32 Samss 004

Materials System Specification
32-SAMSS-004 Manufacture of Pressure Vessels Vessels Standards Committee Members

Naffa'a, M.Y., Chairman Al-Anezi, M.A. Al-Anizi, S.S. Al-Gahtani, M.S. Al-Sharhan, Z.S. Al-Sudairy, J.A. Kim, S.U. Muir, W.R. Niemeyer, D.C.
30 March 2005
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
Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 3 Definitions....................................................... 6 Responsibilities.............................................. 7 Proposals....................................................... 7 Mechanical Design......................................... 8 Nozzles and Manways................................. 14 Internals........................................................ 17 Vessel Support............................................. 18 Clips and Attachments................................. 21 Materials....................................................... 22 Fabrication.................................................... 24 Nondestructive Examination......................... 27 Postweld Heat Treatment............................. 30 Examination, Inspection, Pressure Tests and Repairs................. 31 Nameplates and Stampings......................... 35 Coatings and Painting.................................. 35 Shipping Requirements................................ 36 Drawings, Calculations and Data................. 38
Previous Issue: 29 December 2004 Next Planned Update: 1 January 2010 Revised paragraphs are indicated in the right margin Primary contact: Mahmoud Y. Naffa'a on 8747263
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Document Responsibility: Vessels Issue Date: 30 March 2005 Next Planned Update: 1 January 2010
32-SAMSS-004 Manufacture of Pressure Vessels
Scope 1.1 This specification covers the minimum mandatory requirements for the manufacture of pressure vessels. The requirements are in addition to and supplement the requirements of the ASME Boiler and Pressure Vessel Codes. This specification does not cover pressure vessels that undergo repairs or alterations and pressure vessels stamped "UM" per ASME SEC VIII D1. Pressure vessels having partial or complete cladding shall also conform to 32-SAMSS-031 in addition to the requirements of this specification. Pressure vessels supplied as part of a vendor's off-the-shelf standard design package unit and intended for air or water services (e.g., air dryers, portable air compressors, filtering unit, etc.) with a design pressure no greater than 1.7 MPa (245 psi) and a design temperature no greater than 121C (250F) are exempt ed from meeting the requirements of this standard provided that: a) b) c) 1.5 The vessel is ASME Code stamped, Full penetration welds joints are used, and The vessel is protected against overpressure conditions.
1.2 1.3 1.4
This specification does not include in its scope equipment, which are made of pressure-containing components generally recognized as piping components (pipe, fittings, etc.). Equipment include strainers, pressure containers used for transferring liquids as an integral part of a piping system and devices that serve the purposes of mixing, separating, distributing, metering and controlling flow. Where a licensor's specification requirement is more stringent than that of this specification, the licensor's specification requirement will govern.
1.6
Conflicts and Deviations 2.1 Any conflicts between this Specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be in writing by the Company or Buyer Representative through the Manager, 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
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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 Materials System Specifications 01-SAMSS-016 Qualification of Pipeline and Pressure Vessel Steels for resistance to Hydrogen-Induced Cracking Manufacture of Trays and Packing Manufacture of Clad Vessels and Heat Exchangers
32-SAMSS-020 32-SAMSS-031
Saudi Aramco Engineering Standards SAES-A-004 SAES-A-206 SAES-A-301 SAES-H-100 SAES-H-101 SAES-N-001 SAES-N-100 SAES-N-110 SAES-N-120 SAES-N-130 SAES-N-140 SAES-W-010 SAES-W-014 General Requirements for Pressure Testing Positive Materials Identification Materials Resistant to Sulfide Stress Corrosion Cracking Coating Materials and Application Approved Protective Coating Systems Industrial Insulation Refractory Systems Installation Requirements - Castable Refractories Installation requirements - Extreme Erosion Resistant Refractories Installation Requirements Fireclay Bricks Installation Requirements - Refractory Ceramic Fiber Welding Requirements for Pressure Vessels Weld Overlays and Welding of Clad Materials
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Saudi Aramco Inspection Requirements Form 175-321900 Manufacture of Pressure Vessels
Saudi Aramco Forms and Data Sheets NMR-7919-1 9527-ENG Nonmaterial Requirements for Pressure Vessels Pressure Vessel Data Sheet (herein referred to as data sheet)
Saudi Aramco Standard Drawing AB-036322 3.2 Industry Codes and Standards American Institute of Steel Construction AISC M011 American Petroleum Institute API RP 934 Materials and Fabrication requirements for 2Cr-1 Mo & 3Mo Steel Heavy Wall Pressure Vessels for High Temperature, High Pressure Hydrogen Service Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and Petrochemical Plants Avoiding Environmental Cracking in Amine Units Manual of Steel Construction Anchor Bolt Details
API PUBL 941
API RP 945
American Society of Civil Engineers ASCE 7 Minimum Design Loads for Buildings and Other Structures
American Society of Mechanical Engineers (Boiler and Pressure Vessel Codes) ASME SA-20 ASME SA-388 ASME SA-435 ASME SEC II ASME SEC IIC Specification for General Requirements for Steel Plates for pressure Vessels Ultrasonic Examination of Heavy Steel Forgings Straight Beam Ultrasonic Examination of Steel Plates Material Specifications Parts A, B and D Specification for Welding Rods, Electrodes, and Filler Metals
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ASME SEC V ASME SEC VIII D1 ASME SEC VIII D2 ASME B16.5 ASME B16.11 ASME B1.20.1 ASME B16.20 ASME B16.21 ASME B16.25 ASME B16.47 ASME PCC-1
Nondestructive Examination Rules for Construction of Pressure Vessels Rules for Construction of Pressure Vessels, Alternative Rules Pipe Flanges and Flanged Fittings NPS through NPS 24 Forged Steel Fittings, Socket Welding and Threaded Pipe Threads, General Purpose (Inch) Metallic Gaskets for Pipe Flanges-Ring-Joint, Spiral-Wound, and Jacketed Nonmetallic Flat Gaskets for Pipe Flanges Butt-welding Ends Large Diameter Steel Flanges NPS 26 through NPS 60 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
American Society for Testing and Materials ASTM A307 Standard Specification for Carbon Steel Bolts and Studs
American Society for Nondestructive Testing ASNT CP-189 U.S. Military Specifications MIL C16173 Corrosion Preventive Compound, Solvent Cutback, Cold-Application Standard for Qualification and Certification of Nondestructive Testing Personnel
National Association of Corrosion Engineers NACE RP0472 Methods of Control to Prevent In-Service Cracking of Carbon Steel Welds in P-1 Materials in Corrosive Petrochemical Refining Environments Recommended Practice for Prevention, Detection and Correction of Deaerator Cracking
NACE RP0590
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Process Industry Practices VEFV1100 Welding Research Council WRC 107 WRC 297 4 Definitions AARH: Average arithmetic roughness height, which is a measure of surface texture. Cyclic Service: Services that require fatigue analysis per AD-160 of ASME SEC VIII D2. This applies to Division 1 and Division 2 of ASME SEC VIII. Design Engineer: The Engineering Company responsible for specifying on the data sheet the mechanical design requirements for pressure vessels. High - Alloy Steels: Steels with a total alloying content more than 5%. Hot Forming: Forming operations carried out at an elevated temperature such that recrystallization occurs simultaneously with deformation. Hydrogen Service: Process streams containing relatively pure hydrogen and component streams containing hydrogen with a partial pressure of 350 kPa abs (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. Other services as determined by the project design may also be designated as lethal services. Low - Alloy Steels: Steels with a total alloying content of less than 5% but more than specified for carbon steels. MDMT: Minimum design metal temperature, determined by the Design Engineer. Nominal Thickness: Thickness of a pressure vessel section (head or shell) after forming. Pressure Vessel and Vessel: As defined in the ASME Boiler and Pressure Vessel Codes. Saudi Aramco Engineer: The Supervisor of the Process Equipment Unit, Consulting Services Department, Dhahran. Welding Research Council Bulletin Welding Research Council Bulletin Vessel/S&T Heat Exchanger Standard Details
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Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco Inspection Department to inspect pressure vessels to the requirements of this specification. Thick Wall Vessel: A vessel or portion of a vessel with nominal thickness greater than 50 mm. Unfired Steam Drums: As defined in ASME SEC VIII D1, paragraph U-1 (g)(2). Utility Services: Water, air and nitrogen services. Vessel Manufacturer: The company responsible for the manufacture of new pressure vessels in accordance with this specification. Wet Sour Service: Following process streams containing water and hydrogen sulfide: i) ii) Sour water with a hydrogen sulfide (H2S) concentration above 2 mg/L (2 ppm) and a total pressure of 400 kPa absolute (65 psia) or greater. Hydrocarbon services meeting the definition of sour environments in SAES-A-301, where the H2S concentration of 2 mg/L (2 ppm) or more in the water phase is equivalent to H2S partial pressure of 0.05 psia. Sour crude systems upstream of a stabilization facility and sour gas upstream of a sweetening or dehydration plant are examples of such environments. Hydrocarbon systems exposed to an environment with a H2S concentration above 50 mg/L (50 ppm) in the water phase, regardless of H2S partial pressure.
iii)
Responsibilities The Vessel Manufacturer is responsible for the manufacture of pressure vessels, which includes complete mechanical design, Code and structural calculations, supply of all materials, fabrication, nondestructive examination, inspection, testing, surface preparation, and preparation for shipment in accordance with the completed data sheet and the requirements of this specification.
Proposals 6.1 6.2 6.3 The Vessel Manufacturer's proposal shall be based on details for individual vessels and the requirements of this specification. The Vessel Manufacturer may offer an alternative design, but must quote on the base inquiry documents. The proposal shall include a detailed description of any exception to the requirements of this specification.
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Mechanical Design 7.1 General 7.1.1 All pressure vessels shall be designed in accordance with the rules of the Boiler and Pressure Vessel Codes, ASME SEC VIII D1 or ASME SEC VIII D2 (herein referred to as the Codes), and the requirements of this specification. The ASME SEC VIII D1 or ASME SEC VIII D2, to which a vessel is to be manufactured, shall be in accordance with the data sheet. Should the Vessel Manufacturer have any part of a stress analysis executed by a third party, the Vessel Manufacturer shall advise the Saudi Aramco Engineer. No proof testing shall be permitted unless specifically approved by the Saudi Aramco Engineer. Application of ASME Code Cases to the manufacturing of pressure vessels requires approval of the Saudi Aramco Engineer. Unfired steam drums shall be manufactured and stamped in accordance with the requirements of this specification. All welded joints of category A, B, C and D shall be complete fusion full penetration welds, except for joint welds of slip-on flanges specified per paragraph 8.1.3 of this specification.
7.1.2 7.1.3
7.1.4 7.1.5 7.1.6 7.1.7
7.2
Design Pressure The value of design pressure(s) shall be in accordance with the data sheet.
Commentary Note: Design pressure is the maximum difference in pressure between the inside and the outside of a vessel, or between the chambers of a combination unit. The term internal design pressure is used when the internal pressure is greater than the external pressure. However, the term external design pressure is used when the internal pressure is less than the external pressure.
7.2.1 7.2.2
Unless otherwise specified on the data sheet the design pressure will be assumed to be at the top of the vessel in the operating position. Design pressure(s) acting at the bottom of vessels shall take into account pressure heads, both static and dynamic, due to the maximum liquid levels.
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7.2.3
For the case of multi-compartment vessels, the design pressure differential for the partition(s) separating the compartment(s) shall be as specified on the data sheet. The external design pressure and corresponding temperature shall be as specified on the data sheet. For vessels that contain packing, the requirements for the design of packing bed supports shall be as specified on the data sheet.
7.2.4 7.2.5 7.3
