32 Samss 027

Materials System Specification
32-SAMSS-027 Manufacture of Electric 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
6 September 2008
Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Previous Issue: 6 November 2006
Scope................................................................... 2 Conflicts and Deviations...................................... 2 References........................................................... 2 Definitions............................................................ 4 Responsibilities.................................................... 5 Proposals............................................................. 5 Design................................................................. 6 Mechanical Design of Pressured Components.. 10 Nozzles.............................................................. 13 Supports............................................................. 16 Clips and Attachments....................................... 18 Materials............................................................ 19 Fabrication......................................................... 19 Nondestructive Testing...................................... 21 Postweld Heat Treatment (PWHT).................... 23 Inspection, Pressure Tests................................ 24 Nameplates and Stampings............................... 28 Coatings and Painting........................................ 28 Shipping Requirements...................................... 28 Drawings, Calculations and Data...................... 30
Next Planned Update: 6 September 2013 Page 1 of 30
Primary contact: Anizi, Salamah Salem on 966-3-8746139

CopyrightSaudi Aramco 2008. All rights reserved.
Document Responsibility: Heat Transfer Equipment Issue Date: 6 September 2008 Next Planned Update: 6 September 2013
32-SAMSS-027 Manufacture of Electric Heat Exchangers
Scope 1.1 This specification covers the minimum mandatory requirements for the thermal design, mechanical design, materials, fabrication, inspection and testing of new electrical immersion-type heaters (hereinafter referred to as exchangers) in hydrocarbon, hydrogen, and utility services. The requirements of this specification are in addition to and supplement the requirements of TEMA and the ASME Pressure Vessel Code Section VIII Division 1.
1.2
Conflicts and Deviations 2.1 Any conflicts between this Specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Saudi Aramco Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be in writing by the Company or Buyer Representative through the Standards Committee Chairman, Consulting Services Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran.
2.2
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 SAES-A-112 SAES-A-206 Hydrostatic Testing Fluids Meteorological and Seismic Design Data Positive Material Identification
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SAES-H-001 SAES-H-101 SAES-W-010
Selection Requirements for Industrial Coatings Approved Protective Coating Systems Welding Requirements for Pressure Vessels
Saudi Aramco Inspection Requirements Form 175-323400 Heat Exchangers: Electrical, Immersion-type
Saudi Aramco Forms and Data Sheets Form SA 2713-ENG Form NMR-7922-3 Form SA 9541-ENG Safety Instruction Sheet Shell and Tube Heat Exchangers Non-material Requirements for Electric Heat Exchangers Electric Exchanger Data Sheet (hereinafter referred to as data sheet)
Saudi Aramco General Instructions 3.2 Industry Codes and Standards American Society of Mechanical Engineers (Boiler and Pressure Vessel Codes) ASME SEC V ASME SEC VIII D1 ASME B16.11 ASME B16.5 ASME B16.20 ASME B16.25 ASME SA-20 Non-destructive Examination Rules for Construction of Pressure Vessels Forged Steel Fittings, Socket-welded and Threaded Pipe Flanges and Flanged Fittings Metallic Gaskets for Pipe Flanges - Ring-Joint, Spiral-Wound, and Jacketed Butt-weld Ends Standard for General Requirements for Steel Plates for Pressure Vessels
American Society for Nondestructive Testing ASNT CP-189 ASNT SNT-TC-1A Standard for Qualification and Certification of Nondestructive Testing Personnel Recommended Practice for Qualification and Certification of NDT Personnel
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International Organization for Standardization NACE MR0175/ ISO 15156 Petroleum and Natural Gas Industries Materials 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 Fire Protection Association NFPA 70 Process Industry Practices VEFV1100 Vessel/S&T Heat Exchanger Standard Details National Electrical Code
Tubular Exchanger Manufacturers Association Welding Research Council WRC-107 4 Definitions AARH: Average arithmetic roughness height, which is a measure of surface texture. Alloy Materials: Includes stainless steels and high alloy steels. Cyclic Service: Services that require fatigue analysis per AD-160 of ASME SEC VIII D2. Design Engineer: The Engineering Company responsible for specifying on the data sheet the mechanical design requirements for exchangers. Exchanger Manufacturer: The company responsible for the manufacture of exchangers. Hydrogen Service: Process streams containing relatively pure hydrogen and component streams containing hydrogen with a partial pressure of 350 kPa (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. Minimum Thickness: Thickness required for withstanding all primary loads, excluding allowance for corrosion.
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Welding Research Council Bulletin
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 Standards Committee Chairman. 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. Sour Service: Process streams containing hydrogen sulfide for the following conditions: 1) 2) Sour water with a hydrogen sulfide (H2S) concentration above 2 mg/L (2 ppmw) and a total pressure of 400 kPa absolute (65 psia) or greater. Hydrocarbon services meeting the definition of sour environments in NACE MR0175/ISO 15156 as shown below. a) b) 5 Dissolved H2S in free water (liquid) with a concentration of >50 mg/L (50 ppmw) or, H2S in gas with a gas phase with 0.05 psia or greater partial pressure.
Responsibilities 5.1 The Exchanger Manufacturer is responsible for the manufacture of exchangers, which includes hydraulic, thermal design, electrical design, mechanical design, code and structural calculations, flow induced vibration, supply of all materials, fabrication, non-destructive examination, inspection, testing, surface preparation, and preparation for shipment, in accordance with the completed data sheet and the requirements of this specification. The Design Engineer is responsible for specifying the electrical, hydraulic, thermal and mechanical design requirements and completing the data sheet.
