Engineering Encyclopedia

Saudi Aramco DeskTop Standards

COURSE OBJECTIVE EXERCISE

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.

Chapter : Mechanical For additional information on this subject, contact

File Reference: MEX-210.06 PEDD Coordinator on 874-6556
Engineering Encyclopedia Evaluating Heat Exchanger Design and Installation

Course Objective Exercise

Section Page

INFORMATION ............................................................................................................... 2

INTRODUCTION............................................................................................................. 2

WORK AIDS.................................................................................................................... 3

WORK AID 1: PROCEDURE FOR DETERMINING WHETHER A

CONTRACTOR DESIGN PACKAGE FOR A NEW HEAT EXCHANGER MEETS
SAUDI ARAMCO REQUIREMENTS............................................................................... 3

WORK AID 2: PROCEDURE FOR DETERMINING THE NECESSARY

MAINTENANCE OR REPAIR REQUIREMENTS FOR AN EXISTING HEAT
EXCHANGER.................................................................................................................. 9

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Course Objective Exercise

INFORMATION

INTRODUCTION
Previous modules covered the material that is necessary for
participants to achieve the overall course objective. This module
does not present any new technical material. Instead, this
module provides participants with the opportunity to apply the
material that was discussed during the course to solve actual
work tasks. The work tasks used in this module are provided by
the participants and consist of either a heat exchanger
Contractor Design Package or a heat exchanger Inspection and
History Report. The typical content of these items was
discussed in earlier modules.

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Course Objective Exercise

WORK AIDS

WORK AID 1: PROCEDURE FOR DETERMINING WHETHER A

CONTRACTOR DESIGN PACKAGE FOR A NEW HEAT
EXCHANGER MEETS SAUDI ARAMCO
REQUIREMENTS
This Work Aid provides an overall procedural summary of the steps that are required in
order to review a Contractor Design Package for a new heat exchanger. The Work Aid
highlights the information that must be obtained and reviewed and references
appropriate prior modules and Work Aids for additional information. Note that reviewers
must always look for information that may be missing from the packages that they
review. Reviewers also cannot assume that this Work Aid contains everything that
should be checked. participants must also use their own experience, prior reviews that
they have made, problems that they have seen, and anything else that may be useful in
performing their evaluations.
Note that this Work Aid only contains information that is specific to heat exchangers.
participants must remember to consider topics that were discussed in MEX 202
relative to pressure vessels that also apply to heat exchangers.
1. Identify the information that is contained in the Contractor Design Package
that is to be reviewed to determine if the information is complete. Note that
there will be some variations in this information based on whether the heat
exchanger is a shell-and-tube type or an air-cooled type. The Contractor
Design Package should include at least the following items:
• Heat exchanger Design Specification Sheet.
• Fabrication drawings for all heat exchanger components, such as the
shell, heads, channel, tubesheet, header box, tubes, flanges, and nozzles.
• Material specifications for all heat exchanger components.
• Inspection requirements.
• Hydrotest requirements.
• Original design calculations for all heat exchanger components.
• Completed Safety Instruction Sheet.

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Course Objective Exercise

2. Gather all the industry and Saudi Aramco reference material that must be used to
evaluate the Contractor Design Package. This reference material includes the
following items:
• ASME Code Section VIII Division 1 or Division 2 (as appropriate)
• ANSI/ASME B16.5
• For a shell-and-tube heat exchanger:
- TEMA
- API-660
• For an air-cooled heat exchanger:
- API-661
• SAES-E-001
• SAES-A-004
• SAES-A-005
• SAES-W-001
• SAES-W-010
• For a shell-and-tube heat exchanger:
- 32-SAMSS-007
• For an air-cooled heat exchanger:
- 32-SAMSS-011
3. Identify the specified design temperature, design pressure, and other design
conditions.
Shellside Tubeside
Design Temperature, °C (°F)
Shellside Tubeside
Design Pressure, kPa (psig)
Corrosion Allowance, mm (in.)
Service
Special Service Considerations
Sour Wet Yes No
Lethal Yes No

