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SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Receiving Inspection of Air-Cooled Heat Exchanger SAIC-E-2005 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A Document Verification

Final Disposition Report was reviewed by the Contractor and Schedule "Q",
A1 submitted to Saudi Aramco within two weeks of acceptance of Att. III, Para.
material or equipment. 3.22

Final Disposition Report includes the following as a minimum:

a. Narrative details of Quality activities performed during
manufacturing and fabrication of the equipment or material.
b. Copies of SAUDI ARAMCO approved waivers to SAUDI Schedule "Q",
A2 ARAMCO’s requirements. Att. III, Para.
c. All SA-175 CONTRACTOR witnessed inspections. 3.24
d. Copies of supplier quality records as specified in SA-175.
e. Copies of all NCR's with final dispositions and resolutions.
f. Outstanding punch list items from pre-shipment inspections.

The Exchanger Manufacturer has submitted final records in 32-SAMMS-011,

A3
accordance with Form NMR-7922-2, Nonmaterial Requirements Para. 5.13
All materials for pressure and non-pressure components conform
32-SAMSS-011,
A4 with Data sheet & are in accordance with Table 1.
Para. 8.1.1
All materials, except carbon steels, is alloy (and verified by the 32-SAMSS-011,
A5
Exchanger Manufacturer in accordance with SAES-A-206). Para. 8.1.9

Exchangers have been Code stamped, with nameplates and

32-SAMSS-011,
A6 nameplate mounting brackets located such that they are not covered
Para. 10.5
by insulation, and are easily readable.

Clad exchangers conformed to 32-SAMSS-031 in addition to the 32-SAMSS-011,

A7
requirements of of 32-SAMSS-011. Para. 1.1.8
Exchangers in lube and seal oil services conformed to 32-SAMSS- 32-SAMSS-011,
A8
013 in addition to the requirements of 32-SAMSS-011. Para. 1.1.9

For Carbon or low-alloy steel the minimum nominal Tube/Plug

Sheets thickness is 20 mm including any corrosion allowance and for API 661 Para
A9
High-alloy steel or other material is 15mm excluding the corrosion 7.1.6.1.6
allowance. For Ref Att-1 Table-1

B Walkthrough of the equipment

Air cooled heat exchanger has no visible damage to the shell, fans or Schedule "Q",
B1
its appurtenances. Att IV,

Each tube bundle have one header free to move with thermal
32-SAMSS-011,
B2 expansion of the tubes and have teflon sliding plates at the moving
Para. 7.1.1.14
end both on structure and on bundle.

Steel used for slide plates is type 316 stainless steel. 32-SAMSS-011,
B3
(NOTE: Carbon steel slide plates shall not be used.) Para. 8.4.7
Plugs are coated with thread lubricant suitable for the design API 661
B4
conditions of the exchanger. Para. 9.5.1

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Receiving Inspection of Air-Cooled Heat Exchanger SAIC-E-2005 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Connections; where a process stream is likely to be stagnant,

projection is limited to 2.5 times connection nominal diameter for 32-SAMSS-011,
B5
vertical connections & 3.5 times connection nominal diameter for Para. 7.1.9.23
horizontal connections.

Integrally reinforced openings (with no reinforcing pads) are provided 32-SAMSS-011,

B6 Design
for all services and design conditions. Para. 7.1.9.24

All nozzles are attached to the header by full penetration full fusion 32-SAMSS-011,
B7 Design
welds. Para. 7.1.9.25

The maximum tube length is 15000 mm, unless otherwise approved 32-SAMSS-011,
B8 Design
by the Saudi Aramco Engineer. Para. 7.1.11.2

The fin type selection are as follows:

1) Fins shall be extruded (integral) type for process inlet temp of
up to and including 300°C.
2) Mechanically embedded fins may be used for a process fluid inlet
temperature of up to 400°C.
32-SAMSS-011,
B9 3) Welded fins, carbon steel on carbon steel, may be specified for a Design
Para. 7.1.11.7
process fluid inlet temperature of up to 450°C.
4) Embedded fins shall be used for cyclic service.
5) Fins, which are bonded to the outside surface of the tubes by hot-
dip galvanizing or brazing, shall not be used.
6) Other types of fins requires approval by the SA Engineer.

