32 Samss 007

Materials System Specification
32-SAMSS-007 21 June 2020

Manufacture of Shell and Tube Heat Exchangers
Document Responsibility: Heat Transfer Equipment Standards Committee
Contents
1 Scope ............................................................. 7
2 Normative References.................................... 9
3 Terms and Definitions .................................. 12
4 General ........................................................ 15
5 Proposal Information Required ..................... 16
6 Drawings and Other Required Data ............. 17
7 Design .......................................................... 18
8 Materials ....................................................... 38
9 Fabrication ................................................... 49
10 Inspection and Testing ................................. 63
11 Preparation for Shipment ............................. 76
12 Supplemental Requirements ........................ 80
Revision Summary ............................................... 81
Table 1 - Nondestructive Examination
Requirements ....................................... 82
Table 2 - Welds Encroachment Requirements .... 83
Previous Issue: 21 July 2019 Next Planned Update: 21 June 2025

Page 1 of 84
Contact: QAHTAM29
©Saudi Aramco 2020. All rights reserved.
Saudi Aramco: Company General Use

Document Responsibility: Heat Transfer Equipment Standards Committee 32-SAMSS-007
Issue Date: 21 June 2020
Next Planned Update: 21 June 2025 Manufacture of Shell and Tube Heat Exchangers
Paragraph Number Change Type

(Addition, Modification, Technical Change(s)
Previous Revision Current Revision Deletion)
(21 Jul 2019) (20 Jun 2020)
1.1 1.1 Modification Paragraph modified
NA 1.8 Addition Paragraph added
Paragraph modified
1.10.1 1.9.1 Modification
Paragraph number revised
Paragraph modified
SAES-A-133, SAES-E-004,
2.1 2.1 Addition
SAES-L-132, 32-SAMSS-013
2.1 2.1 Deletion SAES-L-133
2.2 2.2 Addition IOGP S-614
2.2 2.2 Deletion API STD 660, ASME SA-388
HIC Environment definition

3.21 NA Deletion
deleted
Hydrogen Services definition
NA 3.22 Addition
added
SSC Environment definition
3.29 NA Deletion
deleted
NA 3.30 Addition Sour Service definition added
Special Forgings definition

NA 3.31 Addition
added
Paragraph modified
3.30 3.32 Modification
NA 4.14 Addition New paragraph added
Paragraph modified
Aligned with IOGP S-614 section
4.15 NA Deletion
7.2.1
Paragraph modified
Paragraph modified
Page 2 of 84


6.1.2 NA Deletion
5.6
6.2.4 NA Deletion
5.6
7.1 7.1 Addition “and Design Pressure”
NA 7.1.3 Addition New paragraph added
Paragraph modified
7.1.3 & 7.14.1 7.1.4 Modification
7.3.6 NA Deletion
7.3.6
7.4.11 NA Deletion
7.4.11
Reference to Saudi Aramco
7.5.1.10 NA Deletion
Engineer
Engineer
Engineer
7.5.2.5 NA Deletion
7.5.2.5
7.5.2.6 7.5.2.6 Modification Paragraph modified
NA 7.5.2.7 Addition New paragraph added
NA 7.5.2.8 Addition New paragraph added

7.5.3.1 NA Deletion
7.5.3.1
No change
7.5.3.4 7.5.3.9 Modification
7.5.3.5 NA Deletion
7.5.3.7
7.5.5.4 NA Deletion
7.5.5.4
7.6.3 7.6.3 Modification Dual units added
7.6.4 7.6.4 Modification Paragraph modified

7.6.5 NA Deletion
Engineer

7.6.14 NA Deletion
Engineer
7.6.15 NA Deletion
Engineer
Engineer
Page 3 of 84

7.6.16.2 NA Deletion Covered in paragraph 7.6.15
7.6.16.3 NA Deletion Aligned with API 660 section 9.3
Dual units added

7.6.18.2 7.6.18.2 Modification / Deletion
Group I g. deleted
Aligned with API 660 section
7.6.19 NA Deletion
7.7.8
Covered in SAES-E-004
7.6.21 NA Deletion
paragraph 8.1.7
7.6.22 NA Deletion
7.6.1
7.6.23 NA Deletion
paragraph 8.1.8
paragraph 8.2.3
Dual units added
7.6.25 7.6.20 Addition / Modification
7.6.26 NA Deletion
Engineer
7.11.5 NA Deletion Aligned with TEMA section G-7.2
Paragraph modified
Dual units added

Dual units added
Dual units added
8.5.3 8.1.7.3 Addition / Modification
Dual units added
8.5.6 8.1.7.6 Addition / Modification
Paragraph modified
Paragraph modified
Paragraph modified
8.1.16 NA Deletion
Engineer
8.1.17 NA Deletion
Engineer
Dual units added
Paragraph modified
Paragraph modified
8.3.3 8.3.3 Addition Dual units added
Page 4 of 84

85 %
Paragraph modified
Dual units added
9.1.9.2 9.1.11.2 Addition / Modification
No change
No change
9.2 NA Deletion
9.2.1
Paragraph modified
Paragraph modified

9.5.15 NA Deletion
8.1.8
No change
No change
No change
Sour service
Sour service
Dual units added
Paragraph modified
Page 5 of 84

Dual units added

Paragraph modified
9.13 9.13 Addition Dual units added
Paragraph modified
10.1.41.5 10.1.51.5 Modification
No change
10.1.41.6 10.1.51.6 Modification
Paragraph modified
10.1.41.7 10.1.51.7 Modification
Paragraph modified
Paragraph modified
Paragraph modified
Paragraph modified
10.2.25 & 10.2.26 10.2.25 Modification Paragraph modified
10.3.1 10.3.1 Addition Dual units added
National Board registration is not

10.3.6 10.3.6 Addition
required

11.1.13 NA Deletion
11.1.4
11.1.15 NA Deletion
11.1.4
Paragraph modified
Paragraph modified
11.1.21.1 11.1.19.1 Modification
Paragraph modified
11.1.21.4 11.1.19.4 Modification
Paragraph modified
Table 2 Table 2 Addition Dual units added
Page 6 of 84

This specification is written as an overlay to IOGP S-614, December 2018, following the same
section structure, to assist in cross-referencing the requirements. Where sections from the IOGP
S-614 are not covered in this specification, there are no supplementary requirements or
modifications to the respective section.
The following section numbers refer to IOGP S-614, December 2018, which is part of this
specification. Modifications to the IOGP S-614 defined in this specification are identified as
Add (add to section or add new section), Replace (part of or entire section) or Delete.
1 Scope
1.1 Add new section
This specification covers the minimum mandatory requirements for the

manufacture of shell and tube heat exchangers (hereinafter referred to as
exchangers) and stand-alone bundles.
1.2 Add new section
This specification does not cover the following:

a) “UM” stamped exchangers per ASME SEC VIII D1.
b) Exchangers used as part of heating, ventilation, and air conditioning
(HVAC) systems.
c) Exchangers used as integral radiators.
d) Sulfur Recovery Unit (SRU) steam drums.
e) Non-process exchangers used as part of packaged equipment like
compressors, motors, pumps and turbines.
1.3 Add new section
Exchangers that do not meet either partially or completely the requirements

of IOGP S-614 or TEMA standards shall be evaluated for acceptance by
Saudi Aramco Engineer based on the following:
a) Full design details, specifying changes from IOGP S-614 or TEMA
requirements.
b) LSTK and process licensors shall guarantee the thermal performance
and mechanical integrity, supported by detailed calculations.
1.4 Add new section
Page 7 of 84

