32 Samss 028

Materials System Specification
32-SAMSS-028 6 September 2008

Manufacture of Double Pipe Heat Exchangers
Heat Transfer Equipment Standards Committee Members
Anizi, Salamah Salem, Chairman
Bagawi, Jamil Jarallah, Vice Chairman
Fernandez, Gabriel Thomas
Harbi, Abdullah Mohammed Saeed
Gahtani, Moraya Saif
Rumaih, Abdullah Mohammad
Dossary, Musfir Abdullah
Mansour, Khalid Mohammad
Guthami, Mohammed Mohsen
Anezi, Mohammed Ali
Hamam, Ibrahim Hassan
Naffaa, Mahmoud Youniss
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Definitions....................................................... 5
5 Responsibilities.............................................. 6
6 Proposals....................................................... 6
7 Thermal Design.............................................. 7
8 Mechanical Design......................................... 7
9 Nozzles......................................................... 11
10 Supports....................................................... 13
11 Clips and Attachments................................. 13
12 Materials....................................................... 13
13 Fabrication.................................................... 15
14 Nondestructive Testing................................. 16
15 Heat Treatment............................................ 19
16 Inspection and Pressure Tests..................... 20
17 Nameplates and Stampings......................... 23
18 Painting........................................................ 24
19 Shipping Requirements................................ 24
20 Drawings, Calculations and Data................. 26
Previous Issue: 30 March 2005 Next Planned Update: 6 September 2013

Page 1 of 28
Primary contact: Anizi, Salamah Salem on 966-3-8746139
Copyright©Saudi Aramco 2008. All rights reserved.

Document Responsibility: Heat Transfer Equipment 32-SAMSS-028
Issue Date: 6 September 2008
Next Planned Update: 6 September 2013 Manufacture of Double Pipe Heat Exchangers
1 Scope
1.1 This specification covers the minimum mandatory requirements for the
mechanical design, materials, fabrication, inspection and testing of new double
pipe and multitube hairpin heat exchangers (hereinafter referred to as
exchangers). It does not cover exchangers that undergo repairs or alterations.
1.2 The requirements in this specification are in addition to and supplement the
requirements of the ASME Boiler and Pressure Vessel Code.
1.3 Where a licensor specification requirement is more stringent than that of this
specification, this licensor specific requirement shall govern.
2 Conflicts and Deviations
2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.
3 References
Materials or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedure

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

SAES-A-007 Hydrostatic Testing Fluids and Lay up Procedures
SAES-A-206 Positive Material Identification
SAES-H-001 Selection Requirement for Industrial Coating
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SAES-H-100 Painting Requirements for Industrial Facilities

SAES-H-101 Approved Protective Coating Systems
SAES-H-101V Approved Saudi Aramco Data Sheets - Paints and
Coatings
SAES-W-010 Welding Requirements for Pressure Vessels
Saudi Aramco Materials System Specification

01-SAMSS-016 Qualification of Pipeline and Pressure Vessel
Steels for Resistance to Hydrogen-Induced
Cracking
Saudi Aramco Inspection Requirements

Form 175-323100 Manufacture of Heat Exchangers
Saudi Aramco Forms and Data Sheet

Form 2714-ENG Data Sheet
Form NMR-7922-1 Non-material Requirements for Shell and Double-
Pipe Heat Exchangers
Saudi Aramco Standard Drawing

AE-036250 Ferrules for 0.75 inch Outside Diameter Tubes
(Sheets 1 & 2)
3.2 Industry Codes and Standards
American Petroleum Institute

API STD 660 Shell-and-Tube Heat Exchangers for General
Refinery Services
API PUBL 941 Steels for Hydrogen Service at Elevated
Temperatures and Pressures in Petroleum
Refineries and Petrochemical Plants
API RP 945 Avoiding Environmental Cracking in Amine Units
American Society of Civil Engineers

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

ASME SEC II Material Specifications Parts A, B and D
Page 3 of 28
ASME SEC V Non-destructive Examination

ASME SEC VIII D1 Rules for Construction of Pressure Vessels
ASME SEC VIII D2 Rules for Construction of Pressure Vessels,
Alternative Rules
ASME B2.1 National Pipe Threads
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.11 Forged Steel Fittings, Socket Welding and
Threaded
ASME SA-688 Welded Austenitic Stainless Steel Feedwater
Heater Tubes
American Society for Nondestructive Testing

ASNT CP-189 Standard for Qualification and Certification of
Nondestructive Testing Personnel
ASNT SNT-TC-1A Recommended Practice for Qualification and
Certification of Nondestructive Testing
Personnel
International Organization for Standardization

NACE MR0175/ Petroleum and Natural Gas Industries Materials
ISO 15156 for Use in H2S-Containing Environments in Oil
and Gas Production
U.S. Military Standards and Federal Specifications

MIL-C-16173 Corrosion Preventive Compound, Solvent
Cutback, Cold-Application
National Association of Corrosion Engineers

NACE RP0472 Methods of Control to Prevent In-Service
Cracking of Carbon Steel Welds in P-1
Materials in Corrosive Petrochemical Refining
Environments
Tubular Exchanger Manufacturers Association
Welding Research Council