Maximum Allowable Working Pressure 7.3.1 The Vessel Manufacturer shall calculate the maximum allowable working pressure (MAWP) acting on the top of a vessel, in the hot and corroded condition in accordance with the applicable Code. The MAWP of a vessel shall not be limited by flange ratings. The Vessel Manufacturer must ensure, by calculation, that the stresses imposed during shop and field (erected position) hydrotesting of a completed vessel do not exceed 90% of the minimum yield stress value of every pressure component.
7.3.2 7.3.3
7.4
Design Temperature 7.4.1 7.4.2 The value of design temperature(s) shall be as specified on the data sheet. Where there are differences in the design temperatures for different zones in a vessel, the extremities of these zones will be shown on the data sheet.
7.5
Minimum Design Metal Temperature (MDMT) 7.5.1 7.5.2 The values 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 Section 12 of this specification.
7.6
Service and Description 7.6.1 The service of a vessel; hydrocarbon, hydrogen, caustic, amine, wet sour, steam or utility and whether the service is cyclic and/or lethal shall be as specified on the data sheet.
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7.6.2 7.7
The process description of a vessel (for examples: Amine Regenerator, Air Receiver) shall be specified on the data sheet.
Joint Efficiency 7.7.1 7.7.2 The joint efficiency shall be as specified on the data sheet. A joint efficiency of 85% or higher shall be specified for the design of all pressure containing components of ASME SEC VIII D1 pressure vessels. A joint efficiency of 50% shall be specified for the following details: a) b) Shell-to-bottom head weld joint that is not exposed for nondestructive examination from outside the vessel. Intermediate head-to-shell welds joints shall be designed using a joint efficiency of 50%.
7.7.3
7.8
Corrosion Allowance 7.8.1 A corrosion allowance is to be added to all pressure containing carbon and low chrome alloy steels which are in contact with the process fluid, including, shells, heads nozzle/manway necks, covers, and nonremovable internals. The amount of corrosion allowance shall be as specified on the data sheet. The corrosion allowances required for tray assemblies and tray supports shall be in accordance with the requirements of 32-SAMSS-020.
7.8.2 7.8.3 7.9
Minimum Thickness 7.9.1 Minimum thickness of a pressure vessel shall be adequate to withstand the combined stresses of all loads in accordance with the applicable Code and this specification. In no case, shall the nominal thickness of shells and heads be less than the following: a) b) Carbon steels, 6 mm. Low chrome alloy steels, 5 mm.
7.9.2
7.10
Head Types 7.10.1 Refer to the data Sheet for the type of head.
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7.10.2 7.10.3 7.10.4
The type of heads to be used shall be ASME 2:1-ellipsoidal or ASME hemispherical. ASME flanged and dished heads (torispherical) may be used only for air and water services up to a design pressure of 690 KPa (100 psi). One piece construction shall be used for heads of nominal thickness greater than 50 mm and for heads in vessels in cyclic, hydrogen or lethal services. Other types of head construction shall require prior approval of Saudi Aramco Engineer as defined in this specification. Where a forged skirt-to-head junction ring according to ASME SEC VIII D2, Figure AD-912-1(k) is used in vessels in cyclic, hydrogen or lethal services one piece construction shall be used for the remaining portion of head. Other types of construction for this head portion shall require prior approval of Saudi Aramco Engineer as defined in this specification. Heads in thick wall vessels shall be hemispherical unless 2:1 ellipsoidal heads are deemed more economical. Minimum inside radius of knuckles for conical transition sections or torispherical heads shall be as follows: a) Not be less than 15% of the outside diameter of the adjoining cylindrical section with conical section of thickness more than 2 inches. Not be less than 10% of the outside diameter of the adjoining cylindrical section with conical section of transition sections or torispherical heads with thickness more than 0.75 inch or less than 2 inches. Not be less than 6% of the outside diameter of the adjoining cylindrical section with conical section of transition sections or torispherical heads with thickness 0.75 inch and less.
7.10.5
7.10.6 7.10.7
b)
c)
7.10.8
Reinforcing for conical transition sections in thick wall vessels shall be provided by increased plate thickness. The use of reinforcing rings is prohibited.
7.11
Loads 7.11.1 Wind and Earthquake Loads a) The Vessel Manufacturer shall calculate the static effects of loads due to wind and the effects due to earthquake loads acting on the
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vessel in the operating position accordance with the requirements of this specification. b) The wind speed, earthquake zone, and soil coefficient corresponding to the site location shall be as specified on the data sheet. Vessels shall be designed for wind and earthquake loads in accordance with ASCE 7. With reference to ASCE 7, the wind Category Classification to be used in the calculations of wind loads shall be Category III, and the Seismic Hazard Exposure Group to be used in calculations of earthquake loads shall be Group III. Wind pressures shall be assumed to act on the projected surface area of the pressure vessel and shall include due allowances for platforms, ladders, piping, insulation, and equipment supported from the pressure vessel as specified on the data sheet. The maximum allowable deflection in the corroded condition at the top tangent line of a vessel shall not exceed 150 mm / 30 m of height.
c) d)
e)
f)
7.11.2
Wind-induced Vibration a) Vertical vessels shall be checked for wind-induced vibration by the Vessel Manufacturer when: H > 30 m with H/D ratio > 15 or, when W/HD < 400 Where: H is the height of the vessel in meters, including the supports D is the diameter of vessel in meters. (For multi-diameter vessels the diameter shall equal the weighted diameter of the top third). W is the weight of the vessel in kilograms in both the erected empty and operating conditions. b) The use of vortex breakers or guying devices in order to maintain stresses, due to wind-induced vibration within allowable limits, is prohibited. The fatigue life of those vessels susceptible to wind induced vibration shall be a minimum of one million cycles. The fatigue
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c)
curves in ASME SEC VIII D2 shall be used for the materials at the specified design temperature. 7.11.3 Weight of Liquid Contents a) b) 7.11.4 The maximum operating liquid level (s) of the vessel shall be shown on the data sheet, together with the density of the liquid. The liquid level of liquid on trays shall be included when calculating the operating weight.
Piping, Equipment and External Loads a) The Vessel Manufacturer shall ensure that local stresses imposed on a vessel due to piping, 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, WRC 297 or a finite element analysis. Refer to the data sheet for piping and equipment loads imposed on a vessel.
b) 7.12
Load Combinations 7.12.1 All components of a vessel, including their supports, shall be designed to withstand the combined stresses resulting from the following: a) b) c) Internal and/or external design pressures, as applicable. All other loads exerted on the component and specified in section 7.11. All pressure vessel components whether shop or field fabricated shall be designed to withstand a full hydrostatic test in the erected position. Combined stresses due to full hydrostatic test and wind or earthquake loads shall not exceed 90% of the lowest Specified Minimum Yield Strength (SMYS) of the materials of construction at test temperature. However, forces produced, due to wind or earthquake design conditions, may be reduced to 40% of its values.
7.12.2 7.13
Moments or forces acting on a vessel due to external piping are to be added to those moments and forces due to other external primary loads.
Stress Analysis 7.13.1 For vessels designed in accordance with ASME SEC VIII D1, refer to the data sheet for stress analysis requirements.
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7.13.2
For vessels designed in accordance with ASME SEC VIII D2, the specific components of a vessel requiring detailed stress analysis shall be as specified on the data sheet.
Nozzles and Manways 8.1 General 8.1.1 The quantities, sizes, ratings, (ASME pressure classes), facings, elevations, and orientations of nozzles and manways shall be as specified on the data sheet. Unless otherwise specified on the data sheet, the minimum projections for nozzles and manway necks, as measured from the outside surface of the shell or head to the face of a flange, shall meet the following requirements: a) b) c) d) 6 inches for NPS 6 nozzles and smaller. 8 inches for NPS 8 nozzles and larger and manways necks. For insulated vessels, projection shall be sufficient to allow bolting without interference with the insulation. For vessel drain connections and other connections, where a process stream is likely to be stagnant, the projection shall not exceed three times the connection nominal diameter.
8.1.2
8.1.3
Flanges, nozzles and manways shall be of the following types in all services: a) b) 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 Codes and approved by the Saudi Aramco Engineer. Slip-on type flanges with seamless pipe nozzle necks or rolled plate with 100% radiography are permissible for vessels, other than those exempted in paragraph 1.5 of this specification, for only air and water services up to and including 121C (250F) design temperature and 1.7 MPA (245 psi) design pressure.
c)
d)
8.1.4
Nozzles less than 2-inch NPS are not permissible except for utility services.
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8.1.5
Threaded or socket-welded connections are prohibited in the following services and conditions: a) b) c) d) e) f) Lethal service. Hydrogen service. Caustic service. Continuous or intermittent vibration. Any service where crevice corrosion or severe erosion may occur. Services where leakage would result in serious consequences for the operation or safety of plant or personnel.
8.1.6 8.1.7
Threaded connections shall conform to ASME B1.20.1. Threaded or socket-welded connections with 3000# rating conforming to ASME B16.11 may be used for 1- inch NPS and smaller vents, drains and instrument connections in services other than those specified in paragraph 8.1.5 of this standard. Vessels in services other than Utility services shall be provided with a minimum 2-inch NPS flanged steam-out connection. The ends of butt-welded connections shall be in accordance with ASME B16.25. The Vessel Manufacturer shall design nozzles that are required for the supporting of mechanical mixers and shall include the additional loads and dimensional tolerances as specified on the data sheet. As a minimum, four gusset plates for the reinforcement of nozzles supporting mixers shall be provided. All nozzles and manways in thick wall vessels shall be weld neck, long weld neck or contour forged, as required by this specification, with inside corner radius of 13 mm minimum. Design of flanged connections with stud bolts of diameter 1 inch and above shall be such as to provide clearance to permit use of a stud and bolt tensioning device.
8.1.8 8.1.9 8.1.10
8.1.11 8.1.12
8.1.13
8.2
Reinforcement of Openings 8.2.1 Reinforcement of vessel openings shall be in accordance with the applicable Code and this specification.
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8.2.2 8.2.3
The thickness of reinforcing pads shall not exceed the shell or head thickness of a vessel. Integrally reinforced openings (with no reinforcing pads) shall be provided under the following services and design conditions: a) b) c) d) e) f) Cyclic services. Carbon steel with thickness 50 mm and greater. Low chrome steels with thickness 25 mm and greater. Openings which are 900 mm and larger with design temperatures 400C and greater. Vessels with design temperatures above 425C. Hydrogen services.
8.2.4 8.3
Use of internal reinforcing elements is not permitted.
Flange Ratings, (ASME Pressure Classes) and Facings 8.3.1 8.3.2 The ASME pressure classes and facings shall be as specified on the data sheet. Pressure ratings for standard flanges shall be in accordance with the following: a) b) 8.3.3 ASME B16.5 for flanges NPS 24 and smaller. ASME B16.47, Series A for flanges larger than NPS 24.
Gasket seating surfaces shall comply with the following: a) b) c) d) 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 rings joint flanges in all services, 63 AARH. For Nonmetallic gaskets, 250 to 500 AARH.
8.3.4 8.4
Machined surfaces other than gasket contact faces shall not exceed 500 AARH.
Manways 8.4.1 The data sheet shall specify the number, nominal inside diameter, and locations of manways.
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8.4.2
All manways shall be circular. The manway covers shall be hinged or provided with handling davits as specified on the data sheet, according to PIP VEFV1100.
8.5
Weld Attachment Details 8.5.1 All nozzles and manway necks shall be attached by welding completely through the total thickness of the vessel shell, head or nozzle wall, including any reinforcement. Backing rings used in attaching nozzles and manways to vessels shall be removed after welding. Permissible types of nozzles larger than NPS 4 and manway necks weld-attachments are: a) b) 8.5.3 Division 1 vessels: Figure UW-16.1 (c), (d), (e), (f-1), (f-2), (f-3), (f-4) or (g). Division 2 vessels: Figure AD-610.1: (c), (d), (e), (e-1), (g) or weld attachments in paragraph 8.5.4(b).