For grade mounted exchangers, headroom clearance below unit,

excluding driver arrangement, is not less than 2150 mm between fan 32-SAMSS-011,
B10
ring and grade for forced draft units and between tube bundle and Para. 7.3.1.9
grade for induced draft units.

Ensure the following:

1) The clearance between the fan tip and fan ring, the fan ring length
SAES-E-007,
B11 and the shape are acceptable.
Para. 9
2) The fan curves provided are valid for specific fan ring specified by
the Exchanger Manufacturer.

Actuators for auto-variable pitch fans are provided with maximum

32-SAMSS-011,
B12 pitch stops and the the design blade setting are marked on the hub
Para. 7.2.3.18
nameplate.

Removable fan guards are provided for both the forced and the 32-SAMSS-011,
B13
induced draft exchangers. Para. 7.2.6.1

32-SAMSS-011,
B14 Belt tensioning adjustment is possible without removal of fan guards.
Para. 7.2.8.2.14

Belt drives are provided with jack screws or an equivalent means of API 661
B15
initial belt-tensioning and/or retensioning. Para. 7.2.8.2.4

32-SAMSS-011,
B16 All control louvers are provided with side mounted hand wheels.
Para. 7.2.10.26

All external non-pressure welded attachments have their corners 32-SAMSS-011,

B17
rounded to a minimum radius of 50 mm and are fully seal welded. Para. 9.1.1.10

A sign: "Caution – Exchanger Has Been Postweld Heat Treated – Do

32-SAMSS-011,
B18 Not Weld", is painted on a postweld heat treated exchanger and
Para. 9.2.8
located such that it is clearly visible from grade.

All Walkways, Platforms, Ladders, Hoops, Handrails, Guards & Schedule "Q",
B19
Stairs, are as per drawings and free from mechanical damage. Att IV,

C Coating of External Surface

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Receiving Inspection of Air-Cooled Heat Exchanger SAIC-E-2005 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Apllied coating is free of application deficiencies, mechanical damage

Schedule "Q",
C1 or pre-mature failure, ie: signs of corrosion and blistering.
Att IV,
(Refer to SAES-H-100)

Type Coating applied is suitable for the service condition of the of the SAES-E-007,
C2
equipment per SAES-H-101. Para. 11.3

D Insulation (if furnished by Vendor)

The extent and thickness of external insulation installed meets the

SAES-E-007,
D1 thickness requirement stated in the data sheet in accordance with
Para. 11.1
SAES-N-001.

Insulation installed is acceptable using Inspection Checklist, SAIC-N- Schedule "Q",

D2
2010 (for cold insulation) or SAIC-N-2016 (for hot insulation). Att IV,

E Fireproofing

The extent of fireproofing required on exchanger supports are in

SAES-E-007,
E1 accordance with the requirements of SAES-B-006 and specified on
Para. 12.1
the data sheet.

F Nozzles

SAES-E-007,
NPS 2½, 3½, and 5 nozzles are not used.
F1 Para. 8.1.3 & Design
All main flow nozzles are flanged.
8.1.4

Threaded or socket-welded connections are not used in hydrogen,

lethal, wet sour and caustic services. However, for other services,
threaded or socket-welded connections with 6000-lb rating
SAES-E-007,
F2 conforming to ASME B16.11 may be used for NPS 1-1/2 and smaller
Para. 8.1.5
vents, drains and instrument connections. Commentary note: This
requirement is intended for vents, drains and instruments
connections that may be attached to header or nozzles.

In total condensing services, a minimum of NPS 1½ connection is SAES-E-007,

F3
provided as a vent and located at the condensate outlet header. Para. 8.1.6

SAES-E-007,
F4 Pressure ratings of flanges are in accordance with ASME B16.5.
Para. 8.2.3

Flange facings are raised face or ring-type joint .

