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32-SAMSS-011
Manufacture of Air-Cooled Heat Exchangers
19 February 2013
Scope............................................................. 2
Normative References.................................... 3
General........................................................... 7
Proposals....................................................... 7
Documentation............................................... 8
Design............................................................ 8
Materials....................................................... 15
10
11
12
Supplemental Requirements........................ 25
Page 1 of 27
The following paragraph numbers refer to API STD 661, 5th Edition, March 2002,
which is part of this specification. The text in each paragraph below is an addition,
exception, modification, or deletion to API STD 661 as noted. Paragraph numbers not
appearing in API STD 661 are new paragraphs to be inserted in numerical order.
1
Scope
This specification covers the minimum mandatory requirements for the manufacture of
new air-cooled heat exchangers (herein referred to as exchangers). It does not cover
exchangers that undergo repairs or alterations.
This specification does not cover skid mounted exchangers, or exchangers that are part
of air conditioning equipment or exchangers that do not fall in the general exchanger
types covered in API STD 661.
1.1
GENERAL
1.1.1
The Design Engineer is responsible for specifying the process data, the
mechanical design requirements, and completing the API exchanger data sheet.
1.1.2
1.1.3
1.1.4
When specified, compliance with the latest edition of ASME SEC VIII D2,
Pressure Vessels, Alternative Code Rules is mandatory.
1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
Exchangers in lube and seal oil services shall also conform to 32-SAMSS-013.
1.1.9
Exchangers in lube and seal oil services shall also conform to in addition to
the requirements of this specification.
Page 2 of 27
1.1.10
1.1.11
The edition of the Code to be used for the manufacture of exchangers shall
be the edition in effect at time of purchase.
1.1.12
1.2
CONFLICTING REQUIREMENTS
1.2.1
1.2.2
Any conflicts between this specification and other Saudi Aramco Materials
System Specifications (SAMSSs), Saudi Aramco Engineering Standards
(SAESs), Industry codes and standards, and Saudi Aramco Standard
Drawings (SASDs) and Forms shall be resolved in writing by the Company
or Buyer Representative through the Manager, Consulting Services
Department of Saudi Aramco, Dhahran.
1.2.3
Normative References
Materials or equipment supplied to this specification shall comply with the latest edition
in effect at time of purchase of the references listed below, unless otherwise noted.
Saudi Aramco References
Saudi Aramco Engineering Procedure
SAEP-302
Page 3 of 27
17-SAMSS-503
32-SAMSS-013
32-SAMSS-031
Noise Control
SAES-A-112
SAES-A-206
SAES-H-001
SAES-W-010
Form NMR-7922-2
API RP 945
Page 4 of 27
Nondestructive Examination
ASME B16.5
ASME SA-20
ASME SA-435
NACE MR0175 /
ISO 15156
3.12
Amine Services: All amine solutions including MEA, DGA and ADIP.
3.13
3.14
3.15
3.16
Exchanger Unit: One or more tube bundles in one or more bays for an
individual service.
3.17
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3.27
3.28
3.29
2.
2.
3.
Commentary Note:
HIC resistant steel is not required in caustic services, lean amine systems
and rich amine DGA systems.
General
Proposals
5.12
5.13
5.14
The following shall be guaranteed for the length of the warranty period
specified in the purchase order or contract documents:
1)
2)
drop.
3)
4)
Documentation
6.1
Approval Information
6.1.4
6.1.5
6.2
Final Records
(Exception) The Exchanger Manufacturer shall prepare and submit final
records in accordance with Form NMR-7922-2, Nonmaterial Requirements.
Design
7.1
7.1.1
General
7.1.1.14
Each tube bundle shall have one header free to move with thermal
expansion of the tubes and shall have sliding plates at the moving end both
on structure and on bundle.
7.1.3
7.1.3.4
The MDMT shall be used to determine the requirements for impact testing
in accordance with Section 8 of this specification.
7.1.4
7.1.4.2
For exchangers subjected to steam out, the Design Engineer shall specify on
the data sheet the external design pressure and corresponding temperature.
Page 8 of 27
7.1.4.3
7.1.6
Headers
7.1.6.1
General
7.1.6.1.1
7.1.6.1.10
7.1.6.2
7.1.6.2.3
7.1.8
Gaskets
7.1.8.10
Cover plate and bonnet joints shall be designed with confined or semiconfined gaskets.
7.1.8.11
7.1.9
1.
3.