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 Add new section
The design and fabrication of high pressure and non-conventional types of

heat exchangers such as waste heat boilers, SRU condensers, vertical
vaporizers, Texas Towers, etc. shall be performed by manufacturers who
have previous experiences verified by licensers or the Design Engineer.
1.6 Add new section
Where a requirement of a licensor’s or a relevant industry standard/

specification is more stringent than that of this specification, the most
stringent requirement will govern.
1.7 Add new section
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.
1.8 Add new section
This specification cover in-kind replacement of in-service exchangers and

components. The Design Engineer/Exchanger Manufacturer is responsible to
take into consideration the as-built dimensions.
1.9 Add new section
Conflicting Requirements
1.9.1 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.
1.9.2 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.
Page 8 of 84

2 Normative References
Unless otherwise noted in this specification, materials or equipment designed to this

specification shall comply with the “applicable edition” of the references listed below.
The “applicable edition” is the standards cut-off 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 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
SAES-A-133 Internal Corrosion Protection Requirements
SAES-E-004 Design Criteria of Shell and Tube Heat Exchangers
SAES-H-001 Coating Selection and Application Requirements for
Industrial Plants and Equipment
SAES-L-132 Materials Selection for Pipelines, Piping, and
Process Equipment
SAES-M-001 Structural Design Criteria for Non-Building
Structures
SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-016 Welding of Special Corrosion-Resistant Materials
Saudi Aramco Materials System Specifications

01-SAMSS-016 Qualification of Plates for Pressured Equipment
and Storage Tanks for Resistance to Hydrogen-
induced Cracking
01-SAMSS-043 Carbon Steel Pipes for On-Plot Piping
01-SAMSS-046 Stainless Steel and Nickel Alloy Pipes
02-SAMSS-005 Butt Welding Pipe Fittings
Page 9 of 84

02-SAMSS-011 Forged Steel and Alloy Flanges

02-SAMSS-013 Stainless Steel and Nickel Alloy Butt Welding Pipe
Fittings
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-7922-1 Non-material Requirements for Shell and Tube and
Double-Pipe Heat Exchangers
2.2 Industry Codes and Standards
American Concrete Institute

ACI 318 Building Code Requirements for Structural Concrete
American Petroleum Institute

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)
American Society of Civil Engineers

ASCE 7- 2005 Edition Minimum Design Loads for Buildings and Other
Structures
Page 10 of 84

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-435 Straight Beam Ultrasonic Examination of Steel Plates
ASME SA-688 Specification for Welded Austenitic Stainless Steel
Feedwater Heater Tubes
ASME SEC II Materials
ASME SEC V Nondestructive Examination
ASME SEC VIII D1 Rules for Construction of Pressure Vessels
ASME SEC VIII D2 Rules for Construction of Pressure Vessels,
Alternative Rules
ASME B16.5 Pipe Flanges and Flanged Fittings
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 E45 Standard Test Methods for Determining the
Inclusion Content of Steel
American Society for Nondestructive Testing

ASNT CP-189 Standard for Qualification and Certification of
Nondestructive Testing Personnel
International Association of Oil and Gas Producers

IOGP S-614 Supplementary Specification to API 660 Shell and
Tube Heat Exchangers
International Standards Organization

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-
Materials for use in H2S-Containing
Environments in Oil and Gas Production
Page 11 of 84

National Association of Corrosion Engineers

NACE SP0472 Methods and Controls to Prevent In-Service
Environmental Cracking of Carbon Steel
Weldments in Corrosive Petroleum Refining
Environments
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 Replace section with
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.
Hydrogen Service: Process streams containing hydrogen with an absolute

partial pressure of 350 kPa (50 psi) and higher.
MDMT: Minimum design metal temperature determined by the Design

Engineer and specified in the data sheet.
Pressure Design Code: ASME SEC VIII.
Page 12 of 84

3.17 Add new section
AARH: Average arithmetic roughness height, which is a measure of surface

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

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

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

such that re-crystallization occurs simultaneously with deformation.
Hydrogen Services: Process streams containing hydrogen with an absolute

partial pressure of 350 kPa (50 psi) and higher.
Lethal Services: Process streams containing a concentration of hydrogen

sulfide (H2S) 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.
Low-Alloy Steels: Steels with a total alloying content of less than 5% but
more than specified for carbon steels.
Page 13 of 84

Minimum Thickness: Thickness required for withstanding all primary

loads, excluding allowance for corrosion.
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.
Saudi Aramco Buyer: The person or company authorized by Saudi Aramco

to procure exchangers to the requirements of this specification.
Saudi Aramco Engineer: The chairman of the Heat Transfer Equipment

Standards Committee.
Saudi Aramco Inspector: The person or company authorized by the Saudi

Aramco Inspection Department to inspect exchangers to the requirements of
this specification.
Sour Service: In exchangers, process conditions, as defined in SAES-A-

133, that can result in sulfide stress cracking (SSC) and hydrogen induced
cracking (HIC).
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.
Thick Wall: Nominal thickness of a pressure-retaining exchanger’s

component (shell, head, nozzle, etc.) greater than 50 mm (2 in).
Page 14 of 84

Utility Services: Water, air, and nitrogen services.
4 General
All exchangers shall be designed in accordance with the rules of the Boiler
and Pressure Vessel Codes, ASME SEC VIII D1 or ASME SEC VIII D2
(hereinafter referred to as the Codes), and the requirements of this
specification.
The Exchanger Manufacturer shall comply with applicable local, state, and
national codes, and insurance requirements.
When thermal and hydraulic design is in the scope of supply of the

exchanger manufcaturer, design requirements shall be in accordinace with
SAES-E-004.
4.15 Replace first sentence with
The design loads for the analysis of heat exchanger supports shall be in
accordinace with this specification.
Stress analyses according to the Code rules shall be executed by the

Exchanger Manufacturer. A third party under full control and responsibility
of the Exchanger Manufacturer may execute only finite element analysis.
No proof testing shall be permitted.
The Exchanger Manufacturer is responsible for the thermal/hydraulic design

(rating) and verification of the Design Engineer's thermal/hydraulic design,
if applicable.
Page 15 of 84

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

penetration welds.
The Exchanger Manufacturer shall neither prepare nor certify a User’s

Design Specification.
5 Proposal Information Required
The proposal shall include a detailed description of any exception to the

requirements of this specification.
When the pressure design code does not include rules necessary for the
design of all components the method of analysis to be applied shall be
approved by the Saudi Aramco Engineer.
Application of ASME Code Cases to the manufacturing of exchangers shall

be on case-by-case basis.
5.9 Add new section
The Exchanger Manufacturer may offer an alternative design, but must

quote on the base inquiry documents.
Page 16 of 84

Performance Guarantees
The following shall be guaranteed for the length of the warranty period
specified in the purchase order or contract documents:
1) Exchangers shall meet thermal/hydraulic performance requirements
under continuous operation at design conditions specified on the data
sheets. Thermal, hydraulic, 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
6.1.4 Replace section with
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.
6.1.6 Add new section
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.
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.
The Exchanger Manufacturer shall prepare drawings, calculations, and data

in accordance with SA-7922-1, Nonmaterial Requirements, in addition to
IOGP S-614 requirements. Calculations shall include, but not limited to:
a. ASME SEC VIII calculations.
b. Wind and earthquake calculations, as applicable.
Page 17 of 84

