat treatment cycles by exchanger manufacturer specified per
paragraph 8.1.15 of this specification. The tests to be performed shall
include, but not limited to, all of the mechanical tests required by the
original material specification.
9.5.26 In addition to the requirement of paragraph 9.5.23 of this specification,

welding procedures and production test coupons (if required by code) for
exchangers in sour service shall be subject to additional supplementary
impact and hardness tests with one PWHT cycle. Hardness testing shall
comply with NACE MR0175/ISO 15156.
9.5.27 When production test coupons require multiple thermal heat treatment cycles
to be simulated, the multiple cycles shall not be combined into one cycle.
9.6 Heat Treatment
9.6.3 (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 un-stabilized or non-low carbon
stainless steels or Nickel base alloys in accordance with
ASME SA-688.
Page 38 of 59
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.
9.6.12 Postweld heat treatment (PWHT) shall be done when required by the
applicable Code or when specified on the data sheet.
9.6.14 Code exemptions for postweld heat treatment (PWHT) of ferritic materials
based on the use of austenitic or nickel-based electrodes are not permitted
for exchangers in sulfide stress cracking environments as defined in this
specification.
9.6.15 Code exemptions for postweld heat treatment of P4 and P5 materials are not
permitted for applications involving the following:
a) Environments containing wet H2S
b) Hydrogen services
c) Materials exceeding 2.5% nominal chromium content
9.6.16 The maximum post weld heat treating soaking temperature for quenched and
tempered carbon and low alloy steel materials shall not exceed either the
tempering temperature shown on the Mill Test Reports or the following:
 650°C maximum for carbon steel
 700°C maximum for low alloy steels.
For Cr-Mo materials covered by API RP 934-A, alternative tempering and

PWHT temperatures are acceptable if qualified in accordance with this
specification.
9.6.17 Final postweld heat treatment (PWHT) shall follow all welding and repairs
but shall be performed prior to any hydrotest or other load test.
9.6.18 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"
9.6.19 Postweld heat treatment (PWHT) shall be in accordance with the

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

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

a) Dead weight at intended PWHT soaking temperature.
b) Temperature gradients in equipment wall due to the intended PWHT
procedure.
c) Mechanical restraints that may prevent the equipment from free
movement (expansion/ contraction) during PWHT.
9.7 Dimensional Tolerances
9.7.5 Fabrication tolerances shall be in accordance with the more stringent of the
applicable Code, TEMA, and PIP document VEFV1100.
9.7.6 Use of fitness-for-service assessment methodology to qualify the design of

components that do not satisfy the fabrication tolerances according to this
specification is prohibited.
9.8 Gasket Contact Surfaces other than Nozzle Flange Facings
9.8.1 (Exception) Gasket seating surfaces shall comply with the following:
1) For spiral wound gaskets, 125 to 250 AARH, in all services, except
hydrogen.
2) For spiral wound gaskets in hydrogen service, 125 to 150 AARH.
3) The 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.
9.9 Tube Holes
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
Page 40 of 59
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 General
a) Cold forming for carbon steels shall be performed at temperatures
within the range of above 20°C (68°F) and below 120°C (248°F).
b) Hot forming is any forming performed above the austenite phase start
temperature of 740°C (1364°F).
c) All tempering heat treatments for all carbon steels must be at least
25°C (45°F) above the nominal PWHT temperature as given in the
applicable ASME code for the respective material. The tempering
temperature must not exceed the temperature stated in the steel
manufacturers Material Test Certificate.
d) There are no restrictions for tempering temperature of 1 Cr- ½ Mo,
1 ¼ Cr- ½ Mo, 2 ¼ Cr-1 Mo, 2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and
3 Cr-1 Mo- ¼ V steels, provided that the requirements of paragraph
8.1.15 are met.
e) Forming and rolling of plates of 1 Cr- ½ Mo, 1 ¼ Cr- ½ Mo, 2 ¼ Cr-1
Mo, 2 ¼ Cr-1 Mo- ¼ V, 3 Cr-1 Mo and 3 Cr-1 Mo- ¼ V steels shall be
performed with a minimum through-thickness temperature of 177°C
(350°F). Forming at ambient temperature is prohibited.
9.12.2 Cold Forming

