32 Samss 035

Materials System Specification
32-SAMSS-035 Manufacture of Heat Recovery Steam Generators Heat Transfer Equipment Standards Committee Members
Anizi, Salamah Salem, Chairman Bagawi, Jamil Jarallah, Vice Chairman Anezi, Mohammed Ali Dossary, Musfir Abdullah Fernandez, Gabriel Thomas Gahtani, Moraya Saif Guthami, Mohammed Mohsen Hamam, Ibrahim Hassan Harbi, Abdullah Mohammed Saeed Mansour, Khalid Mohammad Moore, Mark Andrew Naffaa, Mahmoud Youniss Rumaih, Abdullah Mohammad
26 December 2009
Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 2 Definitions and Abbreviations......................... 5 Responsibilities.............................................. 6 Proposals....................................................... 6 Performance Guarantee................................. 8 Design............................................................ 8 Superheater.................................................. 14 Economizers................................................. 15 Ductwork....................................................... 16 Stacks........................................................... 17 Insulation and Refractories........................... 17 Noise Attenuation......................................... 18 Connections, HRSG Trim and Instruments.. 18
Previous Issue: 20 November 2007 Next Planned Update: 19 November 2012 Revised paragraphs are indicated in the right margin Primary contact: Anizi, Salamah Salem on 966-3-8746139
CopyrightSaudi Aramco 2009. All rights reserved.
Page 1 of 29
Document Responsibility: Heat Transfer Equipment Issue Date: 26 December 2009 Next Planned Update: 19 November 2012
32-SAMSS-035 Manufacture of Heat Recovery Steam Generators
Table of Contents (cont'd) 16 17 18 19 20 21 22 23 24 1 Scope This specification covers the minimum mandatory requirements for the manufacture of new Heat Recovery Steam Generator Unit downstream of a Combustion Gas Turbine (CGT) (herein referred to as HRSG). 2 Conflicts and Deviations 2.1 Any conflicts between this Specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Saudi Aramco 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, 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. Supplemental Fuel Burning Equipment........ 21 Painting........................................................ 23 Fabrication.................................................... 23 Nondestructive Testing................................. 24 Postweld Heat Treatment............................. 25 Inspection and Equipment Testing............... 25 Nameplates and Stampings......................... 27 Preparation for Shipment............................. 27 Drawings, Calculations and Data................. 29
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 Procedures SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement
Page 2 of 29
SAEP-341 SAEP-1140 SAEP-1142
Equipment Life Cycle Cost Procedure Qualification and Certification of NDT Personnel Qualification of Non-Saudi Aramco NDT Personnel
Saudi Aramco Engineering Standards SAES-A-004 SAES-A-005 SAES-A-102 SAES-A-112 SAES-A-206 SAES-B-054 SAES-H-001 SAES-H-100 SAES-H-101 SAES-J-602 SAES-L-008 SAES-N-001 SAES-N-100 SAES-N-110 SAES-N-120 SAES-N-130 SAES-N-140 SAES-W-010 Pressure Testing Safety Instruction Sheet Air Pollutant Emission Source Control Meteorological and Seismic Design Data Positive Material Identification Access, Egress, and Material Handling for Plant Facilities Selection Requirements for Industrial Coatings Painting Requirements for Industrial Facilities Approved Protective Coating Systems Burner Management, Combustion and Waterside Control Systems for Watertube Boilers Selection of Valves Basic Criteria, External Insulation Refractory Systems Installation Requirements - Castable Refractory Installation Requirements - Extreme Erosion Resistant Refractories Installation Requirements - Fireclay Bricks Installation Requirements - Refractory Ceramic Fiber Welding Requirements for Pressure Vessels
Saudi Aramco Materials System Specifications 32-SAMSS-009 34-SAMSS-611 34-SAMSS-617 General Purpose Steam Turbines Safety Relief Valves, Conventional and Balanced Types Fire Monitoring Systems
Page 3 of 29
34-SAMSS-619 34-SAMSS-830
Flame Monitoring and Burner Management Systems Programmable Logic Controllers
Saudi Aramco Inspection Requirements Form 175-329000 Heat Recovery Steam Generator (HRSG)
Saudi Aramco Forms and Data Sheets Form 2694-1-ENG Form 7305-ENG Form 9550-ENG Form NMR-7913 Safety Instruction Sheet Equipment Noise Data Sheet Watertube Boiler Data Sheets (herein referred to as data sheet) Non-material Requirements for Industrial Watertube Boilers
Saudi Aramco General Instructions GI-0150.003 3.2 Industry Codes and Standards American Institute of Steel Construction AISC M011 AISC M013 Manual of Steel Construction Detailing for Steel Construction Ionizing Radiation Protection
American Society of Civil Engineers ASCE 7 Minimum Design Loads for Buildings and Other Structures
American Society of Mechanical Engineers ASME PTC 4.4 ASME SEC I ASME SEC V ASME SEC VIII Gas Turbine Heat Recovery Steam Generator Power Boilers Nondestructive Examination Rules for Construction of Pressure Vessels
American Society for Testing and Materials ASTM A435 ASTM D1066 Standard Specification for Straight-Beam Ultrasonic Examination of Steel Plates Practice for Sampling Steam
Page 4 of 29
National Fire Protection Association NFPA 85C Standard for the Prevention of Furnace Explosions/Implosions in Multiple Burner Boiler-Furnaces
U.S. Military Standards and Federal Specifications MIL-C-16173 3.3 Government Regulations Presidency for Meteorology and Environment (PME) Document No. 1409-01 4 Definitions and Abbreviations Definitions HRSG: Within the scope of ASME SEC I, Power Boilers, and this specification. CGT: Combustion Gas Turbine. HRSG Piping: Within the scope of ASME SEC I, Power Boilers, Figures PG-58.3.1 and PG-58.3.2, and this specification. Design Engineer: The Engineering Company responsible for specifying the design requirements for HRSGs on the data sheet, in accordance with the requirements of this specification. Heating Surface: The flat projected area, excluding refractory covered surfaces. Saudi Aramco Engineer: The Supervisor of the Process Equipment Unit, Consulting Services Department, Dhahran. Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco Inspection Department to inspect HRSGs to the requirements of this specification. Abbreviations (Levels and Rating) HHCO: High-High Water Level Cut-out HLCO: High Water Level Cut-out LLCO: Low-Low Water Level Cut-out LWL: Low Water Level