8.5.2
Permissible types of nozzle weld-attachments for vessels with NPS 4 and smaller connections are: a) b) Division 1 vessels: Figure UW-16.1 (a), (a-1), (b) or weld attachments in paragraph 8.5.2(a). Division 2 vessels: Figure AD-610.1 (a), (b), or weld attachments in paragraphs 8.5.2(b) or 8.5.4(b).
8.5.4
Permissible types of nozzle and manway weld-attachments that require 100% radiography according to Table 4 of this specification are: a) b) Division 1 vessels: Figure UW-16.1: (f-1), (f-2), (f-3) or (f-4). Division 2 vessels: Figure AD-613.1: (a), (b), (c), (c-1), (d) or (e).
8.5.5
NPS 4 and smaller connections attached to nozzles or manways shall be according to paragraph 8.5.3 of this specification.
Internals 9.1 All fixed and removable internals, including trays, packing, distributors, screens, etc. shall be specified on the data sheet.
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9.2
Tray rings and tray supports that are welded to vessels shall be designed by the tray manufacturer and supplied and installed by the Vessel Manufacturer in accordance with the requirements of 32-SAMSS-020. The Vessel Manufacture shall design, supply and install all other internals, except for trays, as specified on the data sheet. All removable internals are to be designed so that they may be passed through tray and vessel manways. Internal ladder rungs shall be provided by the Vessel Manufacturer according to PIP document VEFV1100.
9.3 9.4 9.5
10
Vessel Support 10.1 General 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.2 Refer to the data sheet for the type of support. Each vessel shall be designed as a self-supporting unit in accordance with the requirements of the applicable Code and AISC. All supports shall be continuously welded to the vessel. The material of anchor bolts shall be in accordance with this specification. Base plates shall be designed by the Vessel Manufacturer 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 5170 kPa.
Supports for Vertical Vessels 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 vessels. The Vessel 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.
10.2.3
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10.2.4
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 vessel centerline. Hot-box design when specified for skirt-supported vessels with design temperatures greater than 260C (500F) shall be in accordance with PIP VEFV1100 and dimensions that meet the intent of reducing the thermal gradient at the skirt-to-vessel junction. One minimum 500 mm diameter skirt access opening shall be provided for vessels with diameters equal to and larger than 1200 mm. For vessels with diameters less than 1200 mm, skirt access opening diameter shall be minimum one half of the vessel diameter. Skirt access opening diameters smaller than the above specified shall require prior approval of the Saudi Aramco Engineer. It is the vessel 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 Vessel Manufacturer shall provide skirt bracing to prevent buckling during shipping and lifting in the field. Head-to-shell weld in thick wall vessels and vessels in cyclic, hydrogen or lethal services shall not be covered by the skirt in order to be readily accessible for nondestructive examinations (magnetic particle, radiography, ultrasonic, etc.).
10.2.5
10.2.6
10.2.7 10.2.8 10.2.9
10.2.10 Details of the joint between skirt and vessel shall be as follows: a) b) ASME SEC VIII D2, Figures AD-912-1(g), AD-912-1(h), AD-912-1(j) or weld build-up. For thick wall vessels and vessels in cyclic, hydrogen or lethal services: i) Only forged skirt-to-head junction ring per ASME SEC VIII D2, Figures AD-912-1(k), or weld build-up shall be used for skirt-to-head weld joints. The joint shall provide a smooth transition, minimizing peak stress concentration effects. The inner radius of the weld build-up and forged skirt-to-head junction ring shall be minimum 25 mm (1 inch). Backing strips used to join the skirt to a forged or weld build-up details, shall be removed after completion of welding. All welds shall be ground smooth flush contour.
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ii)
Forged single butt welding component integral with the vessel shell or weld metal build-up shall be used for skirtto-shell attachment. The joint shall provide a smooth transition, minimizing peak stress concentration effects. The inner radius of the weld build-up and forged detail shall be minimum 1 inch. Backing strips used to join the skirt to a forged or weld build-up details, shall be removed after completion of welding. All welds shall be ground smooth flush contour.
10.2.11 Shell-to-internal heads joint shall provide for a smooth transition, minimizing peak stress concentration effects. The joint shall be made by forging butt-welding component integral with the vessel shell or weld metal build-up. Backing strips used to join the skirt to a forged or weld build-up details, shall be removed after completion of welding. All welds shall be ground smooth flush contour. 10.3 Supports for Horizontal Vessels 10.3.1 Horizontal vessel shall be supported by two saddles with anchor bolts. The vessel shall be fixed at one saddle support and free to slide at the other saddle. The data sheet shall specify locations of the fixed and sliding saddles and dimension from vessel centerline to underside of saddle base plate. The shell shall be analyzed in accordance with the "LP Zick" method. Saddle supports and the vessel shell shall be analyzed for operating and hydrotest loads including any piping, wind or other external loads. Wear pads a minimum of 10 mm thick are to be supplied at the junction of the saddle and the vessel, and shall be continuously welded to the shell. Wear pads shall have all corners rounded to a 50 mm minimum radius, and shall have one inch NPT vent hole at the lowest elevation. The anchor bolt holes on the sliding-end saddle shall be slotted to facilitate thermal expansion.
10.3.2 10.3.3
10.3.4
10.3.5 10.4
Anchor Bolts 10.4.1 10.4.2 The Vessel Manufacturer shall determine the size and number of anchor bolts required. Anchor bolts shall straddle vessel centerlines on the north-south, eastwest axes.
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10.4.3 10.4.4
Anchor bolts shall not be less than 19 mm minimum nominal diameter. The allowable stress (based on ASTM A307 Grade B material) shall be as follows: a) b) 104 MPa (tension). External loads (Wind or Earthquake, plus operating weight). 69 MPa (shear). External loads (Wind or Earthquake, plus operating).
10.4.5 10.4.6
Vessels supported on skirts, lugs or legs shall be provided with an even number of anchor bolts with a minimum of four anchor bolts. Vessels 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 The Vessel Manufacturer shall supply and install all clips and attachments as specified on the data sheet. All internal and external attachments, including clips, welded directly to pressure parts are to be attached by continuous welding except for blank square nuts used for external insulation where tack welding is allowed.
11.2
Insulation Support Rings 11.2.1 11.2.2 11.2.3 The data sheet shall specify the extent and thickness of external insulation. Vertical vessels, which are externally insulated, shall be provided with insulation supports in accordance with SAES-N-001. The bottom heads of vertical vessels that are externally insulated shall be provided with 12 mm blank nuts. Blank nuts shall be welded on edge and located on 300 mm square centers. Vertical vessels, which are not externally insulated, shall be provided with a 5 mm thick steel weather cap on the skirt to provide a flashing for fire-proofing.
11.2.4
11.3
Fireproofing Supports
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11.3.1 11.3.2 11.4
The extent and thickness of fireproofing shall be specified on the data sheet. The Vessel Manufacturer shall supply and install supports required for fireproofing materials.
Grounding Lugs All pressure vessels shall be provided with a grounding lug connection welded to the vessel support in accordance with PIP VEFV1100.
11.5
Equipment Davit 11.5.1 11.5.2 A davit for the lifting of equipment shall be supplied when specified on the data sheet. The davit shall be in accordance with PIP VEFV1100.
12
Materials 12.1 General 12.1.1 All materials required for pressure and non-pressure components shall be specified on the data sheet in accordance with Table 1, Acceptable Materials for Carbon and Low-Alloy Steels. The Vessel Manufacturer may propose alternative materials at time of proposal, with prior approval of Saudi Aramco Engineer. Alternative materials must comply with all the requirements of the applicable Code and this specification. Use of high alloy steels shall be based on the design temperature, minimum design metal temperature and intended service, with prior approval of the Saudi Aramco Engineer as defined in this specification. All materials must be clearly identified and provided with legible original or certified true copies of Mill Test Certificates. Lack of adequate identification and certification shall be cause for rejection. Suitability of steels with nominal chromium content not exceeding 5% to be used for vessels in hydrogen services with design temperature of 343-593C (650-1100F) shall be qualified through chemical analysis, mechanical testing including but not limited to tensile, hardness, micro-hardness and temper embrittlement tests and ultrasonic and magnetic particle examinations. Materials specifications and tests procedures for base and weldments materials shall be submitted to
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12.1.2
12.1.3
12.1.4
12.1.5
Saudi Aramco Engineer for review and approval prior to ordering the materials from the mill. 12.1.6 12.1.7 12.1.8 All materials, except carbon steels, shall be alloy-verified by the Vessel Manufacturer in accordance with SAES-A-206. The use of C- Mo steels in hydrogen services is prohibited. Materials with properties enhanced by heat treatment cycles such as tempering, intermediate stress relief (ISR) and the final post weld heat treatment shall be tested to verify that their mechanical properties have been retained after all heat treatment cycles. These tests shall also include two additional postweld heat treatment cycles to account for future repairs or alteration. Layered construction is prohibited for all vessels.
12.1.9 12.2
HIC Resistant Materials Hydrogen Induced Cracking (HIC) resistant steel qualified in accordance with 01-SAMSS-016 shall be specified for the following environments with normal operating temperatures between 0C (32F) and 150C (302F): a) Sour water service with a hydrogen sulfide (H2S) concentration above 2 mg/L (2 ppm) and a total pressure of 400 Kpa absolute (65 psia) or greater. Hydrocarbon services meeting the definition of sour environments in SAES-A-301, where the H2S concentration of 2 mg/L (2 ppm) or more in the water phase is equivalent to H2S partial pressure of 0.05 psia. A hydrocarbon system exposed to an environment with a H2S concentration above 50 mg/L (50 ppm) in the water phase,regardless of H2S partial pressure.
Commentary Note: HIC resistant steel is not required in lean amine systems and rich amine DGA systems.
b)
c)
12.3
Gasket Materials 12.3.1 The materials of construction for spiral wound gaskets shall be as follows with flexible graphite filler suitable for the intended service: a) For vessels with design metal temperatures from -100C to 0C: Type 304 or 316 Stainless Steel (SS) windings with solid Type 304 or 316 Stainless Steel outer centering rings.
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b)
For vessels with design metal temperatures from 1C to 425C: Type 304 or 316 SS windings with solid carbon steel outer centering rings.
c)
For vessels with design metal temperatures above 425C: Type 321 or 347 SS windings with solid Type 304 or 316 for inner and outer centering rings.
d) 12.3.2
For vessels in vacuum or catalyst services, inner ring shall be either Type 304 or 316 Stainless Steel (SS).
Material specification for sheet gaskets shall be non-asbestos conforming to ASME B16.21, and must be chemically resistant and mechanically suitable for the service conditions.
12.4
Impact Testing 12.4.1 The Vessel Manufacturer shall determine impact test requirements of materials based on the values of the minimum design metal temperature (MDMT), unless lower test temperature is specified on the data sheet. Impact testing requirements for materials not listed in Table 1, shall be obtained from the Saudi Aramco Engineer. 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. For Div. 1 vessels the impact testing exemptions of UG-20 (f), UCS-66 (b)(1) and (3), UCS-68(c), UG-84 (b)(2) and by reference to Table UG-84.4 are not permitted. For Div. 2 vessels the exemptions of AM-213.1 and AM-218.2 are not permitted.
12.4.2 12.4.3
12.4.4
13
Fabrication 13.1 Fabrication Tolerances 13.1.1 13.1.2 13.2 Fabrication tolerances shall be in accordance with the applicable Code, and PIP document VEFV1100. Dished heads shall achieve at least the minimum required thickness in all areas after forming.
Forming and Assembly

