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Materials System Specification

32-SAMSS-022 Manufacture of Components for Flare Systems Flare Systems Design Standards Committee Members
Nowaishi, K.K., Chairman Al-Anizi, S.S. Al-Awwami, A.N. Al-Harbi, A.D. Khouie, S.B. Kim, S.U. Naffa'a, M.Y.

30 June, 2002

Saudi Aramco DeskTop Standards


Table of Contents 1 2 3 4 5 6 7 8 9 10 11 Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 2 Definitions...................................................... 4 Responsibilities.............................................. 6 Proposals....................................................... 6 Design............................................................ 7 Materials......................................................... 9 Welding......................................................... 10 Fabrication.................................................... 10 Inspection..................................................... 11

Previous Issue: 29 March, 2000 Next Planned Update: 1 July, 2007 Revised paragraphs are indicated in the right margin

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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

Scope 1.1 This specification covers the minimum mandatory requirements for the design, fabrication, materials, and inspection of new flare systems and includes: flare stacks, flare tips, dry gas seals, liquid-seals, and flare knockout drums. This specification does not include requirements for incinerators, or equipment used for the burning of combustibles on ships. This specification does not prohibit the use of vendor proprietary designs required for flare systems.

1.2 1.3

Conflicts and Deviations 2.1 Any conflicts between this Specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs) Standard Drawings (SASDs), or industry standards, codes, and forms shall be in writing by the Company or Buyer Representative through the Manager, Process & Control Systems 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 SAEP302 and forward such requests to the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2

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 Documents Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standards SAES-N-100 SAES-N-110 Refractory Systems Installation Requirements, Castable Refractories

Saudi Aramco Materials System Specification 32-SAMSS-004 Manufacture of Pressure Vessels

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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

Saudi Aramco Inspection Requirements Form 175-326700 Flare Tips

Saudi Aramco Forms and Data Sheets 7305-ENG Noise Data Sheet

Saudi Aramco-Flare System Forms (herein after referred to as data sheets) 9547-ENG 9548-ENG 9549-ENG 9561-ENG 9562-ENG 3.2 Industry Codes and Standards American Petroleum Institute API STD 601 Metallic Gaskets for Raised-Face Pipe Flanges and Flanged Connections Flare System, Flare Tip Data Sheet Flare System, General Data Sheet Flare System, Flare Knockout/Seal Drum Data Sheet Flare System-Process Data Sheet Flare System-Utility Data Sheet

American Society of Civil Engineers ASCE 7 Minimum Design Loads for Buildings and Other Structures

American Society of Mechanical Engineers (Boiler and Pressure Vessel Code) ASME SEC IX ASME B16.5 ASME B16.9 ASME B16.11 ASME B31.3 ASME B16.47 Welding and Brazing Qualifications Pipe Flanges and Flanged Fittings Factory made Wrought Steel Butt Welding Fittings Forged Steel Fittings, Socket Welding, and Threaded Chemical Plant and Petroleum Refinery Piping Large Diameter Steel Flanges NPS 26 Through NPS 60 (Series A)

American Society of Testing and Materials ASTM A105 Standard Specification for Forgings, Carbon Steel for Piping Components

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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

ASTM A182

Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings and Valves and Parts for High Temperature Service Alloy-Steel and Stainless Steel Bolting Materials for High Temperature Service Carbon and Alloy Steel Nuts and Bolts for High Pressure and High Temperature Service Heat-Resistant Chrome and Chrome-Nickel Stainless Steel for Pressure Vessels Stainless and Heat-Resisting Steel Bars and Shapes Seamless and Welded Austenitic Stainless Steel Pipe Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex), for PressureContaining Parts Stainless and Heat-Resisting Steel Wire Nickel-Iron-Chromium Alloy Rod and Bar Nickel-Iron-Chrome Alloy Plate, Sheet and Strip Nickel-Iron-Chromium-Molybdenum-Copper Alloy (UNS N08825) Plate, Sheet, and Strip Nickel-Iron-Chromium-Molybdenum-Copper Alloy (UNS N08825) Rod and Bar

