Materials System Specification

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers 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. Walsh, M.P.

31 August, 2003

Saudi Aramco DeskTop Standards

Table of Contents

1 2 3 4 5 6 7 8 9 10

Scope............................................................. 2 Conflicts and Deviations................................ 2 References..................................................... 2 Definitions...................................................... 3 Mechanical Design......................................... 3 Material Specifications................................... 4 Nondestructive Testing.................................. 5 Fabrication..................................................... 5 Postweld Heat Treatment.............................. 6 Inspection, Pressure Tests and Shop Repairs.................................. 6

Previous Issue: 31 July, 1999 Next Planned Update: 1 September, 2008 Revised paragraphs are indicated in the right margin Primary contact: Mahmoud Y. Naffa'a on 874-7263

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CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Vessels Issue Date: 31 August, 2003 Next Planned Update: 1 September, 2008

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

Scope 1.1 This specification covers the minimum mandatory requirements for the manufacture of new pressure vessels and shell-and-tube heat exchangers in hydrocarbon, hydrogen, caustic, amine, wet sour, steam, and utility services with corrosion resistant cladding and weld overlays. This specification shall be used as a supplement to 32-SAMSS-004 or 32-SAMSS-007 when applicable. Where a licensor's specification requirement is more stringent than that of this specification, the licensor's specification requirement shall govern.

1.2 1.3

Conflicts and Deviations 2.1 Any conflicts between this Specification and other applicable Saudi Aramco Materials Systems Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran, before issuance of a Purchase Order. For conflicts identified after a Purchase Order is issued, the conflicts needs to be resolved prior to equipment shipment. 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

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 Engineering Standards SAES-A-206 SAES-W-014 Positive Material Identification Weld Overlays and Welding of Clad Materials

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CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Vessels Issue Date: 31 August, 2003 Next Planned Update: 1 September, 2008

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

Saudi Aramco Materials System Specifications 32-SAMSS-004 32-SAMSS-007 3.2 Industry Codes and Standards American Society of Mechanical Engineers (Boiler and Pressure Vessel Codes) ASME SA-20 ASME SA-263 ASME SA-264 ASME SA-265 ASME SA-578 Standard Specifications for General Requirements for Steel Plates for Pressure Vessels Corrosion Resistant Chromium Steel Clad Plate Sheet and Strip Stainless Chromium Nickel Steel Clad Plate Sheet and Strip Nickel and Nickel Base Alloy Steel Clad Plate Straight Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special Applications Manufacture of Pressure Vessels Manufacture of Shell and Tube Heat Exchangers

Tubular Exchangers Manufacturers Association (TEMA) 4 Definitions Heat Exchangers: Shell and tube types. Minimum Thickness: The value of the design thickness required to withstand all primary loads, excluding allowance for corrosion. Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco Inspection Department to inspect pressure vessels and heat exchangers to the requirements of this specification. Equipment Manufacturer: The company responsible for the manufacture of clad pressure vessels or heat exchangers in accordance with this specification. 5 Mechanical Design 5.1 5.2 5.3 The base material nominal thickness shall be used for strength calculations. The minimum base metal thickness for pressure vessel shells and heads shall be 10 mm. The minimum base metal thickness for shell and tube heat exchangers shall be in accordance with TEMA.
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Document Responsibility: Vessels Issue Date: 31 August, 2003 Next Planned Update: 1 September, 2008

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

Material Specifications 6.1 Clad Pressure Parts 6.1.1 6.1.2 6.1.3 The material of the corrosion resistant cladding shall be in accordance with the data sheet. Clad materials shall be alloy-verified, before their use, by the Equipment Manufacturer in accordance with SAES-A-206. Corrosion resistant linings shall be provided by one of the following methods as specified on the data sheet: 1) Integrally clad plates (rolled or explosion bonded), for shells, heads, and connections. Unless otherwise specified on the data sheet, the minimum thickness of cladding shall be 3.0 mm. 2) Weld overlaid plates, for shells, heads, and connections. Unless otherwise specified on the data sheet, the method of weld overlay shall be such as to produce a minimum of 3.0 mm thickness meeting the specified chemical composition. 3) Integrally clad and weld overlaid tube sheets in shell-and-tube heat exchangers. Unless otherwise specified on the data sheet, the minimum thickness of cladding shall be in accordance with TEMA. 6.1.4 6.1.5 6.1.6 6.2 Non-integral strip linings shall not be used. Clad heads shall be purchased to inside diameter size to prevent internal misalignment between the cladding of the shell and heads. Integrally clad plates shall be supplied in accordance with: ASME SA-263, or ASME SA-264, or ASME SA-265, as applicable.

Clad Non-pressure Parts The materials for internal and external clips and attachments shall be in accordance with 32-SAMSS-004 or 32-SAMSS-007, as applicable.