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13.2.1
Tapered transitions shall be made only on the external surface of the vessel, according to the rules of the applicable Code, in the following conditions: a) b) There will be an interference with the removal of a vessel's internals. Vessels that have strict requirements regarding smooth internal profiles for flow or cyclic loading conditions or internal volume constraints.
13.2.2
The beveled edges of weld preparations for carbon steel plates with thickness 25 mm and thicker and all ferrous 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 adjoining shell or head. All re-rolling or forming of the shell sections is to be completed prior to radiography. 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 under stresses due to pressure. It is the responsibility of the manufacturer to ensure that requirements of paragraphs 7.11.4 and 14.2.4 of this specification are met in the vicinity of the welds. Tapped tell-tale holes " NPT shall be provided at low location in reinforcing pads for attachments, including nozzles and manways, as follows: a) b) One hole in single piece reinforcing pad. Where a pad is split, each segment shall have at least one hole.
13.2.3 13.2.4
13.2.5 13.2.6
13.2.7
13.2.8 13.2.9
Split-reinforcing pad sections shall be welded together without using a backing strip. Telltale holes in external attachment pads, including nozzle reinforcing pads, shall be plugged with grease, wooden plugs or other non-pressure retaining material to prevent moisture ingress between the pad and the
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vessel pressure-retaining component. Telltale holes in internal attachment pads shall be seal welded. 13.2.10 Internal and external welded attachment pads shall have their corners rounded to a minimum radius of 50 mm radius and shall be fully sealwelded. Use of suitable non-pressure retaining sealing material is permitted on externally welded attachments that can not be fully seal welded, due to inaccessibility, after prior approval of the Saudi Aramco Engineer. 13.2.11 No tack welding is permitted between heads and skirts on the inside of skirts. 13.2.12 Large vessels that cannot be completely shop fabricated shall be designed to minimize the amount of field welding, radiography and heat treatment. Where adjacent sections are of such a size that shop fabrication and field assembly is required, the sections shall be match marked to ensure proper field fit up. 13.2.13 Leg supports, lug supports, lifting lugs and other attachments that will impose stress levels higher than the acceptable limits per the acceptable Code shall be welded to an attachment pad. The pad shall be a minimum of 10 mm (3/8") thick or equal to the shell thickness, whichever is less. Attachment loads must comply with paragraph 7.11.4 above and pads shall not cover pressure retaining welds. 13.2.14 Forming and heat treatment 13.2.14.1 Heat-treatment, as a separate operation, shall be performed after a forming operation (hot or cold) for any of the conditions listed below. The heat treatment shall be annealing, normalizing, normalizing and tempering, or quench and tempering, as required. Heads and other double-curvature components with nominal thickness exceeding 50 mm. Heads and other double-curvature components made of P-No. 3, 4, 5, 9A or 9B materials. Any hot-formed component.
Commentary Note: Nominal thickness of heads is its thinnest portion measured after forming.
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13.2.14.2 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 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. 13.2.15 Bolt tensioning device shall be used for bolting up flanged connections with stud bolts of diameter 1- inch and above. Bolt-up of flanges with stud bolts of diameter less 1- inch shall be according to ASME PCC-1 requirements. 13.3 Welding All welding shall be in accordance with the requirements of SAES-W-010. 14 Nondestructive Examination 14.1 General 14.1.1 All required Nondestructive Examination (NDE) shall be performed in accordance with inspection procedures that are in complete compliance with ASME SEC V and this specification. This written procedure shall address each inspection method and technique used including acceptance criteria. When required by the purchase order the procedure(s) shall be submitted to Saudi Aramco Inspection Department for approval. All Nondestructive Examination, including Magnetic Particle and Liquid Penetrant examinations, shall be performed by personnel certified in accordance with ASNT CP-189, or equivalent National Certification Programs that has been approved by the Saudi Aramco Inspection Department. Personnel responsible for interpretation of Nondestructive Examination results shall be certified to a minimum of Level II. All required NDE for final acceptance of the vessel, prior to pressure testing, shall be performed after the completion of all welding and repairs. In vessels requiring PWHT, all NDE for final acceptance shall be performed after the final PWHT. All pressure and non-pressure welds shall be visually inspected where accessible. All segments of longitudinal, circumferential or built-up head pressure weld seams covered or rendered inaccessible by
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14.1.2
14.1.3
14.1.4
internals, lifting lugs or other attachments shall be fully radiographed the entire affected length plus 25 cm (10 inches) either side prior to installation of the attachment. 14.1.5 Magnetic particle examination or liquid penetrant examination per the applicable Code shall be performed on the surfaces of hot formed and reheat treated parts.
14.2
Radiographic Examination 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. Following are radiography examination requirements in addition to those in Table 4: Butt welds in forged skirt-to-head junction ring, conforming to ASME SEC VIII D2, Figure AD-912-1 (k), shall be 100% radiographed. 14.2.4 Where it is not possible to meet the spacing requirement in paragraph 13.2.6 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: 14.2.4.1 If the nozzle is installed onto or encroaching on a butt weld in the vessel wall: a) Radiograph of the butt weld in the vessel 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.
14.2.2
14.2.3
b)
14.2.4.2
Where an attachment weld of a reinforcing pad or a structural component will either intersect or encroach on a butt-weld in the vessel wall: a) The butt weld shall be radiographed for a length equal to the projection of the intersecting or encroaching
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segment of the attachment weld plus a minimum of 50 mm on either side. b) Perform magnetic particle examination on the vessel side of the joint attaching the reinforcing pad or structural component.
14.2.4.3
It is the responsibility of the manufacturer to ensure that requirements of paragraph 7.11.4 of this specification at the attachment are met.
14.3
Ultrasonic Examination Following are ultrasonic examinations requirements in addition to those in Table 5: 14.3.1 Ultrasonic examination is required for thick wall vessels as follows: 14.3.1.1 Plates and Welds a) All plates, including plate-like forgings, such as shell rings shall be ultrasonically examined by the Vessel Manufacturer in accordance with ASME SA-435. All pressure retaining welds and vessel support attachment full-penetration welds shall be 100% ultrasonically examined after final heat treatment.
b)
14.3.1.2
Forgings All forgings, except plate-like forgings and standard shall be ultrasonically examined by the equipment manufacturer in accordance with ASME SA-388. Acceptance criteria shall be in accordance with ASME SEC VIII D2, paragraph AM-203.2(c).
14.3.2 14.4
Ultrasonic examination is required for the whole weld metal build-up skirt-to-vessel joints in paragraph 10.2.10 of this specification.
Magnetic Particle Examination 14.4.1 14.4.2 Permanent magnetic yokes are not permitted. Prods are not permitted for use on air-hardenable materials, materials that require impact testing, and on the fluid side of pressured components for vessels in wet sour service.
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14.4.3
Except for non-Ferro magnetic materials, wet fluorescent magnetic particle examination using an AC yoke is required for the following: a) All internal welds and areas where temporary welds have been removed for vessels in wet sour, caustic, amine, de-aeration and hydrogen services. All internal and external welds and areas where temporary welds have been removed when the nominal thickness of pressured components is 25 mm and thicker. Vessel support attachment fillet welds.
b)
c) 14.4.4
In thick Wall Vessel 14.4.4.1 All edges prepared for welding and all openings shall be magnetic particle examined in accordance with the applicable Code. Forgings shall be examined on all surfaces, utilizing wet fluorescent magnetic particle method after final machining. All defects shall be removed and repaired by welding in accordance with SAES-W-010.
Exception: Except for welding edges, liquid penetrant examination is acceptable as an alternative to magnetic particle examination.
14.4.4.2
14.4.4.3
All welds, including areas where temporary welds have been removed, are to be wet fluorescent magnetic particle examined.
14.4.5
Magnetic particle examination is required for the whole weld-up skirtto-vessel joints in paragraph 10.2.10 of this specification after each 6 mm depth of weld deposit. For non-Ferro magnetic materials, liquid penetrant examination shall be used.
14.5
Hardness Testing Weld hardness testing shall be in accordance with the requirements of SAES-W-010.
15
Postweld Heat Treatment 15.1 Postweld heat treatment 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 postweld heat treatment of ferritic materials based on the use of austenitic or nickel-based electrodes are not permitted. Code exemptions for postweld heat treatment of P4 and P5 materials are not permitted for applications involving either wet sour or hydrogen services or for materials exceeding 1.25% nominal chromium content. The maximum postweld heat treating soaking temperature for quenched and tempered carbon steel and C- Mo materials shall not exceed the temperature at which the test pieces were heat treated, as shown on the Mill Test Reports or 650C maximum for carbon steel, 690C maximum for C- Mo and 700C for low chrome alloy steels. Final postweld heat treatment shall follow all welding and repairs but shall be performed prior to any hydrotest or other load test. A sign shall be painted on a postweld heat treated vessel and located such that it is clearly visible from grade reading: "Caution-Vessel Has Been Postweld Heat Treated-Do Not Weld"
15.4
15.5 15.6
15.7
Postweld heat treatment shall be in accordance with the requirements of SAES-W-010.
16
Examination, Inspection, Pressure Tests and Repairs 16.1 Examination 16.1.1 The responsibility for examination rests with the Vessel Manufacturer in accordance with the applicable Code and the requirements of this specification. Additional examination of any weld joint at any stage of the fabrication may be requested by the Saudi Aramco Inspector, including repeating examination of previously examined joints. The Saudi Aramco Inspector also has the right to request or conduct independent Nondestructive Examination of any joint. If such examination should disclose nonconformance to the requirements of the applicable Code or this specification, all repair and Nondestructive examination costs shall be done at the Vessel Manufacturer's expense. All necessary safety precautions shall be taken for each examination method.
16.1.2
16.1.3
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16.1.4
Surface irregularities, including weld reinforcement, inhibiting accurate interpretation of the specified method of nondestructive examination shall be ground smooth. Examination of all welds shall include a band of base metal at least one inch wide on each side of the weld.
16.1.5 16.2
Inspection 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. 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 or 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 Vessel Manufacturer shall provide the Saudi Aramco Inspector all reasonable facilities to satisfy him that the work is being performed as specified. The fabricator shall furnish, install, and maintain in a safe operating condition all necessary scaffolding, ladders, walkways, and lighting for a safe and thorough inspection. Pressure vessels manufactured in accordance with this specification are subject to verification by the Saudi Aramco Inspector in accordance with Saudi Aramco Inspection Requirements Form 175-321900, Manufacture of Pressure Vessels. Prior to final inspection and pressure testing, the inside and outside of the vessel shall be thoroughly cleaned of all slag, scale, dirt, grit, weld spatter, paint, oil, etc.
16.2.3
16.2.4
16.2.5
16.2.6
16.2.7
16.2.8
16.2.9
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16.2.10 Inspection at the mill, shop, or fabrication yard shall not release the Vessel Manufacturer from responsibility for repairing or replacing any defective material or workmanship that may be subsequently discovered in the field. 16.3 Pressure Testing 16.3.1 After completion of all external and internal welding, nondestructive examination, repairs and heat treatment, as applicable, and prior to painting, vessels shall be pressure tested using water as the testing media in accordance with the applicable Code, SAES-A-004 and this specification. Pneumatic testing in lieu of hydrostatic testing requires the approval of the Manager of the Saudi Aramco Inspection Department. Hydrostatic test pressure shall be held for a minimum of one hour per 25 mm of vessel thickness and in no case less than one hour. No acceptance of pressure testing shall be made prior to postweld heat treatment. All welded attachments provided with telltale holes shall be pneumatically tested at minimum 35 kPa (5 psi) prior to heat treatment and vessel pressure testing. Telltale holes must not be plugged during the vessel pressure test. The use of shellacs, glues, lead, etc., on gaskets during testing is prohibited. No paint or primer shall be applied to a vessel prior to hydrostatic testing. The Vessel Manufacturer shall furnish all test materials and facilities, including blinds, bolting, and gaskets. Hydrostatic pressure testing shall be performed with gaskets and bolting identical to those required in service and as specified on the data sheet. These gaskets may be used as service gaskets if the bolted joint is not disassembled after completion of hydrostatic pressure testing. The manufacturer shall supply the following: a) b) Minimum two sets of spare gaskets with a blind flange for each manway and blinded nozzle in the vessel. Minimum one set of service gasket set and two sets of spare gaskets for each nozzle with companion flanges in the vessel.
16.3.2 16.3.3
16.3.4
16.3.5 16.3.6
16.3.7
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c) 16.3.8
All bolting with minimum 10% spare bolting (3 minimum for each size) per vessel.
The test pressure measured at the top of the vessel shall be: 16.3.8.1 For Division 1 vessels: 1.3 times the Maximum Allowable Working Pressure (MAWP) of the vessel multiplied by the lowest ratio (for the materials of which the vessels is constructed) of the allowable stress for the test temperature to the allowable stress for the design temperature. See UG-99(b) of Div. 1. For Division 2 vessels: 1.25 times the Maximum Allowable Working Pressure (MAWP) of the vessel multiplied by the lowest ratio (for the materials of which the vessels is constructed) of the allowable stress for the test temperature to the allowable stress for the design temperature. See AT-301, Div. 2.
16.3.8.2
16.3.9
Water used for pressure testing shall be potable. For vessels manufactured from stainless steel, the water shall not contain more than 50 ppm chlorides with pH value of 10 to 11 at the time of filling the vessel.
16.3.10 The temperature of the water during hydrostatic testing shall be maintained at not less than 17C throughout the testing cycle. 16.3.11 Vertical vessels that are tested in the horizontal position shall be adequately supported such that the primary stresses in any part of the vessel do not exceed 90% of the minimum specified yield strength of the vessel material. 16.3.12 Horizontal vessels shall be tested while resting on their permanent support saddles without additional supports or cribbing. 16.3.13 After testing the vessel, it shall be completely drained and thoroughly dried including around internals. 16.4 Manufacturing Repairs 16.4.1 The Saudi Aramco Engineer must review and approve crack repair procedures, required by the applicable Code, prior to commencement of repairs. 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.
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16.4.2
After completion of repairs required by the applicable Code the following shall be repeated: a) b) Heat treatment of 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. A weld map of all repairs shall be made a part of the final vessel documentation. The weld map shall include the nondestructive examination procedure and results, the welding procedure specifications and stress relief charts.
c)
17
Nameplates and Stampings 17.1 17.2 17.3 Each vessel shall be identified by a nameplate and marked with the information required by the applicable Code and the requirements of this specification. Vessels manufactured inside and outside Saudi Arabia shall be Code stamped for all services in accordance with the applicable Code. Nameplates and nameplate mounting brackets shall be located such that they will not be covered by insulation and are easily readable from grade or a platform. Brackets shall extend from the outside of vessel to clear insulation, and with sufficient access for surface preparation, and painting. The nameplate markings as required by the applicable Code shall be stamped or engraved such that the nameplate material is permanently deformed with the symbols. Nameplates shall be 3-mm minimum thickness and manufactured from type 304 stainless steel or Monel and continuously welded to the mounting bracket according to PIP VEFV1100. The mounting bracket material shall conform to Table 1 in this specification. The bracket shall be continuously seal welded and positioned such as not to allow for collection of moisture or rain. For internally coated vessels, the nameplate shall show: the Saudi Aramco Painting System Numbers, type of coating, brand name, and date of application.
17.4
17.5
17.6
18
Coatings and Painting 18.1 Type of coating and painting systems to be applied shall be as specified on the Vessel data Sheet.
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18.2
Surfaces to be coated shall be cleaned and prepared prior to its coating in accordance with the applicable coating and painting systems, in accordance with SAES-H-100. Gasket contact surfaces shall be properly protected from blasting and shall not be coated or painted.
18.3
19
Shipping Requirements 19.1 General 19.1.1 19.1.2 Vessel shall be protected against corrosion during shipping and at fabrication yard and construction sites. Prior to shipping, vessels are to be completely and thoroughly dried and cleaned from all loose scales, weld slags, dirt and debris to the satisfaction of the Saudi Aramco Inspector. The Vessel Manufacturer is responsible for ensuring that the vessels and internals being shipped are adequately braced and shall provide temporary supports where appropriate to ensure adequate supporting of the vessel during shipment. Vessels partially shop fabricated and/or liable to suffer distortion during transit and erection shall be suitably braced. All ends that will be open during shipment shall be covered to prevent ingress of dirt and other foreign matters. The Vessel Manufacturer shall advise the Saudi Aramco Engineer of the method of protection for review and approval. Markings shall be done with water-insoluble materials that contain no harmful substances that would attack or harmfully affect the vessel at both ambient and design temperatures. Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, or any other halogens. Export packaging marking and shipping shall be in accordance with the purchase order.
19.1.3
19.1.4
19.1.5
19.1.6 19.1.7 19.2
Internal Protection 19.2.1 The interior surfaces of vessels, including internals, shall be protected from corrosion by use of a nontoxic vapor phase corrosion inhibitor such as COTEC VCI-309 or 307 or equivalent, (depending on the metallurgy of the vessel) applied at a rate of 0.1 kg/m.
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19.2.2
The inhibitor selected must be appropriate for the metallurgy of the vessel. Desiccants may only be used with approval of the Saudi Aramco Engineer. Vessels must be sealed vapor tight using metallic covers, for inhibitors to be effective. Nitrogen blanketing, temporary rust preventive coatings in accordance with MIL C16173 Grade IV (example: Tectyl 846) or a vapor proof bag with moisture control may be used for carbon and low chrome alloy steels. Nitrogen blanketing at a pressure of 35 Kpa (5 psi) shall be provided for vessels made completely of Austenitic Stainless Steels and vessels internally cladded or weld-overlayed with Austenitic Stainless Steels in the following conditions: a) b) Ocean shipment. Where vessel is not undergoing fabrication, construction activities, after hydrotesting or prior to commissioning.
19.2.3 19.2.4
19.2.5
19.2.6
Temporary coatings for use on vessels 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 vessels that have permanent internal coatings covering the vessel wall partially, the Vessel Manufacturer shall contact the Saudi Aramco Engineer for any corrosion protection required. Use of non-toxic desiccants is considered acceptable as an alternative internal protection measure against corrosion for vessels which warranty will be revoked by using non-toxic vapor phase inhibitor; provided that the following conditions are met: a) b) c) Calcium chloride desiccants shall not be used. The desiccant must be removed on site prior to operating the vessel. Measures shall be taken to ensure that the adsorbent material in the protected vessel will not be harmed by vapor phase inhibitor that may be introduced through the process stream from upstream equipment.
19.2.7
19.2.8
19.3
External Protection
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19.3.1
The protection of external surfaces shall be obtained by using one of the following: a) A hard temporary preservative in accordance with MIL C16173, 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. For solid Stainless Steel vessels, 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 C16173 Grade IV.
b)
c)
19.3.2
Threaded nozzle connections shall be protected with threaded plugs. However, telltale holes in reinforcing pads shall be protected with wooden plugs or packed with rust preventative grease such as Denso paste. Flanged connections and all other machined surfaces shall be protected by a coating such as MIL C16173 Grade IV, which is easily removed in the field and fitted with 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 specified for service.
19.3.3
19.3.4
19.3.5
20
Drawings, Calculations and Data 20.1 20.2 The Vessel Manufacturer shall Prepare drawings, calculations, and data in accordance with NMR-7919-1, Nonmaterial Requirements. Drawings and calculations that are approved by the Design Engineer shall not relieve the Vessel Manufacturer from the responsibility to comply with the Codes, and this specification. Vessel manufacturer shall prepare drawings which indicate the ultrasonic thickness of the vessel shell section, heads and nozzles. An adequate number of readings shall be taken to represent the actual thickness of the components.
20.3
Page 38 of 44
20.4
All approved data sheets, drawings and forms are to be submitted to Engineering Drawings Services Division (EDSD) for inclusion into Corporate Drawings Management System.
Revision Summary Major revision. Editorial revision to replace NACE MR0175 with newly approved SAES-A-301.
29 December 2004 30 March 2005
Page 39 of 44
Table 1 Acceptable Materials for Carbon and Low - Alloy Steels