Page 5 of 29
Corrosion Preventive Compound, Solvent Cutback, Cold-Application
MCR: Maximum Continuous Rating NWL: Normal Water Level 5 Responsibilities 5.1 The HRSG Manufacturer is responsible for the thermal design, mechanical design, (Code and structural calculations), and supply of all materials, fabrication, inspection, testing, and preparation for shipment, in accordance with the Code, the completed data sheet and this specification. The Design Engineer is responsible for specifying the design requirements for HRSGs, as noted on the data sheet, and for specifying (supplied by others), the balance of HRSG instrumentation in accordance with the industry standard requirements, for both field and control room instruments, which shall include the following: 1) 2) 3) 4) 5.3 Feedwater regulatory controls Steam drum level indication and shutdown instruments Flue gas and waterside analyzers Desuperheater controls, if desuperheater provided.
5.2
Unless specified on the data sheet, the HRSG Manufacturer's supply of instrumentation shall be limited to the following: 1) 2) All instrument connections Thermowells
Proposals 6.1 General 6.1.1 6.1.2 6.1.3 6.2 The HRSG Manufacturer's proposal shall be based on details for individual HRSGs as outlined on the data sheet. The HRSG Manufacturer may offer an alternative design, but must quote on the base inquiry documents. The HRSG Manufacturer's proposal shall include a detailed description of any exception to the requirements of this specification.
Detailed Requirements The HRSG Manufacturer is to supply the following information with the
Page 6 of 29
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) A completed data sheet. A curve of steam outlet temperature versus steam load for each fuel specified. Circulation design criteria, including: all flows, temperatures, pressures, and pressure drops, for each circuit of the HRSG offered, complete with a circuit diagram. A list of users operating HRSGs of the same design and under similar operating conditions. Tubular surface corrosion/erosion allowances. Design criteria for determining the number and sizing of supply and riser tubes and headers. Sizes of observation ports. Anticipated maximum tube metal temperatures for each stage of superheaters along with procedures for determining those temperatures. The pressure and flowrate required for superheater spraywater if applicable.
4) 5) 6) 7) 8) 9)
10) Tube cleaning procedures. 11) Technical description of vibration restraints and their predicted metal temperatures. 12) Dimensional drawing(s) showing internals of drums, materials of drums and headers, inside diameters, drum and header thicknesses, water and steam circuit arrangements, casing, casing structure and flue and duct arrangements. 13) A cross-sectional sketch of steam drums showing the location of internals, all water levels, and the highest downcomer. The sketch shall also show the useful water volume in the steam drum below the NWL, LWL, and LLCO. 14) Locations of access doors, observation ports, platforms, stairways, and ladders on a general arrangement type drawing. 15) Acid dew point temperature and a justification of material selection and the provisions for protecting external surfaces of tubesheets and tube bends in header boxes against acid dew point corrosion.
Page 7 of 29
16) Steam and water quantities, water temperature requirements, and a description of water washing procedures. 17) Turndown ratio from maximum to minimum operating range. 18) Minimum load obtainable with different CGT firing schemes. 19) A completed noise data sheet with a detailed description of acoustical design. 20) Location and sizes of openings required for water washing. 21) Materials of all pressure components, heat transfer components and heat transfer supports. 7 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) Steam outlet pressure and temperature downstream of the nonreturn valve as specified on the data sheet operating at 100% MCR. Efficiency at 100% MCR with steam conditions and CGT fuels fired as specified. Unless otherwise specified on the data sheet, a maximum concentration of 100 ppb (parts per billion) total dissolved solids (TDS) and 20 ppb each of sodium and silica in saturated steam at any load within a HRSG's controlled range. Flue gas emission levels at all specified operating conditions. Sound levels at all specified operating conditions.
4) 5) 8
Design 8.1 General 8.1.1 8.1.2 The design of HRSGs, HRSG piping, and associated equipment shall conform to the Code, and the completed data sheet. The design and construction of HRSGs and all auxiliary equipment shall be of a proven and commercially demonstrated design and performed satisfactorily for a minimum of five years. HRSGs shall be designed to operate continuously in the automatic control mode, but with manual control override capabilities; under all conditions specified on the data sheets (e.g., operating with the CGT at peak load for extended periods).
8.1.3
Page 8 of 29
8.1.4