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.
6.3 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 and Design Pressure
Unless otherwise specified by the Design Engineer, differential pressure

design shall not be used.
The value(s) of design temperature(s) and design pressure(s) shall be as

specified on the data sheet.
The value of the minimum design metal temperature (MDMT) shall be as

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
Page 18 of 84

Exchangers having partial or complete cladding shall conform to

32-SAMSS-031 in addition to the requirements of this specification.
7.3 Shell Supports
7.3.5 Add to end of section
The exchanger shall be fixed at one saddle support and free to slide at the
other saddle.
The allowable concrete bearing stress to be used for the design of baseplates
shall be 10,340 kPa (1,400 psi).
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.
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.
Anchor Bolts
7.3.11.1 Add new section
The Exchanger Manufacturer shall determine the size and number of anchor
bolts required.
Anchor bolts shall be in compliance with Standard Drawing AA-036322

Sht. 001 (Rev. 07 or later).
Page 19 of 84

Anchor bolts shall not be less than 19 mm (0.75 in) minimum nominal
diameter.
The design of anchor bolts shall be in accordance with the requirements of

Appendix D of ACI 318.
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 (0.125 in) as a corrosion allowance.
Exchangers supported on saddles shall be provided with an even number of

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

east-west axes.
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).
Exchangers supported on lugs shall be provided with minimum one anchor

bolt per support.
7.4 Stationary and Floating Heads
Page 20 of 84

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
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.
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.
7.5.2 Tubesheets
7.5.2.6 Replace section with
Vertical exchangers with fixed tubesheets shall be provided with flanged

vents and drains through the tubesheets. In cases where tubesheet thickness
limits the nozzle size, smaller tubesheet vents and drains shall be used.
7.5.2.7 Replace item a) with
a) lethal, hydrogen and cyclic services;
7.5.2.8 Replace section with
When the tubesheet design is outside of the scope of design code (e.g. thin
flexible tubesheets, large un-tubed areas, etc.), finite element analysis shall
be used to verify the design. Other design methods shall be subject to the
review of the Saudi Aramco Engineer.
All stationary tubesheets with through bolting design shall have non-
threaded bolt holes.
Page 21 of 84

7.5.3 Baffles and Support Plates
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.).
7.5.4 Impingement Protection
7.5.4.7 Add to list
(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.
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.
7.6 Nozzles and Other Connections
7.6.1 Add to section after first sentence
Flanges shall be in accordance with ASME B16.5 pressure rating.
7.6.2 Replace second sentence with
The ends of butt-welded connections shall be in accordance with ASME

B16.25.
Page 22 of 84

Drains, vents and instrument connections smaller than NPS 40 ( NPS 1½)
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;
e) Pressure-retaining parts thicker than 50 mm (2 in);
f) Unfired steam boilers with design pressure exceeding 350 kPa (50 psi).
Attachment welds of such connections to the blind flange shall be treated as
category-D weld joint. Accordingly, attachment details and Nondestructive
Examination (NDE) requirements shall be similar to those required for the
exchanger per this specification.
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.
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) 150 mm (6 in) for NPS 150 (NPS 6) nozzles and smaller.
b) 200 mm (8 in) for NPS 200 (NPS 8) nozzles and larger.
Page 23 of 84

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.
Reinforcment pads shall not be used for nozzles in design

conditions/services Group I per Section 7.6.18.2 of this specification.
Nozzle types shall be in accordiance with Section 7.6.18.2 of this

specification.
The thickness of reinforcing pads shall not be less than the greater of the
nominal wall thickness minus the total corrosion allowance or 10 mm (0.375
in) and in no case greater than 50 mm (2 in).
The quantities, types, sizes, ratings, (ASME pressure classes), facings,

elevations, and orientations of nozzles and manways shall be as specified on
the data sheet.
Attachment Details for Nozzles, Manways and their Connections
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.
Permissible types of nozzles, manways, and their connections shall be

according to the table below.
Page 24 of 84

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 (2 in) Case-1
All nozzle sizes and
b. Unfired steam boilers with design pressure
manway necks Figure UW-16.1,
exceeding 350 kPa (50 psi) Table 4.2.13,
details:
details: (1), (2),
c. Lethal, hydrogen and cyclic services Case -2 (f-1), (f-2), (f-3) or
(3), (4), (5) or (6)
Connections (f-4)
d. Openings larger than 900 mm (36 in) (Note 1)
attached to nozzles
e. Design temperature greater than 400°C (750°F) and manways
(Note 1)
f. Low alloy steel exchangers with design
thickness greater than 25 mm (1 in) (Note 1)
- Table 4.2.10,
details: (1), (2),
(3), (4), (6), (7) or
Figure UW-16.1, (8)
Case-1 details: (a), (a-1),
NPS 100 (NPS 4) (b), (c), (d), (e), (f- - Table 4.2.11,
and smaller 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),
Case-2 details: (a), (b), (3), (4), (6), (7) or
Group II Connections to NPS (c), (d), (e), (f-1), (8)
100 (NPS 4) and (f-2), (f-3), (f-4) or
Design conditions and services other than those in smaller nozzles (g). - Table 4.2.13,
group I of this table (Note 2) details: (1), (2),
(3), (4), (5) or (6)
Case-3 Figure UW-16.1, - Table 4.2.10,
Nozzles larger than details: (c), (d), details: (3), (4),
NPS 100 (NPS 4) (e), (f-1), (f-2), (f- (6), (7) or (8)
and manway necks 3), (f-4) or (g)
- Table 4.2.11,
Case-4 Figure UW-16.1,
detail (2)
Connections details: (c), (d),
attached to nozzles (e), (f-1), (f-2), (f-
- Table 4.2.13,
larger than NPS 100 3), (f-4) or (g)
details: (1), (2),
(NPS 4) and
(3), (4), (5) or (6)
manways (Note 3)
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.
Page 25 of 84