Nondestructive Testing 7.1 Ultrasonic Testing of Plates

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CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Vessels Issue Date: 31 August, 2003 Next Planned Update: 1 September, 2008

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

7.1.1

Integrally clad plates shall be ultrasonically tested at the mill in accordance with ASME SA-578. Any un-bonded areas are to be repaired in accordance with the supplementary requirement S6, Level I of ASME SA-578. A report on all repairs that have taken place shall be supplied by the mill. Where a corrosion resistant integrally bonded lining is applied by rolling, the bond between the lining and base metal shall be ultrasonically tested in accordance with ASME SA-578, Level I. All integrally clad pressure components shall be ultrasonically tested after forming in accordance with ASME SA-578, Level I. Areas of cut-outs, including a 50 mm band adjacent to the cut-out shall be ultrasonically tested to ASME SA-578, for lack of bond. Lack of bond in these areas is not permitted.

7.1.2

7.1.3 7.1.4

7.2

Weld Overlays Weld overlays shall be in accordance with SAES-W-014.

Fabrication 8.1 Forming and Assembly 8.1.1 Fabrication methods shall be such as to avoid any damage to the cladding or contamination of the cladding by scale, dirt, etc. particularly during rolling and forming. The preparation of plate edges for welding shall be done by shearing, machining, grinding or thermal cutting. The beveled edges shall be magnetic particle tested for linear discontinuities. Defects shall not exceed limits as per ASME SA-20. Where size permits, connections shall be either rolled from clad plate and the longitudinal weld 100% radiographed to the applicable Code, or shall be weld overlaid. Loose sleeve liners are not permitted. Larger than NPS 4 solid alloy nozzles are not permitted. NPS 4 and smaller solid alloy nozzles are permitted with prior concurrence of the Supervisor of the Material Engineering Unit.

8.1.2

8.1.3

8.1.4 8.1.5

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Document Responsibility: Vessels Issue Date: 31 August, 2003 Next Planned Update: 1 September, 2008

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

8.2

Welding All welding shall be in accordance with the requirements of SAES-W-014.

8.3

Welding Attachments 8.3.1 Attachments supporting light loads, which will result in tensile or shear stress less than 6.9 MPa (1,000 psi), may be welded directly to the cladding. The Equipment Manufacturer shall ensure that the bond strength is adequate to carry the imposed load and the area shall be ultrasonically tested, in accordance with ASME SA-578, Level I. Lack of bond is not permitted in these areas. Attachments other than those specified in paragraph 8.3.1 of this specification shall be welded directly to the shell. The materials of the attachment shall be of the same ASME specification as the base material. The attachment shall be full penetration welded to the base material. Cladding shall be applied after completion of welding the attachment. Where attachment is to be welded to the base metal after cladding the vessel, clad shall be stripped-back to weld the attachment. The attachment and the stripped-back area shall be then weld overlaid.

8.3.2

8.3.3

8.3.4

Postweld Heat Treatment When heat treatment is required, the procedure shall be such that it will not impair the mechanical properties of the base material or the corrosion resistance of the cladding.

10

Inspection, Pressure Tests and Shop Repairs 10.1 Inspection 10.1.1 After cutting-back the cladding, the Equipment Manufacturer shall perform a chemical check (acid etching) to confirm complete removal of the cladding material. All welds in the base metal which are to be covered by a corrosion resistant overlay and the surfaces of all weld overlays shall be dye penetrant tested in accordance with the applicable Code.

10.1.2

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Document Responsibility: Vessels Issue Date: 31 August, 2003 Next Planned Update: 1 September, 2008

32-SAMSS-031 Manufacture of Clad Vessels and Heat Exchangers

10.1.3

Clad material shall be alloy-verified for meeting its specified chemical composition according to requirements of this specification and SAES-W-014.

10.2

Pressure Tests 10.2.1 10.2.2 Equipment or parts of equipment which are clad shall be hydrotested with water having chloride content not greater than 50 ppm. Immediately following hydrotesting, the equipment shall be completely drained and dried to the satisfaction of the Saudi Aramco Inspector.

10.3

Shop Repairs 10.3.1 10.3.2 10.3.3 The Equipment Manufacturer shall advise the Saudi Aramco Inspector of all major repairs to be made to the cladding or base metal. The Equipment Manufacturer shall prepare repair procedures and submit to the Saudi Aramco Inspector for review and approval. Major repairs are defined as follows: 1) 2) 10.3.4 10.3.5 Cladding Material: Un-bonding as defined in ASME SA-578 supplement S6. Base Material: Undercuts and all linear indications in the base materials.

Plate edge laminations shall be completely removed and the laminated areas repaired. Repairs to cladding shall be ultrasonically tested to ASME SA-578, Level I. All repair surfaces shall be dye penetrant tested in accordance with the applicable Code.

31 August, 2003

Revision Summary Major revision.

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