Equipment and components of standard manufacture shall be provided to ensure the availability of spare parts. Components need not be products of the HRSG Manufacturers, however, the HRSG Manufacturer shall assume full responsibility for all components supplied regardless of their source. The design of HRSGs located outdoors shall be suitable for continuous operation at the summer design temperature for a particular site. Regardless of climatic conditions, all external surfaces shall be selfdraining and protected against corrosion. Open covers (roof and sides only) shall be provided with over firing aisles. HRSGs and auxiliaries, including control instrumentation, shall be designed for continuous operation during electrical power outages through an uninterrupted power supply system (to be provided by others). The HRSG Manufacturer shall submit an estimate of the electrical power required. HRSGs and auxiliaries shall be capable of sustained operation in automatic control mode at 100% MCR for a minimum period of two years between shutdowns required for the complete testing and inspection (T&I) of an HRSG. HRSGs shall be capable of accommodating a rate of change of 10% MCR per minute over the control range of the HRSG, for both an increasing and decreasing steam demand, without causing a level shutdown or water carryover during the transient condition.
8.1.5 8.1.6
8.1.7
8.1.8
8.1.9
8.1.10 Circulation calculations at 100% MCR shall be prepared and submitted by the HRSG Manufacturer for review. 8.1.11 Gas passes through HRSG casing, superheaters (if specified) and heat transfer surfaces, as well as flue gas ducts, shall be designed and arranged to prevent vibrations from vortex shedding, impact loadings, and turbulence. HRSG Manufacturer shall submit vibration calculations. 8.1.12 All water and steam piping shall extend 1.0 m beyond the battery limits of the HRSG; the Design Engineer shall specify exact locations. 8.1.13 Space and access shall be provided for the inspection, cleaning, removal, and maintenance of tube bundles, headers and valves. The HRSG floor casing shall be a minimum of 1 m above grade. 8.1.14 Guards or personal protection type insulation shall be provided around operating areas where exposed surfaces are hotter than 65C.
Page 9 of 29
8.1.15 Facilities shall be provided for the complete draining of all water from the fire side of HRSG units after washing. Drains openings shall be a minimum of 75 mm diameter and be sealed against overheating and escape of flue gases. 8.1.16 Enclosures for instrumentation and electrical equipment shall be selected for the area classification specified on the data sheet. 8.1.17 Pinch-point at evaporator outlet shall be within the range of 8 to 15C. 8.1.18 Approach-point at economizer outlet shall be within the range of 2 to 5C. 8.2 Corrosion Allowances The minimum corrosion allowance for tubes and other pressure components shall be 1.5 mm. 8.3 Structure and Casing 8.3.1 The gas path enclosure casing plate shall be an internal casing rectangular box open in both ends for entry and exit of the gas stream. Transition ducts shall be provided at the inlet and exit of the HRSG for connection to the gas source and to a duct or stack exhausting to the atmosphere. Tubes, headers and drums shall be supported with an external structural framework integral to the casing plate.
8.3.2 8.4
Steam Generating and Superheater Tubes 8.4.1 8.4.2 8.4.3 8.4.4 All tubes shall be seamless steel or electric resistance welded (ERW) steel. ERW tubes shall not be used in superheaters. All tubes shall have a minimum outside diameter of 38 mm. Tube material shall be selected based on the highest anticipated metal temperatures and flue gas composition. Tube configurations shall allow the free natural circulation of water and steam, in the proper direction, at all loads, and installed to allow complete draining of each tube. Vertical tubes shall be supported or guided, or both, to prevent sagging and vibration, and to permit expansion.
8.4.5
Page 10 of 29
8.4.6 8.5
The minimum wall thicknesses of tubes shall be: 4 mm, for carbon steel and 3 mm for alloy steels.
Drums and Headers 8.5.1 The maximum allowable working pressure, per the Code shall be at least 7% or 100 KPa (15 psig), whichever is the greater above maximum operating drum pressure. Downcomers and internals shall be designed to ensure positive circulation under all loads. Steam drum sizing shall satisfy the following criteria: 1) 2) The inside diameter shall be not less than 1220 mm with a ratio of length (tangent to tangent) to diameter no greater than 6:1. The steam space shall be adequately sized to contain steam separation equipment necessary to attain the guaranteed steam purity specified throughout the control range. The water holding capacity between the LWL and LLCO shall be sufficient to sustain one-minute evaporation at MCR with no feedwater flow. The LLCO shall be located not less than 50 mm above the top of the highest downcomer. A rise in water level (swell) above the NWL shall not cause a carryover or actuation of the HLCO. A fall in water level (shrinkage) below the NWL resulting shall not cause the actuation of the LLCO.
8.5.2 8.5.3
3)
4) 5) 6) 8.5.4
When intermediate headers are required within a circulating circuit, restrictions to HRSG circulation caused by headers shall be considered. Headers shall be protected from heat from flue gases. Drum connections shall be a minimum of inch NPS. The wall thickness of connections up to and including 2 inch NPS shall be schedule 160 minimum. Pipe sizes of 1 inch, 5 inch, and 7 inch NPS shall not be used. A manway shall be provided at both ends of steam drum and provided with hinged covers.
8.5.5 8.5.6 8.5.7 8.5.8
Page 11 of 29
8.5.9
The facings of flanged connections shall be either the raised face or ring joint types. However, for economy of parts, the type of facing for new HRSGs shall be the same as existing HRSGs at the same site location.
8.5.10 Steam drum shall be welded, postweld heat treated, and 100% radiographically tested in accordance with the Code. 8.5.11 Headers shall be constructed of seamless steel pipe. Where needed to facilitate safety, operation, maintenance, and inspection, headers shall be provided with inlet nozzles, outlet nozzles, inspection openings, drains, vents, and connections for blowdown, and chemical cleaning. 8.5.12 Drums with wall thicknesses 50 mm and thicker shall have nozzle connections as follows: 1) 2) 8.6 Connections 6 inch NPS and larger per Figures PW-9.1 (q-1), (q2), (q-3), or (q-4) of ASME SEC I. Connections 4 inch and less as per (1) above or Figure PW-9.1 (a), (b), (c), (g), or (h) of ASME SEC I.