NOTE: Flat face flanges may be used in utility services. ASME
SAES-E-007,
pressure classes & facings shall be as specified on data sheet.
F5 Para. 8.2.1 &
Equipment specifies
8.2.4
flange facings to be compatible with ASME B31.3 Code Piping -
Identify associated piping specs

G Gaskets

The design of spiral wound gaskets are as follows:

1) For all services and design temperatures, spiral wound gaskets
are with solid outer centering rings. 2)
For design temps above 450°C, spiral wound gaskets are with solid SAES-E-007,
G1
outer centering rings & inner confining rings. Para. 8.4.2
3) For exchangers in continuous vacuum service, irrespective of
design temperature or design pressure, spiral wound gaskets are
solid outer centering rings & inner confining rings.

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Receiving Inspection of Air-Cooled Heat Exchanger SAIC-E-2005 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Gaskets for nozzle connections in utility services may be specified as

SAES-E-007,
G2 non-asbestos conforming to ASME B16.21, & must be chemically
Para. 8.4.4
resistant and mechanically suitable for the service conditions.

H Storage, Handling & Preservation

The Contractor's Handling, Storage & preservation procedure is Schedule "Q",

H1
available and approved. Att IV, Para. 5,6
1) The internals of exchangers are protected from corrosion by
use of a non-toxic vapor phase corrosion inhibitor such as
CORTEC VCI-309 or 307 or equivalent, applied at a rate of 0.3
kg/m³ fogged into the space. 32-SAMSS-011,
H2 2) Para. 11.4
Alternatively, nitrogen blanketing at a pressure of 5 psig may be used
or temporary coatings as per MIL-C-16173-D Grade IV (eg. Tectyl
846) was used.

Corrosion inhibitors for use on exchangers with stainless steel and

32-SAMSS-011,
H3 monel tubes are chloride free, suitable for intended use, and do not
Para. 11.4
result in crevice corrosion.
Flanged connections and other machined surfaces have been
protected/ covered by a suitable coating and fitted with a 3 mm thick 32-SAMSS-011,
H4
steel /wood cover, and neoprene gaskets with 4 bolts Equ spaced. Para. 11.5

For ocean shipment, flanged connections are covered with heavy 32-SAMSS-011,
H5
duty plastic bags securely taped to the nozzles. Para. 11.5

Lube-oil and seal-oil exchangers are demonstrated to meet the

H6 cleanliness requirements of API STD 614. SAEP-1028
See Attachment 2 & API 614 Inspector's Checklist.

Exchangers are completely dried and cleaned from all loose scales, 32-SAMSS-011,
H7
weld slags, dirt and debris. Para. 11.6

L LESSONS LEARNED (RECEIVING INSP & HANDLING TIPS TO PREVENT MAJOR PROJECT REWORK - ADD VALUE)

In-Situ Pressure Tests of New Fin Fan Coolers (Air-Cooled heat

Exchangers) are mandatory at Saudi Aramco. This is in addition to
SAES-A-004,
the manufacturer's pressure test. SEE ATTACHMENT 3.
L1 Para.
MAKE CERTAIN FIN FANS ARE CAREFULLY
6.4.5
HANDLED!!! BE CERTAIN THAT THESE
IN-SITU TESTS WILL PASS!!!
REMARKS:

ATTACHMENTS:
1. 32-SAMSS-011 Tables 1 & 2 (Exchanger Material & Impact Test Reqmts) & API 661 Table-1 Thickness of
Header 2 - API 614 (Lubrication, Shaft-Sealing, & Control-Oil
Systems & Auxiliaries, Appendix C (Inspector's Checklist) 3 - IN-SITU TESTING &
CARE OF FIN FAN COOLERS (MUST READ)
REFERENCE DOCUMENTS:
1. SAES-E-007, Design Critiera of Air-Cooled Heat Exchangers, (09 April 2015)
2. 32-SAMSS-011, Manufacture of Air-Cooled Heat Exchangers, (23 June 2010)
3. Schedule "Q", Quality Requirements
4. SAES-H-001, Painting Requirements for Industrial Facilities, (10 April 2011)
5. API 614, Lubrication, Shaft-Sealing and Control-Oil Systems, (5th Edition, APRIL 2008)
6. SAEP-1028, Chemical Cleaning and Flushing of Lube/Seal Oil and Fluid Power Systems, (12 January 2009)
7. API 661, Air Cooled Heat Exchangers For General Refrinery service, (February 2006)