a) Heat treatment requirements for Carbon Steels (P-1), Low Alloy Steels
(P-3, 4, 5, 9A and 9B), High Alloy Steels and Non-ferrous Materials
shall be as follows:
Material Fiber Elongation Strain εf (%) Heat Treatment Requirement
None
Less than or equal to 5 (Exception: PWHT per the applicable Code
shall be performed for cold spun heads)
Carbon Steels P-1 Greater than 5 & equal to or less than 10 PWHT per the applicable Code
Normalizing, Normalizing and tempering or
Greater than 10 quenching and tempering, as required to
maintain original material properties.
Low Alloy Steels P-3, None
Less than or equal to 3
P-4, P-5, P-9A, & P9B (Exception: PWHT per the applicable Code
Page 41 of 59
Material Fiber Elongation Strain εf (%) Heat Treatment Requirement

shall be performed for cold spun heads)
Greater than 3 & equal to or less than 10 PWHT per the applicable Code
Normalizing, normalizing and tempering or
Greater than 10 quenching and tempering, as required to
maintain original material properties.
Table 6.2 of ASME SEC VIII D2
(Exception: Austenitic stainless steel
High Alloy Materials Table 6.2 of ASME SEC VIII D2 formed heads shall be solution annealed
irrespective of the calculated fiber
elongation strain εf)
Non-ferrous Materials Table 6.3 of ASME SEC VIII D2 Table 6.3 of ASME SEC VIII D2
b) Calculation of forming fiber elongation strain εf (%) shall be according

to the following:
Type of Part Being Formed Fiber Elongation Strain εf (%)
For double curvature heads that are formed from one-

piece or welded multi-piece blanks by any process that
εf = 100 ln [Db/(Df -2t)] [1]
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 εf = 100 t / Rfd [2]
of ellipsoidal or torispherical heads)
Cylinders and cones formed from plate εf = (50 t / Rfc) [1-(Rfc / Ro)] [3]
Where:
ln is the natural logarithm
Db is the diameter of unformed blank plate or diameter of intermediate product
Df is the outside diameter of the finished product
Rfd 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)
Rfc is the mean radius of curvature of finished product (mean radius of cylinder, mean
radius of the smaller diameter of cone)
Ro is the mean radius of initial product (flat plate) or the intermediate product (in case of
unformed initial product equals to infinity)
t is the nominal thickness of the plate before forming or intermediate product
Page 42 of 59
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) Need for heat treatment of all double curvature circular products (e.g., spherical crowns,
semi-ellipsoidal 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.
iii) 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.
iv) 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.
vi) Austenitic stainless steel formed heads shall be solution annealed irrespective of the
calculated fiber elongation strain εf
9.13 Bolt tensioning device shall be used for bolting up flanged connections with
stud bolts of diameter 1-½ inch and above. Bolt up of flanges, irrespective
of bolt diameter shall be according to ASME PCC-1 requirements.
9.14 Correction of fit-up offsets of the closing longitudinal butt joint in a rolled
shell ring shall be achieved by only employing rolling machine operation
until the deviations are within the specified Code tolerances.
9.15 Alignment of pre-formed sections of multi-piece exchangers head at butt

joints, with fit-up deviations exceeding the Code tolerances, shall be
achieved by only reforming (employing pressing machine) the head
segments until the deviations are within the specified limits.
9.16 Alignment of completely fabricated sections at girth joints (shell ring-to-