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Course Objective Exercise

4. Determine if the specified design conditions that are summarized in Step 3 meet
Saudi Aramco requirements. Refer to MEX 210.03, Work Aid 1.
5. Determine if the specified materials meet Saudi Aramco material selection
requirements. Refer to MEX 210.01, Work Aid 1 for shell-and-tube heat
exchangers and Work Aid 2 for air-cooled heat exchangers. Use the tables that
follow to record the specified information and your conclusions.
a. Shell-and-tube heat exchangers

Specified Material Acceptable

Exchanger Component
Specification Yes No
Tubes

Stationary tubesheet/cladding
Floating tubesheet/cladding
Channel or bonnet/cladding
Channel cover/cladding
Shell/cladding
Shell cover/cladding
Backing ring
Floating head cover/cladding
Baffles/supports
Longitudinal baffle
Supports
Bolting: Shell cover to shell

Channel to shell

Channel cover to channel

Floating head cover to

tubesheet

Gaskets: Shell cover to shell

Shell to stat. tubesheet

Channel to stat. tubesheet

Channel cover to channel

Floating head cover to tubesheet

Nozzle neck/flanges

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Course Objective Exercise

b. Air-cooled heat exchanger

Specified Material Acceptable
Exchanger Component
Specification Yes No
Tubes
Header
Tubesheet
Plugsheet
Plug
Nozzle neck/flange
Plug Gasket
Hub
Fan Blade

6. Determine if the specified mechanical design calculations and dimensions for heat
exchanger components are acceptable. Refer to MEX 210.03, Work Aid 2 for shell-
and-tube heat exchangers and Work Aid 3 for air-cooled heat exchangers. Use the
checklists that follow to record your conclusions.
a. Shell-and-tube heat exchangers
Acceptable
Component
Yes No
Girth Flanges
Header
Flat (channel) cover
Internal floating head
Tubesheet
Tubes
Pass partition
Nonpressure containing components

b. Air-cooled heat exchangers

Acceptable
Component
Yes No
Tube bundle
Header

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Course Objective Exercise

7. Determine if the Safety Instruction Sheet for a shell-and-tube heat exchanger has
been correctly completed. Refer to MEX 210.03, Work Aid 4.
8. Determine if the fabrication details for the heat exchanger are acceptable. Refer to
MEX 210.04, Work Aid 1. As a minimum, check the following items:
a. For a shell-and-tube heat exchanger:

• Fabrication details in accordance with 32-SAMSS-007, TEMA, and API-660.

These include items such as the following:
- Welding procedures and details
- Nozzle welds
- Weld hardness for exchangers in sour wet service
- Pass partition plate welding
- Heat treatment

• Tube-to-tubesheet joint details

• Dimensional tolerances in accordance with TEMA and API-660
b. For an air-cooled heat exchanger:

• Fabrication details in accordance with 32-SAMSS-011 and API-661. These

include items such as the following:
- Welding procedures and details
- Gasket contact surfaces
- Pass partition plate welding

• Tube-to-tubesheet joint details

• Dimensional tolerances in accordance with API-661
9. Determine if the specified testing and inspection plans are acceptable. Refer to
MEX 210.04. The following checklist may be used to assist in this determinations.
a. General inspection and testing requirements

• Extent of radiography specified:

Spot 100%
Consistent with weld joint efficiency used?
Yes No

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Course Objective Exercise

• Other specified inspections:

Acceptable? Yes No

• Type of pressure test specified:

Hydrostatic Pneumatic
If pneumatic, confirm that there is justification for a pneumatic pressure test,
that its use has been approved, and that detailed procedures and safety
precautions have been prepared.