Integrally reinforced contour shaped attachments made partially or

completely of weld build up are prohibited.
Flange Ratings (ASME Pressure Classes) and Facings
The ASME pressure classes and facings shall be as specified on the data sheet.
Bolted joints specified with non-ASME flanges shall be designed to meet all
anticipated loading conditions of the exchanger.
Gasket seating surfaces shall comply with the following:

a) For spiral wound gaskets, 3.2 to 6.3 micro-meter (125 to 250 micro-
inch) AARH, in all services, except hydrogen.
b) For spiral wound gaskets in hydrogen service, 3.2 to 3.8 micro-meter
(125 to 150 micro-inch) AARH.
c) The sidewalls of rings joint flanges in all services, 1.6 micro-meter (63
micro-inch) AARH.
d) For Nonmetallic gaskets, 6.3 to 12.5 micro-meter (250 to 500 micro-
inch) AARH.
Flatness of gasket contact surfaces shall be measured after completion of all

welding and any required postweld heat treatment (PWHT).
Manways
Page 26 of 84

The number, nominal inside diameter and locations of manways shall be as

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.
7.7 Flanged External Girth Joints
A body flange shall be constructed of a single-piece forging.
7.11 Handling Devices
7.11.3 Add to end of section
Protective plugs shall be fully engaged.
Shell lifting devices shall be designed such that the lifted parts hang
vertically when suspended. lifting devices on insulated exchangers shall be
of sufficient standout to clear insulation.
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.
7.12 Requirements for Hydrogen Service
7.12.1 Replace first sentence with
Totally enclosed spaces between attachment welds and the pressure

boundary shall be eliminated.
Kettle Reboilers
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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 (3 in).
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 (2 in) semi-circular drain hole.
Maximum Allowable Working Pressure
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.
The MAWP of an exchanger shall not be limited by components such as

nozzle flanges, fittings, reinforcing pads, etc.
Joint Efficiency
A joint efficiency of 85% or higher shall be specified for the design of all
pressure containing components of ASME SEC VIII D1 exchangers.
Loads
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.
Page 28 of 84

b) Wind and earthquake loads shall be calculated for the exchanger

in accordance with ASCE 7 (2005 Edition), using Occupancy
Category IV and based on design data corresponding to the site
location per SAES-A-112.
c) Wind pressures shall be assumed to act on the projected surface area of
the exchanger and shall include due allowances for any platforms,
ladders, piping, insulation, and equipment supported from the
exchanger as specified on the data sheet.
d) Earthquake loads shall include due allowances for platforms, ladders,
piping, insulation, and equipment supported from the exchanger as
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.
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.
Thermal Loads
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Thermal Loads are loads caused by thermal transients and restraining

thermal expansion/interaction of the exchanger and/or its support(s).
Load Combinations
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.
Anchor bolts shall be designed for load combinations, based on the allowable
stress design method (Service Loads) in accordance with SAES-M-001.
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
Combined stresses due to test pressure, including static head, and minimum
of 25% 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.
The use of a pneumatic test may be considered when it will result in

significant cost savings in the exchanger and/or its supporting
Page 30 of 84

structural/foundation. Such test requires prior approval of the Saudi Aramco

Inspector.
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.
Stress Analysis
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.
The Design Engineer is responsible for specifying the heat transfer

coefficients to be used for all thermal stress analysis.
Thermal Analysis
1) A thermal stress analysis is required for an exchanger, if a thermal
gradient (calculated under steady state operating conditions and, if
applicable, transient operating conditions) across any exchanger
section exceeds 65°C (150°F), in a distance equal to the square root of
R times T, where:
- R is the radius of the exchanger component under consideration, and
- T is the thickness of the component under consideration
- R and T have the same units.
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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.
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.
Local Stress Analysis
Stress analysis due to piping, equipment, lifting, supports, and other external
loads shall be completed in accordance with the procedures as detailed in
WRC 537, WRC 297 or a finite element analysis.
Page 32 of 84

Shell and Channel Covers
The type of heads to be used shall be ASME 2:1 ellipsoidal or ASME

hemispherical, unless as allowed in Section 7.18.2 of this specification.
ASME dished flat heads (with knuckle) and ASME torispherical heads may
be used for only air and water services with a design pressure not exceeding
690 kPa (100 psi).
One-piece construction shall be used for any of the following: i) heads with
nominal thickness greater than 50 mm (2 in) ii) exchangers in any of cyclic,
hydrogen or lethal services. Other types of head construction (welded multi-
piece blank, crown, petals, etc.) shall be on a case-bycase basis.
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.
Heads in exchangers with design thickness greater than 50 mm (2 in) shall

be hemispherical unless 2:1 ellipsoidal heads are deemed more economical.
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
50 mm (2 in).
b) Not be less than 10% of the outside diameter of the adjoining
cylindrical section with conical transition section or torispherical heads
Page 33 of 84

with thickness more than 19 mm (0.75 in) and less than or equal to 50
mm (2 in).
c) Not be less than 6% of the outside diameter of the adjoining cylindrical
section with conical transition section or torispherical heads with
thickness less than or equal to 19 mm (0.75 in).
Reinforcing for conical transition sections in thick wall exchangers shall be

provided by increased plate thickness. The use of reinforcing rings is
prohibited.
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.
Joint details in Section 7.18.7 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.
Longitudinal Baffles (TEMA 'F' shells)
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.
Clips and Non-Pressure Retaining Attachments
Page 34 of 84

General
The Exchanger Manufacturer shall supply and install all clips and attachments
as specified on the data sheet.
Insulation Support
Support for insulation system shall be according to the data sheet.
The Exchanger Manufacturer shall supply and install supports required for
insulation.
Refractory Supporting System
Anchoring system of refractory lining shall be according to the data sheet.
The Exchanger Manufacturer shall supply and install anchoring system

required for refractory.
Fireproofing Supports
Support for fireproofing system shall be according to the data sheet.
The Exchanger Manufacturer shall supply and install supports required for
fireproofing materials.
Page 35 of 84

Grounding Lugs
All exchangers shall be provided with a grounding lug connection welded to

the fixed exchanger support in accordance with PIP VEFV1100.
All internal and external attachments, including clips, welded directly to

pressure-retaining parts, shall be fully seal welded.
Coatings and Painting Systems
Type of coating and painting systems shall be as specified on the data sheet
in accordance with SAES-H-001.
Surfaces to be coated shall be cleaned and prepared prior to its coating in

accordance with SAES-H-001.
Gasket contact surfaces shall be properly protected from blasting and shall
not be coated or painted.
General
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.
Page 36 of 84

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.
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.
For tube bundles that can be rotated 180 degrees, additional impingement
plate, bundle runners, etc., shall be provided.
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.
Nominal Thickness
Nominal thickness of shells and heads shall not be less than the following:
a) Carbon steels, 6 mm (0.25 in).
b) Low alloy steels, 5 mm (0.20 in).
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 greater than 150 mm (6 in), forged ring
construction shall be used.
Page 37 of 84

8 Materials
8.1 General
Impact Testing
8.1.7.1 The Exchanger Manufacturer is responsible of determining the required

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

8.1.7.3 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 Joule (30/24 ft-lb) for carbon steels thicker than 50 mm (2 in)
2) As specified by ASME SEC VIII D2, but not less than 34/27 Joule
(25/20 ft-lb)
3) As specified by the licensor’s specification, but not less than
34/27 Joule (25/20 ft-lb)
4) 55/48 Joule (40/35 ft-lb) 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.
8.1.7.4 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.
Page 38 of 84

8.1.7.5 Impact testing is required, with no exception, for exchangers made of low
alloy steels.
8.1.7.6 Impact testing of materials and welding procedures are required when test
temperature is lower than -28°C (-18°F).
8.1.7.7 Baffle plates, sealing strips, tie-rods, sliding bars, tubes, spacers, and support
plates are exempt from impact testing requirements.
All carbon, low alloy and high alloy steels required for pressure and non-
pressure components shall be as specified on the data sheet.
Use of alternative materials of construction for carbon and low alloy steels
exchangers shall be on a case-by-case basis. Alternative materials must
comply with all the requirements of the applicable Code and this
specification.
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.
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.
Material test report is requested to be certified as per 175-323100 and 175-