5.2
Proposals 6.1 6.2 The Exchanger Manufacturer's proposal shall be based on details for individual exchangers and the requirements of this specification. The Exchanger Manufacturer may offer an alternative design, but must quote on the base inquiry documents.
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6.3 6.4
The proposal shall include a detailed description of any exception to the requirements of this specification. 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 performance requirements under continuous operation at design conditions specified on the data sheets. Thermal guarantee shall be in accordance with TEMA paragraph G-5. Exchangers shall be free from damaging flow induced tube vibration.
2) 7 Design 7.1
General Exchangers may be installed either horizontally or vertically, as specified on the data sheet.
7.2
Thermal Design Exchangers shall be thermally designed in accordance with the process design data specified on the data sheet, TEMA R, and the requirements of this specification.
7.3
Heating Elements and Construction 7.3.1 7.3.2 7.3.3 7.3.4 The number, length, and arrangement of heating elements shall be determined by the Exchanger Manufacturer. Heating elements shall be evenly distributed across the cross section of the shell. Heating elements shall be provided with suitable spacers and supports in order to maintain the elements in proper alignment with the shell. Heating elements shall consist of 80% Ni-20% Cr or 70% Ni-30% Cr alloy heating wire, packed with magnesium oxide insulation, enclosed in a tubular sheath, and rated for a maximum allowable temperature of 700C. The element outside diameter shall be 12.7 mm (0.5 in) nominal size. The minimum diameter shall be 10.2 mm (0.4 in) and the maximum diameter shall be 15.2 mm (0.6 in). Heating elements shall be designed for a minimum of 100,000 hours of continuous service at the maximum allowable sheath temperature.
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7.3.5
7.3.6
7.3.7
The heating elements shall have an unheated length in the stagnant flow region of the heater between the heater flange face and the inlet or outlet nozzle, as applicable. As a minimum, two full, solid baffle plates shall be located in the unheated length in order to minimize heat losses through the heater flange. Generally, the process inlet (cold process side) shall be at the same side as the unheated length. All heating element sheaths shall be of seamless construction, 18 BWG minimum wall thickness. All sheaths (both heating elements and thermocouples) shall be seal welded to the heater flange. Bushing type connections or silver solder are not permitted in any service. Bite type couplings are not permitted in hydrocarbon or hydrogen services. The over-temperature cut-off actuating device will be supplied by others.
7.3.8
7.3.9 7.3.10 7.3.11 7.3.12
7.3.13 7.4
Thermocouples 7.4.1 Exchangers shall be equipped with two over-temperature thermocouples, welded to the sheaths of two heating elements located in the area of highest anticipated sheath temperature (at hot process end). Each bundle in exchangers with multiple heating element bundles, shall be provided with two thermocouples. Construction of thermocouples shall be grounded junction chromelalumel (type K) in a mineral oxide insulated metal sheath. Thermocouple wire shall be 20 gauge, minimum. The potential of the ground thermocouples shall be the same as that of the ground. Thermocouple sheaths shall be of the same material as the heating element sheath. Sheathed thermocouples shall be brought outside through the heating element closure sheet and shall terminate in a dedicated encapsulated transition splice inside a polarized waterproof connector. Extension wiring (16 gauge minimum) from the waterproof connector shall
7.4.2 7.4.3
7.4.4 7.4.5
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terminate in a terminal box. The extension wire shall be twisted and shielded. 7.4.6 7.5 Heating elements with thermocouples must be suitably tagged, i.e., type K (+), type K (-) inside terminal boxes.
Terminal Boxes 7.5.1 7.5.2 Terminal and junction boxes shall not be attached directly to the heating element enclosure. Terminal boxes and junction boxes shall be located a minimum of 150 mm away from the heating element enclosure for cooling and leak detecting purposes. Terminal boxes shall be mounted so that thermal conduction from the heater body to the boxes is minimized. The Exchanger Manufacturer shall specify the anticipated internal temperature of the terminal box, and the recommended insulation design and material for the incoming feeder conductors. The Exchanger Manufacturer shall advise if high temperature wiring is required at terminal boxes. Terminal boxes shall be moisture resistant and explosion proof type. The use of terminal boxes in hazardous area Classes and Divisions shall be evaluated and approved by Loss Prevention Engineer. Group shall be designated on the data sheet. Covers for terminal boxes shall be removable for access to connections. Terminal blocks shall be provided for power connections. Each terminal box shall be provided with a solid ground connection point for attachment of the external wiring. Heating elements shall be arranged to form a balanced "delta" connected load. Spacing between terminals of different phases or buses in terminal junction boxes shall be not less than that allowed by National Electrical Codes (NFPA 70) unless adequate shielding to prevent arcing is provided. All heater terminal boxes shall be provided with 0.25 inch NPT connection (plugged) in each terminal box for nitrogen purge. All entries for electrical connections shall be fitted with NPT conduit hubs.
7.5.3
7.5.4 7.5.5
7.5.6
7.5.7
7.5.8 7.5.9
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7.5.10
Radiation shields shall be provided between terminal boxes and heater flanges. The diameter of the shield shall be equivalent to the outside diameter of the heater flange. Exchanger supply power shall be as specified on the data sheet. Unless otherwise specified, the Exchanger Manufacturer shall provide a minimum of 10% spare capacity to allow for downward voltage variation.
7.5.11
7.6
Controls 7.6.1 The Exchanger Manufacturer shall provide the power control system. Unless otherwise specified by Saudi Aramco, power equipment located outdoors shall be in enclosures meeting the requirements of paragraph 7.5.5. The Exchanger Manufacturer shall provide ground fault interrupt protection to shut down the exchanger in the event of elements shorting to the ground.