WRC 107 Welding Research Council Bulletin: Local
Stresses in Spherical and Cylindrical Shells
Due to External Loadings
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4 Definitions
AARH: Average arithmetic roughness height, which is a measure of surface texture.
Cyclic Service: Services that require fatigue analysis per AD-160 of ASME SEC VIII
D2. This applies to Division 1 and Division 2 of ASME SEC VIII.
Design Engineer: The Engineering Company responsible for specifying on the data
sheet the thermal and mechanical design requirements for heat exchangers.
Double Pipe Exchanger: Consists of a single tube enclosed within a U-shaped pipe
shell.
Exchanger Manufacturer: The company responsible for the manufacture of new

exchangers in accordance with this specification.
Hot Forming: Forming operations carried out at an elevated temperature such that re-
crystallization occurs simultaneously with deformation.
Hydrogen Service: Process streams containing relatively pure hydrogen and

component streams containing hydrogen with a partial pressure of 350 kPa abs (50 psia)
and higher.
Lethal Services: Process streams containing a concentration of hydrogen sulfide in

excess of 20% by volume shall be considered as lethal service. Other services as
determined by the project design may also be designated as lethal services.
Low-Alloy Steels: Steels with nominal chromium contents of 5% chrome and/or

nominal nickel content up to 3%.
Minimum Thickness: Thickness required for withstanding all primary loads,

excluding allowance for corrosion.
Multitube Exchanger: Consists of multitubes within a U shaped shell.
MDMT: Minimum design metal temperature, determined by the Design Engineer.
Nominal Thickness: Thickness required for withstanding all primary loads, including
allowance for corrosion.
Saudi Aramco Engineer: The Supervisor of the Process Equipment Unit, Consulting
Services Department, Dhahran.
Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco
Inspection Department to inspect exchangers to the requirements of this specification.
Utility Services: Water, air and nitrogen services.
Page 5 of 28
Wet Sour Services: Following process streams containing water and hydrogen sulfide:
1) Sour water with a hydrogen sulfide concentration above 2 milligrams per liter.
2) Crude containing hydrogen sulfide when transported or processed prior to
completion of stabilization.
3) Gas or hydrocarbon condensate containing hydrogen sulfide when transported or
processed prior to completion of sweetening or hydrogen sulfide stripping.
4) Multiphase services when the partial pressure of hydrogen sulfide is above
0.34 kPa abs (0.05 psia) in the gas phase or a concentration of hydrogen sulfide
above 2 milligrams per liter in the water phase.
Wet Sour HIC Services: All of the above wet Sour Services where the H2S
concentration in the water phase is above 50 milligrams per liter.
Exception:
Lean and rich DGA services, other lean amine services, and caustic services are not
included.
5 Responsibilities
5.1 The Design Engineer is responsible for specifying the thermal and mechanical
design requirements and completing the Saudi Aramco data sheet in accordance
with this specification. The Design Engineer must also provide out the thermal
design calculations.
5.2 The Exchanger Manufacturer is responsible for the thermal design (rating) and
verification of the Design Engineer's thermal design, if applicable. The
Exchanger Manufacturer is also responsible for the manufacture of exchangers,
which includes the complete mechanical design, Code and structural
calculations, supply of all materials, fabrication, nondestructive examination,
inspection, testing, surface preparation, and preparation for shipment, in
accordance with the completed data sheet and the requirements of this
specification.
6 Proposals
6.1 Exchanger Manufacturer's proposal shall be based on details for individual

exchangers as outlined on the data sheet. A completed data sheet shall be
submitted for each exchanger quoted.
6.2 The Exchanger Manufacturer may offer an alternative design, but must quote on
the base inquiry documents.
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6.3 The proposal shall include a detailed description of any exception to the
requirements of this specification.
7 Thermal Design
7.1 The size of each exchanger unit, if specified on the data sheet, must be verified
by the Exchanger Manufacturer at time of proposal.
7.2 All data represented by the letter M on the data sheet is the responsibility of the
Exchanger Manufacturer.
8 Mechanical Design
8.1 General
8.1.1 All exchangers shall be mechanically designed in accordance with the

rules of ASME SEC VIII D1, (hereinafter referred to as the Code), and
the requirements of this specification.
8.1.2 The edition of the Code to which exchangers are to be manufactured,

shall be in accordance with the data sheet.
8.1.3 Should the Exchanger Manufacturer have any part of a stress analysis
executed by a third party, the Exchanger Manufacturer shall advise the
Saudi Aramco Engineer.
8.1.4 No proof testing shall be permitted unless specifically approved by the

Saudi Aramco Engineer.
8.1.5 Application of ASME Code Cases to the manufacture of exchangers

requires approval of the Saudi Aramco Engineer.
8.1.6 Exchangers shall be designed to withstand the combined stresses of all

loads in accordance with the Code, and this specification.
8.2 Design Pressure
8.2.1 The value of design pressure(s) shall be in accordance with the data
sheet.
8.2.2 The Design Engineer shall specify on the data sheet the external design
pressure and corresponding temperature.
8.2.3 For exchangers subjected to steam out, the Design Engineer shall
specify on the data sheet the external design pressure and
corresponding temperature.
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8.3 Maximum Allowable Working Pressure
8.3.1 The Exchanger Manufacturer shall calculate the maximum allowable

working pressure (MAWP) acting on both sides of the exchanger, in
the hot and corroded condition in accordance with the applicable Code.
8.3.2 The calculations shall be based on the nominal as-built thicknesses

excluding thicknesses required for corrosion. The MAWP of an
exchanger shall not be limited by flange ratings.
8.4 Design Temperature
8.4.1 The value of the design temperature(s) shall be in accordance with the
data sheet.
8.4.2 The design temperature of shell to tube closures shall be the higher of
the shell-side or tube-side design temperatures.
8.4.3 The design temperature of flanges shall be the higher of the shell-side
or tube-side design temperatures.
8.5 Minimum Design Metal Temperature
8.5.1 The value of the minimum design metal temperature (MDMT) shall be
as specified on the data sheet.
8.5.2 The MDMT shall be used to determine the requirements for impact
testing in accordance with this specification.
8.6 Joint Efficiency
8.6.1 The joint efficiency shall be specified on the data sheet.
8.6.2 A joint efficiency of 85% or higher shall be used for the design of all
pressure containing components of ASME SEC VIII D1 exchangers.
8.7 Corrosion Allowances
The amount of corrosion allowance shall be as specified on the data sheet.
8.8 Loads
8.8.1 Wind and Earthquake Loads