323500.
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,
Page 39 of 84

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 Section 8.12 of this
specification, provided that fracture toughness requirements specified in
these documents and this standard are met.
Use of solid high alloy steels shall be limited to permitted grades as per
SAES-L-132. Use of solid stainless steel, if not prohibited by SAES-L-132,
shall be on a case-by-case basis based on the design temperature, minimum
design metal temperature and intended service.
All materials shall be alloy-verified by the Exchanger Manufacturer in

accordance with SAES-A-206 requirements.
Use of C-½ Mo steels in hydrogen services is prohibited.
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.
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
Page 40 of 84

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.
c) Standard flanges according to ASME B16.5 and B16.47.
1. For flanges with T equal to or less than 50 mm (2 in), specimens
shall be removed in accordance with the material specification.
2. For flanges with T greater than 50 mm (2 in), 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
Page 41 of 84

treatment. The separate test forgings should be heat-treated in the same

furnace charge and under the same conditions as the production
forgings.
Layered constructions are prohibited for all exchangers.
Materials for exchangers in de-aeration service shall be in accordance with

NACE SP0590.
Materials for exchangers exposed to sour service/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, as defined in this specification, 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.
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.
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
Page 42 of 84

considering thermal treatments specified in Section 8.1.20 of this

specification.
Material for nameplate mounting brackets shall be of the same type and
material grade as the pressure retaining component to which it is attached.
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 (0.75 in).
Materials of supports shall be as follows:

1) Lugs: same material as exchanger wall base material. If lugs are not
welded directly to the exchanger wall (i.e., pads are used between lugs
and the exchanger wall), the used pads shall be of the same material as
the exchanger wall base material and the lugs material can be different.
Supports of exchangers described in Section 8.1.28 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. If saddles
are not welded directly to the exchanger wall (i.e., pads are used
between saddles and the exchanger wall), the used pads shall be of the
same material as the exchanger wall base material and the lugs
material can be different.
External attachments, other than those in Section 8.1.29 of this specification,

and internal attachments welded to the exchanger shall be of the same
material as the exchanger wall base material. Welding of stainless steel
internal attachments to carbon steel pressure-retaining parts of exchangers in
non-sour service shall be on a case-by-case basis.
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.
Page 43 of 84

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.
SA-105 shall not be used for applications requiring impact testing.
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.
Materials for exchanger exposed to sour service/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 and 02-SAMSS-013. Forged piping
components do not require HIC testing. Welded pipes shall meet the
requirements of
01-SAMSS-043.
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.
Page 44 of 84

All raw materials used for exchanger components (tubesheets, tubes, shells,
channels, nozzles, heads, covers, rings, standard flanges, etc.) shall be
procured from approved Saudi Aramco suppliers where applicable.
All heat exchanger flanges shall be procured in accordance with

02-SAMSS-011 requirements from approved Saudi Aramco suppliers.
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.
All heat exchanger forged and wrought fittings shall be procured in

accordance with 02-SAMSS-005 requirements from approved Saudi Aramco
suppliers.
The inclusion content of forgings shall be rated using one of the methods
specified in ASTM E45.
8.2 Requirements for Carbon Steel in Sour Service
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
The materials of construction for spiral wound gaskets shall be as follows

with flexible filler suitable for the intended service:
Service Winding Filler Guiding Ring(s)
Design Temperature Type 304 or 316 Solid outer;
Graphite
from -100°C to 0°C Stainless Steel Type 304 or
Page 45 of 84

Service Winding Filler Guiding Ring(s)

(-148°F to 32°F) (SS) 316 (SS)
Design Temperature
Type 304 or Solid outer;
above 0°C to 425°C Graphite
316 SS Carbon Steel (CS)
(32°F to 797°F)
Design Temperature Solid inner and
Type 321 or
above 425°C Vermiculite outer; Type 304
347 SS
(797°F) or 316 SS
Per Per Solid inner;
Vacuum (including
Temperature Temperature Type 304 or
due to steam out)
Range Range 316 SS
8.4 Tubes
Bare tubes shall be procured from approved Saudi Aramco suppliers per
applicable tubes' commodities.
8.7 Add new section
All forgings shall be forged as close as practicable to finished shape and size
to develop metal flow in a direction most favorable for resisting the stresses
encountered in service.
8.8 Add new section
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 Section 8.1.20 of this
specification. Acceptance value is 85 % of values listed in ASME SEC IID,
Table - U for the test temperature.
8.9 Add new section
Special Testing for Steels under Scope of API RP 934-A
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.
Page 46 of 84

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.
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 (Third
Edition, January 2019), paragraph 7.4.2.
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.
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
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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.
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 a screening 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.
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.
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 48 of 84

The phosphorous content of 1 Cr- ½ Mo and 1 ¼ Cr-½ Mo steels shall not

exceed 0.007% in weight.
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.
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.
9 Fabrication
9.1 Shells
9.1.1 Replace second paragraph with
Welds Encroachment
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 Section 9.1.1.4, 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 Section
7.16.3 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 Section 9.1.1.4 of this specification.
NDE per Section 9.1.5 of this specification shall be performed, where the
optimized fabrication layout and/ or process design requirements do not
Page 49 of 84

absolutely allow meeting the spacing requirement in Section 9.1.1.1 of this

specification.
It is prohibited to cover butt welds in wall of exchangers that will undergo

PWHT by structural attachments (with or without reinforcing pads).
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.
Where the optimized fabrication layout and/or process design requirements

do not absolutely allow meeting the spacing requirement in Section 9.1.1.1
of this specification, NDE per Table 2 of this specification shall be
performed.
The beveled edges of weld preparations for carbon steel plates with
thickness 25 mm (1 in) 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.
Plate edge laminations revealed per examination method in Section 9.1.6 of

this specification shall be completely removed and repaired.
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.
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All re-rolling or forming of the shell sections is to be completed prior to

radiography.
Reinforcing/Wear Pads
Reinforcing and wear pads for internal and external welded attachments
shall be sized to meet requirements of Section 7.16.3 of this specification.
Pads shall be a minimum of 10 mm (0.375 in) thick, but shall not exceed the
shell thickness; with all of their corners rounded to a minimum radius of 50
mm (2 in). The distance from the closest edge of any attachment to the
closest edge of the reinforcing pad shall not be less than 50 mm (2 in).
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 Section 9.1.10.1 of this specification shall be
provided.
For exchangers in cyclic service, reinforcing/wear pads are not permitted.

