Inspection Procedure

01-SAIP-38 14 September 2014

Brazed Aluminum Heat Exchanger Inspection Requirements
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope……………........................................... 2
2 Purpose.......................................................... 2
3 References..................................................... 2
4 Definitions....................................................... 3
5 Instructions……………………………..….…… 5
6 Responsibilities……………………..….……… 9

Appendix A………………………………………… 11
Appendix B………………………………………… 12

Previous Issue: 12 May 2014 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 14
Primary contact: Kakpovbia, Anthony Eyankwiere on +966-13-8801772

Copyright©Saudi Aramco 2014. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

1 Scope

1.1 This SAIP describes minimum requirements for inspection of brazed aluminum
heat exchangers (BAHE) in Saudi Aramco operating facilities.

1.2 The SAIP does not apply to Saudi Aramco project activities and shall not be
included in purchase orders or contract documents issued to outside agencies.

2 Purpose

The purpose of this procedure is to ensure:

2.1 the structural integrity of BAHEs in Saudi Aramco operations and uniform
compliance with all requirements of this procedure.

2.2 minimum inspection requirements for controlling and mitigating mercury

hazards are in place to enhance personal and operational safety and fulfill the
requirements of Saudi Aramco Engineering Standards for mercury rich process
stream related activities.

2.3 BAHE inspection is conducted at planned intervals to maintain asset integrity,

reliability, process stream containment and external condition requirements.

2.4 BAHE inspection program including its requirements, tools, procedures, roles
and responsibilities are well defined and auditable.

2.5 adequate resources are provided for BAHE inspection to mitigate liquid metal
embrittlement (LME), amalgam corrosion (AMC) and other likely damage
mechanisms associated with BAHE operation.

3 References

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-1135 On-Stream Inspection Administration
SAEP-1161 Testing & Inspection (T&I) Reporting Procedure

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-005 Safety Instruction Sheet

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

Saudi Aramco General Instructions (GIs)

GI-0002.100 Work Permit System
GI-0002.102 Pressure Testing Safely
GI-0006.012 Isolation, Lockout and Use of Hold Tags

3.2 Industry Codes and Standards

ALPEMA - 1994 Brazed Aluminum Plate-Fin Heat Exchanger
Manufacturer’s Associations

American Society of Mechanical Engineers

ASME SEC II, V, VIII & IX Boiler and Pressure Vessels
ASME B31.3 Process Piping
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.4 Large Diameter Steel Flanges, Series

American Society for Testing and Materials

ASTM E 94 Recommended Practice for Radiographic Testing

American Society of Civil Engineers

ASCE 7 Minimum Design Loads for Buildings and Other
Structures

American Welding Society

AWS A2.4 Symbols for Welding and Non-destructive Testing

American Petroleum Institute

API RP 520 PT II Sizing, Selection, and Installation of Pressure-
Relieving Devices in Refineries
API RP 521 ERTA Guide for Pressure-Relieving and Depressuring
Systems
API Guide for Inspection of Refinery Equipment, Chapter VII

4 Definitions

Liquid Mercury Embrittlement (LME): Intergranular attack by liquid mercury that

produce sub-yield brittle fracture of susceptible alloys under the appropriate conditions
of stress and environment. The key ingredients for LME cracking to occur are as
follows:

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

● Mecury in direct contact with an aluminum surface.

● A susceptible aluminum microstructure and alloy composition.
● Temperature above the freezing point of mercury (-38.9°C).
● Stress (mechanical or thermal) or residual stress from welding.
● A breach in the aluminum oxide layer that covers the surface of the aluminum.
● Magnesium as an alloy component in base metal or weld.
● Al3Mg2 precipitation in the aluminum alloy grain boundaries.

Alteration: is a physical change to a component described on the original Equipment

Data Sheet that affects the pressure containing capability of the heat exchanger.

Corrosion Allowance: is any metal thickness in excess of the minimum thickness

required by pressure design.

Corrosion Rate: is the amount of metal thickness loss that occurs during a fixed time
period and is usually measured on mils per year (mpy).