shell ring and head-to-shell ring), with fit-up deviations exceeding the Code
tolerances, shall be achieved by only reforming the shell (using rolling
machine) or head (employing pressing machine), whichever is out-of-true,
until the deviations are within the specified limits.
9.17 All hot forming procedures require simulated production test coupons per
paragraph 9.5.25 of this specification.
Page 43 of 59
9.18 Welds Encroachment
9.18.1 It is the responsibility of the Exchanger Manufacturer to ensure that the outer
edge of welds attaching manways, nozzles (with and without reinforced
pads) and other structural attachments (with and without reinforced pads),
except those in paragraph 9.18.4, to pressure-retaining components shall not
be closer than 1 inch from the adjacent edge of any other weld. It is the
responsibility of the manufacturer to ensure that requirements of paragraph
7.17.3 of this specification are met in the vicinity of the welds.
Commentary Note:
Weld spacing requirements for nozzle/ manway welds in exchangers under the
scope of API RP 934-A constructed of 2 ¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V
shall be according to paragraph 9.18.4 of this specification.
9.18.2 NDE per paragraph 10.1.45 shall be performed, where the optimized
fabrication layout and/ or process design requirements do not absolutely allow
meeting the spacing requirement in paragraph 9.18.1 of this specification.
9.18.3 It is prohibited to cover butt welds in wall of exchangers that will undergo
PWHT by structural attachments (with or without reinforcing pads).
9.18.4 Nozzle/ manway welds in exchangers under the scope of API RP 934-A
constructed of 2¼ Cr-1 Mo- ¼ V and 3 Cr-1 Mo- ¼ V steels shall be located
without intersecting any circumferential or longitudinal welds. Adjacent
edges of circumferential or longitudinal welds and welds attaching nozzles /
manways shall not be closer than the greater of 50 mm (2 in.) and one
thickness of head or shell.
10 Inspection and Testing
10.1 Quality Control
10.1.19 The responsibility for examination rests with the Exchangers Manufacturer
in accordance with the applicable Code and the requirements of this
specification.
10.1.20 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.
10.1.21 All required Nondestructive Examination (NDE) shall be performed in

accordance with inspection procedures that are in complete compliance with
ASME SEC V and this specification. This written procedure shall address
each inspection method and technique used including acceptance criteria.
Page 44 of 59
The procedure(s) shall be submitted to Saudi Aramco Inspection Department

for approval.
10.1.22 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.
10.1.23 All required NDE for final acceptance of the exchanger shall be performed
after the completion of all welding and repairs and prior to pressure testing.
In exchangers requiring PWHT, all NDE for final acceptance shall be
performed after the final PWHT.
10.1.24 Use of fitness-for-service assessment methodology to qualify exchanger

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

applicable Code shall be performed on the surfaces of hot formed and reheat
treated parts.
10.1.26 All pressure and non-pressure welds in exchangers that are not required to
undergo PWHT shall be visually inspected where accessible. All segments
of longitudinal, circumferential or built-up head pressure weld seams
covered or rendered inaccessible by internals, lifting lugs or other
attachments shall be fully radiographed over the entire affected length plus
minimum 50 mm (2 in.) either side prior to installation of the attachment.
10.1.27 Additional examination of any weld joint at any stage of the fabrication may
be requested by the Saudi Aramco Inspector, including re-examination of
previously examined joints. The Saudi Aramco Inspector also has the right
to request or conduct independent NDE of any joint. If such examination
should disclose nonconformance to the requirements of the applicable Code
or this specification, all repair and NDE costs shall be done at the Exchanger
Manufacturer's expense.
10.1.28 All necessary safety precautions shall be taken for each examination method.
10.1.29 Surface irregularities, including weld reinforcement, inhibiting accurate

interpretation of the specified method of nondestructive examination shall be
ground smooth.
10.1.30 Examination of all welds shall include a band of base metal at least one inch
Page 45 of 59
wide on each side of the weld.
10.1.31 The Saudi Aramco Inspector shall have free access to the work at all times.
10.1.32 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.
10.1.33 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.
10.1.34 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.
10.1.35 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.
10.1.36 The Exchanger Manufacturer shall provide the Saudi Aramco Inspector all
reasonable facilities to satisfy him that the work is being performed as
specified.
10.1.37 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.
10.1.38 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.
10.1.39 Inspection at the mill, shop, or fabrication yard shall not release the Exchanger
Manufacturer from responsibility for repairing or replacing any defective
material or workmanship that may be subsequently discovered in the field.
10.1.40 Radiographic Examination
10.1.40.1 All radiography shall be performed with intensifying screens. Only lead or
lead foil (fluoro-metallic) screens shall be permitted unless otherwise
approved by the Saudi Aramco Inspection Department.
10.1.40.2 Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as