All bolting with minimum 10% spare bolting (3 minimum for each
size) per exchanger.
Page 9 of 27
7.1.9.4
through
7.1.9.10
(Exceptions)
Flanged connections shall be one of the following types:
1)
2)
Forged steel welding neck flange with seamless pipe, or rolled plate
with 100% radiography. Nozzle flange bore shall match the nozzle
neck bore.
3)
7.1.9.11
7.1.9.23
7.1.9.24
7.1.9.25
7.1.9.27
7.1.10
7.1.10.4
The Design Engineer shall calculate the forces and moments acting on
inlet and outlet connections based on allowable bundle movements and
frictional forces advised by the Exchanger Manufacturer. The Design
Page 10 of 27
Engineer shall also take into account the moments and forces acting on the
headers due to piping loads.
7.1.11
Tubes
7.1.11.2
7.1.11.7
2)
3)
4)
5)
Fins, which are bonded to the outside surface of the tubes by hot-dip
galvanizing or brazing, shall not be used.
6)
7.1.11.14
Design and selection of fins shall be such that fins will not suffer any
distortion when subjected to the design requirements with fans out of service.
7.1.11.15
Tube sizes and spacing shall be uniform throughout bundles in the same Unit.
7.2
Air-side Design
7.2.1
General
7.2.1.1
The Design Engineer shall specify all meteorological data, and location of
exchanger with respect to other buildings and equipment on the data sheet.
7.2.1.5
Hot-air re-circulation units shall be designed so that the motors and the
drivers are not exposed to heated re-circulated air temperature higher than
their design temperature.
7.2.1.6
Gear- box vents, oil filters, sight glasses and lubrication connections shall
be located outside the plenums.
7.2.1.7
7.2.2
Noise Control
7.2.2.1
(Exception) Design Engineer shall specify limits for the sound pressure
levels (SPL) per fan at the designated locations, on Form 7305-ENG.
The Exchanger Manufacturer shall complete Form 7305-ENG and ensure
that the required limits as specified for SPL can be achieved by supplying
test results of a representative bay.
7.2.3
7.2.3.14
7.2.3.18
7.2.3.19
Induced draft fans shall have all mounting and bearing arrangements
designed to allow removal and installation of fans and hubs without
damaging the bundles.
7.2.4
7.2.4.7
7.2.4.8
7.2.4.9
7.2.6
Fan Guards
7.2.6.1
(Exception) Removable fan guards shall be provided for both the forced
and the induced draft exchangers.
7.2.7
Drivers
7.2.7.1
General
7.2.7.1.3
7.2.7.2
7.2.7.2.10
7.2.8.2
Belt Drives
7.2.8.2.1
7.2.8.2.14
7.2.9
7.2.9.1
7.2.10
Louvers
7.2.10.18
7.2.10.26
All control louvers shall be provided with side mounted hand handles.
7.3
Structural design
7.3.1
General
7.3.1.7
7.3.1.9
7.3.1.10
7.3.1.12
Page 13 of 27
7.3.1.13
Each tube bank shall be provided with a grounding lug connection welded
to the support of each unit.
7.3.1.15
7.3.2
Vibration Testing
7.3.2.2
7.3.2.4
Vibration in any axis on all bearings shall be less than 4 mm/sec, and
10 m/sec. sec. (1 g) RMS in the frequency range of 0-5 kHz.
7.3.2.5
7.3.2.6
7.3.3
7.3.3.1
7.3.5
7.3.5.9
7.3.5.10
A 1070 mm wide platform shall be provided for each header for the length
of each header. Crosswalks 760 mm wide shall connect header access
platforms at the ends of each bank. An intermediate walkways intervals
shall be provided when the bank length exceeded 40 m. Interconnections
between maintenance and header walkways shall not be used to satisfy the
intermediate connection requirements.
Page 14 of 27
7.3.5.11
One stairway from grade to both header walkway and maintenance walkway
shall be provided and one ladder at the other end. For banks 60 m or more
in length one stairway shall be provided at each end of each bank.
7.3.5.12
Pipe- rack -mounted banks 60 m and shorter shall be provided with one
stairway at one end and ladder at the other. Banks greater than 60 m shall
have intermediate ladders to grade on each side and spaced not more than
30 m with access to both maintenance and header walkways.
Auxiliary stairs shall be used at changes in walkway elevations and offsets
around obstructions.
7.3.5.13
7.3.6
Lifting Devices
7.3.6.7
Structures shall be designed to permit use for the handling and rigging of
driver assemblies that are not accessible to mobile handling and lifting
equipment.