1) The Exchanger Manufacturer shall calculate the static effects of
loads due to wind and the effects due to earthquake loads acting
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on an exchanger in the operating position in accordance with the

2) The wind speed, earthquake zone, and soil coefficient
corresponding to the site location shall be as specified on the data
sheet.
3) Exchangers shall be designed for wind and earthquake loads in
accordance with ASCE 7.
4) With reference to ASCE 7, the wind Category Classification to
be used in the calculations of wind loads shall be Category III,
and the Seismic Hazard Exposure Group to be used in
calculations of earthquake loads shall be Group III.
5) Wind pressures shall be assumed to act on the projected surface
area of the exchanger.
8.8.2 Piping, Equipment and External Loads

1) The Exchanger Manufacturer shall ensure that local stresses
imposed on the exchanger due to piping and equipment, lifting,
supports and other external loads do not exceed the allowable in
accordance with the applicable Code. The stress analysis shall be
completed in accordance with the procedures as detailed in WRC
107 or a finite element analysis.
2) Piping and equipment loads imposed on the exchanger shall be as
specified on the data sheet.
8.9 Load Combinations
8.9.1 All components of the exchanger, including their supports, shall be

designed to withstand the combined stresses resulting from the
following:
1) Internal and/or external design pressures
2) All other loads exerted on the component and specified in Section
8.8.
3) All exchanger components shall be designed to withstand a full
hydrostatic test in the erected position. Allowable stresses to be
used shall be in accordance with the Code (90% of yield at test
temperature). However, forces produced due to design, wind or
earthquake loads may be reduced by 40% for this short time field
hydrostatic test.
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8.9.2 Moments or forces acting on the exchanger due to external piping are
to be added to those moments and forces due to other external primary
loads.
8.10 Stress Analysis
Stress analysis shall be carried out as specified on the data sheet.
8.11 Tubes and Tube Bundles
8.11.1 Unless otherwise specified on the data sheet, the tube outside diameters
and tube wall thicknesses shall be in accordance with API STD 660.
8.11.2 The minimum tube outside diameter shall be 19.05 mm (0.75 inch).
8.11.3 Unless otherwise approved by the Saudi Aramco Engineer, the length
of U tubes measured to their tangent lines shall not exceed 6 m.
8.11.4 Where more than one exchanger of identical mechanical design,

pressure rating and materials is required for the same service, tube
bundles shall be inter-changeable.
8.11.5 Tubeside elements shall be removable without cutting.
8.11.6 The inner tube shall be without intermediate weld.
8.11.7 The exchangers with sea water flowing through the tubes shall be fitted
with ferrules (tube end protectors) at the inlet end of the tubes. For
tube materials other than those given in this specification, the
requirement for ferrules shall be confirmed with the Saudi Aramco
Engineer.
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 Saudi Aramco Engineer.
8.12 Closures
8.12.1 Elements shall be designed to be removable through the use of bolted

closure joints.
8.12.2 Packed closures may be used only when the shell side fluid is a utility
service.
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8.13 Interconnecting Piping
Interconnecting piping connecting exchangers in series/parallel arrangements,

for the same exchanger unit, shall be designed and furnished by the Exchanger
Manufacturer.
9 Nozzles
9.1 General
9.1.1 The sizes, ratings (ASME pressure classes), and facings of exchanger
inlet and outlet nozzles shall be as specified on the data sheet.
9.1.2 Flange bolt holes shall straddle the normal horizontal and vertical
centerlines of the exchanger.
9.1.3 Projections measured from the outside of shells to the face of flanges
shall be sized so that studs may be removed from the back of a flange
without interference with insulation.
9.1.4 Flanged connections shall be one of the following types:

1) Forged steel long welding neck
2) Forged steel welding neck flange with seamless pipe, or rolled
plate with 100% radiography. The bores of nozzle flanges shall
match the nozzle neck bore.
3) Studded nozzles and proprietary designs may be offered as
alternatives provided their designs are in accordance with the
Code and with prior approval of the Saudi Aramco Engineer.
4) However, for utility services up to and including 120°C (250°F)
design temperature and 1.7 MPa ga (200 psig) design pressure,
nozzles may be slip-on type flanges with seamless pipe nozzle
necks or rolled plate with 100% radiography.
9.1.5 Threaded or socket-welded connections are prohibited in hydrogen,

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

connections that may be attached to shell or nozzles.
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9.1.6 Threaded connections shall conform to ASME B2.1.
9.2 Reinforcement of Openings
9.2.1 Reinforcement of exchanger openings shall be in accordance with the

applicable Code and this specification.
9.2.2 The thickness of reinforcing pads shall not exceed the shell thickness
of the exchanger.
9.3 Integrally reinforced openings (with no reinforcing pads) shall be provided

under the following services and design conditions:
1) Cyclic services
2) Carbon steel with shell thickness 50 mm and greater
3) Low-alloy steels with shell thickness 25 mm and greater
4) Exchangers with design metal temperatures greater than 425°C
5) Hydrogen service
9.4 Ratings (ASME Pressure Classes) and Facings
9.4.1 The ASME pressure classes and facings shall be as specified on the
data sheet.
9.4.2 Pressure ratings shall be in accordance with ASME B16.5.
9.4.3 Gasket seating surfaces shall comply with the following:

1) For spiral wound gaskets, 125 to 250 AARH, in all services,
except hydrogen
2) For spiral wound gaskets in hydrogen service, 125 to 150 AARH
3) The side-walls of ring joint flanges in all services, 63 AARH
4) For non-metallic gaskets, 250 to 500 AARH
9.4.4 The surface roughness of machined surfaces, other than gasket contact
faces, shall not exceed 500 AARH.
9.5 Weld Attachment Details
9.5.1 All nozzle necks for exchangers in hydrocarbon, hydrogen, caustic,

amine, wet sour, and steam services shall be attached by welding
completely through the total thickness of the exchanger shell, including
any reinforcement.
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9.5.2 Permissible types of nozzle weld-attachments shall be in accordance

with Figure UW-16.1 (c), backing rings are to be removed, (d), (e), (f-
1), (f-2), (f-3), (f-4) and (g).
10 Supports
Exchangers shall be supported by two movable type supports.
11 Clips and Attachments
11.1 All exchangers shall be provided with a grounding lug connection welded to a
support.
11.2 Exchangers with component weight up to and including 27 kg (60 lb.) shall be
provided with at least one lifting lug per component.
11.3 Components in excess of 27 kg (60 lb.) require two lifting lugs per component.
11.4 Shells shall be provided with lifting lugs in suitable locations to permit lifting of
the complete exchanger. The lugs shall be designed such that the lifted parts
hang vertically when suspended from the lugs. Lugs on insulated exchangers
shall be of sufficient standout to clear insulation.
The Exchanger Manufacturer shall supply and install supports required for
fireproofing materials.
12 Materials
12.1 General
12.1.1 All materials required for pressure and non-pressure components shall
be specified on the data sheet in accordance with Table 1, Acceptable
Materials for Carbon and Low-Alloy Steels and the requirements of
this specification.
12.1.2 The Exchanger Manufacturer may propose alternative materials at time

of proposal, but the alternative materials must comply with all the
requirements of the Code and this specification.
12.1.3 Materials other than those listed in Table 1 of this specification shall
not be permitted without the prior approval of the Saudi Aramco
Engineer.
Page 13 of 28
12.1.4 All materials must be clearly identified and provided with Mill Test
Certificates. Lack of adequate identification and certification shall be
cause for rejection.
12.1.5 Suitability of low alloy steels for use for exchangers in hydrogen
services above 205°C (400°F) shall be qualified through chemical
analysis, mechanical testing including but not limited to tensile,
hardness, microhardness, temper embrittlement tests and
nondestructive examinations (ultrasonic, wet fluorescent magnetic
particle, etc.). Materials specifications and tests procedures for base
and weldments materials shall be submitted to Saudi Aramco Engineer
for review and approval prior to ordering the materials from the mill.
12.1.6 All materials, except carbon steels, shall be alloy verified by the
Exchanger Manufacturer in accordance with SAES-A-206.
12.1.7 The use of C-½ Mo steels in hydrogen services is prohibited.
12.1.8 Materials with properties enhanced by heat treatment cycles such as

tempering, intermediate stress relief (ISR) and the final post weld heat
treatment shall be tested to verify that their mechanical properties have
been retained after all heat treatment cycles. These tests shall also
include two additional postweld heat treatment cycles to account for
future repairs or alteration.
12.1.9 HIC Resistant Materials
For exchangers designated for wet sour services HIC (hydrogen

induced cracking) as defined in this specification with design
temperatures between 0°C and 200°C, all plates for shells and heads
shall be made of HIC resistant steel. HIC resistant steel shall be
qualified in accordance with 01-SAMSS-016.
12.2 Impact Testing
12.2.1 The Exchanger Manufacturer shall determine impact testing

requirements of materials for pressure components based on the values
of the minimum design metal temperature (MDMT), unless lower test
temperature is specified on the data sheet.
12.2.2 Baffle plates, bars, tie-rods, spacers, and support plates, are exempt
from impact testing requirements.
12.2.3 Impact testing requirements for materials not listed in Table 1, shall be
obtained from the Saudi Aramco Engineer.
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12.2.4 The minimum acceptable Charpy impact energy values for steels listed
in Table 3 shall be per Table-2 unless larger values are specified on the
data sheet. Materials that are not listed in Table 3 shall be referred to
Saudi Aramco Engineer for classification.
12.2.5 Unless otherwise specified in the design Code, materials of

components, including welding consumables, shall be impact tested, at
the MDMT.
12.2.6 The exemptions of UG-20 (f), CS-66(b)(1) and (3), UCS-68(c), UG-
84(b)(2) and by reference Table UG-84.4 are not permitted for
exchangers within the scope of this specification.
12.2.7 Certified Mill Test Certificates may be used to verify the base
materials impact testing results.
12.3 Gaskets
Gaskets shall be non-asbestos. The materials of construction for spiral wound

gaskets shall be as follows:
1) For exchangers with design temperatures from -100°C to 0°C:
Type 304 or 316 stainless steel (SS) windings with solid Type 304 or 316
stainless steel outer centering rings
2) For exchangers with design temperatures from 1°C to 425°C:
Type 304 or 316 SS windings with solid carbon steel outer centering rings.
3) For exchangers with design temperatures above 425°C:
Type 321 or 347 SS windings with solid; Type 304 or 316 outer centering
rings.
4) For exchangers in vacuum service, inner ring shall be either Type 304 or
316 SS.
13 Fabrication
13.1 General
13.1.1 Welds attaching nozzles and their reinforcement pads and other
attachments to pressure components shall not be closer than 20 mm
from any pressure retaining welds.
13.1.2 All nozzles shall be ground flush to the inside curvature of the shell
and inside diameters shall be radiused smooth.
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13.1.3 Where a split reinforcing pad is required, the weld joining the pad
sections shall be oriented with the circumferential direction of the
shell. Tapped tell-tale holes 0.25" NPT shall be provided as follows:
1) One hole in all single piece reinforcing pads
2) Where a pad is split, each segment shall have at least one tapped
hole.
13.1.4 All internal and external welded attachment pads shall have their
corners rounded to a minimum radius of 50 mm radius and shall be
fully seal welded.
13.1.5 All external non-pressure attachments shall be vented through a 0.25"