individual rounded indications. Clustered or aligned tungsten inclusions
shall be removed and repaired.
Page 46 of 59
10.1.40.3 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).
10.1.40.4 100% 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.
10.1.41 Ultrasonic Examination
10.1.41.1 Ultrasonic examination requirements for weld joints categories A, B, C, and D

shall be according to Table 1 of this specification.
10.1.41.2 All plates with thickness more than and including 50 mm (2.0 in.) shall be
ultrasonically examined by the Exchangers Manufacturer in accordance with
ASTM SA578. Acceptance criteria shall be Level C of SA-578.
10.1.41.3 Plates with thickness more than 12.5 mm (0.5 in.) and less than 50 mm
(2.0 in.) shall be ultrasonically examined by the Exchangers Manufacturer in
accordance with ASME SA-435. Any area where one or more
discontinuities produce a continuous total loss of back reflection
accompanied by continuous indications on the same plane (within 5% of
plate thickness) that cannot be encompassed within a 25 mm (1 in.) diameter
circle is unacceptable.
10.1.41.4 100% 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.
10.1.41.5 All forgings shall be 100% ultrasonically examined by the Exchangers

Manufacturer in accordance with ASME SA388. Acceptance criteria shall
be in accordance with ASME SEC VIII D2, paragraph 3.3.4.2. Indications
per ASME SEC VIII D2, paragraphs 3.3.4.3 and 3.3.4.4 are not acceptable.
Page 47 of 59
10.1.41.6 100% conventional ultrasonic examination is required for all full penetration
welds in exchanger supports. Alternatively, 100% radiography examination
shall be used.
10.1.41.7 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.
10.1.41.8 For UT methods that generate permanent records, the manufacturer shall
provide a calibration block according to requirements of ASME SEC V,
without reference reflectors, solely for Saudi Aramco’s use. Reference
reflectors shall be embedded in the block by Saudi Aramco Inspection
Department to verify capabilities of the manufacturer’s equipment
/technique /personnel for employing such methods. Calibration blocks shall
be submitted for evaluation by the Inspection Department prior to
commencement of any work.
10.1.42 Magnetic Particle Examination
10.1.421 Permanent magnetic yokes are not permitted.
10.1.42.2 Prods are not permitted for use on air-hardenable materials, materials which
require impact testing, and on the fluid side of pressured components for
exchangers in environments containing wet H2S.
10.1.42.3 Except for non-ferro magnetic materials, magnetic particle examination

using an AC yoke is required for the following welds:
a) Pressure containing weld joints categories A, B, C, and D per Table 1
of this specification.
b) Welds in exchanger support (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.
Notes: 1. If wet visible MPI is used, a white color contrast coating shall be
applied prior to the examination.
2. Examination shall be performed at the root pass and final weld

surface for items a), b) and c).
Page 48 of 59
10.1.42.4 All edges prepared for welding and all openings in ferromagnetic exchangers
shall be 100% magnetic particle examined in accordance with the applicable
Code.
10.1.42.5 Forgings shall be examined on all surfaces, utilizing wet fluorescent

magnetic particle method after final machining. All defects shall be
removed and repaired by welding in accordance with SAES-W-010.
(Exception: Liquid penetrant examination is acceptable as an alternative to
magnetic particle examination for welding edges.)
10.1.43 Liquid Penetrant Examination
10.1.43.1 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.
Note: Examination shall be performed at the root pass and final weld surface for
items a), b), and c).
10.1.43.2 All edges prepared for welding and all openings in non-ferromagnetic
exchangers shall be 100% liquid penetrant examined in accordance with the
applicable Code.
10.1.44 Weld hardness testing shall be in accordance with the requirements of