Steam Drum Internals 8.6.1 8.6.2 Steam drum internals shall consist of equipment for steam separation, feedwater distribution, chemical feed distribution, and blowdown. Steam separation equipment shall consist of separators, followed by primary and secondary chevron sections designed to meet the purity of steam specified on the data sheet. Proposals for other types of steam separation equipment must be included in the HRSG Manufacturer's proposal and must be substantiated with test results from commercial units that the steam purity entering the superheater will not exceed those specified on the data sheet. All internals shall be designed such that they can be removed without cutting. The design of chemical feed distribution piping shall comply with the following: 1) 2) 3) Be extended through steam drums and be of sufficient length to ensure proper mixing of chemicals. Be perforated Closed at the far end with a threaded cap
8.6.3
8.6.4 8.6.5
Page 12 of 29
4) 5) 8.6.6
Provided with a thermal sleeve Located in the steam drum to avoid short-circuiting of chemicals into the continuous blowdown collection system
HRSG feedwater distribution piping shall be provided with a thermal sleeve and be extended through the steam drum to assure proper mixing of the feedwater with the saturated recirculated water so that thermal shock is avoided. The design of continuous blowdown internal piping shall comply with the following: 1) 2) 3) Located in the area with the highest concentration of HRSG water impurities Be extended as far as possible Be perforated with holes not smaller than 9.5 mm or V-notched on the top
8.6.7
8.7
Drum Intermittent Blowdown 8.7.1 Intermittent blowdown nozzles shall be located on the lowest point of steam drums. The size shall be based on water quality and operation, but shall not be less than 1 inch nor greater than 2 inch NPS. Separate drain valves shall be provided at the lowest point of steam drums as a means for the draining of HRSGs.
8.7.2 8.8
Materials 8.8.1 8.8.2 8.8.3 8.8.4 8.8.5 All materials shall be in accordance with the Code and the selection criteria in this specification for individual components. The maximum tensile strength of tube materials shall be 775 MPa (112 Ksi). Copper-bearing and aluminum alloys component materials are not permitted. Cast iron, or cast steel fittings are not permitted. When tube support design temperatures exceed 600 C and fuels contain a vanadium/sodium ratio between 3:1 and 18:1, tube supports shall be fabricated from high alloy materials: 60% Chromium-40% Nickel or 50% Chromium-50% Nickel materials. High alloy components shall not be welded to carbon steel components.
Page 13 of 29
8.9
Valves 8.9.1 8.9.2 The selection of gate, globe and check valves shall be in accordance with the Code and the Saudi Aramco requirements. Position indicator handles shall be supplied for all ball and plug type valves.
Superheaters 9.1 Superheaters, if provided, shall meet the following requirements: 9.1.1 9.1.2 9.1.3 Superheaters shall be located such that inlet tubes are not located in regions of highest flue gas temperatures. Superheaters shall be an all-welded drainable type. Flow equalization through superheater tubes shall be achieved by the sizing of tubes, inlet header, and outlet headers. Tube inlet restrictions, including swaging, are not permitted. Superheater steam flow should not be less than 0.95 of the average steam mass flow. Superheater elements shall be located and supported to prevent vibration, sagging, and misalignment. Superheater headers and supports shall be located outside gas spaces. All headers shall be provided with drain and vent connections. Intermediate and outlet headers shall be provided with thermowell, test gage, pressure transmitter, and pressure gage connections. The outlet header shall be provided with connections for safety valves and startup vent. All outlet header connections shall be located upstream of the startup vent. The startup vent and its discharge stack shall be sized for not less than 100% MCR steam flow, and shall be provided with a silencer. Silencers shall be provided with suitable drains for condensate removal, and piped to sewer. Finned tubes, with a maximum of seven (7) fins per inch shall be used. The fin thickness shall be a maximum of 1.25 mm and the fin height shall not exceed 25 mm.
9.1.4 9.1.5 9.1.6
9.1.7
9.1.8
Page 14 of 29
9.2
Desuperheaters, if provided, shall meet the following requirements: 9.2.1 9.2.2 9.2.3 Desuperheaters shall be of the water-spray design. Oil-free condensate or demineralized HRSG feedwater shall be used as the spray medium. A spray-type desuperheater mixing chamber with an alloy steel liner shall be provided.
10
Economizers 10.1 General 10.1.1 If economically justifiable, economizers shall be provided and designed to avoid steaming at all loads. 10.1.2 Economizers shall be designed for upward water flow. The water outlet connection shall be located below the LLCO of the steam drum. 10.1.3 The selection of economizer materials shall be based on the flue gas composition and the maximum metal temperature developed during minimum load operation. 10.1.4 A full-size water bypass with double block valves shall be provided for the startup and maintenance of economizers susceptible to acid dewpoint corrosion. Economizer shall be provided with a block valve and a safety valve. 10.2 Economizer Tubes and Tubesheets 10.2.1 Tubes shall be arranged in staggered rows for clean flue gas service and in straight (in-line) rows for fouling service and liquid fuel services. 10.2.2 Economizer tubes subject to acid dewpoint corrosion attack at any load under clean HRSG operating conditions, shall be of the in-line tube arrangement. 10.2.3 Finned tubes, with a maximum of five fins per 25 mm, may be used where the products of combustion are considered to be clean. The fin thickness shall be a minimum of 1.25 mm and the fin height shall not exceed 25 mm. 10.2.4 The materials of construction of tubes and tubesheets shall be selected based on the acid dewpoint corrosion temperature (ADCT) plus 28C.
Page 15 of 29