7.3.6.8
Materials
8.1
GENERAL
8.1.1
8.1.2
(Exception) Cast iron pressure parts shall not be used for any service.
8.1.3
through
8.1.5
8.1.7
8.1.8
All materials for pressure retaining parts must be clearly identified and
provided with Mill Test Certificates. Lack of adequate identification and
certification shall be cause for rejection.
Page 15 of 27
8.1.9
8.1.10
Suitability of low chrome alloy steels for use for exchangers in hydrogen
services above 205C (400F) shall be qualified through chemical analysis,
mechanical testing including but not limited to tensile, hardness, micro
hardness, 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.
8.1.11
8.1.12
8.1.13
Resistant Materials
8.1.13.1
For exchangers designated for wet sour HIC (hydrogen induced cracking)
services as defined in this specification with normal operating design
temperatures between 0C (32F) and 150C (212F), all plates for headers
shall be made of HIC resistant steel qualified in accordance with
01-SAMSS-016.
8.1.14
All the components (header, plain tube, fin tube, nozzle, blade, shaft, fan
ring, plenum, motor and plug) shall be fabricated by Saudi Aramco
approved exchanger manufacturer.
8.2
Headers
8.4
Other Components
8.4.2
8.4.7
Steel used for slide plates shall be type 316 stainless steel. Carbon steel
slide plates shall not be used.
8.4.8
Page 16 of 27
1)
2)
3)
4)
8.5
Impact testing
8.5.1
8.5.2
8.5.3
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
8.5.4
Welding
9.1.1
General
9.1.1.1
through
9.1.1.4
Page 17 of 27
9.1.1.5
Corner weld joints in box headers shall be in accordance with ASME SEC
VIII D1.
9.1.1.6
The beveled edges of carbon steel plates with thickness 25 mm and thicker
and all ferrous alloy plates shall be magnetic particle or liquid penetrant
examined, after cutting, for linear discontinuities. Defects shall not exceed
limits as per ASME SA-20.
9.1.1.7
9.1.1.8
Set-in nozzles shall be ground flush to the inside of the headers with a
smooth inner edge radius.
9.1.1.9
9.1.1.10
9.2
9.2.5
Code exemptions for PWHT of P4 and P5 materials are not permitted for
applications involving either wet sour service or hydrogen or materials
exceeding 1.5% nominal chromium content.
9.2.6
9.2.7
Final PWHT shall follow all welding and repairs but shall be performed
prior to any hydrotest or other load test.
9.2.8
9.2.9
9.3
Tube-to-tubesheet Joints
9.3.1.2
9.3.4.4
Welded tube to tube sheet joint shall not be used for services that require
postweld heat treatment for resistance due to the service such as caustic or
amine.
9.4
9.4.4
For spiral wound gaskets, 125 to 250 AARH, in all services, except
hydrogen.
2)
3)
9.5
Thread lubrication
9.8
2)
2)
9.9
Hot Forming
9.9.1
9.9.2
For any hot forming operation, the procedure shall be submitted to Saudi
Aramco Engineer for approval prior to commencement of any fabrication
requiring hot forming. The procedure shall describe all heat treatment
Page 19 of 27
operations and tests to be performed. The tests shall include, but not
limited to, all of the mechanical tests required by the original material
specification.
10
General
10.1.3
10.1.5
10.1.6
10.1.7
10.1.8
10.1.9
Examination of all welds shall include a band of base metal at least one
inch wide on each side of the weld.
10.1.10
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. 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.
Page 20 of 27
10.1.11
10.1.12
Saudi Aramco may reject the use of any materials, equipment, or tools that
do not conform to the specification requirements, jeopardize safety of
personnel, or impose hazard of damage to Saudi Aramco property.
10.1.13
The Exchanger Manufacturer shall provide the Saudi Aramco Inspector all
reasonable facilities to satisfy him that the work is being performed as
specified.
10.1.14
10.1.15
Prior to final inspection and pressure testing, the inside and outside of the
exchanger shall be thoroughly cleaned of all slag, scale, dirt, grit, weld
spatter, paint, oil, etc.
10.1.16
Inspection at the mill, shop, or fabrication yard shall not release the
Exchanger Manufacturer from responsibility for repairing or replacing any
defective material or workmanship that may be subsequently discovered in
the field.