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

do not absolutely allow meeting the spacing requirement in paragraph 9.18.1
of this specification, NDE per table- 2 shall be performed.
10.2 Pressure Testing
10.2.5-6 (Exception) Water used for pressure testing shall be potable. For exchangers
manufactured from stainless steel, the water shall not contain more than
50 ppm chlorides with pH value not exceeding 7 at the time of filling the
exchanger. The hydrostatic test pressure shall be held for a minimum of one
Page 49 of 59
hour per 25 mm of exchanger shell/channel thickness and in no case less

than one hour.
10.2.14 After completion of all external and internal welding, nondestructive

examination, repair and heat treatment, as applicable, and prior to painting,
exchangers shall be pressure tested using water as the testing media in
accordance with the applicable Code and this specification.
10.2.15 Pneumatic testing for exchangers to be pressure tested at final erection site
within Saudi Aramco facility requires the approval of Saudi Aramco
Inspection Department.
10.2.16 Pressure testing for acceptance of the exchanger shall not be made prior to
the final postweld heat treatment.
10.2.17 The use of shellacs, glues, lead, etc., on gaskets during testing is prohibited.
No paint or primer shall be applied to an exchanger prior to hydrostatic
testing.
10.2.18 The Exchanger Manufacturer shall furnish all test materials and facilities,
including blinds, bolting, and gaskets.
10.2.19 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.
10.2.20 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.
10.2.21 After completion of exchanger testing, the exchanger shall be completely

drained and thoroughly dried including surfaces of internals. For exchangers
made completely of stainless steels and exchangers internally cladded or
weld-overlaid with these materials, pickling and passivation shall be applied
according to ASTM A380.
Notes: After complete draining of water used for hydrostatic test, the exchangers
shall be dried completely following API STD 660 Section A.8 requirements
in addition to drying the exchangers to a dew point that will ensure a dew
point of (-1°C) or less at the exit points.
Page 50 of 59
The inspection representative must witness and verify the equipment

complete water draining and moisture draying.
10.2.22 For other than differential-pressure design exchangers, test pressure for the
shell side and the tube side shall be as per the applicable code.
10.2.23 For differential-pressure design exchangers, test pressure shall be as per the
applicable code.
10.2.24 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.
10.2.25 Horizontal exchangers are to be tested while resting on their permanent

support saddles without additional supports or cribbing.
10.2.26 All welded attachments provided with telltale holes shall be pneumatically
tested at minimum 100 kPa (15 psig) prior to heat treatment and exchanger
pressure testing. Telltale holes must not be plugged during the exchanger
pressure test.
10.2.27 Minimum test pressure of the exchanger shall be:
10.2.27.1 Hydrostatic Pressure Test

a) For Division 1 exchangers per paragraph UG-99(b):
PT=1.3 MAWP (ST /S)
b) For Division 2 exchangers per paragraph 8.2.1:
Greater of:
i) PT = 1.43 MAWP
ii) PT = 1.25 MAWP (ST/ S)
Where,
PT is the minimum test pressure
S is the allowable stress at design temperature
ST is the allowable stress at test temperature
ST /S is the lowest ratio for the pressure boundary materials,
excluding bolting materials, of which the exchanger is
constructed.
Page 51 of 59
10.2.27.2 Pneumatic and Hydrostatic-Pneumatic Pressure Test

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

a) Metal temperature throughout an exchanger shall be maintained at all
times during pressure testing as follows:
1. At least 17ºC (30°F) above the warmest MDMT based on the
temperature values on the impact test exemption curves of the
applicable code, considering materials of construction for all of the
exchanger’s components.
2. Not below 15°C (59°F).
3. Not above 50°C (122°F), unless there is information on the brittle
characteristics of the equipment material indicating that a higher
test temperature is needed.
b) The temperature of the test water shall be maintained at least 15°C
(59°F) at all times during hydrostatic testing.
c) For pneumatic testing, medium test temperature shall be maintained at
least 11°C (20°F) above the dew point temperature of the testing
medium at all times during pneumatic testing. When compressed air is
used, testing shall be performed when the dew point of air is between -
20°C to -70°C (-4°F to -94°F).
d) The test pressure shall not be applied until the exchanger and the test
fluid are at about the same temperature.
10.2.29 Exchangers shall be protected from being over pressured, while being
pressure tested, by use of pressure test relief valve(s) meeting the following:
a) Relief valves shall prevent pressure from rising more than 3% or 5 psi,
whichever is greater, above the test pressure, provided that requirements
of paragraph 7.18.4 of this specification are met.
b) Sizing of relief valve(s) shall be according to API RP520, Part I.
c) The relief valve(s) shall be tested, dated, and tagged within one week
prior to the pressure test.
Page 52 of 59
d) The pressure test relief valve shall be accompanied with a calibration

certificate that includes the cold differential test pressure (CDTP), test
date and the spring range. The CDTP shall be within the spring range.
10.3 Nameplates and Stampings
10.3.1 Nameplates shall be 3 mm minimum thickness and manufactured from