7.6.2
7.7
Heater-Element Closure Sheet The heater-element closure sheet shall be flanged to the shell per TEMA paragraph R-6 and designed in accordance with TEMA paragraph R-7 and the Code.
7.8
Baffles and Support Plates 7.8.1 Supports of heater elements exposed to process fluids along its axis, longitudinal flow, shall be spaced no more than 600 mm (23.6 in) apart. Supports of heater elements exposed to cross flow shall be based on TEMA recommendations. Exchangers in gas or vapor services shall be investigated by the Exchanger Manufacturer for flow induced vibration of elements through the full operating range of flows, including startup and shutdown conditions. All transverse baffles for element supports and distribution of flow shall be the segmental type, in accordance with TEMA requirements. The minimum metal thickness shall not be less than the specified shell side corrosion allowance. Horizontally cut baffles shall have a V-notch, 25 mm (1 in) wide minimum for drainage.
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7.8.2
7.8.3 7.8.4 7.8.5
7.9
Impingement Baffles 7.9.1 Inlet areas shall be designed to avoid excessive pressure drop and protect elements from impingement damage. Impingement plates for the protection of elements shall not be supported from inlet nozzles, shells or elements. Perforated impingement plates are not acceptable. Impingement baffles shall extend a minimum of 25 mm (1 in) beyond the projection of nozzle inlet bores. The unrestricted entrance flow areas at impingement flow plates shall not be less than the flow area of the inlet nozzles. The nominal thickness of impingement baffle plate shall not be less than 6 mm (.25 in).
7.9.2 7.9.3 7.9.4
Mechanical Design of Pressured Components 8.1 General 8.1.1 All exchangers shall be mechanically designed in accordance with the rules of Pressure Vessel Code, ASME SEC VIII D1 (herein referred to as the Code), TEMA, and the requirements of this specification. All exchangers shall be designed using established calculation procedures. 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.
8.1.2 8.1.3
8.2
Design Pressure 8.2.1 8.2.2 The value of design pressure shall be specified by the Design Engineer on the data sheet. For exchangers subjected to steam out, the Design Engineer shall specify on the data sheet the external design pressure and corresponding temperature.
8.3
Maximum Allowable Working Pressure 8.3.1 The Exchanger Manufacturer shall calculate the maximum allowable working pressure (MAWP) of exchangers in accordance with the Code, in the hot and corroded condition.
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8.3.2
The calculation shall be based on the nominal as-built thicknesses, excluding thicknesses required for corrosion. The MAWP of the exchanger must not be limited by flange ratings.
8.4
Design Temperature 8.4.1 8.4.2 8.4.3 The value(s) of design temperature(s) shall be as specified on the data sheet. The value of the minimum design metal temperature (MDMT) shall be as specified on the data sheet. The MDMT shall be used to determine the requirements for impact testing in accordance with the code and this specification.
8.5
Service and Description If the exchanger is in hydrogen service, it shall be specified as such on the data sheet. The partial pressure of hydrogen shall also be specified.
8.6
Joint Efficiency 8.6.1 8.6.2 Joint efficiency shall be as specified on the data sheet. A joint efficiency of 85% or higher shall be used for the design of all pressure containing components of the exchangers according to the Code.
8.7
Corrosion Allowance 8.7.1 Corrosion allowance shall be added to all pressure containing components which are in contact with the process fluid, including shells, flanges, nozzle necks, and covers. Unless otherwise specified in the Data Sheet, the minimum corrosion allowance for all exchangers shall be 1.6 mm.
8.7.2 8.8
Minimum Thicknesses 8.8.1 Minimum thickness of exchanger components shall be adequate to withstand the combined stresses of all loads in accordance with the applicable Code and this specification. Thickness of shell, heads and nozzles shall in no case be less than the following:
8.8.2
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1)
Shells and Heads 5 mm including corrosion allowance.
2)
Nozzles ANSI Standard Weight, including corrosion allowance, but not less than that calculated by the rules of the Code.
8.9
Loads 8.9.1 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 on the exchanger in the operating position in accordance with the requirements of this specification. The wind speed, earthquake zone, and soil coefficient corresponding to the site location shall be as specified on the data sheet. Exchangers shall be designed for wind and earthquake loads in accordance with ASCE 7. The Design Engineer shall determine the basic wind speed corresponding to the Saudi Aramco site in accordance with SAES-A-112. The basic wind speed shall be specified on the data sheet. Wind pressures shall be assumed to act on the projected surface area of the exchanger and shall include allowance for platforms, ladders, piping, insulation, and equipment supported from the exchanger.
2)
3) 4)
5)
8.9.2
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 limits 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. Piping and equipment loads imposed on the exchanger shall be as specified on the data sheet.
2)
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Nozzles 9.1 General 9.1.1 9.1.2 9.1.3 9.1.4 All nozzles shall be flanged or prepared for butt welding. Quantities, sizes, ratings (ASME pressure classes) and facings of nozzles shall be as specified on the data sheet. Flange bolt holes shall straddle the normal horizontal and vertical centerlines of the exchanger. For exchanger drain connections and other connections, where a process stream is likely to be stagnant, the projection shall be limited to a maximum of three times the connection nominal diameter. Projections shall also be sized so that studs may be removed from the back of a flange without interference with insulation. For all hydrocarbon and hydrogen services, nozzles shall be of the following types: 1) 2) Forged steel, long welding neck 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. Studded nozzles and proprietary designs may be offered as alternatives provided their design is in accordance with the Code and has the prior approval of the Saudi Aramco Engineer.
9.1.5
3)
9.1.6