(The value of the ADCT shall be calculated on the basis of a 5% conversion of sulfur dioxide to sulfur trioxide). 10.2.5 The ADCT shall be calculated on the basis of 5% conversion of sulfur dioxide to sulfur trioxide. 10.2.6 The design temperature of tubes shall exceed the calculated ADCT by 28C. 11 Ductwork 11.1 General Flue gas ducting from the outlet to the stack, with all the necessary appurtenances, shall be furnished by the HRSG Manufacturer as specified on the data sheet. The system shall include supports, expansion joints, hangers, access doors, dampers, isolation plates, and connections for the measurement of gas flow, temperature, and pressure. 11.2 Design 11.2.1 Ducts shall be designed, arranged, and installed in a manner to prevent vibration, distortion, and undue noise. 11.2.2 Ducts shall be gastight. The maximum velocity of flue gas shall not exceed 8.24 m/s. 11.2.3 Ducts shall be capable of withstanding an internal transient pressure of 14 KPa (2 psi). 11.2.4 The minimum thickness of flue gas ducts shall be 4.8 mm. 11.2.5 Where more than one HRSG exhausts to a common stack, an isolating plate, complete with davits, and flange spreaders, shall be provided in the discharge ducting of each HRSG. Isolation plates shall be designed for tight shut-off and maximum fan discharge pressure. 11.2.6 Flanged connections shall be complete with flanges, erection bolts, and nuts. Flanges shall be seal welded in the field. 11.2.7 Ductwork shall be shop-fabricated for field assembly, including the installation of supports required for external insulation or internal refractory lining. 11.2.8 An expansion joint manufactured from a suitable fabric shall be provided between force draft fans and the discharge ducting to HRSG.
Page 16 of 29
11.2.9 Internal lining shall be provided where the metal temperature is less than the calculated value for ADCT. (The value of ADCT shall be calculated on the basis of a 5% conversion of sulfur dioxide to sulfur trioxide). 12 Stacks 12.1 12.2 Unless otherwise specified on the data sheet, stacks shall be furnished by the HRSG Manufacturer. HRSGs shall be provided with a self supported stack. For multiple HRSGs a common self supported stack can be used. A stack height above grade shall be determined by plant and environmental regulations. HRSGs shall be designed to operate in compliance with local environmental regulations. The HRSG Manufacturer shall calculate and guarantee emission rates of nitrogen oxides and sulfur oxides. The emission rates shall be expressed in Lb/MM BTU's when the HRSG is operated at its design rate firing the fuels specified. Flue gas emissions (NOx, CO, particulates, hydrocarbons, etc.) will not exceed the specified levels. Where the stack metal temperature at any operating load can be less than the calculated value for ADCT a 50-mm castable refractory lining shall be provided. (The value of ADCT shall be calculated on the basis of 5% conversion of sulfur dioxide to sulfur triodxie). All external attachments to the shell shall be continuously welded. The design of refractory systems shall be in accordance with Saudi Aramco Requirements.
12.3 12.4
12.5
12.6 12.7
13
Insulation and Refractories 13.1 General 13.1.1 Headers, drums, air heaters, economizer casings, windboxes, external superheater headers, exposed tubes, hot gas ducts, hot air ducts, steam turbines, and other heated and exposed surfaces shall be insulated in accordance with Saudi Aramco Requirements. 13.1.2 The design and installation of refractory systems shall be in accordance with Saudi Aramco Requirements.
Page 17 of 29
13.2
Ductwork 13.2.1 Corners of insulation on ductwork shall be protected with metal corner beading. Insulation on ducts shall be properly supported and securely fastened. 13.2.2 Clips or welding studs for holding wires and bands shall be spaced a maximum of 450 mm on center. Exposed supports, duct doors, and other parts that project through the insulated surfaces shall be insulated for protection of personnel. 13.2.3 Where the metal temperature of a duct, at any operating load, is less than the calculated value of the ADCT a 50 mm castable refractory lining shall be provided.
14
Noise Attenuation 14.1 14.2 The Design Engineer shall specify limits for the sound pressure levels (SPL) and sound power levels (PWL) at the designated locations. The HRSG Manufacturer shall ensure that the required limits as specified for SPL and PWL can be achieved by supplying test results of a representative HRSG. HRSGs shall be designed and provided with the acoustical treatment necessary to meet the specified noise levels. This shall include burner mufflers and acoustical lining for plenums, ducts, and stacks, vent silencer as required.
14.3
15
Connections, HRSG Trim and Instruments 15.1 General 15.1.1 The HRSG Manufacturer shall supply all connections and equipment in accordance with this specification. 15.1.2 All instrument connections, except thermowells, shall be provided with separate block valves to permit removal of devices without affecting other active devices. 15.1.3 Steam drum connections shall be provided for level instrumentation in accordance with SAES-J-602. 15.1.4 Connections shall be provided for the chemical cleaning of HRSGs, superheaters, and economizers.
Page 18 of 29
15.1.5 Drain connections shall be provided for draining all water after shutdown or boilout. Valves shall be 2 inch NPS minimum and located at the lowest point on the water drum to allow complete drainage of HRSGs in one hour or less at a pressure of 35 KPa g (5 psig). 15.1.6 Connections shall be provided for the quick draining of all accumulated water in areas of furnaces, superheaters, HRSG banks, and economizers following water washing of external tube surfaces. 