Type 304 stainless steel or Monel and continuously welded to the mounting
bracket according to PIP VEFV1100.
10.3.4 Each exchanger shall be identified by a nameplate and marked with the
information required by the applicable Code and the requirements of this
specification.
10.3.5 Nameplate and nameplate mounting brackets shall be located such that the
nameplate will not be covered by insulation and is easily readable from
grade or platform. Brackets shall extend from the outside of the exchanger
to clear insulation, and with sufficient access for surface preparation and
painting. The nameplate markings as required by the applicable Code shall
be stamped or engraved such that the nameplate material is permanently
deformed with the symbols.
10.3.6 Exchangers shall be Code stamped for all services in accordance with the
applicable Code.
10.3.7 The mounting bracket shall be continuously seal-welded and positioned such
as not to allow for collection of moisture or rain.
10.3.8 Nameplate for internally coated exchangers shall show: the Saudi Aramco
Painting System Numbers, type of coating, brand name, and date of
application.
10.4 Manufacturing Repairs
10.4.1 The Saudi Aramco Engineer must review and approve crack repair
procedures, required by the applicable Code, prior to commencement of the
repairs. It is the responsibility of the manufacturer to ensure that repairs
done by the mill of any material defects, per the applicable Code, are
documented.
10.4.2 After completion of repairs required by the applicable Code, the following
shall be repeated:
a) Heat treatment of the repaired section if it has been heat-treated prior
to the repairs.
Page 53 of 59
b) All nondestructive examinations (radiography, magnetic particle, dye-

penetrant, etc.) performed on the repaired section prior to the repairs.
c) A weld map of all repairs shall be made a part of the final exchanger
documentation. The weld map shall include the nondestructive
examination procedure and results, the welding procedure
specifications and stress relief charts.
11 Preparation for Shipment
11.1 Protection
11.1.2 (Exception) Prior to shipping, exchangers are to be completely and

thoroughly dried and cleaned from all loose scales, weld slags, dirt, and
debris to the satisfaction of the Saudi Aramco Inspector.
11.1.5 (Exception) All threaded connections shall be protected with threaded plugs
of compatible materials and by the use of an appropriate lubricant with rust
preventive compound such as Cortec VpCI-369 or equivalent.
11.1.12 The Exchanger Manufacture shall protect the equipment from mechanical
and corrosion damage in order to assure that the equipment will be
serviceable after shipping, storage, and construction. The duration of these
activities is assumed to be 24 months. If longer period is specified, the
required protection measures shall be determined on a case-by-case basis.
11.1.13 Flanged connections and all other machined surfaces shall be protected by a
coating suitable for the metallurgy of the exchanger and can be easily
removed in the field. Connections shall be fitted with steel or wood cover,
3 mm thick and neoprene gaskets.
11.1.14 Covers shall be securely attached by a minimum of four bolts equally

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

harmful substances that would attack or harmfully affect the exchanger base
metal or its coating at both ambient and design temperatures.
Page 54 of 59
11.1.18 Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury,
chlorine, or any other halogens.
11.1.19 Export packaging marking and shipping shall be in accordance with the
purchase order.
11.1.20 The Exchanger Manufacturer is responsible for ensuring that the exchangers
and internals being shipped are adequately braced and shall provide
temporary supports where appropriate to ensure adequate support of the
exchanger during shipment.
11.1.21 Internal & External Protection
11.1.21.1 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.
11.1.21.2 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.
11.1.21.3 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, etc.
11.1.21.4 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 11.1.21.1, above. External surfaces shall be protected by spraying
Page 55 of 59
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.
11.1.22 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. 23 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.
11.1.24 Nitrogen blanketing at a pressure of 35 kPa (5 psi) shall be provided for