For utility services, nozzles shall be of the following types: 1) 2) The types as specified in paragraphs 9.1.5 (1), (2) and (3) Slip-on type flanges with seamless pipe nozzle necks (or rolled plate with 100% radiography) up to and including 400C (750F) design metal temperature and 2.07 MPa (300 psi) design pressure.
9.1.7 9.1.8
Ends of butt welded connections shall be in accordance with ASME B16.25. Threaded or socket-welded connections are prohibited in hydrogen, lethal, wet sour and caustic services. However, for other services, threaded or socket-welded connections with 6000-lb rating conforming
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to ASME B16.11 may be used for NPS 1 and smaller vents, drains and instrument connections.
Commentary Note: This requirement is intended for vents, drains and instrument connections that may be attached to shell or nozzles.
9.1.9
When 100% radiography is required, per paragraph 14.2.6 of this specification, on nozzle or manway connections to an exchanger, integrally reinforced contour forged connections according to Figure UW-16.1: (f-1), (f-2), (f-3) or (f-4) of the Code shall be used.
9.2
Reinforcement of Openings 9.2.1 9.2.2 9.2.3 Reinforcement of exchanger openings shall be in accordance with the applicable Code and this specification. The thickness of reinforcing pads shall not exceed the exchanger shell thickness. Integrally reinforced openings (with no reinforcing pads) shall be provided under the following services and design conditions: 1) 2) 3) 4) 5) 6) 7) 9.2.4 Exchangers with design metal temperatures greater than 425C Hydrogen service Lethal services Hydrogen services Cyclic services Weld joints where any of the pressure retaining materials requires impact testing per the applicable Code or this specification. Weld joints requiring full radiography per UW-11 of the Code.
Use of internal reinforcing elements is not permitted.
9.3
Flange Ratings (ASME Pressure Classes) and Facings 9.3.1 9.3.2 9.3.3 The ASME pressure classes and facings shall be as specified on the data sheet. Pressure ratings shall be in accordance with ASME B16.5. All flange facings connections shall be raised face or ring-type joint. Flat face flanges may be used in utility services only.
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9.3.4
Gasket seating surfaces shall comply with the following: 1) 2) 3) For spiral wound gaskets, 125 to 250 AARH, in all services, except hydrogen. For spiral wound gaskets in hydrogen service, 125 to 150 AARH. The side-walls of ring joint flanges, in all services, 63 AARH.
9.3.5 9.4
Surface roughness of machined surfaces, other than gasket contact faces, shall not exceed 500 AARH.
Weld Attachment Details 9.4.1 9.4.2 All nozzle necks shall be attached by welding completely through the total thickness of the exchanger shell, including any reinforcement. Permissible types of nozzle weld-attachments shall be in accordance with the Code, Figure UW-16.1 (a), (b), (c), (backing rings are to be removed), (d), (e), (f-1), (f-2), (f-3), (f-4) and (g).
9.5
Gaskets 9.5.1 Gaskets for exchanger heater-flange to shell-flange shall be confined and shall either be the spiral wound or double-jacketed type, in accordance with ASME B16.20. The materials of construction for spiral wound gaskets shall be as follows with flexible graphite filler suitable for the intended service: 1) For exchangers with design temperatures from -100C to 0C: 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 1C to 425C: Type 304 or 316 SS windings with solid carbon steel outer centering rings. 3) For exchangers with design temperatures above 425C: 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.
9.5.2
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10
Supports 10.1 General 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.2 Refer to the data sheet for the type of support. All supports shall be continuously welded to the exchanger. The material of anchor bolts shall be in accordance with this specification. Exchanger Manufacturer shall design base plates for all loading conditions in accordance with this specification. The allowable concrete bearing stress to be used for the design of base plates shall be 10340 kPa (1400 psi).
Supports for Vertical Exchangers 10.2.1 10.2.2 The data sheet shall specify the type, location and overall dimensions required for the design of supports for vertical exchangers. The Exchanger Manufacturer shall design all supports required, including skirts, legs, lugs, base-plates, number of anchor bolts in accordance with the data sheet. Skirts shall have a minimum thickness of 6 mm. The mean corroded diameter of the shell and the mean diameter of the skirt shall coincide [rounded off to the nearest 3 mm], and shall be symmetrical about the exchanger centerline. One 600 minimum 500 mm inside diameter skirt access opening shall be provided for exchangers with diameters equal to and larger than 1200 mm. For exchangers with diameters less than 1200 mm, skirt access opening diameter shall be minimum one half of the exchanger diameter. Skirt access opening diameters smaller than the above specified shall require prior approval of the Saudi Aramco Engineer. It is the exchanger manufacturer's responsibility to determine the need for reinforcing the opening, according to the applicable Code. Piping passing through skirt openings shall be adequately supported to prevent damage during shipment. The Exchanger Manufacturer shall provide skirt bracing to prevent buckling during shipping and lifting in the field.
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10.2.3 10.2.4
10.2.6
10.2.7 10.2.8
10.3
Supports for Horizontal Exchangers 10.3.1 Horizontal exchangers shall be supported by two saddles. The exchangers shall be fixed at one saddle support and free to slide at the other saddle. The data sheet shall specify the locations of the fixed and sliding saddles, and dimensions from exchanger centerline to underside of saddle base plate, and locations of fixed and sliding saddles. Saddle supports shall be designed to prevent deformation under all load conditions. Wear pads a minimum of 10 mm thick with shall be supplied at the junction of the saddle and the exchanger, and shall be continuously welded to the shell. Wear pads shall have all corners rounded to a 20 mm minimum radius, and shall have one inch NPT vent hole at the lowest elevation. The shell shall be analyzed in accordance with the "LP Zick" method. Saddle supports and the exchanger shell shall be analyzed for operating and hydrotest loads including any piping, wind or other external loads. The anchor bolt holes on the sliding-end saddle shall be slotted to facilitate thermal expansion. The fixed support shall be located at the inlet (cold side) end of the exchanger. Additionally, consideration shall be given to external loads from connected piping. Fixed saddle anchor bolts shall be designed for a minimum longitudinal force equal to 1.5 times the weight of the bundle. Stacked exchangers shall be designed for a shim allowance of 6 mm at the intermediate support.