15.2 HRSG Trim The minimum HRSG trim requirements to be provided by the HRSG Manufacturer, shall be as follows: 1) Safety valves for drums, superheater outlets, and economizers in accordance with the requirements of the Code. Valves shall be complete with discharge piping to a point 3 m above the nearest platform. Safety valves shall be equipped with lifting levers. A steam outlet stop valve and a screw-down nonreturn valve, each with a pressure-sealed bonnet and of approved HRSG quality. A pressureequalizing warm-up line of not less than 2 inch NPS shall be provided around stop valve. Intermittent blowdown valves, using two valves in series at each blowdown nozzle. The outside valve shall be quick-opening, except at water wall headers. HRSG feedwater shutoff and check valves. HRSG vent valves, using two valves in series at each location. Valves for obtaining representative saturated steam samples, using two valves in series (double block) at each takeoff from the steam drum. If the HRSG design includes a series of small-diameter tubes between the steam drum and superheater header, the sample points shall be spaced no more than 1.5 m apart. Sample connections shall be in accordance with ASTM D1066. Continuous blowdown valves, using two valves in series. The downstream control valve shall be a hand-operated, V-port valve with a micrometer indicator or a V-port valve with TDS/conductivity control. Chemical feed valves, using two block valves in series and a check valve. Superheater drain and vent valves, using two valves in series at each location.
2)
3)
4) 5) 6)
7)
8) 9)
10) Lower header drain valves, using two valves in series for each connection.
Page 19 of 29
11) A sample connection with two valves in series for obtaining representative water samples. The sample connection shall be located upstream of the continuous blowdown control valve. 12) Lower drum drain valves, using two valves in series at each location. 13) Valves for obtaining representative final steam samples, using two valves in series at each takeoff point on the superheater discharge piping. Sample points shall be in accordance with ASTM D1066. 14) Three sample coolers (in accordance with ASTM D1066), each with a rack, valving and drainage trough. The sample piping and valving shall be arranged such that HRSG water, saturated steam, and final steam each have a dedicated cooler. 15) Desuperheater water shutoff and check valves. 16) Economizer outlet stop valve and screwdown nonreturn valve, where a water bypass is included. 17) Economizer water bypass stop valve and a screw-down nonreturn valve, if a bypass is included. 18) Economizer safety valve (in accordance with the Code) if a bypass is included. 15.3 Pipework The minimum piping to be supplied by the HRSG Manufacturer shall be as follows: 1) 2) 3) 4) 5) 6) 7) 15.4 Steam piping from the superheater outlet header to the main stop valve Interconnecting steam piping between superheater stages and the desuperheater Saturated steam piping from the steam drum to the superheater inlet header Interconnecting piping from the economizer to the steam drum HRSG feedwater piping from the check valve to the economizer inlet header Complete piping for the aspirating air system from a single point supply connection to all users All drain piping from the source to 1 m above grade
Instrumentation and Safety Relief 15.4.1 The minimum instrument requirements shall be in accordance with the Code and the following:
Page 20 of 29
1) 2) 3) 4) 5)
Sample connections for oxygen and combustible analyzers at HRSG outlet. Connections for the measurement of opacity, particulate matter, sulfur dioxide, nitrogen oxides, oxygen, and carbon monoxide Connections for draft gages at HRSG inlet and outlet. A minimum of four knife-edge thermocouple devices mounted on selected superheater tubes to measure tube metal temperatures. Thermocouple wells for measuring the steam temperature after each stage of superheaters, including the steam temperature before and after the desuperheater. Thermowells shall also be provided for measuring the temperature of the feedwater to and from the economizer.
15.4.2 All instrumentation shall be in accordance with the Code, NFPA 85C, and Saudi Aramco 11. 16 Supplemental Fuel Burning Equipment 16.1 General 16.1.1 16.1.2 Duct-burners shall operate continuously over the specified operation span and shall be capable to operate efficiently at low CGT loads. Unless required for emission requirements, duct-burners shall ensure complete combustion of the specified fuels within the range of excess oxygen in the CGT products of combustion. Flame profiles of all duct-burners shall be contained within the confines of the burner space without flame impingement on duct lining, and tubes and without flame penetration through opposing tubes. The HRSG Manufacture shall provide optical flame scanners to ductburner assemblies as detailed by the Design Engineer in accordance with SAES-J-602 and 34-SAMSS-617. Quality of products of combustion shall satisfy the flue gas emission requirements at all specified operating conditions. Duct-burner design shall permit safe shutdown or lightoff of a burner at maximum capacity at all loads of CGT.
16.1.3
16.1.4
16.1.5 16.1.6
Page 21 of 29
16.1.7
All duct-burner hardware (including piping, tubing, hoses, valves, and cocks) shall be of steel construction. Cast iron, copper alloys, and aluminum alloys, are not permitted. The proposed duct-burner design shall be compatible with the burner management system in accordance with this specification. Duct-burners shall be designed to meet sound level limitations as specified in this specification.
16.1.8 16.1.9
16.1.10 Duct-burner curves shall be submitted and shall show the fuel consumption over the burner turndown range against fuel pressure required at the burner, excess oxygen, and burner draft loss requirement. 16.1.11 All safety shutoff and vent valves on duct-burner/ignitors shall be as specified by the Design Engineer in accordance with SAES-J-602. 16.2 Igniters (Pilots) 16.2.1 16.2.2 Class 2 or Class 3 gas igniters, as defined in NFPA 85C shall be supplied. Igniters shall be the automatic air and gas type, complete with an electric spark igniter and designed to utilize excess oxygen supplied by the CGT combustion product. Igniters shall be blowout proof and capable of attaining ignition while maximum combustion air flows through the burner. Igniters shall be designed to resist radiation from burners and CGT combustion gas.
16.2.3 16.2.4 16.3
Duct-burner Piping 16.3.1 16.3.2 16.3.3 16.3.4 Piping for duct-burners shall be supplied with breakaway connections located as practical to burners. Fuel headers shall be supplied with blow-down connections. All piping and valving shall be located, from a single-point entry, for fuel to the duct-burner assembly. Fuel oil shut-off valves shall be located as close as possible to headers with no dead legs.