ASTM A193 ASTM A194 ASTM A240 ASTM A276 ASTM A312 ASTM A351

ASTM A580 ASTM B408 ASTM B409 ASTM B424 ASTM B425

Manufacturers Standardization Society MSS SP-44 4 Definitions Barrel: The cylindrical portion of a flare tip which includes the shell, windshield, and flare tip to flare stack flange. Design Engineer: The Engineering Company responsible for specifying on the data sheets the process and mechanical design requirements for flare systems. Dry Gas Seal: A device used to reduce the amount of purge gas required to maintain a safe level of oxygen upstream of the seal. Steel Pipe Line Flanges

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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

Flare Tip Assembly: Includes the barrel, steam piping, pilots, nozzles, ignitors and jets. Flare Manufacturer: The company responsible for the manufacture of complete flare systems, or components of flare systems, in accordance with this specification. Flare System: Includes all piping, valves, pressure vessels and devices downstream of relief/depressuring outlet block valves, to and including flare tip(s). Flash Back Protection System: A system to prevent a flame front from traveling back to the upstream piping and equipment. Normally flash back is caused when air (oxygen) is inadvertently introduced into the flare system. Liquid Seal Drum: A horizontal or vertical vessel in which a liquid (usually water) level is used to maintain a positive pressure in the relief system upstream of the seal drum, under conditions of no flow. Also used for staging between flares or a flare gas recovery system and a flare. Main Flare Knockout Drum: A vessel, located in either a main flare header or at the base of a flare stack, which removes liquids that condense in or are carried over into the flare system. Maximum Continuous Flow: A flow which may be continuous for periods from a few minutes to days or weeks. An example is flaring associated gas. (The maximum continuous flow in a unit relief header, in a multi-unit plant, may not be the flow that contributes to the maximum continuous flow in the main flare header). Maximum Instantaneous Flow: This flow is due to depressurization and/or an emergency relief. It is the maximum sum of the loads resulting from any single contingency considered for emergency relief and/or emergency shutdown requiring depressurization, and the plant(s) or unit(s) feed gas flow associated with that relief or shutdown situation. Multitip Multistage Flare: A flare made up of a number of stages, where each stage usually has more than one tip. The tips are of proprietary designs and are designed to burn smokeless and with low radiation due to the high velocity flow from each tip. It is usually staged by means of control valves and rupture devices (as a safety backup to each control valve). It may be elevated or low level. Normal Continuous Flow: The flow due to combustible purge gas and other small continuous sources and normal venting. Pipe Type Flare Tip: A flare tip which is constructed from a pipe or thin-walled hollow cylinder with addition of pilots and flame retention devices for flame stability. The flare gas passes through the tip.

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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

Saudi Aramco Engineer: The Supervisor of the Flare & Relief Systems Unit, Downstream Process Engineering Division of P&CSD, Dhahran. Unit Knockout Drum: A vessel, located in a unit or close to the boundaries of a unit which retains liquid carryover and/or condensate discharged from a unit relief header and discharges the vapor to a main flare header. 5 Responsibilities 5.1 5.2 The Design Engineer is responsible for specifying the process and mechanical design requirements and completing the data sheets. The Flare Manufacturer is responsible for the design (process systems, mechanical and structural), supply of materials, fabrication, non-destructive testing, and preparation for shipment of flare stacks, flare tips, liquid-seals, and knockout drums in accordance with the completed data sheets and this specification.

Proposals 6.1 General 6.1.1 6.1.2 6.1.3 6.2 The Flare Manufacturer's proposal shall be based on details as outlined on the data sheets. The Flare Manufacturer may offer an alternative design, but must quote on the base inquiry documents. The Flare Manufacturer's proposal shall include a detailed description of any exception to the requirements of this specification.

