02-SAMSS-009

Materials System Specification 02-SAMSS-009

30 November, 2004

Design and Fabrication of Scraper Traps Piping Standards Committee Members Nasri, Nadhir Ibrahim, Chairman Dib, Tony George., Vice Chairman Balhareth, Nasser Mohammad Khashab, Jaafar M. Mullen, Marshall Anson Bannai, Nabeel Saad Qahtani, Khalid Daifallah Rumaih, Abdullah Mohammad Kim, Steve Un Holland, Brad John Dossary, Mohammad Battal Fadley, Gary Lowell Otaibi, Bander Abdulaziz Ramadan, Mousa Sadiq Teraiki, Abdullah Mohammad Phan, Howard Cong Lewis, Trevor Mahmoud, Khalid Ahmed

Saudi Aramco DeskTop Standards Table of Contents

1 2 3 4 5 6 7 8 9 10 11 12

Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 2 Purchase Order Information........................... 4 Design............................................................ 5 Components................................................... 5 Material.......................................................... 9 Fabrication.................................................... 10 Coatings....................................................... 10 Quality Requirements................................... 10 Documentation............................................. 11 Export Packing, Marking, and Shipping....... 11

Appendix – A: Branch Connections Chart.......... 13

Previous Issue: 31 October, 2000 Next Planned Update: 1 December, 2009 Revised paragraphs are indicated in the right margin Primary contact: Nasri, Nadhir Ibrahim on 8734525

Page 1 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

1

02-SAMSS-009 Design and Fabrication of Scraper Traps

Scope This specification defines the minimum mandatory requirements governing the design, fabrication and material selection of permanent scraper traps for line sizes 4-inch and larger and for pressure ratings Classes 150 through 1500. The scraper traps covered by this specification are for launching and/or receiving of a single (cleaning, batching, displacement and/or instrumented) scraper for water or hydrocarbon pipelines onshore or offshore.

2

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 resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2

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.

References The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by 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-H-001

Selection Requirements for Industrial Coatings

SAES-H-101

Approved Protective Coating Systems

SAES-L-101

Regulated Vendor List for Pipes, Fittings and Gaskets

SAES-W-011

Welding Requirements for On-Plot Piping

Page 2 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

SAES-W-012

02-SAMSS-009 Design and Fabrication of Scraper Traps

Welding Requirements for Pipelines

Saudi Aramco Materials System Specifications 01-SAMSS-016

Qualification of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking

02-SAMSS-005

Butt-Welding Pipe Fittings

Saudi Aramco Inspection Requirements Form SA-175-026100

Butt Welding Pipe Fittings

Form SA-175-026800

Traps, Scraper

Form SA-175-091900

Coating: Shop Applied for Fabricated Piping and Process Equipment

EN-10204/DIN50049

Inspection Documents for the Delivery of Metallic Products

Saudi Aramco Standard Drawings

3.2

AE-036175

Details of Heavy Welding Boss for Threaded Connections to Vessels and Lines

AE-036643

Details of Heavy Welding Boss for Socket Weld Connections

AB-036719

Reinforcement of Welded Branch Connections

Industry Codes and Standards American Petroleum Institute API SPEC 5L

Specification for Line Pipe

American Society of Mechanical Engineers ASME B16.5

Pipe Flanges and Flanged Fittings

ASME B16.9

Steel Buttwelding Fittings

ASME B31.3

Process Piping

ASME B31.4

Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols

ASME B31.8

Gas Transmission and Distribution Piping Systems

Page 3 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

ASME SEC VIII

02-SAMSS-009 Design and Fabrication of Scraper Traps

Boiler and Pressure Vessel Code, Div. 1, Pressure Vessels

American Society for Testing and Materials ASTM A36

Carbon Structural Steel

ASTM A216

Steel Castings, Carbon, Suitable for Fusion Welding, for High Temperature Service

ASTM A515

Pressure Vessel Plates, Carbon Steel, for Intermediate- and High-Temperature Service

ASTM A516

Pressure Vessel Plates, Carbon Steel, for Moderate- and High-Temperature Service

ASTM A537

Pressure Vessel Plates, Heat Treated, Carbon Manganese-Silicon Steel

ASTM A662

Pressure Vessel Plates, Carbon- Manganese, for Moderate and Lower Temperature Service

Manufacturers Standardization Society MSS-SP-75

High Test Wrought Welding Fittings

National Association of Corrosion Engineers

4

NACE MR0175-2002

Material Requirements-Sulfide Stress Cracking Resistant Metallic Material for Oil Field Equipment