Attachments shall be welded using full penetration groove welds and smooth
contour fillet welds.
Telltale Holes in Reinforcing Pads
DN8 (¼ in NPT) telltale vent holes 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.
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Telltale holes shall be located at the lowest position accessible for inspection
with center of the hole 25 mm (1 in) 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 (1 in) from the closest edge of the pad.
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.
Segments of split reinforcing pad shall be welded together without using a

backing strip.
9.3 Connection Junctions
Replace section with
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.
Minimum inside corner radius of integrally reinforced contour nozzles and

manways shall be 13 mm (0.5 in).
9.5 Welding
All welding shall be in accordance with the requirements of SAES-W-010

and SAES-W-016.
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All welded joints of category A, B, C, and D shall be complete fusion full

penetration welds.
Backing strips that remain in place on the inside of a component after

completion of welding shall not be used.
Dissimilar metal welds (DMW) are not permitted in sour service as defined
in this specification and all other requirements of SAES-W-010.
When postweld heat treatment is required, simulated post weld heat

treatment of production test plates and weld procedure qualification shall be
subjected to a minimum two additional postweld heat treatment cycle.
Complete weld procedure qualification mechanical testing shall be

performed both after the first heat treatment cycle and all additional cycles.
9.5.25 Replace item a) and b) with

a) base materials:
1. carbon steel material, an increase in CE more than the value qualified
in the procedure qualification record, when any of the following
conditions apply:
i. subject to sour service regardless of their wall thickness;
ii. the wall thickness greater than 38 mm (1.5 in), regardless of the
service;
iii. subject to PWHT due to service, regardless of their wall
thickness;
2. from type 22Cr duplex to type 25Cr duplex or vice versa.
b) welding consumables:
1. consumable brand name when impact testing is required;
2. for FCAW-gas shielded, any increase of size in consumable than the
qualification;
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3. for SAW, whenever the welding flux is changed from one

consumable brand name to another.
Preheating shall be in accordance with the requirements of SAES-W-010.
The preheat temperature shall be in accordance with the requirements of

SAES-W-010 and SAES-W-016.
The chemical composition of welding consumables and as-welded deposits

during procedure qualification shall meet the requirements of API RP 582.
The maximum interpass temperature shall not exceed the values listed in
below table.
Interpass Temperature Limits
Material Maximum interpass temperature

austenitic stainless steel and nickel
175 °C (350 °F)
alloy materials
22Cr Duplex 150 °C (300 °F)
25Cr Duplex 100 °C (212 °F)
For austenitic stainless steel, 22Cr and 25Cr duplex material, the maximum
variation in heat input shall be ± 10 %.
Where a split-reinforcing pad is required, the weld joining the pad sections
shall be oriented with the circumferential direction of the shell. Welding the
pad sections together shall be done without using a backing strip.
Page 54 of 84

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.
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.
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 Section 8.1.20 of this
specification).
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.
Weld overlay per Section 9.5.42 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).
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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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.
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
Section 8.1.20 (a) and Section 8.1.20 (b) of this specification.
Production Test Coupons, if required as per Code, shall be subject after

welding to the production heat treatment time per Section 8.1.20 (a) and
Section 8.1.20 (b) of this specification.
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
Section 8.1.20 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.
In addition to the requirement of Section 9.5.46 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.
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

1) The following tubes shall be stress relief heat treated after cold forming
and bending:
Page 56 of 84

a) U bends, including 150 mm (6 in) 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.
b) U bends, including 150 mm (6 in) of straight portions measured
from the tangent lines of all stabilized or low carbon stainless
steels or Nickel base alloys.
For quenched and tempered or normalized and tempered carbon steel

materials, the post weld heat treatment holding temperature shall be at least
25 °C (45 °F) below the original tempering temperature of the base metal.
Postweld heat treatment (PWHT) shall be done when required by the

applicable Code or when specified on the data sheet.
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 sour service as defined in this specification.

Code exemptions for postweld heat treatment of P4 and P5 materials are not
permitted for applications involving the following:
a) Sour service
b) Hydrogen services
c) Materials exceeding 2.5% nominal chromium content
Page 57 of 84

The maximum postweld 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 (1202 °F) maximum for carbon steel
• 700°C (1292 °F) 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.
Final postweld heat treatment (PWHT) shall follow all welding and repairs
but shall be performed prior to any hydrotest or other load test.
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"
Postweld heat treatment (PWHT) shall be in accordance with the

requirements of SAES-W-010 and this specification.
The holding temperature for service related postweld heat treatment shall be
as per SAES-W-010.

It is the responsibility of the Exchanger Manufacturer to ensure structural
stability of the exchanger that will undergo PWHT, considering but not
limited to the following:
a) Dead weight at intended PWHT soaking temperature.
b) Temperature gradients in equipment wall due to the intended PWHT
procedure.
Page 58 of 84

c) Mechanical restraints that may prevent the equipment from free

movement (expansion/contraction) during PWHT.
9.7 Dimensional Tolerances
Fabrication tolerances shall be in accordance with the more stringent of the

applicable Code, TEMA, and PIP document VEFV1100.
Use of fitness-for-service assessment methodology according to

API 579-1/ASME FFS-1 or design by analysis according to
ASME SEC VIII D2, Part 5 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

Gasket seating surfaces shall comply with the following:
1) For spiral wound gaskets, 3.2 to 6.3 micro-meter (125 to 250 micro-
inch) AARH, in all services, except hydrogen.
2) For spiral wound gaskets in hydrogen service, 3.2 to 3.8 micro-meter
(125 to 150 micro-inch) AARH.
3) The side-walls of ring joint flanges in all services, 1.6 micro-meter (63
micro-inch) AARH.
4) For non-metallic gaskets, 6.3 to 12.5 micro-meter (250 to 500 micro-
inch) AARH.
9.9 Tube Holes
Tubesheet tube hole diameters and tolerances shall be special close fit when
tube bundle vibration is suspected or when exchanger is in cyclic service.
Tube expanding procedures shall incorporate stops to prevent tube

expansion past tubesheet faces.
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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.
The Exchanger Manufacturer shall submit a mock-up sample of the tube to

tubesheet weld when tubes are strength welded to the tubesheet. This sample
shall contain a minimum of four tubes and shall be prepared using the same
materials and fabrication procedures (including heat treatment) as are to be
used in actual production. Approval from the Saudi Aramco Inspector is
required prior to start of production. No need to repeat the test if similar joint
design was done in the past 6-months.
Forming and Heat Treatment
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 Section
8.1.20 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.
Page 60 of 84

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.
None
Less than or equal to 3 (Exception: PWHT per the applicable Code
shall be performed for cold spun heads)
Low Alloy Steels P-3,
P-4, P-5, P-9A, & P9B 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:
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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
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
Bolt tensioning device shall be used for bolting up flanged connections with
stud bolts of diameter 38 mm (1.5 in) and above. Bolt up of flanges,
Page 62 of 84

irrespective of bolt diameter shall be according to ASME PCC-1

requirements.
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.
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.
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.
All hot forming procedures require simulated production test coupons per
Section 9.5.48 of this specification.
10 Inspection and Testing
10.1 Quality Control
All required Nondestructive Examination (NDE) shall be performed in

accordance with inspection procedures that are in complete compliance with
ASME SEC V and this specification. This written procedure shall address
each inspection method and technique used including acceptance criteria.
The procedure(s) shall be submitted to Saudi Aramco Inspector.
Page 63 of 84

Positive material identification shall be carried out at the exchanger

manufacturer’s shop in accordance with SAES-A-206.
The extent of positive material identification shall be in accordance with

SAES-A-206.
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.
For 22Cr duplex and 25Cr super duplex stainless steels, corrosion testing,
impact testing, ferrite measurement and microstructure examination shall be
in accordance to SAES-W-016.
The responsibility for examination rests with the Exchangers Manufacturer

in accordance with the applicable Code and the requirements of this
specification.
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 and 175-323500.
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.
Page 64 of 84