NPT telltale hole.
13.2 Welding
All welding shall be in accordance with the requirements of SAES-W-010.
14 Nondestructive Testing
14.1 General
14.1.1 All Nondestructive Testing (NDT) shall be performed in accordance

with the Exchanger Manufacturer's written procedure prepared in
accordance with ASME SEC V with the scope of NDT and
acceptance/rejection criteria as defined by the referencing Code section
and this specification.
14.1.2 All NDT shall be performed by personnel certified in accordance with

the Exchanger Manufacturer's written practice prepared in accordance
with ASNT SNT-TC-1A, or at the option of the Exchanger
Manufacturer ASNT CP-189. Other schemes of personnel certification
shall be at the sole discretion and approval of the Saudi Aramco
Inspector. Personnel responsible for interpretation of NDT results
shall be certified by the Saudi Aramco Inspection Department.
14.1.3 All NDT on exchangers which are to be postweld heat treated shall be
made after postweld heat treatment.
14.1.4 All pressure and non-pressure welds shall be visually inspected where
accessible. All segments of longitudinal, circumferential or built-up
head pressure weld seams covered or rendered inaccessible by
internals, lifting lugs or other attachments shall be fully radiographed
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the entire affected length plus 10 inches either side prior to installation
of the attachment.
14.2 Radiographic Testing
14.2.1 Joint efficiencies shall be in accordance with the data sheet.
14.2.2 100% radiography is required for exchangers for the following services
and design conditions:
1) Lethal services
2) Hydrogen services
3) Cyclic services
4) Weld joints where any of the pressure retaining materials requires
impact testing per the applicable Code or this specification.
5) Exchanger weld joints requiring full radiography per the
applicable Code (see UW-11 for Division 1 exchangers and
AF-220 for Division 2 exchangers).
14.2.3 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.
14.2.4 Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as

individual rounded indications. Clustered or aligned tungsten
inclusions shall be removed and repaired.
14.2.5 Radiographic film interpretation shall be done by personnel certified in

accordance with ASNT CP-189 to ASNT Level II Film Interpreter or
approved equivalent by the Saudi Aramco Inspection Department.
14.2.6 Where it is not possible to meet the spacing requirement in paragraph

13.1.1 of this specification such that a nozzle or an attachment weld of
a reinforcing pad or a structural component will either intersect or
encroach on a butt weld the following shall be performed:
14.2.6.1 If the nozzle is installed onto or encroaching on a butt weld

in the exchanger wall:
1) radiograph of the butt weld in the exchanger wall for a
length equal to three times the diameter of the opening
with the center of the opening at mid-length.
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2) Where a reinforcing pad is required, the butt weld

shall be ground flush and radiographed, prior to the
installation of the reinforcing pad.
14.2.6.2 Where an attachment weld of a reinforcing pad or a

structural component will either intersect or encroach on a
butt-weld in the exchanger wall:
1) the butt weld shall be radiographed for a length equal
to the projection of the intersecting or encroaching
segment of the attachment weld plus a minimum of
50 mm on either side.
2) Perform magnetic particle examination on the
exchanger side of the joint attaching the reinforcing
pad or structural component.
14.3 Ultrasonic Testing
Where radiography as required by the applicable Code, approved drawings or

special instructions is deemed inaccessible or inconclusive, ultrasonic testing
may be substituted with approval of the Saudi Aramco Engineer.
14.4 Magnetic Particle Testing
14.4.1 Permanent magnetic yokes are not permitted.
14.4.2 Prods are not permitted for use on air-hardenable materials, materials
which require impact testing, and on the fluid side of pressured
components for exchangers in wet sour service.
14.4.3 Magnetic particle examination shall be performed on hot formed

surfaces and for parts that undergo reheat treatment as per the
applicable Code.
14.4.4 Except for non-ferro-magnetic materials, wet fluorescent magnetic

particle examination using an AC yoke is required for the following:
1) All internal welds, including temporary internal welds for
exchangers in wet sour, caustic, amine and hydrogen services.
2) All internal and external welds for all services made using the
SMAW welding process when the nominal thickness of
pressured components is 25 mm and thicker.
3) Exchanger support attachment welds.
Page 18 of 28
14.5 Hardness Testing
Weld hardness testing shall be in accordance with the requirements of

SAES-W-010.
14.6 Liquid Penetrant Testing
Liquid penetrant testing shall be conducted on all structural attachment welds on

pressured components of non-ferrous materials and which are attached after the
hydrotesting of the exchanger.
15 Heat Treatment
15.1 Postweld Heat Treatment
15.1.1 Postweld heat treatment (PWHT) shall be done when required by the
Code or when specified on the data sheet.
15.1.2 Code exemptions for PWHT of ferritic materials based on the use of
austenitic or nickel-based electrodes are not permitted.
15.1.3 Code exemptions for PWHT of P4 and P5 materials are not permitted
for applications involving either wet sour or hydrogen service or for
materials exceeding 2.5% nominal chromium content.
15.1.4 The maximum PWHT soaking temperature for carbon steel and C-0.5
Mo materials shall not exceed the temperature at which the test pieces
were heat treated as shown on the Mill Test Certificates, or 650°C for
carbon steel and 690°C for C-0.5 Mo.
15.1.5 The maximum PWHT soaking temperature for low alloy steels shall
not exceed the tempering temperature at which test pieces and
components were heat treated as shown on Mill Test Certificates, but
shall be not less than 700°C.
15.1.6 PWHT shall follow all welding and repairs but shall be performed
prior to any hydrotest or other load test.
15.1.7 The following sign shall be painted on the postweld heat treated
exchanger:
CAUTION-EXCHANGER HAS BEEN POSTWELD HEAT