components that cannot be protected properly by the use of vapor phase
inhibitor due to inaccessible difficulties such as shell's internal surface for
fixed tubesheet heat exchangers.
11.1.25 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.
11.1.26 For exchangers which have permanent internal coatings, the Exchanger
Manufacturer shall contact the Saudi Aramco Engineer for any corrosion
protection required.
11.1.27 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.
11.1.28 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.
Page 56 of 59
11.1.29 Bolt heads shall also be protected with a rust preventative compound to
prevent corrosion during shipment, storage, and construction.
11.1.30 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 this specification in
addition to API STD 660 requirements.
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.
29 June 2017 This major revision to the specification is to:
1. Overlay and align with API STD 660.
2. Re-affirm its contents against company needs.
3. Clarify some requirements in the document.
Page 57 of 59
Table 1 - Nondestructive Examination Requirements

Weld Joint Radiography Ultrasonic Liquid Penetrant (LP)
Category (RT) (UT) or Magnetic Particle (MP)
Per Design Code Criteria
A and B See Notes (2) & (3) 100%
(Spot or 100%) (1) & (3)
(3)
C 100% See Notes (2) & (3) 100% (6)
D See Note (4) See Note (4) See Note (4)

Notes:
(1) 100% RT is required for exchangers under any of the following services or design conditions:
 Weld joints requiring full radiography per the applicable code.
 Lethal services.
 Hydrogen services.
 Cyclic services.
 Unfired steam boilers with design pressure exceeding 50 psi.
 Thick wall exchangers.
(2) 100% conventional UT is required.
(3) 100% UT, employing methods that generate permanent records may be used as a substitute for the
combination of 100% RT and 100% conventional UT specified for exchangers under common services and
design conditions per notes 1 and 2 of this table. Such UT methods must be approved by Inspection
Department prior to commencement of any work.
(4) Inspection for Category - D weld joint shall meet the following:
a) 100% RT and 100% Conventional UT on joints for design conditions/ services Group I per paragraph
7.6.18.2 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 7.6.18.2 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 7.6.18.2 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.
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 7.6.18.2 shall be
according to note 4 of this table.
(6) 100% MT or 100% LP shall be applied to the root pass and final surface of lap-welded Category - C weld joint.
Page 58 of 59
Table 2 - Welds Encroachment Requirements