[Note: The numbers in ( ) refer to the specific notes at the end of the table]
Design Temperature 1 to 425C SA-516 Grade 70, or SA-537, Class 1 or SA-285 Grade C (1) SA-106, Grade B SA-53, Grade (B) (1) SA-105 SA-234 WPB
Vessel Component Shells, heads, nozzle & manway necks, and reinforcing pads Pipe, Nozzle and manway necks Forged flanges Wrought fittings
-100 to -47C SA-203 Grades D or E
-46 to 0C
351 to 645C SA-387 Grades 11, 12 or 22
SA-516 Grade 70N, or SA-537, Class 1 SA-333, Grade 6 SA-350 LF2 SA-420 WPL6
SA-333, Grade 3 SA-350 LF3 SA-420 WPL3
Studs/nuts for pressure connections Internal attachment clips (3) External attachment clips (3)
SA-320 L43/ SA-194 Grades 4 or 7 SA-203 Grades D or E SA-203 Grades D or E
SA-320, L7 w/ SA-194 Grade 2H SA-516 Grade 70N, or SA-537, Class 1 SA-516 Grade 70N, or SA-537 Class 1 SA-516 Grade 70N, or SA-537, Class 1 or SA-285 Grade C (1) SA-307, Grade A or C
SA-193 B7/ SA-194 Grade 2H SA-516, Grade 70 or SA-537, Class 1 SA-285, Grade (C) (1) SA-516, Grade 70 or SA-537 Class 1 SA-285, Grade C or SA-36 (1) SA-516 Grade 70, or SA-285, Grade C or SA-36 (1) SA-307, Grade A or C
SA-335 Grades P11, 12 or 22 SA-182 Grades F11, 12 or 22 SA-234 Grades WP11, WP12 and WP22 SA-193 B5, or B16 w/ SA-194, Grade 3 SA-387 Grades 11, 12 or 22 SA-387 Grades 11, 12 or 22
Vessel supports: saddles, skirts, legs, lugs and base rings (2) Anchor bolts (4)
General Notes: A) B) C) D)
SA-203 Grades D or E
SA-387 Grades 11, 12 or 22
SA-307, Grade A or C
SA-307, Grade A or C
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. Materials for pressure vessels in amine service shall be selected in accordance with Table 1 and API RP 945. Materials for pressure vessels for de-aeration service shall be in accordance with Table 1 and NACE RP0590. Materials for vessels in environments specified in paragraph 12.2 of this specification with normal operating temperatures up to 150C (302F), shall be in accordance with Table 1, with the following revisions: i) ii) iii) iv) v) Forged flanges and forged fittings are restricted to: SA-350 LF1 or LF2 or SA-266 Grade 4. Flanges above 24-inch diameter shall be SA-266, Grade 4. Studs and nuts are restricted to: SA-193 B7M or L7M and SA-194 Grade 2HM. It shall satisfy the requirements of SAES-A-301 and NACE RP0472. Shells and heads formed from plate shall be manufactured from HIC resistant steels that meet the testing requirements of 01-SAMSS-016. Piping components used in the manufacture of a pressure vessel within the scope of this specification shall be manufactured from HIC resistant steels that meet the testing requirements of 01-SAMSS-016.
E) F)
Low alloy steels shall not be mixed, i.e., a vessel requiring 1- Cr- Mo materials shall have all components manufactured from 1- Cr- Mo. Low alloy steels shall be specified in the normalized and tempered heat-treated condition.
Page 40 of 44
G) H) I)
The material for nameplate mounting brackets shall be of the same type and material grade as the shell material. Impact testing of materials and welding procedures are required when MDMT is lower than -28C. Impact testing of materials is only required when MDMT is -27 to -18C. Impact testing of welding procedures is not required for this temperature range, (unless otherwise required by the applicable Codes) or if the consumable classifications per ASME SEC IIC has impact property requirements at -46C or lower.
Specific Notes: 1) 2) Only SA-36, SA-283, and SA-285 materials shall be used for vessel's components in water and air services. The materials of supports shall be as follows: i) ii) iii) 3) 4) Legs and lugs: same material as shell Skirts: same ASME material as the shell base material for a minimum distance of 300 mm measured below the vesselto-shell connection line, unless thermal calculations require additional length. Saddles: same ASME material as the shell base material.
All internal and external attachment clips on vessels shall be of the same ASME material as the pressure parts. Anchor bolts shall be according to SASD AB-036322.
Table 2 Charpy-V Impact Test Requirements