TREATED-DO NOT WELD
15.1.8 The sign shall be located such that it is clearly visible from the ground.
Page 19 of 28
15.1.9 PWHT shall be in accordance with the requirements of SAES-W-010.
15.2 Heat Treatment of Tubes
15.2.1 The following tubes shall be heat treated after cold forming and
bending:
1) U bends, including 300 mm of straight portions measured from
the tangent lines of all carbon steel tubes for exchangers in
caustic, wet sour and amine services
2) Monel, brass and all chrome alloy tubes in all services
15.2.2 The following tubes shall be solution annealed:

1) Entire tubes manufactured of unstabilized stainless steels in
accordance with ASME SA-688. The solution annealing
temperature shall be 1070°C.
2) U bends, including 300 mm of straight portions measured from
the tangent lines of all stabilized stainless steels.
16 Inspection and Pressure Tests
16.1 Inspection
16.1.1 The responsibility for inspection rests with the Exchanger

Manufacturer in accordance with the applicable Code and the
16.1.2 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.
16.1.3 Inspection procedures shall be established in accordance with

ASME SEC V. A written procedure for each inspection method and
technique, including acceptance criteria, to be used shall be submitted
to the Saudi Aramco Inspector for approval. Qualification of the
procedure by the Exchanger Manufacturer may be required, as
determined by the Saudi Aramco Inspector. Inspection procedures in
conformance with other standards are acceptable only with the
approval of the Saudi Aramco Inspector.
16.1.4 Written reports and evaluations of all inspections performed by the

Exchanger Manufacturer shall be made and submitted to the Saudi
Page 20 of 28
Aramco Inspector, at a frequency to be determined by the Saudi

Aramco Inspector.
16.1.5 Additional inspection of any weld joint at any stage of the fabrication
may be requested by the Saudi Aramco Inspector, including re-
inspection of previously inspected joints. The Saudi Aramco Inspector
also has the right to request or conduct independent NDT of any joint.
If such testing should disclose gross non-conformance to the
requirements of the Code or this specification, all repair and NDT costs
shall be done at the Exchanger Manufacturer's expense.
16.1.6 Prior to final inspection and pressure testing, the inside and outside of
exchangers shall be thoroughly cleaned of all slag, scale, dirt, grit,
weld spatter, paint, oil, etc.
16.1.7 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.
16.1.8 All appropriate safety precautions shall be taken for each inspection
method.
16.1.9 All NDT shall be done by or under the supervision of personnel

certified to ASNT CP-189 or approved equivalent for the particular
method or technique to be used.
16.1.10 Surface irregularities, including weld reinforcement, inhibiting

accurate interpretation of the specified method of NDT shall be ground
smooth.
16.1.11 Inspection of all welds shall include a band of base metal at least one
inch wide on each side of the weld.
16.2 Inspection Access
16.2.1 The Saudi Aramco Inspector shall have free access to the work at all
times.
16.2.2 Saudi Aramco shall have the right to inspect the fabrication at any state
and to reject material or workmanship which does not conform to the
specified requirements.
16.2.3 Saudi Aramco reserves the right to inspect, photograph, and/or

videotape all material, fabrication, coating, and workmanship and any
Page 21 of 28
materials, equipment, or tools used or to be used for any part of the

work to be performed.
16.2.4 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.
16.2.5 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.
16.2.6 The Exchanger Manufacturer shall provide the Saudi Aramco

Inspector all reasonable facilities to satisfy him that the work is being
performed as specified.
16.2.7 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.
16.3 Pressure Tests
16.3.1 After completion of all external and internal welding and heat
treatment and prior to any painting, exchangers shall be pressure tested
using water as the testing media in accordance with the applicable
Code and this specification. Pneumatic testing in lieu of hydrostatic
testing requires the approval of the Saudi Aramco Engineer.
16.3.2 No preliminary pressure testing shall be made prior to postweld heat

treatment.
16.3.3 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.
16.3.4 The Exchanger Manufacturer shall furnish all test materials and
facilities, including blinds, bolting, and gaskets.
16.3.5 After testing, the exchanger shall be completely drained and

thoroughly dried including around the internals.
16.3.6 Test pressure for the tube side shall be 1.5 times its calculated MAWP
in the new and cold (ambient temperature) condition multiplied by the
lowest ratio (for the materials of which the tube is constructed) of the
allowable stress for the test temperature to the allowable stress for the
design temperature. Test pressure for the shell side is calculated
similarly.
Page 22 of 28
16.3.7 Water used for pressure testing shall be potable. For exchangers
manufactured from stainless steel, the water shall not contain more
than 50 ppm chlorides.
16.3.8 The temperature of the water during hydrostatic testing shall be

maintained at not less than 17°C throughout the testing cycle.
16.3.9 It is the responsibility of the Exchanger Manufacturer to ensure that the

temperature of the water is a minimum of 17°C above the ductile to
brittle transition temperature of the material.
16.3.10 All welded attachments provided with telltale holes shall be

pneumatically tested at 30 kPa (5 psig) prior to heat treatment and
pressure testing. Telltale holes must not be plugged during pressure
testing.
16.3.11 Exchangers designed for stacking shall be hydrotested in the stacked

position.
16.3.12 Hydrostatic test pressure shall be held for a minimum of one hour per
25 mm of exchanger shell thickness and in no case less than one hour.
17 Nameplates and Stampings
17.1 Each exchanger shall be identified by a nameplate and marked with the
information required by the applicable Code and the requirements of this
specification.
17.2 Exchangers manufactured inside and outside Saudi Arabia shall be Code
stamped for all services, in accordance with the applicable Code.
17.3 The nameplate and its mounting bracket shall be located such that the nameplate
is easily readable from grade or platform. Brackets shall extend from the
outside of exchanger to clear insulation, and with sufficient access for surface
preparation, and painting. The nameplate markings as required by UG-116 of
the Code shall be stamped or engraved such that the nameplate material is
permanently deformed with the symbols.
17.4 Nameplates shall be 3 mm minimum thickness and manufactured from type 304
stainless steel or Monel and welded to the mounting bracket.
17.5 The mounting bracket material shall conform to Table 1, General Note (F) and
shall be continuously welded to the exchanger.
Page 23 of 28
18 Painting
18.1 The type of painting system to be used shall be in accordance with the
SAES-H-001 and SAES-H-101V attached to the purchase order.
18.2 Prior to painting, surfaces shall be cleaned to remove all scale, rust, grease, dirt,
weld spatter and foreign objects.
18.3 Gasket contact surfaces shall not be painted.
19 Shipping Requirements
19.1 General
19.1.1 Prior to shipping, exchangers are to be dried and then cleaned from all
loose scales, weld slags, dirt and debris to the satisfaction of the Saudi
Aramco Inspector.
19.1.2 The Exchanger Manufacturer is responsible for ensuring that the