10.2
Quality Control
10.2.1
10.2.1.1
10.2.1.2
10.2.1.3
Lethal services
2)
Hydrogen services
3)
Cyclic services
4)
5)
10.2.1.4
2)
10.2.1.5
10.2.8
10.2.13
10.2.14
10.2.15
10.2.16
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
10.2.17
10.3
Pressure Test
10.3.3
1)
2)
3)
For lube-oil and seal-oil exchangers the fluid to be used for pressure
testing shall be the system fluid.
10.3.4
10.3.8
10.3.9
10.3.10
For Division 1 exchangers: Test pressure shall be 1.3 times its calculated
MAWP in the hot and corroded condition multiplied by the lowest ratio (for
the materials of which the tube side is constructed) of the allowable stress
for the test temperature to the allowable stress for the design temperature.
For Division 2 exchangers: Test pressure be 1.25 times its calculated
MAWP in the hot and corroded condition multiplied by the lowest ratio (for
the materials of which the tube side is constructed) of the stress intensity for
the test temperature to the stress intensity for the design temperature.
10.3.11
10.5
Nameplates
10.5.1
10.5.4
10.5.5
10.5.6
10.5.7
The empty and water flooded weights of bundles shall be marked on the
nameplates.
Page 23 of 27
11
11.2.1
through
11.2.4
11.2.5
11.2.6
11.3
11.3.1
11.4
11.5
11.6
11.7
Exchangers shall be protected from salt water and salt water spray during
shipment.
Page 24 of 27
12
Supplemental Requirements
12.1
General
The requirements of API STD 661 section 12 shall be applied for the
conditions outlined in API STD 661 paragraph 12.1 if specified by the
Design Engineer.
12.3
Examination
12.3.14
19 February 2013
Revision Summary
Revised the Next Planned Update. Reaffirmed the content of the document, and reissued
with editorial revision to change the primary contact person.
Page 25 of 27
-46 to 0C
Nozzle necks
SA-333 Grade 6
1 to 425C
SA-516 Grade 60
SA-516 Grade 70, or
SA-537 Class 1 or
(1)
SA-285 Grade C
SA-106 Grade B
(1)
SA-53 Grade B
351 to 645C
SA-387
Grades 11, 12, or 22
SA-335 P11, 12, or 22
SA-334 or
SA-249 Type 304
SA-179 or SA-214
SA-350 LF2
SA-105
Wrought fittings
SA-420 WPL6
SA-234 WPB
Studs/nuts for
pressure connections
SA-320 L7 w/
SA-194 Grade 4
SA-193B7/
SA-194 Grade 2H
Tubes
(2)
SA-179 or SA-214 or
SA-213 Type 304
SA-182
F11, 12, or 22
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 30C 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 212F (100C), 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, Grade 4, S2, or S9.
Flanges above 24-inch diameter shall be SA-266, Grade 4, S2, or S9.
(2)
Studs and nuts are restricted to: SA-193 B7M or L7M and SA-194 Grade 2HM.
(3)
(D) Low alloy materials shall not be mixed, i.e., an exchanger requiring 1 1/4 Cr-1/2 Mo materials for pressure
components shall have all pressure parts (with the exception of tubes) manufactured from 1 1/4 Cr-1/2 Mo.
(E)
All chrome 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 header.
Specific Notes:
(1)
SA-36, SA-53, SA-283, and SA-285 materials may be used for utility services only.
(2)
Tubes in hydrogen, wet sour, amine and caustic services shall be seamless.
Page 26 of 27
t < 1/2
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
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.
SA 53
SA 105
SA106
SA 182
SA 182
SA 203
SA 204
SA 266
SA 266
SA 333
SA 333
SA 333
SA 335
SA 336
SA 336
SA 350
SA 350
SA 387
SA 387
SA 442
SA 516
SA 533
SA 537
SA 420
SA 234
SA 234
Material Specification
Gr. B
Gr. B
Gr. F11 and F12
Gr. F22
Gr. D and E
Gr. A, B and C
Gr. 1
Gr. 2 and 4
Gr. 1
Gr. 3
Gr. 6
Gr. P11, P12 and P22
Gr. F12
Gr. F11 and F22
Gr. LF2
Gr. LF3
Cl. 1, Gr. 11, 12 and 22; Cl. 2, Gr. 12
Cl. 2, Gr. 11 and 22
Gr. 55 and 60
Gr. 70
Cl. 1
Cl. 1
Gr. WPL3 and WPL6
Gr. WPB
Gr. WP11, WP12 and WP22
Page 27 of 27