Inspector: as described in this SAIP, is a member of the proponent's Operations

Engineering Inspection Group or is an assigned Shops Inspector.

Integrity: means soundness - i.e., free from flaws or defects.

Equipment Data Sheet: is a document furnished by the Manufacturer certifying that

materials, construction, and workmanship conform to Company and industrial
requirements.

Minimum Required Thickness, (Tm): as defined in ASME SEC VIII, is the

calculated thickness required based on the design pressure and temperature exclusive of
corrosion allowance. When the Tm limit is reached, action must be taken to repair,
retire, or derate the equipment.

Repair: is the work necessary to restore a heat exchanger to a safe operating condition.

Rerating: refers to any change, i.e., temperature, pressure, thickness, etc., which would
affect the maximum allowable working pressure. This change is to be documented by
revising the Safety Instruction Sheet and the Equipment Data Sheet.

Safety Instruction Sheet (SIS): gives the minimum allowable thickness based on the
temperature and pressure for each component, and specifies test pressures (refer to
SAES-A-005).

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

5 Instructions

5.1 Safety

5.1.1 All inspection and testing shall be in compliance with GI-0002.100,

“Work Permit System”.

5.1.2 Inspection and testing shall be in compliance with GI-0006.012,

“Isolation, Lockout and Use of Hold Tags”.

5.1.3 Pressure testing shall be in compliance with GI-0002.102, “Pressure

Testing Safely”.

5.1.4 Personal Protection Equipment (PPE) specified for inspection of

equipment in Mercury Rich Process Environment (HgRPE) shall be used
by all involved in inspection and condition evaluation according to this
SAIP.

5.1.5 Ensure that equipment is isolated from all sources of hydrocarbon,

liquid, gases or vapors, prior to making the internal inspection.

5.2 Records

5.2.1 Maintain a permanent and progressive set of records for each exchanger.
These records shall contain copies of the Equipment Data Sheet, Safety
Instruction Sheets (SIS) according to SAES-A-005, and exchanger
number, current condition of the equipment, previous repairs, alterations,
rerating, corrosion rates, and remaining life predictions.

5.2.2 Review records when operating conditions change which could affect the
potential damage mechanisms or corrosion rates. New corrosion
evaluations and run length should be calculated.

5.2.3 Use Checklist provided in Appendix B in addition to the requirement of

SAEP-1161 to document any inspection findings.

5.2.4 Checklists provided in this procedure is a guide on minimum

requirements for conducting surveys. Proponents can include additional
items to the indicated minimum.

5.3 Inspection Intervals

5.3.1 Annual external survey shall be performed on all equipment in HgRPE

and ancilliary systems in plant as per applicable MSAER requirements.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

5.3.2 Pneumatic pressure testing shall be performed every 60 months as part of

the T&I of BAHE for compliance with SAEP-20 requirements.

5.3.3 Nondestructive examination (NDE) requirements specified in this SAIP

shall be performed every 60 months or earlier following any process
upset involving the BAHE.

5.4 Extent of Inspection

5.4.1 Review the operating and inspection history of the BAHE and plan
extent of inspection ensuring compliance with ALPEMA and MSAER.

5.4.2 Perform external visual Inspection according to.MSAER.

5.4.3 Inspect the external condition of inlet and outlet connections.

5.4.4 Inspection of BAHE requires full opening of flanged connection, with

accessible plate areas being cleaned. Accessible plates and platens should
be examined for corrosion, erosion or other defects, with particular
attention to the gasket faces where crevice corrosion may have developed.
Tie-bolts should be checked for possible deformation and cracking.
Reassembly and pressure testing should follow the vendor's procedures.

5.4.5 Moisture from the air should not be allowed into the BAHE in the event
of a shutdown or process upset. Ingress of moisture adds additional risk
to corrosion and cracking failure modes. Isolation and nitrogen purge of
BAHE during shutdown activities is required.