Minimum Required Impact Value for Full Size Specimen at MDMT, Joules Reference Thickness, t, inch
Material Class 1a 1b 2a 2b 2c 3
Notes: 1) 2) 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. See Table 3 for material specification.
t 34/27 34/27 34/27 34/27 34/27 34/27
<t1 34/27 34/27 34/27 34/27 34/27 34/27
1<t2 34/27 34/27 34/27 34/27 47/38 34/27
t>2 34/27 34/27 34/27 47/38 61/48 34/27
Page 41 of 44
Table 3 Material Classes

Class 1a 2b 2a 2b 2c 3 2b 2b 2c 1a 3 2a 2b 2c 2c 2b 3 2b 2c 2a 2b 2c 2b 2c 2c 2c SA 53 SA 105 SA 106 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 Gr. B Gr. F11 and F12 Gr. F22 Gr. D and E Gr. A, B and C Cl. 1 Cl. 2 and 4 Gr. 1 Gr. 3 Gr. 6 Gr. P11, P12 and P22 Cl. F12 and F22A Cl. F22 Gr. LF2 Gr. LF3 Cl. 1, Gr. 11, 12 and 22 Cl. 2, Gr. 5, 12, 21 and 22 Gr. 55 and 60 Gr. 70 Cl. 1 Cl. 1 Gr. WPL3 and WPL6 Gr. WPB Gr. WP11, WP12 and WP22 Material Specification Gr. B
Page 42 of 44
Table 4 Radiography Requirements for Vessels