Use of fitness-for-service assessment methodology to qualify exchanger

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

applicable Code shall be performed on the surfaces of hot formed and reheat
treated parts.
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.
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.
All necessary safety precautions shall be taken for each examination method.
Surface irregularities, including weld reinforcement, inhibiting accurate

interpretation of the specified method of nondestructive examination shall be
ground smooth.
Examination of all welds shall include a band of base metal at least one inch
wide on each side of the weld.
Page 65 of 84

The Saudi Aramco Inspector shall have free access to the work at all times.
Saudi Aramco shall have the right to inspect the fabrication at any stage and
to reject material or workmanship, which does not conform to the specified
requirements.
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.
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.
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.
The Exchanger Manufacturer shall provide the Saudi Aramco Inspector all
reasonable facilities to satisfy him that the work is being performed as
specified.
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.
Page 66 of 84

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.
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.
Radiographic Examination
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.
Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as

individual rounded indications. Clustered or aligned tungsten inclusions
shall be removed and repaired.

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).
Page 67 of 84

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

D shall be according to Table 1 of this specification.
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.
Plates with thickness more than 12.5 mm (0.5 in) and less than 50 mm
(2 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.

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.
All forgings shall be 100% ultrasonically examined by the forging facility

prior to machining (i.e. at rough forging stage) and 100% ultrasonically
examined by the equipment manufacturer for all accessible areas of the
finished forging.Ultrasonic examination shall be in accordance with 02-
Page 68 of 84

SAMSS-011 and shall include A788 S20 for Straight-Beam Examination

and A508 requirements for Angle-Beam Examination.
100% conventional ultrasonic examination is required for all full penetration

welds in exchanger supports. Alternatively, 100% radiography examination
shall be used.
Detection method and acceptance criteria of reheat transverse cracking in

submerged arc welds in 2 ¼ Cr-1 Mo- ¼ V and
3 Cr-1 Mo- ¼ V steels shall be according to API RP 934-A, Annex A.
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.
Magnetic Particle Examination
Permanent magnetic yokes are not permitted.
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 sour service.

Except for non-Ferro magnetic materials, magnetic particle examination
using an AC yoke is required for the following welds:
Page 69 of 84

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).
All edges prepared for welding and all openings in ferromagnetic exchangers
shall be 100% magnetic particle examined in accordance with the applicable
Code.
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.)
Liquid Penetrant Examination

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.
Page 70 of 84

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).
All edges prepared for welding and all openings in non-Ferro magnetic
exchangers shall be 100% liquid penetrant examined in accordance with the
applicable Code.
Weld hardness testing shall be in accordance with the requirements of

SAES-W-010.
10.2 Pressure Testing
The testing fluid shall be in accordiance with SAES-A-007 and the

hydrostatic test pressure shall be held for a minimum of one hour per 25 mm
(1 in) of exchanger shell/channel thickness and in no case less than one hour.
The water quality specification used for pressure testing shall be in

accordiance with SAES-A-007.
10.2.14 Add to section after first sentence
For 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 95% of the minimum specified yield strength of the
exchanger material.
Hydrostatic pressure testing shall be performed with the same gaskets and
bolting as those required in service for all body flanges, custom designed
flanges, permanently blinded connections and as specified on the data sheet.
These gaskets may be used as service gaskets if the bolted joint is not
disassembled after the completion of hydrostatic pressure testing.
Page 71 of 84

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 (full-hydrostatic, full-pneumatic or
hydrostatic-pneumatic) in accordance with the applicable Code, SAES-A-
007 and this specification.
Pneumatic testing for exchangers to be pressure tested at final erection site

within Saudi Aramco facility requires the approval of the Manager of the
Saudi Aramco Inspection Department.
Pressure testing for acceptance of the exchanger shall not be made prior to
the final postweld heat treatment.
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.
The Exchanger Manufacturer shall furnish all test materials and facilities,
including blinds, bolting, and gaskets.

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.
Page 72 of 84

After completion of pressure 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.
The inspection representative must witness and verify the equipment

complete water draining and moisture draying.
Pickling and passivation could be applied before the hydrotest of the

exchanger
For other than differential-pressure design exchangers, test pressure for the
shell side and the tube side shall be as per the applicable code.
For differential-pressure design exchangers, test pressure shall be as per the

applicable code.
Horizontal exchangers are to be tested while resting on their permanent

support saddles without additional supports or cribbing.
Telltale holes in external attachments must not be plugged during the

exchanger pressure test. Telltale holes in internal attachments must be seal
welded prior to pressure testing of the exchanger.
The minimum test pressure of the exchanger shall be:
10.2.26.1 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:
Page 73 of 84

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.
10.2.26.2 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)
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
Page 74 of 84

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.
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 Section 7.17.4 of this specification are met.
b) Sizing of relief valve(s) shall be according to API RP520, Part I.
c) The relief valve(s) shall be tested, dated, and tagged within one week
prior to the pressure test.
d) The pressure test relief valve shall be accompanied with a calibration
certificate that includes the cold differential test pressure (CDTP), test
date and the spring range. The CDTP shall be within the spring range.
10.3 Nameplates and Stampings
10.3.1 Replace first sentence with
The nameplates shall be 3 mm (0.12 in) minimum thickness and

manufactured from Type 304 stainless steel or Monel and continuously
welded to the mounting bracket according to PIP VEFV1100.
Each exchanger shall be identified by a nameplate and marked with the

information required by the applicable Code and the requirements of this
specification.
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.
Page 75 of 84

Exchangers shall be Code stamped for all services in accordance with the
applicable Code. National Board registration is not required.
The mounting bracket shall be continuously seal-welded and positioned such

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

After completion of repairs required by the applicable Code, the following
shall be repeated:
a) Heat treatment of the repaired section if it has been heat-treated prior
to the repairs.
b) All nondestructive examinations (radiography, magnetic particle, dye-
penetrant, etc.) performed on the repaired section prior to the repairs.
c) A weld map of all repairs shall be made a part of the final exchanger
documentation. The weld map shall include the nondestructive
examination procedure and results, the welding procedure
specifications and stress relief charts.
11 Preparation for Shipment
11.1 Protection
Page 76 of 84

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.
All threaded connections shall be protected with threaded plugs or caps of

compatible materials and with the use of an appropriate lubricant containing
a volatile corrosion inhibitor (VCI). Polytetrafluoroethylene (PTFE) tape
shall not be used.
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.
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.
Telltale holes in reinforcing pads shall be protected with wooden plugs or

packed with rust preventative grease.
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 operating temperatures.
Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury,

chlorine, or any other halogens.
Page 77 of 84

Export packaging marking and shipping shall be in accordance with the

purchase order.
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.
Internal & External Protection
For carbon steel and stainless steel fully assembled heat exchangers, spray
interior surfaces (both shell and tube side) with a volatile corrosion inhibitor
(VCI). The dosage rates shall be as per VCI manufacturer recommendations.
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, compatible VCI product shall be
specified. Exchangers must be sealed vapor tight using metallic covers for
the inhibitor to be effective.
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.
Solid stainless steel exchangers which are to be shipped via 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. 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. Equipment that is an emergency
spare for long term storage shall be 100% wrapped and sealed in 10-mil
thick anticorrosion polyethylene film containing vapor phase corrosion
Page 78 of 84

inhibitor. Stainless steel exchangers shipped by ocean freight must be

protected from sea spray, rain, etc.
Tube bundles shipped separately from shells must be adequately protected

and supported to prevent mechanical and corrosion damage. Tube internals
shall be protected using a volatile corrosion inhibitor (VCI) as detailed in
Section 11.1.19.1 of this specification. External surfaces shall be protected
by spraying with a volatile corrosion inhibitor (VCI). 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
volatile corrosion inhibitor (VCI). Equipment that is an emergency spare for
long term storage shall be wrapped in 10-mil thick anticorrosion
polyethylene film containing vapor phase corrosion inhibitor.
Use of Nitrogen blanketing with temporary rust preventive substance such as

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.