exchangers being shipped are adequately braced and shall provide
temporary supports where appropriate to ensure adequate supporting of
the exchanger during shipment.
19.1.3 Marking shall be done with water-insoluble material that contains no

harmful substances that would attack or harmfully affect the exchanger
at ambient and operating temperatures.
19.1.4 The marking material shall be free of lead, sulfur, zinc, cadmium,
mercury, chlorine, or other halogens.
19.1.5 Export packaging, marking and shipping shall be in accordance with

the purchase order.
19.2 Internal Protection
19.2.1 The internal surfaces of the exchangers shall be protected from

corrosion by use of a non-toxic vapor phase corrosion inhibitor such as
CORTEC VCI-309 or 307 or equivalent, applied at a rate of 0.3 kg/m³.
19.2.2 The inhibitor selected must be appropriate for the metallurgy of the
exchanger. Desiccants may only be used with approval of the Saudi
Aramco Engineer.
19.2.3 Exchangers must be sealed vapor tight using metallic covers, for the
inhibitor to be effective.
Page 24 of 28
19.2.4 Nitrogen blanketing, temporary rust preventive in accordance with

MIL-C-16173 Grade IV (example: Tectyl 846) or a vapor proof bag
with moisture control may be used.
19.2.5 Temporary coatings for use on exchangers with corrosion resistant

linings (stainless steel and monel clad) must be chloride free, suitable
for its intended use and not result in crevice corrosion.
19.3 External Protection
19.3.1 The protection of external surfaces shall be obtained by using one of

the following and as directed in the Purchase Order:
1) A hard temporary preservative in accordance with MIL-C-16173,
Grade I, which can be removed at site prior to surface preparation
and application of the Saudi Aramco coating and painting system
in the shop.
2) Prepare the surface and apply the complete (primer and final
coatings) Saudi Aramco surface preparation, and coating and
painting system in the shop.
3) Solid stainless steel exchangers, which are to be shipped via
ocean freight, shall be protected using a temporary protective
system compatible with stainless steel and suitable outdoor
exposure in accordance with MIL-C-16173 Grade IV.
19.3.2 Threaded nozzle connections shall be protected with threaded plugs.

However, tell-tale holes in reinforcing pads shall be protected with
wooden plugs or packed with a rust preventative grease such as Denso
paste.
19.3.3 Flanged connections and all other machined surfaces shall be protected
by a coating such as MIL-C-16173 Grade IV, which is easily removed
in the field and fitted with a steel or wood cover, 3 mm thick and
neoprene gaskets.
19.3.4 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.
19.3.5 Flanges with permanent blind flanges or covers shall be secured with
the gaskets and bolting required for service.
Page 25 of 28
20 Drawings, Calculations and Data
20.1 The Exchanger Manufacturer shall prepare drawings, calculations, and data in
accordance with Form NMR-7922-1, Non-material Requirements.
20.2 Drawings and calculations which are approved by the Design Engineer shall not
relieve the Exchanger Manufacturer of the responsibility to comply with the
Code, and this specification.
Revision Summary
6 September 2008 Major revision.
Page 26 of 28
Table 1 – Acceptable Materials for Carbon and Low-Alloy Steels

Exchanger Design Metal Temperature
Component -100 to -47°C -46 to 0°C 1 to 425°C 426 to 645°C
SA-516
SA-516
SA-203 Grade 70, or SA-387
Grade 70N
Grade D or E SA-537 Class 1 or Grade 11, 12 or 22
or SA-537 Class 1
SA-285 Grade C (1)
Shell pipe SA-333 SA-333 SA-106 SA-335
Grade B or SA-53
Nozzle pipe Grade 3 Grade 6 P11, 12 or 22
Grade B (1)
Tubes, (Baffles, tube SA-249 SA-334 or SA-179 or SA-179 or SA-214
supports) (2)(4) Type 304 SA-249 Type 304 SA-214 or SA-213 Type 304
Forged flanges SA-182
SA-350 LF3 SA-350 LF2 SA-105
and forged fittings F11, 12 or 22
SA-234
Wrought fittings SA-420 WPL3 SA-420 WPL6 SA-234 WPB
WP 11, 12 or 22
Studs/nuts for SA-320 L43/ SA-320 SA-193B7/ SA-193
pressure SA-194 L7/SA-194 SA-194 B5, or B16/SA-194
connection Grades 4 or 7 Grade 2H Grade 2H 2H or 2
General Notes:
(A) Materials for hydrogen service shall be selected in accordance with API PUBL 941 using a value for the
hydrogen partial pressure 10% above the design partial pressure and a temperature of 30°C above the design
temperature.
(B) Materials for exchangers in amine service shall be selected in accordance with Table 1 and API RP 945.
(C) Materials for exchangers in wet sour service, with design temperature up to 200°C, shall be in accordance
with Table 1, with the following revisions:
(1) Forged flanges and forged fittings are restricted to: SA-350 LF1 or LF2 or SA-266, Class 4, S2.1.
(2) Studs and nuts are restricted to: SA-193 B7M or L7M and SA-194 Grade 2HM.
(3) Satisfy the requirements of NACE MR0175/ISO 15156 and NACE RP0472.
(4) For exchangers under the service conditions specified in paragraph 12.1.9.1, shells and heads formed
from plate shall be manufactured from HIC resistant steel.
(D) Materials for pressure components in sea water service shall be in accordance with Table 1 with the following
revisions:
(1) Carbon steel pressure components in contact with sea water shall be clad or weld overlayed with Monel.
(2) Tube material shall be either Cu/Ni SB-111 (Alloy Number C71500) or Titanium SB-338 Grade 2.
(E) Low alloy material shall be specified in the normalized and tempered heat treated condition.
(F) The material for nameplate mounting brackets shall be of the same type and material grade as the shell material.
(G) Impact testing of materials and welding procedures are required when MDMT is lower than -28°C.
(H) Impact testing of materials is only required when MDMT is -27 to -18°C. Impact testing of welding procedures
is not required for this temperature range, (unless otherwise required by the applicable Codes), if the
consumable classifications per ASME SEC IIC have impact property requirements at -46°C or lower.
Specific Notes:
(1) SA-53 and SA-285 materials shall only be used for utility services.
(2) Tubes in hydrogen, wet sour, amine and caustic services shall be seamless.
(3) Movable shell support plates shall be of the same ASME material as the shell material.
(4) Baffles, tube supports, and impingement protection shall be of the same basic material as the tubes except for
high alloy steel tubes when these components may be of carbon steel provided shell side fluid does not
require more corrosion resistant material. For titanium tubes, the materials for these components shall be
subject to approval from Saudi Aramco Engineer.
Page 27 of 28
Table 2 – Charpy-V Impact Test Requirements