Detailed Requirements The Flare Manufacturer is to supply the following information with the proposal. This information is necessary and will be used to complete the technical evaluation of the quotation. The quotation will be technically unacceptable if any of the information required is not included. (1) (2) (3) (4) Completed data sheets A list of users operating flares of the same design and under similar operating conditions Steam pressure and flow required for all specified flaring scenarios Dimensional drawing(s) showing internals of seal drums
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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

(5) (6) (7) 6.3

Acid dew point temperature and a justification of material selection and the provisions for protecting against acid dew point corrosion A completed noise data sheet Form 7305-ENG with a detailed description of acoustical design Materials of all components

Performance Guarantees The following shall be guaranteed for the length of the warranty period specified in the purchase order or contract documents: (1) (2) (3) (4) Proper operation at all specified flaring scenarios Sound levels at all specified operating conditions Maximum radiation intensities Emission levels at all specified operating conditions

Design 7.1 General 7.1.1 7.1.2 Flare stacks, flare tips, liquid-seals, knockout drums, and seal drums shall be sized in accordance with the data sheets. The method of attaching a flare tip to a flare stack shall be flanged, except for the inner barrel of air assisted flares if the flange will interfere with air flow. Flare stacks, flare tips, and liquid-seals shall be designed in accordance with ASME B31.3. (Flare stacks and flare tips do not require hydrostatics pressure tests). Flare stacks shall be designed to resist the effects of wind and earthquake loads acting on the flare stack. Wind and earthquake loads shall be calculated in accordance with ASCE 7 using the wind speeds, exposure factors, soil coefficients and earthquake zones specified on the data sheets. With reference to ASCE 7, the classification for wind and earthquake shall be Category III, (essential structures) and the seismic hazard exposure factor shall be Group III classification.

7.1.3

7.1.4 7.1.5

7.1.6

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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

7.1.7 7.1.8

The design metal temperature of a flare systems shall be in accordance with the applicable data sheet. The minimum thickness of flare tip barrels, shall be per Table 1. Table 1 Minimum Thickness of Flare Tip Barrels
Barrel Diameter
Up to and including 3 ft Greater than 3 ft

Minimum Thickness
1/4 inch 3/8 inch

7.2

Steam Piping 7.2.1 7.2.2 Steam piping shall be designed in accordance with the requirements of ASME B31.3. Steam rings, if required, shall be located a minimum of 18 inches from the top of a flare tip and a minimum of 2 inches outside of any external insulating refractory. All supports required for steam piping shall be designed with allowances for thermal expansion.

7.2.3 7.3

Flanges, Gaskets and Fittings 7.3.1 7.3.2 7.3.3 7.3.4 Piping flanges shall be ASME Class 150, raised face, weld neck types. Slip-on plate type flanges may be used for the flare tip barrel to stack flanges. The dimensions and pressure ratings of flanges up to and including 24 inch NPS shall be in accordance with ASME B16.5. The dimensions of flanges above 24 inch NPS shall be in accordance with either ASME B16.47 Series A, or MSS SP-44 and shall match flare stack flanges.
Commentary Note: The dimensions of replacement flare tips shall match existing flare stack flanges.

7.3.5 7.3.6

The dimensions of gaskets shall be in accordance with API STD 601. The dimensions and ratings of forged fittings and wrought fittings shall be in accordance with ASME B16.9 and ASME B16.11 respectively.
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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

Materials 8.1 Metallic materials required for flare tip barrels and piping components on a flare tip shall be in accordance with the material specifications detailed in Table 2. Table 2 Acceptable Metallic Materials
Product Form & Flare Tip Component Plates: barrel & welded attachments Plate type flanges Flanges: flare tip to flare stack steam piping (at bottom of tip) Pipe: steam risers, pilot gas, ignitor steam rings feeder to steam ring (above tip to flare stack flange) Pipe fittings: steam risers, pilot gas steam riser at bottom of tip Refractory V and Y type anchors Stud bolts Nuts Castings: steam jets and nozzle tips Gaskets Flare gases with up to 1 mol% H2S B409 UNS N08810, or N08811 B409 UNSN08810 or N08811, or A240 Type 304 A182 F304 or B562 UNS N08810 A105 or A182 F300 series A312 Type 309 or 310 A312 Type 321H S6 or Type 347H S6 A312 Type 309, 310, 321 or 347 Flare gases above 1 mol% H2S A240 Type 309, or 310 A240 Type 304, 309, or 310

A182 F304 or 310 A105 or A182 F300 series A312 Type 309 or 310 A312 Type 321H S6 or Type 347H S6 A312 Type 309, 310, 321 or 347

A182 F310, A403 WP309, or WP310 A182 F or A403, 300 series A276, A580 or A240 Types 309 or 310 A193 B8C or B8T, Class 1 A194 Grade 8C or 8T A351 CK-20 Spiral wound: Type 347 or 321 windings with 347 or 347 inner and outer rings Graphite filler.