10.3.2
10.3.3
10.3.4
10.3.5 10.3.6
10.3.7 10.3.8 10.4
Anchor Bolts 10.4.1 10.4.2 10.4.3 10.4.4 The Exchanger Manufacturer shall determine the size and number of anchor bolts required. Anchor bolts shall straddle exchanger centerlines on the north-south, east- west axes. Anchor bolts shall not be less than 20 mm minimum nominal diameter. The allowable stress (based on ASTM A307 Grade B material) shall be as follows:
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1) 2) 10.4.5 10.4.6
104 MPa (tension). External loads (Wind or Earthquake, plus operating weight) 69 MPa (shear). External loads (Wind or Earthquake, plus operating)
Exchangers supported on skirts, lugs or legs shall be provided with an even number of anchor bolts with a minimum of four anchor bolts. Exchangers supported on saddles shall be provided with an even number of anchor bolts with a minimum of two anchor bolts per saddle.
11
Clips and Attachments 11.1 General 11.1.1 11.1.2 11.1.3 The Exchanger Manufacturer shall supply and install all clips and attachments as specified by the Design Engineer. Unless otherwise specified, all clips required shall be detail designed by the Design Engineer. All internal and external attachments, including clips, welded directly to pressure parts are to be attached by continuous welding except for blank nuts used for external insulation where tack welding is allowed.
11.2
Grounding Lugs All exchangers shall be provided with a grounding lug connection welded to the fixed exchanger support.
11.3
Lifting Lugs 11.3.1 Exchanger's component with weight up to and including 27 kg (60 lb) shall be provided with at least one lifting lug. Two lifting lugs shall be provided for over 27 kg (60 lb) weight component. 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 have sufficient standout to clear insulation.
11.3.2
11.4
Fireproofing Supports 11.4.1 The extent and thickness of fireproofing shall be specified on the data
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sheet. 11.4.2 11.4.3 The Exchanger Manufacturer shall supply and install supports required for fireproofing materials. If ring type supports are used for vertical exchangers, they shall be provided with drain holes.
12
Materials 12.1 The materials of construction of pressure components shall be selected in accordance with Table 1 below: Table 1 Basic Material Specifications
Basic Material Specification Utility services up to and including 680C design metal temperature Hydrocarbon and hydrogen services up to and including 680C design metal temperature Type 304H stainless steel Inconel 600, Incoloy 800/800H, Type 321 or 347 stainless steel
12.2 12.3 12.4
All items welded to exchangers, such as reinforcing pads, lifting lugs, support saddles, etc., shall have the same material specification as the base material. Material specifications of studs and nuts for bolted connections shall be ASTM designated and compatible with that of the connection. The Exchanger Manufacturer may propose alternative materials at the time of proposal that comply with all the requirements of the applicable Code and this specification. The substitution of higher strength grades of the same, or alternative material, shall not be permitted without the prior approval of the Saudi Aramco Engineer. All materials must be clearly identified and provided with Mill Test Certificates. Lack of adequate identification and certification shall be cause for rejection. All materials shall be alloy verified by the Exchanger Manufacturer in accordance with SAES-A-206.
12.5 12.6 12.7
13
Fabrication 13.1 Forming and Assembly 13.1.1 The preparation of plate edges for welding shall be done by shearing,
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machining, grinding or thermal cutting. 13.1.2 The beveled edges of alloy plates shall be magnetic particle examined for linear discontinuities. Defects shall not exceed limits as per ASME SA-20. Plate edge laminations revealed by magnetic particle examination 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 an adjoining shell section or shell flange. All re-rolling or forming of the shell sections must be completed prior to radiography. Layout of shell plates shall be made in such a manner that nozzles and their reinforcements are not located within 20 mm of any weld seams. All nozzles shall be ground flush to the inside curvature of the exchanger with an inside corner radius of the least of the nozzle thickness or 13 mm. Tapped telltale holes " NPT shall be provided in reinforcing pads as follows: 1) 2) 13.1.9 One hole in single piece reinforcing pad. Where a pad is split, each segment shall have at least one tapped hole.
13.1.3 13.1.4
13.1.5 13.1.6 13.1.7
13.1.8
The weld joining the sections of a split-reinforcing pad shall be oriented with the circumferential direction of the shell. Welding the pad sections together shall be done without using a backing strip.
13.2.10 All internal and external non-pressure welded attachments shall be fully seal welded and shall have their corners with a smooth radius. 13.2.11 Welds attaching manways, nozzles and their reinforcement pads and other structural attachments to pressure components shall not be closer than 20 mm (toe-to-toe) from any welds stresses due to pressure. It is the responsibility of the manufacturer to ensure that requirements of paragraph 8.9.2 of this specification are met in the vicinity of the welds.
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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. 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. Final acceptance of the exchanger shall be based on completion of all required NDE after the final postweld heat treatment. All pressure and non-pressure welds shall be visually inspected where accessible.
14.1.2
14.1.3 14.1.4 14.2