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.
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.
Page 79 of 84

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.
Exchangers that have permanent internal coatings, the Exchanger

Manufacturer shall contact the Saudi Aramco Engineer for any corrosion
protection required.
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 the Saudi Aramco Engineer.
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.
Bolt heads shall also be protected with a rust preventative compound to

prevent corrosion during shipment, storage, and construction.
Spare bolts shall be protected with a rust preventative compound to prevent

corrosion during shipment, storage, and construction.
12 Supplemental Requirements
General
Exchangers shall be manufactured in accordance with the requirements of

IOGP S-614 and this specification.
Page 80 of 84

Revision Summary
21 June 2020 Major revision.
21 July 2019 Editorial revision to remove reference.
29 April 2019 Editorial revision to confirm the contents.
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.
1 December 2013 Major revision.
23 June 2010 Editorial revision to add paragraph 8.1.11.
15 August 2009 Editorial revision to replace cancelled SAES-A-301 with NACE MR0175/ISO 15156.
5 April 2008 Editorial revision.
20 November 2007 Major revision.
Page 81 of 84

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)
C 100% (3) See Notes (2) & (3) 100% (6)
D See Note (4) See Note (4) See Note (4)
Notes:
(1) 100% RT is required for exchangers under any of the following services or design conditions:
• Weld joints requiring full radiography per the applicable code.
• Lethal services.
• Hydrogen services.
• Cyclic services.
• Unfired steam boilers with design pressure exceeding 350 kPa (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 Section 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 Section 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 Section 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 (0.25 in) 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 Section 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 82 of 84

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
weld in exchanger wall.
center 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. Section 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
weld in exchanger wall.
center of the opening at mid-length.
4. Reinforced nozzle or manway with N/A
the reinforcing pad encroaching on (Such detail is not permitted per
the butt weld in exchanger wall. Section 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. Section 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
attachment weld plus a minimum of
reinforcing pad, encroaching on Same as when PWHT is required.
50 mm (2 in) on either side. Minimum
a butt weld in exchanger wall.
length of the radiographed weld is
300 mm (12 in).
equal to the projection of the reinforcing
(b) Reinforced structural attachment, pad attachment weld plus a minimum of
N/A
50 mm (2 in) on either side. Minimum
with the reinforcing pad covering (See prohibition in Section 9.1.1.3 of
length of the radiographed weld is 300
a butt weld in exchanger wall. this specification)
mm (12 in).
(c) Structural attachment, without a equal to the projection of the structural
N/A
attachment weld plus a minimum of 50
reinforcing pad, covering a butt (See prohibition in Section 9.1.1.3 of
mm (2 in) on either side. Minimum length
weld in exchanger wall. this specification)
of the radiographed weld is 300 mm (12
in).
(d) Reinforced structural attachment, length equal to the projection of the
with the reinforcing pad reinforcing pad attachment weld plus
Same as when PWHT is required.
encroaching on a butt weld in a minimum of 50 mm (2 in) on either
exchanger wall. side. Minimum length of the
radiographed weld is 300 mm (12 in).
MP or LP on the entire outermost fillet
7. Structural attachment (with or without weld of each attachment on the
reinforcing pads), including vacuum exchanger side per Section 10.1.52
Same as when PWHT is required.
stiffeners and tray support rings, or Section 10.1.53, as applicable,
encroaching: after completion of all welds in all
attachments.
Page 83 of 84

Case PWHT is required (Notes 1, 2) PWHT is not required

(a) Another structural attachment
(with or without reinforcing
pads).
(b) Reinforced nozzle or manway.
(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 Section 10.1.33 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 84 of 84

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What are the main requirements for heat exchanger design and fabrication?

What are the main requirements for heat exchanger design and fabrication?

What nondestructive examination methods are required for heat exchangers?

What nondestructive examination methods are required for heat exchangers?

Materials System Specification

32-SAMSS-007 21 June 2020

Previous Issue: 21 July 2019 Next Planned Update: 21 June 2025

©Saudi Aramco 2020. All rights reserved.

Saudi Aramco: Company General Use

Paragraph Number Change Type

1.2 1.2 Modification Paragraph modified

1.3 1.3 Modification Paragraph modified

1.5 1.5 Modification Paragraph modified

NA 1.8 Addition Paragraph added

2.1 2.1 Deletion SAES-L-133

2.2 2.2 Addition IOGP S-614

2.2 2.2 Deletion API STD 660, ASME SA-388

HIC Environment definition

NA 3.30 Addition Sour Service definition added

Special Forgings definition

NA 4.14 Addition New paragraph added

NA 4.15 Addition New paragraph added

NA 5.7 Addition New paragraph added

Saudi Aramco: Company General Use

Aligned with IOGP S-614 section

7.1 7.1 Addition “and Design Pressure”

NA 7.1.3 Addition New paragraph added

7.5.2.6 7.5.2.6 Modification Paragraph modified

NA 7.5.2.7 Addition New paragraph added

NA 7.5.2.8 Addition New paragraph added

Aligned with IOGP S-614 section

7.6.3 7.6.3 Modification Dual units added

7.6.4 7.6.4 Modification Paragraph modified

Reference to Saudi Aramco

NA 7.6.11 Addition New paragraph added

NA 7.6.13 Addition New paragraph added

Reference to Saudi Aramco

Saudi Aramco: Company General Use

7.6.16.2 NA Deletion Covered in paragraph 7.6.15

7.6.16.3 NA Deletion Aligned with API 660 section 9.3

Dual units added

7.11.5 NA Deletion Aligned with TEMA section G-7.2

NA 7.12.1 Addition New paragraph added

Dual units added

8.3.3 8.3.3 Addition Dual units added

Saudi Aramco: Company General Use

NA 9.5.4 Addition New paragraph added

NA 9.5.18 Addition New paragraph added

NA 9.5.19 Addition New paragraph added

NA 9.5.25 Addition New paragraph added

NA 9.5.28 Addition New paragraph added

NA 9.5.29 Addition New paragraph added

NA 9.5.32 Addition New paragraph added

NA 9.5.35 Addition New paragraph added

NA 9.5.36 Addition New paragraph added

Aligned with IOGP S-614 section

NA 9.6.16 Addition New paragraph added

Saudi Aramco: Company General Use

9.7.6 9.7.6 Modification Paragraph modified