Minimum Required Impact Value for Full Size Specimen at MDMT, Joules
Reference Thickness, t, inch
Material Class t<½ ½<t<1 1<t<2 t>2

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

Class Material Specification
1a SA 53 Gr. B
2b SA 105
2a SA106 Gr. B
2b SA 182 Gr. F11 and F12
2c SA 182 Gr. F22
3 SA 203 Gr. D and E
2b SA 204 Gr. A, B and C
2b SA 266 Cl. 1
2c SA 266 Cl. 2 and 4
1a SA 333 Gr. 1
3 SA 333 Gr. 3
2a SA 333 Gr. 6
2b SA 335 Gr. P11, P12 and P22
2b SA 336 Gr. F12
2c SA 336 Gr. F11 and F22
2b SA 350 Gr. LF2
3 SA 350 Gr. LF3
2b SA 387 Cl. 1, Gr. 11, 12 and 22; Cl. 2, Gr. 12
2c SA 387 Cl. 2, Gr. 11 and 22
2a SA 442 Gr. 55 and 60
2b SA 516 Gr. 70
2c SA 533 Cl. 1
2b SA 537 Cl. 1
2c SA 420 Gr. WPP3 and WPL6
2c SA 234 Gr. WPB
2c SA 234 Gr. WP11, WP12 and WP22
Page 28 of 28

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Materials System Specification

32-SAMSS-028 6 September 2008

Saudi Aramco DeskTop Standards

Previous Issue: 30 March 2005 Next Planned Update: 6 September 2013

Copyright©Saudi Aramco 2008. All rights reserved.

2 Conflicts and Deviations

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

Saudi Aramco Engineering Standards

SAES-H-100 Painting Requirements for Industrial Facilities

Saudi Aramco Materials System Specification

Saudi Aramco Inspection Requirements

Saudi Aramco Forms and Data Sheet

Saudi Aramco Standard Drawing

3.2 Industry Codes and Standards

American Petroleum Institute

American Society of Civil Engineers

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

ASME SEC V Non-destructive Examination

American Society for Nondestructive Testing

International Organization for Standardization

U.S. Military Standards and Federal Specifications

National Association of Corrosion Engineers

Tubular Exchanger Manufacturers Association

Welding Research Council

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

Exchanger Manufacturer: The company responsible for the manufacture of new

Hydrogen Service: Process streams containing relatively pure hydrogen and

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

Low-Alloy Steels: Steels with nominal chromium contents of 5% chrome and/or

Minimum Thickness: Thickness required for withstanding all primary loads,

Multitube Exchanger: Consists of multitubes within a U shaped shell.

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

Utility Services: Water, air and nitrogen services.

6.1 Exchanger Manufacturer's proposal shall be based on details for individual

8.1.1 All exchangers shall be mechanically designed in accordance with the

8.1.2 The edition of the Code to which exchangers are to be manufactured,

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

8.1.5 Application of ASME Code Cases to the manufacture of exchangers

8.1.6 Exchangers shall be designed to withstand the combined stresses of all

8.2 Design Pressure

8.3 Maximum Allowable Working Pressure

8.3.1 The Exchanger Manufacturer shall calculate the maximum allowable

8.3.2 The calculations shall be based on the nominal as-built thicknesses

8.4 Design Temperature

8.5 Minimum Design Metal Temperature

8.6 Joint Efficiency

8.6.1 The joint efficiency shall be specified on the data sheet.

8.7 Corrosion Allowances

The amount of corrosion allowance shall be as specified on the data sheet.

8.8.1 Wind and Earthquake Loads

on an exchanger in the operating position in accordance with the

8.8.2 Piping, Equipment and External Loads

8.9 Load Combinations

8.9.1 All components of the exchanger, including their supports, shall be

8.10 Stress Analysis

Stress analysis shall be carried out as specified on the data sheet.

8.11 Tubes and Tube Bundles

8.11.4 Where more than one exchanger of identical mechanical design,

8.11.5 Tubeside elements shall be removable without cutting.

8.11.6 The inner tube shall be without intermediate weld.

Saudi Aramco Standard Drawing AE-036250 gives ferrules details for

8.12.1 Elements shall be designed to be removable through the use of bolted