Case PWHT is required (Notes 1, 2) PWHT is not required
RT of butt weld in exchanger for a
1. Nozzle or manway without a
length equal to three times the
reinforcing pad installed onto a butt Same as when PWHT is required.
diameter of the opening with the center
weld in exchanger wall.
of the opening at mid-length.
RT of butt weld in exchanger for a length
equal to three times the diameter of the
2. Nozzle or manway with a reinforcing N/A
opening with the center of the opening at
pad installed onto a butt weld in (Such detail is not permitted per
mid-length.
exchanger wall. paragraph 7.6.18.2 of this specification)
The butt weld shall be ground flush prior to
installation of the pad.
3. Nozzle or manway, without a
length equal to three times the
reinforcing pad, encroaching on a butt Same as when PWHT is required.
diameter of the opening with the center
weld in exchanger wall.
of the opening at mid-length.
4. Reinforced nozzle or manway with the N/A
reinforcing pad encroaching on the butt (Such detail is not permitted per
weld in exchanger wall. paragraph 7.6.18.2 of this specification)
mid-length.
5. Reinforced nozzle or manway with N/A
penetration encroaching the butt weld (Such detail is not permitted per
mid-length.
and the reinforcing pad covering it. paragraph 7.6.18.2 of this specification)
6. Structural attachment, except for vacuum
stiffeners and tray support rings:
(a) Structural attachment, without a length equal to the projection of the
reinforcing pad, encroaching on a attachment weld plus a minimum of 50 Same as when PWHT is required.
butt weld in exchanger wall. mm on either side. Minimum length of
the radiographed weld is 12 inches.
equal to the projection of the reinforcing
(b) Reinforced structural attachment, N/A pad attachment weld plus a minimum of
with the reinforcing pad covering a (See prohibition in paragraph 9.18.3 of 50 mm on either side. Minimum length of
butt weld in exchanger wall. this specification) the radiographed weld is 12 inches.
(c) Structural attachment, without a N/A equal to the projection of the structural
reinforcing pad, covering a butt (See prohibition in paragraph 9.18.3 of attachment weld plus a minimum of 50 mm
weld in exchanger wall. this specification) on either side. Minimum length of the
radiographed weld is 12 inches.
(d) Reinforced structural attachment, length equal to the projection of the
with the reinforcing pad reinforcing pad attachment weld plus a
Same as when PWHT is required.
encroaching on a butt weld in minimum of 50 mm on either side.
exchanger wall. Minimum length of the radiographed
weld is 12 inches.
7. Structural attachment (with or without
reinforcing pads), including vacuum MP or LP on the entire outermost fillet
stiffeners and tray support rings, weld of each attachment on the
encroaching: exchanger side per paragraph 10.1.42
Same as when PWHT is required.
(a) Another structural attachment (with or or 10.1.43, as applicable, after
without reinforcing pads). completion of all welds in all
(b) Reinforced nozzle or manway. attachments.
(c) Nozzle or manway without a
reinforcing pad.
Note 1: NDE for final acceptance of the exchanger shall be performed after the final PWHT per paragraph 10.1.23 of this specification.
Note 2: 100% UT, employing methods that generate permanent records, must be approved by Inspection Department prior to commencement of
any work.
Page 59 of 59

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Materials System Specification

32-SAMSS-007 26 June 2017

Table 1 - Nondestructive Examination

Previous Issue: 1 December 2013 Next Planned Update: 26 June 2020

©Saudi Aramco 2017. All rights reserved.

1.2 This specification does not cover the following:

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

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

1.10 Conflicting Requirements

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

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

Saudi Aramco Engineering Standards

SAES-H-001 Coating Selection and Application Requirements for

Saudi Aramco Materials System Specifications

Saudi Aramco Standard Drawings

Saudi Aramco Inspection Requirements

Saudi Aramco Forms and Data Sheets

2.2 Industry Codes and Standards

American Concrete Institute

American Petroleum Institute

American Society of Civil Engineers

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

ASME SEC V Nondestructive Examination

American Society for Testing and Materials

American Society for Nondestructive Testing

International Standards Organization

NACE SP0590 Prevention, Detection, and Correction of Deaerator

Tubular Exchanger Manufacturers Association (TEMA)

Process Industry Practices

Welding Research Council

3 Terms and Definitions

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

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

3.11 (Exception) MDMT: Minimum Design Metal Temperature determined by

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

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

3.17 Design Engineer: The Engineering Company responsible for specifying on

3.18 Exchanger Manufacturer: The Company responsible for the manufacture

3.20 Hot Forming: Forming operations carried out at an elevated temperature

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

3.22 Lethal Services: Process streams containing a concentration of hydrogen

3.24 Minimum Thickness: Thickness required for withstanding all primary

3.25 Nominal Thickness: Thickness selected as commercially available, and

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

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

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

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

4.3 (Exception) The Exchanger Manufacturer shall comply with applicable

manufacturer may execute only finite element analysis.

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

4.16 Application of ASME Code Cases to the manufacturing of exchangers

4.17 The Exchanger Manufacturer is responsible for the thermal/hydraulic design

4.18 The Exchanger Manufacturer is responsible for the manufacture of

5 Proposal Information Required

5.7 Performance Guarantees

sheets. Thermal, hydraulic, and mechanical guarantee shall be in

6 Drawings and Other Required Data

6.1 Outline Drawings and Other Supporting Data

6.1.1 (Exception) The Exchanger Manufacturer shall prepare drawings,

6.1.2 The Exchanger Manufacturer shall submit flow-induced vibration analysis.

6.2 Information Required After Outline Drawings are Reviewed

6.3 Reports and Records