Radiographic Testing 14.2.1 All radiography shall be performed with intensifying screens. Only lead or lead foil (fluoro-metallic) screens shall be permitted unless otherwise approved by the Saudi Aramco Inspection Department. Tungsten inclusions in Gas Tungsten Arc welds shall be evaluated as individual rounded indications. Clustered or aligned tungsten inclusions shall be removed and repaired. All personnel performing field radiography at Saudi Aramco facilities, sites, and concessionary areas shall maintain full compliance with GI150.003 and be in possession of valid permit to handle and use radioactive ionization materials and equipment. Radiographic film interpretation shall be done by personnel certified in accordance with ASNT CP-189 to ASNT Level II Film Interpreter or approved equivalent.
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14.2.2
14.2.3
14.2.4
14.2.5
100% radiography is required for categories A and B shell and head joints and categories C and D joints for nozzle connections in exchangers for the following services and design conditions: 1) 2) 3) 4) 5) Lethal services Hydrogen services Cyclic services Weld joints where any of the pressure retaining materials requires impact testing per the applicable Code or this specification. Weld joints requiring full radiography per UW-11 of the Code.
Commentary: To facilitate 100% radiography of category-D joints, it shall be according to: Figure UW-16.1: (f-1), (f-2), (f-3) or (f-4) of the Code.
14.2.6
Where it is not practicable to meet the spacing requirement in paragraph 13.2.10 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) Radiography 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. Where a reinforcing pad is required, the butt weld shall be ground flush and radiographed, prior to the installation of the reinforcing pad.
2)
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 of the projection of the intersecting or encroaching segment of the attachment weld plus a minimum of 50mm on either side. Perform magnetic particle examination on the exchanger side of the joint attaching the reinforcing pad or structural component.
2)
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14.2.6.3
It is the responsibility of the manufacturer to ensure that the requirements of paragraph 8.9.2 are met in the vicinity of the attachment welds.
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 submitted with approval of the Saudi Aramco Inspector.
14.4
Magnetic Particle Testing 14.4.1 14.4.2 Permanent magnetic yokes are not permitted. Magnetic particle testing shall be conducted on all structural attachment welds on pressured components of ferro-magnetic materials and which are attached after the hydrotesting of the exchanger. Prods are not permitted for use on air-hardenable materials, and on materials which require impact testing. Except for non-ferro-magnetic materials, wet fluorescent magnetic particle examination using an AC yoke is required for the following: 1) 2) All internal welds, including temporary internal welds for exchangers in hydrogen and hydrocarbon services All internal and external weld for all services made using the SMAW welding process when the nominal thickness of pressured components is 25 mm and thicker.
14.4.3 14.4.4
14.5
Liquid Penetrant Testing Liquid Penetrant testing shall be conducted on all structural attachment welds on pressured components of ferro-magnetic materials and which are attached after the hydrotesting of the exchanger.
14.6
Hardness Testing Weld hardness testing shall be in accordance with the requirements of SAES-W-010.
15
Postweld Heat Treatment (PWHT) 15.1 PWHT shall be done when required by the applicable Code or when specified on the data sheet.
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15.2 15.3
Code exemptions for PWHT of ferritic materials, based on the use of austenitic or nickel based electrodes, are not permitted. Code exemptions for PWHT of P4 and P5 materials are not permitted for applications involving hydrogen service or for materials exceeding 2.5% nominal chromium content. PWHT shall follow all welding and repairs but shall be performed prior to any hydrotest or other load test. The following sign shall be painted on a postweld heat treated exchanger: CAUTION: EXCHANGER HAS BEEN POSTWELD HEAT TREATED-DO NOT WELD
15.4 15.5
15.6 15.7 16
The sign shall be located such that it is clearly visible from the grade. PWHT shall be in accordance with the requirements of SAES-W-010.
Inspection, 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 requirements of this specification. Exchangers manufactured in accordance with this specification are subject to verification by the Exchanger Inspector in accordance with Saudi Aramco Inspection Requirements Form 175-323400. Heating elements to flange seal welds shall be pneumatically or hydrostatically pressure tested by the Exchanger Manufacturer in the shop. The minimum test pressure shall be the greater of 170 kPa (25 psi) or 1.3 times the maximum allowable working pressure. 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 Exchanger Manufacturer's procedure 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.
16.1.2
16.1.3
16.1.4
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16.1.5
Written reports and evaluations of all inspections performed by the Exchanger Manufacturer shall be made and submitted to the Saudi Aramco Inspector, at a frequency to be determined by the Saudi Aramco Inspector. Additional examination of any weld joint at any stage of the fabrication may be requested by the Saudi Aramco Inspector, including examination of previously examined joints. The Saudi Aramco Inspector also has the right to request or conduct independent testing of any joint. If such examination should disclose non-conformance to the requirements of the applicable Code or this specification, all repair and testing costs shall be done at the Exchanger Manufacturer's expense. 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. 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. All appropriate safety precautions shall be taken for each inspection method.
16.1.6
16.1.7
16.1.8
16.1.9
16.1.10 All NDE 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. 16.1.11 Surface irregularities, including weld reinforcement, inhibiting accurate interpretation of the specified method of examination shall be ground smooth. 16.1.12 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 16.2.2 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.
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16.2.3
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.
16.2.4
16.2.5
16.2.6
16.2.7
16.3