Weld Joint Category A and B C D
Notes: 1. 100% RT is required in vessels under any of the following services or design conditions: 2. 3. 4. Lethal services. Hydrogen services. Cyclic services. Unfired steam boilers with design pressure exceeding 50 psi. Vessel weld joints requiring full radiography per the applicable Code (see UW-11 for Division 1 vessels and AF-220 for Division 2 vessels). Thick wall vessels. Butt welds in nozzles attached to weld neck flanges. Butt welds in integrally reinforced contoured fittings.
Radiography (RT) Per Code Design Criteria (Spot or 100%) 100% 100%
Notes (1) and (4) (1), (3) and (4) (1), (2), (3), (4) and (5)
UT for Category-D weld joint in attachments with a reinforcing plate must be performed prior to installing reinforcing plate. UT from accessible side must be conducted after any heat treatment, if applicable. UT methods which generate permanent records may be used as a substitute to radiography in vessels that require 100% RT per the applicable Code and this specification. Such UT methods must be approved by Inspection Department prior to commencement of any work. UT methods which generate permanent records may be used as a substitute to RT where a weld joint can not be readily radiographed, because of the joint geometry, e.g., Category D weld joint using integrally reinforced nozzle without a contour that would facilitate radiography or a nozzle with a reinforcing pad. Such UT methods must be approved by Inspection Department prior to commencement of any work. UT may be substituted for RT for NPS 4 and smaller connections to nozzles and manways. To facilitate 100% radiography of category-D weld joint, it shall be according to: a) b) For Division 1 vessels: Figures UW-16.1: (f-1), (f-2) (f-3) or (f-4). For Division 2 vessels: Figures AD-613.1: (a), (b) (c), (c-1) (d) or (e).
5.
6. 7.
Page 43 of 44
Table 5 Ultrasonic Examination Requirements for Vessels