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative

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SAUDI ARAMCO INSPECTION CHECKLIST
Receiving Inspection of Air-Cooled Heat Exchanger SAIC-E-2005 30-Apr-17 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

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ATTACHMENT 1 - 32-SAMSS-011 Tables 1 & 2 (Exchanger Material & Impact Test Reqmts)

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ATTACHMENT 2 - API 614 (Lubrication, Shaft-Sealing, & Control-Oil Systems & Auxiliaries for Petroleum,
Chemical & Gas Industry Services, Appendix C (Inspector's Checklist)

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Attachment 3 - IN-SITU TESTING & CARE OF FIN FAN COOLERS

1. Follow these simple guidelines to assure good test results.
2. Make certain Fin Fans (on arrival) were treated very carefully.
3. Inspect the load on arrival for proper preservation & damage
The internals of exchangers shall be protected from corrosion by use of a non-toxic vapor phase corrosion inhibitor such as CORTEC VCI-309
or 307 or equivalent, applied at a rate of 0.1 kg/m³ fogged into the space. The inhibitor selected must be appropriate for the metallurgy of the
exchanger. Exchangers must be sealed vapor tight for the inhibitor to be effective. Alternatively, nitrogen blanketing or temporary coatings in
accordance with MIL-C-16173-D Grade IV (example Tectyl 846) may be used. Corrosion inhibitors for use on exchangers with stainless steel
& monel tubes must be chloride free, suitable for its intended use & not result in crevice corrosion. 32-SAMSS-011, Sect. 11

Stainless steel exchangers shall be protected from salt water and salt water spray during shipment. 32-SAMSS-011, Sect. 11

4. Fin Fan Coolers can "twist" if improperly lifted. BEWARE!!!

Properly equipped cranes with "spreader" bars are used for unloading. NEVER ALLOW FORK TRUCK UNLOADING. Follow detailed
manufacturer handling and preservation requirements ... OR YOU CAN COUNT ON ADDED COST DUE TO TUBE/TUBESHEET LEAKS!!!

5. First thing, before it leaves the truck it arrives on! Inspection (camera)
a) Look at the top row of tubes. They should be VERY, VERY STRAIGHT!
b) If they aren't straight, i.e., bowed ... MAJOR PROBLEM!
c) Don't even let it be unloaded BEFORE YOU TAKE PICTURES.
d) Look at underside of the tubes, specifically the tube supports.
e) Severe shipping damage will result in "dislodged" support members.
6. Transit & erection clips & fasteners are checked closely for damage.
MAKE YOUR CLAIM RIGHT AWAY! TAKE EXTRA* PRECAUTIONS!
* The first one arrived damaged ... YOU CAN COUNT ON ALL OF THEM COMING THIS WAY "UNLESS YOU ACT QUICKLY".
* All the good Quality intentions in the world won't fix a badly mishandled Fin Fan Cooler.

*PLAN Proactive supervision at handling points to assure they arrive ok.

7. UNLOAD & STORE ON HARD & EXTREMELY LEVEL SITES ALWAYS.
a) Use good blocks (no nails). Make sure extra support is there & level.
b) NEVER exceed more a few meters between blocks.
8. Plan staging areas close to Units to minimize handling
OK, THIS HAS NOT HAPPENED ... ORDER EXTRA PLUGS & PRAY!
OK, YOU MADE IT THIS FAR OK ... NOW, PRESERVATION EFFORT
9. Corrosion Inhibitors can solidify, beware of opening these up.
10. Limit opening for "fit up" & piping work to good dry weather.
11. Keep system closed except when absolutely necessary.
12. Plan Test at test pressure on Manufacturer's Stamp.
If Chemical Cleaning (usually around 90 psi) is req'd, utilize this opportunity to meet the reqmt. (it's usually close enough)
Perform testing in accordance with good lay-up practices. Be Prepared to pull plugs and allow Proponent a visual exam.
Water removal after testing at low points can be assured by spool dropouts. Test as close to start-up as practical.

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ALWAYS HAVE EXTRA PLUGS ON HAND (OR OVERNIGHT ACCESS AVAILABLE) IN THE EVENT OF TUBE/TUBESHEET LEAKS.

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