5.4.6 Inspection shall involve non-intrusive identification of the locations and

estimation of quantities of mercury holding in BAHE following upsets.
Mercury contamination of BAHE is a key element in determining the
probability of mercury attack and equipment fitness-for-service.

5.4.7 Non-intrusive inspection (radiography, etc.) and intrusive (videoscope,

visual, etc.) inspection techniques shall be performed during T&I.

5.5 Non-Intrusive Inspection

5.5.1 Non-destructive Examinations (NDE)

Applicable non-destructive examinations shall be performed in

accordance with the construction document. Personnel involved in non-
destructive testing shall be qualified to the applicable ASNT as specified
in the MSAER for the technique.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

5.5.2 Perform ultrasonic wall thickness survey at specified locations

designated for on-stream inspection (OSI) according to SAEP-1135
including the headers and nozzles. Assess the readings relative to
previous or the original data as applicable.

5.5.3 More intensive inspection of BAHE is required if a plant upset occurs

which takes the Mercury Removal Unit (MRU) out of operation for any
period of time.

5.5.4 Radiographic examination shall be used to locate mercury accumulations

in the nozzles and in manifold piping. Minimally, radiography shall
include double wall exposure with the film positioned at the 4, 6, and 8
o’clock positions. Additional radiography shall be conducted as required.
Commentary Notes:

● Because of mercury’s high density relative to aluminum, its deposits may

appear as very distinct white spots or patches on radiographs. Mercury
deposits are normally spherical in nature and more likely to be found in
locations adjacent to the weld.

● Condensed mercury indications in radiographs do not always appear as

spherical deposits. Mercury that condenses in sections below the freezing
point will nucleate as very small particles sometimes termed mercury frost.
The solid particles can be carried to significant distances downstream and
then may reside in drains or against flanges as fine deposits which can
diffuse into piping material or manifold surfaces.

5.5.5 Weld orientations relative to fluid flow direction need to be indicated in

radiographs where mercury droplets are found. Upstream and
downstream of backing rings are vulnerable locations.

5.5.6 Radiographic inspections shall include selected nozzles, flanges and

manifold piping with limited selection of header welds. Butt welds on
nozzle necks shall be subjected to 100% radiographic examination where
practicable.
Commentary Note:

A common location of mercury cracking is the butt weld and heat affected
zone on cold box piping. At this location, mercury can be lodged in the
crevice between the backing ring and the pipe adjacent to a weld.

5.5.7 External weldments on BAHE shall be checked by dye penetrant/magnetic

particle inspection (MPI). MPI shall be used for ferromagnetic materials
and dye penetrant inspection for non-ferrous materials and austenitic
stainless steels.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

5.6 Intrusive Inspection

5.6.1 Intrusive Inspection

Videoscope inspection may be considered for intrusive inspection to

assess contamination and defects. Fiber optic inspection tool consisting
of a video camera and optical cable connected to a recording device
should be used to examine the manifold piping, cold box headers and
nozzles.
Commentary Note:

The bore-scope probe needs to have a light of sufficient intensity that

photographic images taken are clear. Probe tip flexibility is also
important such that the probe can enter nozzles.

5.6.2 Flanges should not be opened until the time for inspection and should be
closed immediately after the inspection is complete. It is important to
prevent moisture from entering BAHE equipment. If the equipment is
purged with nitrogen during the inspection the borescope operator must
use breathing air. If the cold box is purged with air, the air must be dry.

5.6.3 A random 10% of accessible areas of the plate/pipe welds shall have
testing for cracks performed by applying fluorescent dye penetrant ink to
one side of the plate, leaving to soak for a minimum of six hours, and
then examining the opposite side under ultraviolet light. In the event of
cracks or defects being found, the 10% shall be increased to 100%.