• Shop hydrotest:
- Pressure, kPa (psig)

• Confirm that inspection and testing is in accordance with Saudi Aramco Form
175 for the specific type of heat exchanger.
b. Confirm that the inspection and testing of shell-and-tube heat exchangers meet the
requirements of 32-SAMSS-007, TEMA, and API-660.

c. Confirm that the inspection and testing requirements of air-cooled heat exchangers
meet the requirements of
32-SAMSS-011 and API-661.

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Course Objective Exercise

WORK AID 2: PROCEDURE FOR DETERMINING THE NECESSARY

MAINTENANCE OR REPAIR REQUIREMENTS FOR AN
EXISTING HEAT EXCHANGER
This Work Aid provides an overall procedural summary of the steps that are required in
order to review the Inspection and History Report for an existing heat exchanger. The
Work Aid highlights the information that must be obtained and reviewed and references
appropriate Work Aids that are contained in MEX 210.05. Note that reviewers must
always look for information that may be missing from the reports that they review.
Reviewers also cannot assume that this Work Aid contains everything that should be
checked. participants must also use their own experience, prior reviews that they have
made, problems that they have seen, and anything else that may be useful in
performing their evaluations.
Note that this Work Aid only contains information that is specific to heat exchangers.
participants must remember to consider topics that were discussed in MEX 202 relative
to pressure vessels that also apply to heat exchangers.
1. Gather the information that is identified in Steps 1 through 3, Step 5 and Step 6 of
Work Aid 1, at least for the portions of the heat exchanger that will be evaluated.
Note that, if it is desired to rerate the heat exchanger for new design conditions,
these new conditions must be identified.
2. Identify the following additional information:
• Year heat exchanger placed into operation .
• Any changes in service and when these changes occurred.
Service Year
3. Review the Inspection and History Report that has been provided and identify the
following:
• Specified initial and subsequent external inspection intervals.
• Changes that have been made to the subsequent inspection intervals and the
reasons for the changes.
• Repairs or alterations that have been made to the heat exchanger, including
information on when and why these modifications were made.
• Defects or deterioration in the heat exchanger that have been noted in the
inspection report. Use the following to assist in gathering the necessary
information:
- Cracks
+ Location
+ Length

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Course Objective Exercise

+ Depth
- General Corrosion
+ Location
+ Length and Width, mm (in.)
+ Remaining Thickness, mm (in.)
- Pitting
+ Location
+ Affected Area, mm2 (in.2)
+ Maximum Depth
- Tube Leaks
+ Location
+ Number
- Tube-to-Tubesheet Joint Leaks
+ Location
+ Number
- Damaged Tubesheet Ligaments
+ Location
+ Number
- Replaced Tubes
+ Location
+ Number
- Leaking Girth Flanges
+ Location
- Tube Vibration Identified
Yes No

If "yes," describe damage (if any)

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Course Objective Exercise

4. Based on the information that was determined in Steps 1 through 3, determine the
appropriate initial and subsequent external and internal inspection frequencies.
Refer to MEX 202.05, Work Aid 1 for the general procedure that is also applicable
to heat exchangers. Note that it may be necessary, based on the information that
is contained in the Inspection and History Report, to adjust the subsequent
inspection frequencies that were originally specified.
5. Based on the information that was determined in Steps 1 through 4, determine if
the heat exchanger is suitable for continued service in view of the corrosion and/or
other deterioration that has been reported. Refer to MEX 210.05, Work Aid 1.
6. If Step 5 determines that the heat exchanger is not suitable for continued operation
at the desired design conditions, determine the appropriate design and fabrication
details for any repairs or alterations that are required. Refer to MEX 202.05, Work
Aid 3 for the general procedure that is also applicable to heat exchangers. Refer to
MEX 210.05 for repair options that apply specifically to heat exchangers.
7. If the heat exchanger is to be rerated to new design conditions, determine if this
rerating is possible based on information that was determined in Steps 1 through 5.
Refer to MEX 210.05, Work Aid 2.
Note: In situations where it is not possible to rerate the heat exchanger to the desired conditions, it may
be desirable to determine the maximum pressure/temperature combinations under which the heat
exchanger is capable of operating.

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