Page 22 of 29
16.3.5
Unless otherwise specified, a strainer with block and bypass valves shall be supplied for liquid fuels, located in the supply lines to each HRSG. Piping shall be arranged to ensure that all manually operated valves are in easy access. Supervisory manually operated valves for each fuel shall be the last valve before duct-burners.
16.3.6
17
Painting 17.1 17.2 All exposed surfaces shall be prepared and painted in accordance with Saudi Aramco Requirements. Gasket contact surfaces shall not be painted.
18
Fabrication 18.1 Forming and Assembly 18.1.1 The layout of shell plates, heads, and head plates shall be made in such a manner that manways, nozzles and their reinforcement are not located within any weld seams. Manways, nozzles and their reinforcement shall not be located within 50 mm of any weld seam. All nozzles and manways shall be ground flush to the inside curvature of the drums and headers, and inside diameters shall be radiused smooth. Where a split-reinforcing pad is required, the weld joining the pad sections shall be oriented with the circumferential direction of the shell. Tapped tell-tale holes inch NPT shall be provided as follows: 1) 2) 18.1.4 18.1.5 18.2 Welding All welding shall be in accordance with the requirements of Saudi Aramco
Page 23 of 29
18.1.2
18.1.3
One hole in all single piece reinforcing pads. Where a pad is split, each segment shall have at least one tapped hole.
All internal and external nonpressure-welded attachments shall be fully seal welded and shall have their radiused corners. All external nonpressure attachments shall be vented through a inch NPT telltale hole.
Requirements. 19 Nondestructive Testing 19.1 General 19.1.1 All Nondestructive Testing (NDT) shall be performed in accordance with the HRSG Manufacturer's written procedure prepared in accordance with ASME SEC V with the scope of NDT and acceptance/rejection criteria as defined by the Code this specification. All NDT personnel shall be qualified in accordance with Saudi Aramco requirements. All NDT on HRSG drums, which are to be postweld and heat-treated, shall be made after postweld heat treatment. All pressure and nonpressure welds shall be visually inspected.
19.1.2 19.1.3 19.1.4 19.2
Radiographic Testing 19.2.1 Radiographic testing of tube support castings shall be given to any cracks or other indications exposed by liquid penetrant inspection that exceeds the quality requirements of ASME SEC I, PG-17. Areas of stress concentration in corners of castings, especially at support lugs, shall be radiographically inspected. At least two spot radiographs shall be taken of the lower flanges of each cast tube support section. One random spot radiograph shall be made for each girth weld and one random radiograph for each two vertical welds of a stack shell. In addition, each vertical and circumferential welds intersection shall be radiographed in the circumferential direction. All personnel performing field radiography at Saudi Aramco facilities, sites, and concessionary areas shall maintain full compliance with GI0150.003 and be in possession of valid permit to handle and use radioactive ionization materials and equipment.
19.2.2
19.2.3
19.2.4
19.3
Ultrasonic Testing 19.3.1 All butt-welds on HRSG piping, 32-mm wall thickness and thicker shall be ultrasonically tested. Ultrasonic examination and interpretation shall be in accordance with ASME SEC VIII.
Page 24 of 29
19.3.2 19.4
Tubesheets and forgings 50 mm and thicker shall be ultrasonically tested in accordance with ASTM A435.
Magnetic Particle Testing 19.4.1 Beveled edges of carbon steel plates with thicknesses 25 mm and thicker and all ferrous alloy plates shall be magnetic particle examined for linear discontinuities. Defects shall not exceed limits as per A12. All internal and external welds for all services made using the SMAW welding process when the nominal thickness of pressured components is 25 mm and thicker shall be magnetic particle tested.
19.4.2
19.5
Hardness Testing Weld hardness testing shall be in accordance with the requirements of Saudi Aramco Requirements.
20
Postweld Heat Treatment 20.1 20.2 Code exemptions for postweld heat treatment of ferritic materials based on the use of austenitic or nickel-based electrodes are not permitted. The maximum postweld heat treating soaking temperature for 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 Certificates or 650C for carbon steel and 690C for C- Mo. The maximum postweld heat treating soaking temperature for low-chrome alloy steels shall not exceed the tempering temperature at which test pieces and components were heat treated as shown on Mill Test Certificates, but shall be not less than 700C. Postweld heat treatment shall follow all welding and repairs but shall be performed prior to any hydrotest or other load test. Postweld heat treating shall be in accordance with the requirements of Saudi Aramco Requirements.
20.3
20.4 20.5
21
Inspection and Equipment Testing 21.1 Inspection 21.1.1 All materials and fabrication shall be subject to inspection by the Saudi Aramco Inspector in accordance with Saudi Aramco Inspection Requirements Form 175-329000.
Page 25 of 29
21.1.2
Written reports and evaluations of all inspections performed by the HRSG Manufacturer shall be made and submitted to the Saudi Aramco Inspector, at a frequency to be determined by the Saudi Aramco Inspector. Written reports and evaluations of all inspections performed by the Vessel Manufacturer shall be made and submitted to the Saudi Aramco Inspector, at a frequency to be determined by the Saudi Aramco Inspector. Prior to final inspection and pressure testing, the inside and outside of HRSGs shall be thoroughly cleaned of all slag, scale, dirt, grit, weld spatter, paint, oil, etc. The Saudi Aramco Inspector shall have free access to the work at all times. All materials, except carbon steels, shall be alloy verified in accordance with Saudi Aramco Requirements. Refractory linings and materials shall be inspected in accordance with Saudi Aramco Requirements.