5.7 Pneumatic Pressure Testing

5.7.1 BAHE shall be pneumatically tested in accordance with the design code
and in accordance with SAES-A-004.

5.7.2 There shall be a minimum of three (3) pneumatic tests consisting of the
following:

5.7.2.1 Hot side for 30 minutes duration

5.7.2.2 Cold side for 30 minutes duration.

5.7.2.3 Hot side and cold side for 30 minutes duration.

5.7.3 Test media shall be dry air or nitrogen, the proponent department
Specialist/Plant Engineering Unit shall develop the package according to
SAES-A-004 and other applicable MSAERs. Approval of the pneumatic
test package is required before testing.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

5.8 Corrosion Rates, Remaining Life and Inspection Interval

5.8.1 Establish the damage mechanisms and corrosion rates for all components
of the BAHE.

5.8.2 Specialist Engineering Unit shall use the established damage mechanism
and corrosion rates to calculate Tm and the remaining life of the BAHE
components.

5.8.3 Specialist Engineering Unit shall use the calculated Tmin to validate
approved EIS run period or revise the EIS to a shorter inspection interval.

6 Responsibilities

6.1 Operations Superintendent

6.1.1 Authorizes partial acceptance or cancellation of IWS.

6.1.2 Authorizes or approves pneumatic testing.

6.2 Area Operations Foreman

6.2.1 Ensures that BAHE equipment are inspected as per the approved EIS.

6.2.2 Notifies inspector of any operations upset relating to BAHE equipment

during OME meeting.

6.3 Maintenance Area Foreman

Ensures welding consumables and welders are compliant with MSAER.

6.4 Engineering Division Head

6.4.1 Ensures adequate resources are available for BAHE equipment

inspection and asset integrity activities.

6.4.2 Regularly reviews reports provided by OIU on status of BAHE

inspection activities.

6.4.3 Reviews and concurs with the pressure testing package developed by
TSU.

6.5 Operations Inspection Unit Supervisor

6.5.1 Issues required reports on BAHE equipment inspection activities in a

timely manner and not later than monthly.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

6.5.2 Ensures adequate resources including specialized equipment and tools

are available for BAHE inspection work activities.

6.5.3 Reviews and concurs with the pressure testing package developed by
TSU.

6.6 Inspector

6.6.1 Report all defects to operation foremen then issue the required IWS and
LBE as needed.

6.6.2 Conduct annual survey and add finding in unit report.

6.6.3 Address survey in a report to shows the statistic of the findings, action
taken and the privies findings, repairs and pending issues.

6.6.4 Discusses with operations foreman the intent to issue IWS as per this
SAIP.

6.6.5 Consults with specialist engineer if needed.

6.6.6 Trend the findings, action taken and the previous findings, repairs and
pending issues.

6.6.7 Inspect major repairs and upgrade of existing BAHE to approved

Engineering drawings.

6.6.8 Inspect all work to the most current MSAER, codes and standards.

6.6.9 Lead special inspection program for BAHE such as videoscope, infrared
scanning.

6.7 Operations Engineer

6.7.1 Reviews, concurs with and supports pressure testing according to the
package developed by TSU.

6.7.2 Review the IWS and check for any related packages or projects.

6.7.3 Ensures impacted equipment is evaluated following any upsets.

6.7.4 Develop MOC if required.

6.7.5 Contacting other units for any assistance if needed.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

6.8 Technical Support Unit (TSU)/Plant Specialist Engineer

6.8.1 Develops and obtains approval for pressure testing package.

6.8.2 Area BAHE Engineer shall provide technical support as needed to clarify
the related standards and to rectify deficiencies.

6.8.3 Give consultants or coordinate with CSD for issues which require their
involvement or consultant.

Revision Summary
12 May 2014 New Saudi Aramco Inspection Procedure.
14 September 2014 Minor revision for inspection of Brazed Aluminum Heat exchangers (BAHE) following
action item of Mercury Mitigation Committee.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

Appendix A - Schematic of BAHE

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 Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

Appendix B - Braced Aluminum Heat Exchanger Inspection Checklist

Attachment I
Report No.: Date prepared:

Equipment No. & Service: Location/ Area: Plant No.:

Reason for Inspection: Date Inspected:

P&E Inspector: Field insp. Supervisor: Unit Supervisor :