A182 F310, A403 WP309, or WP310 A182 F or A403, 300 series A276, A580 or A240 Types 309 or 310 A193 B8C or B8T, Class 1 A194 Grade 8C or 8T A351 CK-20 or CH-20 Spiral wound: Type 347 or 321 windings with 347 or 347 inner and outer rings. Graphite filler.

General Notes: (1) For B409 (incoloy) flare barrels the materials specified for refractory anchors are for the V and Y types only. For refractory anchors and supports that are attached with fillet welds more than 2 inches long use: B408, B409, B424 or B425. Other materials may be substituted for the materials specified above if they are equivalent and approved by the Saudi Aramco Engineer. The materials, for flare tip barrel flanges (forged or plate) may be carbon steel provided that the maximum refractory dryout temperature does not reduce the mechanical properties or chemical composition of the flanges.

(2) (3)

8.2 8.3

Materials for flare stacks shall be in accordance with the data sheets. Materials for castable and insulating refractory shall be in accordance with SAES-N-100.
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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

8.4

Materials for knockout drums and liquid-seals shall be in accordance with 32-SAMSS-004.
Commentary Note: With reference to 32-SAMSS-004, the materials for knockout drum and seal drum shells and heads may be SA285 Grade C or SA283 Grade C.

Welding 9.1 9.2 Flare stacks shall be welded in accordance with ASME B31.3. Flare tip barrels shall be welded in accordance with the following: (1) (2) (3) All welding procedures and welders shall be qualified in accordance with ASME SEC IX. Approved processes are SMAW and GTAW. Any other processes require the approval of the Saudi Aramco Engineer. The filler metal shall match the composition and mechanical properties of the base metal. If two different base metals are to be joined, the filler metal selection shall be approved by the Saudi Aramco Engineer. A weld map shall be prepared to indicate which welding procedure will be used for each weld joint. WPS's, PQR's and weld maps shall be submitted for approval to the Saudi Aramco Inspector prior to the start of fabrication. All WPS's, PQR's and weld maps shall be available at the work site for review at any time. Circumferential and longitudinal butt welds of flare tip barrels shall be full penetration. Use of backing rings or strips are prohibited. All full penetration groove welds shall be welded from both sides. Singlesided groove welds are not permitted unless approved by the Saudi Aramco Engineer. Double-sided welds shall be ground or gouged to sound metal prior to welding the second side.

(4) (5)

(6) (7)

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Fabrication 10.1 General 10.1.1 Fabrication of flare stacks and flare tip barrels shall be in accordance with ASME B31.3 and the following: (1) Longitudinal butt welds shall be 5% randomly radiographed.
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Document Responsibility: Flare Systems Design Issue Date: 30 June, 2002 Next Planned Update: 1 July, 2007

32-SAMSS-022 Manufacture of Components for Flare Systems

(2) (3) 10.1.2 10.1.3 10.2

All welds on flare tip barrels shall be visually examined and penetrant tested over their entire length. All butt and fillet welds on flare tip barrels and flare stacks shall be 100% visually examined and 100% dye penetrant examined.

Fabrication of steam piping shall be in accordance with ASME B31.3 with all butt fully radiographed. Fabrication of knockout and liquid-seal drums shall be in accordance with 32-SAMSS-004.

Refractory Castable type refractory and refractory anchors shall be installed in accordance with SAES-N-110.

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Inspection 11.1 11.2 The Responsibility for inspection rests with the Flare Manufacturer in accordance with the applicable Code and the requirements of this specification. Flare tips are subject to verification by the Saudi Aramco Inspector in accordance with Saudi Aramco Inspection Requirements Form 175-326700.
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with minor changes.

30 June, 2002

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