Pressure Tests 16.3.1 After completion of all external and internal welding and heat treatment and prior to application of paint or primer, exchangers shall be pressure-tested using water as the testing media in accordance with the applicable Code and this specification. No preliminary pressure testing shall be made prior to postweld heat treatment. The use of shellacs, glues, lead, etc., on gaskets during testing is prohibited. The Exchanger Manufacturer shall furnish all test materials and facilities, including blinds, bolting, and gaskets. Service gaskets and bolting that are supplied with the exchanger may be used for pressure testing. They shall be of the type required in service and as specified on the data sheet. After testing, the exchanger shall be carefully drained and thoroughly dried, including around the internals. Test pressure shall be 1.3 times the calculated MAWP in the new and cold (ambient temperature) condition multiplied by the lowest ratio
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16.3.2 16.3.3 16.3.4 16.3.5
16.3.6 16.3.7
(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. 16.3.8 Water used for pressure testing shall be potable. For exchangers manufactured from stainless steel, the water shall not contain more than 50 ppm chlorides. The temperature of the water during hydrostatic testing shall be maintained at not less than 17C throughout the testing cycle.
16.3.9
16.3.10 It is the responsibility of the Exchanger Manufacturer to ensure that the temperature of the water is a minimum of 17C above the ductile to brittle transition temperature of the material. 16.3.11 Vertical exchangers which are tested in the horizontal position shall be adequately supported to prevent deformation. Horizontal exchangers are to be tested on their permanent saddle supports with no intermediate supporting. 16.3.12 All welded attachments provided with telltale holes shall be pneumatically tested at 30 kPa (5 psi) prior to heat treatment and exchanger pressure testing. Telltale holes must not be plugged during the exchanger pressure test. 16.3.13 Hydrostatic test pressure shall be held for a minimum of one hour. 16.4 Repairs during Fabrication 16.4.1 The Saudi Aramco Engineer must review and approve crack repair procedures, required by the applicable Code, prior to commencement of the repair work. It is the responsibility of the manufacturer to ensure that repairs done by the mill of any material defects, per the applicable Code, are documented. After completion of repairs required by the applicable Code, the following shall be repeated: a) b) Heat treat the repaired section if it has been heat-treated prior to the repairs. All nondestructive examinations (radiography, magnetic particle, dye-penetrant, etc.) performed on the repaired section prior to the repairs.
16.4.2
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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. The nameplate and its mounting bracket shall be located such that the nameplate is easily readable from grade or platform. The 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 UG-116 of the Code shall be stamped or engraved such that the nameplate material is permanently deformed with the symbols. Exchangers manufactured inside and outside Saudi Arabia shall be Code stamped for all services in accordance with the Code. Nameplates shall be 3 mm minimum thickness and manufactured from type 304 stainless steel or Monel and welded to the mounting bracket according to PIP VEFV1100. Mounting bracket shall be the same material as the shell, and shall be continuously welded and positioned such as not to allow for collection of moisture or rain.
17.2 17.3
17.4
18
Coatings and Painting 18.1 The types of coating and painting systems to be used shall be in accordance with the data sheet and the Saudi Aramco Painting Systems attached to the purchase order. Prior to coating or painting, internal and external surfaces shall be cleaned to remove all scale, rust, grease, dirt, weld spatter and foreign objects. Gasket contact surfaces shall not be painted.
18.2 18.3 19
Shipping Requirements 19.1 General 19.1.1 Prior to shipping, exchangers are to be completely dried and then cleaned from all loose scale, weld slags, cleaned and thoroughly dried to the satisfaction of the Saudi Aramco Inspector. 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.
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19.1.2
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. The marking material shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, or other halogens. Export packaging, marking and shipping shall be in accordance with the purchase order.
19.1.4 19.1.5 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 COCTEC VCI-309 or 307 or equivalent, applied at a rate of 0.3 kg/m. The inhibitor selected must be appropriate for the metallurgy of the exchanger. Desiccants may only be used with approval of the Saudi Aramco Engineer. Exchangers must be sealed vapor tight for the inhibitor to be effective. Alternatively, nitrogen blanketing or temporary coatings in accordance with MIL-C-16173 Grade IV (example Tectyl 846) or a vapor proof bag with moisture control may be used. 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. For exchangers which have permanent internal coatings, the Exchanger Manufacturer shall contact the Saudi Aramco Engineer for any corrosion protection required.
19.2.2
19.2.3 19.2.4
19.2.5
19.2.6
19.3
External Protection 19.3.1 The protection of external surfaces shall be obtained by using one of the following: 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. Prepare the surface and apply the complete (primer and final coatings) Saudi Aramco surface preparation, and coating and painting system in the shop.
2)
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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. 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. 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. Flanges with permanent blind flanges or covers shall be secured with the gaskets and bolting required for service.
19.3.3
19.3.4
19.3.5
20
Drawings, Calculations and Data 20.1 20.2 The Exchanger Manufacturer shall prepare drawings, calculations, and data in accordance with Form NMR-7922-3, Nonmaterial Requirements. Drawings and calculations which are approved by the Design Engineer shall not relieve the Exchanger Manufacturer of their responsibilities to comply with the applicable Code, and this specification. As-built thickness of pressure components shall be specified by the Design Engineer on the Safety Instruction Sheet (SIS) Form SA 2713-ENG after the completion of fabrication. 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.
20.3
20.4
6 September 2008
Revision Summary Major revision.
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Materials System Specification