Weld Joint Category A and B C D
Notes: 1. 100% UT is required in vessels under any of the following services or design conditions: 2. 3. 4. 5. Lethal services. Hydrogen services. Cyclic services. Thick wall vessels. Butt welds in nozzles attached to weld neck flanges. Butt welds in integrally reinforced contoured fittings.
UT 100% 100% 100%
Notes (1) and (4) (1), (3) and (4) (1), (2),(3) and (5)
UT for Category-D weld joint in attachments with a reinforcing plate must be performed prior to installing reinforcing plate. UT from accessible side must be conducted after any heat treatment, if applicable. UT methods, which generate permanent records, used as a substitute to radiography in vessels must be approved by Inspection Department prior to commencement of any work. UT methods, which generate permanent records, used as a substitute to RT for weld joints that can not be readily radiographed, because of the joint geometry (e.g., Category D weld joint using integrally reinforced nozzle without a contour that would facilitate radiography or a nozzle with a reinforcing pad) must be approved by Inspection Department prior to commencement of any work. UT may be substituted for RT for NPS 4 and smaller connections to nozzles and manways. If ultrasonic examination is not practical for joint D in vessels, with thickness up to 50 mm (2 inches), under services other than those specified in note (1), the whole joint shall be either magnetic particle or liquid penetrant examined after each 6 mm depth of weld deposit.
6. 7.
Page 44 of 44

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Materials System Specification

32-SAMSS-004 Manufacture of Pressure Vessels Vessels Standards Committee Members

Saudi Aramco DeskTop Standards

32-SAMSS-004 Manufacture of Pressure Vessels

1.2 1.3 1.4

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

Saudi Aramco Inspection Requirements Form 175-321900 Manufacture of Pressure Vessels

API PUBL 941

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

7.1.4 7.1.5 7.1.6 7.1.7

32-SAMSS-004 Manufacture of Pressure Vessels

7.2.4 7.2.5 7.3

32-SAMSS-004 Manufacture of Pressure Vessels

7.8.2 7.8.3 7.9

32-SAMSS-004 Manufacture of Pressure Vessels

7.10.2 7.10.3 7.10.4

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

8.1.8 8.1.9 8.1.10

32-SAMSS-004 Manufacture of Pressure Vessels

Use of internal reinforcing elements is not permitted.

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

9.3 9.4 9.5

32-SAMSS-004 Manufacture of Pressure Vessels

10.2.7 10.2.8 10.2.9

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

11.3.1 11.3.2 11.4

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

Forming and Assembly

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

Postweld heat treatment shall be in accordance with the requirements of SAES-W-010.

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

19.1.6 19.1.7 19.2

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

32-SAMSS-004 Manufacture of Pressure Vessels

29 December 2004 30 March 2005

32-SAMSS-004 Manufacture of Pressure Vessels

Table 1 Acceptable Materials for Carbon and Low - Alloy Steels

-100 to -47C SA-203 Grades D or E

351 to 645C SA-387 Grades 11, 12 or 22

SA-333, Grade 3 SA-350 LF3 SA-420 WPL3