21.1.3
21.1.4
21.1.5 21.1.6 21.1.7 21.2
Performance Testing 21.2.1 A test procedure shall be provided by the HRSG Manufacturer, which shall be approved by the Saudi Aramco Inspector including the criteria by which the onsite test results shall be judged for conformance. If the results of a performance test does not conform in with the acceptance criteria, the HRSG Manufacturer shall immediately correct the deficiencies so that the HRSG meets the guaranteed performance. HRSG efficiency shall be based on the higher heating value of the fuel, and the tests shall be made in accordance with ASME PTC 4.4, Performance Test Code. Unless otherwise specified, the acceptance test shall be performed by the HRSG Manufacturer's representative after commissioning. In addition to the Code, the following represent the minimum shop leak tests: 1) 2) Hydrostatic test of all pre-assembled pressure-containing sections, in accordance with the Code A smoke or soap test of all pre-assembled sections
Page 26 of 29
21.2.2
21.2.3
21.2.4 21.2.5
21.2.6
In addition to the Code, the following represent the minimum field leak tests: 1) 2) A hydrostatic test of all pressure parts in accordance with the Code, prior to installation of the casing A smoke or soap test of all fully assembled HRSG and ducting before insulation is installed
21.2.7 21.2.8
Field pressure testing shall be in accordance with Saudi Aramco Requirements. After inspection and testing, HRSGs shall be completely drained of all liquids.
22
Nameplates and Stampings 22.1 22.2 HRSGs manufactured both in Saudi Arabia and outside Saudi Arabia shall be Code stamped. Nameplates and nameplate mounting bracket shall be located such that they will not be covered by insulation and is easily readable from grade or a platform.
23
Preparation for Shipment 23.1 General 23.1.1 23.1.2 23.1.3 23.1.4 23.1.5 The HRSG Manufacturer is responsible for preparing materials for shipment and assuring their arrival on-site in good condition. All components shall be packed, securely anchored and satisfactorily protected for their respective shipment methods. One complete set of installation, operating, and maintenance instructions shall be packaged and shipped with the equipment. Bracing, supports, and rigging connections shall be provided to prevent damage during shipment, lifting and unloading. All instruments and valves, including auxiliary systems, shall be securely mounted, supported, and/or boxed to avoid damage during shipment. All exposed finished and machined surfaces, including bolts, shall be coated with a rust-inhibiting compound.
23.1.6
Page 27 of 29
23.1.7 23.1.8
Bearings and seal assemblies shall be fully protected against the entry of moisture and dirt. Flanged connections and all other machined surfaces shall be protected by a coating, such as MIL-C-16173 Grade IV, which is easily removed in the field. Flanges shall be fitted with a 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.
23.1.9
23.1.10 Markings shall be done with water soluble materials that contain no harmful substances that would attack or harmfully affect coils at both ambient and operating temperature. 23.1.11 Marking materials shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, or any other halogens. 23.1.12 Threaded connections, shall be protected with threaded plugs. 23.2 Internal Protection 23.2.1 The internals of drums and headers 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 1 kg/cubic meter. Desiccants may only be used with approval of the Saudi Aramco Engineer. Drums and headers must be sealed vapor tight using metallic covers, for inhibitors to be effective. Alternatively, nitrogen blanketing, temporary coatings in accordance with MIL-C-16173 Grade IV (example Tectyl 846) or a vapor proof bag with moisture control may be used.
23.2.2 23.2.3
23.3
External Protection The protection of external surfaces shall be obtained by using one of the following: 1) A hard temporary preservative in accordance with MIL-C-16173, Grade I, which can be removed at site prior to surface preparation and application of the Saudi Aramco coating and painting system.
Page 28 of 29
2)
Prepare the surface and apply the complete (primer and final coatings) Saudi Aramco surface preparation, and coating and painting system in the shop.
24
Drawings, Calculations and Data 24.1 24.2 The HRSG Manufacturer shall prepare and submit for approval and review the preliminary and certified drawings and data detailed on. Drawings and calculations which are approved by the Design Engineer shall not relieve the HRSG Manufacturer of the HRSG Manufacturer's responsibilities to comply with the Code, and this specification. The Design Engineer is responsible for the completion of the Safety Instruction Sheet in accordance with the HRSG Manufacturers drawings.
24.3
20 November 2007 26 December 2009
Revision Summary New Saudi Aramco Materials System Specification. Editorial revision to replace 175-321300 with 175-329000.
Page 29 of 29

32 Samss 035

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

32 Samss 035

Caricato da

Copyright:

Formati disponibili

Materials System Specification

Saudi Aramco DeskTop Standards

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

SAEP-341 SAEP-1140 SAEP-1142

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

Flame Monitoring and Burner Management Systems Programmable Logic Controllers

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

Corrosion Preventive Compound, Solvent Cutback, Cold-Application

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

8.5.5 8.5.6 8.5.7 8.5.8

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

9.1.4 9.1.5 9.1.6

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

16.2.3 16.2.4 16.3

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

19.1.2 19.1.3 19.1.4 19.2

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

21.1.5 21.1.6 21.1.7 21.2

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

32-SAMSS-035 Manufacture of Heat Recovery Steam Generators

20 November 2007 26 December 2009

Potrebbero piacerti anche