Saudi Aramco DeskTop Standards

Next Planned Update: 6 September 2013 Page 1 of 30

Primary contact: Anizi, Salamah Salem on 966-3-8746139

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

SAES-H-001 SAES-H-101 SAES-W-010

32-SAMSS-027 Manufacture of Electric Heat Exchangers

Welding Research Council Bulletin

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

7.3.9 7.3.10 7.3.11 7.3.12

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

7.8.3 7.8.4 7.8.5

32-SAMSS-027 Manufacture of Electric Heat Exchangers

7.9.2 7.9.3 7.9.4

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

Shells and Heads 5 mm including corrosion allowance.

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

Use of internal reinforcing elements is not permitted.

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

10.3.7 10.3.8 10.4

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

12.2 12.3 12.4

12.5 12.6 12.7

32-SAMSS-027 Manufacture of Electric Heat Exchangers

13.1.5 13.1.6 13.1.7

32-SAMSS-027 Manufacture of Electric Heat Exchangers

Welding All welding shall be in accordance with the requirements of SAES-W-010.

14.1.3 14.1.4 14.2

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

16.3.2 16.3.3 16.3.4 16.3.5

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

32-SAMSS-027 Manufacture of Electric Heat Exchangers

19.1.4 19.1.5 19.2

32-SAMSS-027 Manufacture of Electric Heat Exchangers

Revision Summary Major revision.

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