Equipment data:
INDIVIDUAL
LAYERS AND
DESCRIPTION HEADERS INTERNAL DESCRIPTION
DISTRIBUTOR
FINS
Material Design Press.: Kg/cm²g/psig
o o
Shell Thick: mm/ in Design Temp.: C/ F
Corrosion Allowance: mm/ in Corrosion allowance: mm/in
A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected
# ITEM A U NA NI COMMENTS
1.0 Inlet Header and Nozzles
Internal Corrosion (Indication of mercury (Hg) buildups, scales, pits,
1.1
buildup)/Cracking. Describe location, appearance and depth if accessible.
1.2 Excessive mercury/ scale presence. Describe
1.3 Weld condition/corrosion and condition of Pass partition plates if any
1.4 Condition of all plug gasket surfaces and threads
1.5 UT measurement- Header box plates and Nozzles
1.6 Internal and external cracks, erosion/corrosion, deposit
1.7 Condition of attachment welds (Includes Lift lugs, etc.)
1.8 Header plug seat/gasket face and threads if any
1.9 Check instrument connection for corrosion damage
1.10 Check the vent and drain for plugging and corrosion
1.11 External coating/painting if any
1.12 DP test all welds externally for cracks or similar damage

2.0 Outlet Header and Nozzles

Internal Corrosion (Indication of mercury (Hg) buildups, scales, pits,
2.1
buildup)/Cracking. Describe location, appearance and depth if accessible.
2.2 Excessive mercury/ scale presence. Describe
2.3 Condition of Pass partition plate and Weld/ corrosion if any
2.4 Condition of all plug gasket surfaces and threads if any
2.5 UT measurement- Header box plates and Nozzles
2.6 Internal and external cracks, erosion/corrosion, foreign deposit
2.7 Condition of attachment welds (Includes Lift lugs, etc.)
2.8 Header plug seat/gasket face and threads
2.9 Check instrument connection for corrosion damage

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 Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-38
Issue Date: 14 September 2014
Next Planned Update: TBD Brazed Aluminum Heat Exchanger Inspection Requirements

Report No.: Date prepared:

Equipment No. & Service: Location/ Area: Plant No.:

Reason for Inspection: Date Inspected:

P&E Inspector: Field insp. Supervisor: Unit Supervisor :

Equipment data:
INDIVIDUAL
LAYERS AND
DESCRIPTION HEADERS INTERNAL DESCRIPTION
DISTRIBUTOR
FINS
Material Design Press.: Kg/cm²g/psig
o o
Shell Thick: mm/ in Design Temp.: C/ F
Corrosion Allowance: mm/ in Corrosion allowance: mm/in
A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected
2.10 External coating/painting if any
2.11 DP test all external welds for cracks or similar defects

3.0 Individual Layers and Internal Distributor Fins A U NA NI COMMENTS

Visually see through the plug holes for individual layers and internal distributor
3.1
fins end thinning and fouling at both headers.
Obtain 10% random RT of headers and at mid-section to evaluate for mercury
3.2
damage and corrosion.
Carry out Boroscope test to all or 10% of individual layers and internal
3.3
distributor fins and evaluate the results.
3.4 Check the side frames for any possible damage.
3.5 Pressure Test using an approved pneumatic test procedure.
Pressure test each stream of the heat exchanger system individually, with the
3.6
other streams unpressurised.
Oxygen-free nitrogen of dewpoint -40°C or better should be
3.7
used as the test medium.
Areas of unacceptable brazing detected by pressure test are blocked using a
proven rectification procedure developed for this purpose according to the
3.8
BAHE manufacturer’s recommended procedure. Blocking of an active layer
requires engineering division head approval.
Throughout this procedure the safety aspects covered in inspection and
3.9
testing shall be rigidly followed.

4.0 Foundation/Supports
4.1 Condition of supporting columns/ beams and fire proofing
4.2 Condition of support bolts
4.3 Condition of foundation

5.0 General
5.1 Check the cold box for any damage or defects
5.2 Check perlite levels on filing the cold box
5.3 Check the drive assembly for any abnormality
5.4 Check ladder and platforms if they are intact

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