NACE TM0284-2003

Evaluation of Pipeline and Pressure Vessel Steel for Resistance to Hydrogen-Induced Cracking

Purchase Order Information The Purchase Order will include the following: a)

Applicable Standard Drawing or design drawing

b)

Applicable ASME design code

c)

Design factor

d)

Design pressure

e)

Hydrostatic test pressure

f)

Design temperature

g)

Service

h)

Corrosion allowance Page 4 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

5

02-SAMSS-009 Design and Fabrication of Scraper Traps

i)

Flange rating and facing (and applicable Standard Drawing for flanges 26-inch and larger).

j)

External Paint requirements

k)

Internal coating or lining requirements

l)

Internal diameter of matching scraper trap valve

Design 5.1

5.2

Design Code 5.1.1

The design Code shall be specified in the purchase order.

5.1.2

Onshore scraper traps are considered within the scope of the respective transportation piping code, ASME B31.4/ASME B31.8 even if they are located inside the plant area.

5.1.3

Offshore scraper traps are considered within the scope of ASME B31.3 piping code unless otherwise specified differently in the purchase order.

Design Calculations The maximum stresses shall be calculated per applicable ASME Code for the design conditions and shall not exceed the allowable stress based on the design factor. Full reinforcements shall be provided on all branch connections. Corrosion allowance shall be as specified in the Purchase Order or in the design drawings attached with the Purchase Order.

5.3

Dimensions The overall dimensions for scraper traps shall be in accordance with the drawing specified in the Purchase Order, or the design drawing attached to the Purchase Order.

6

Components 6.1

Cylindrical Sections Cylindrical sections shall be made from seamless or welded pipe or from rolled and seam welded plate. Materials are specified in Sections 7.2 and 7.3.

6.2

Reducers

Page 5 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

6.3

6.4

02-SAMSS-009 Design and Fabrication of Scraper Traps

6.2.1

Reducers shall have a nominal wall thickness at least equal to the specified nominal wall thickness of the matching pipe (of equal yield strength) at the large end.

6.2.2

Concentric and eccentric reducers shall be either ASME B16.9 type or conical type. The use of conical type reducers is permitted provided that the apex angle does not exceed 12 degrees and the diameters of the reducer and the matching pipe sections are equal in all directions, with a tolerance of 3 mm.

6.2.3

ASME type concentric and eccentric reducers shall have smoothly curved transitions and parallel ends.

6.2.4

Reducers not listed in ASME B16.9 or MSS-SP-75 shall be designed in accordance with ASME B31.3, paragraph 304.6, based on the design pressure of the matching pipe.

Branch Connections 6.3.1

Branch connections shall either be welded, forged or extruded. The type of branch connection shall confirm to the Chart per Appendix-A of this specification.

6.3.2

Reinforcing pads required by the specified code shall be fully welded and shall be provided with a 3 mm-6 mm vent hole. The tapped hole shall be filled with heavy grease.

6.3.3

Tee branches shall have guide bars in accordance with Standard Drawing AC-036548.

6.3.4

Threaded branch connections shall be seal welded up to the first valve. The seal weld shall cover all exposed threads after the joint has been tightened to full thread engagement. The fillet seal weld shall have a minimum throat thickness of 2 mm and shall merge smoothly into the pipe metal outside of the thread. PTFE (Teflon) tape or joint compound shall not be used in threaded, seal welded connections.

Flanges Flanges shall be weld neck type. Flange rating and facing shall be as specified in the Purchase Order.

6.5

Bosses and small fittings

Page 6 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

If bosses are to be installed for branch connections 1-½ inch nominal pipe size and smaller, they shall be in accordance with Standard Drawings AE-036175 or AE-036643. Threaded or socket welded fittings shall be class 3000 rating for ASME class up to 900 pressure ratings, and class 6000 rating for ASME class 1500 pressure rating. 6.6

Quick Opening Closures 6.6.1

All traps shall be provided with quick opening end closures, designed to allow one man operation for both opening and closing. The closure shall comply with the requirements of ASME SEC VIII D1, paragraph UG-35. All closures shall be procured from an approved manufacturer per SAES-L-101 requirements.

6.6.2

The locking mechanism -

The locking mechanism of the closure shall be of the clamp-ring, band lock or threaded type. Other locking mechanism proposals shall be stated in the vendor's quotation and approved by the Chairman of the Piping Standards Committee.

-

Threaded type closures shall be limited to trap size of 24-inch NPS or smaller.

-

The C-clamp type quick closure with bolt tightening from both sides of the door is not permitted.

6.6.3

All closure doors shall be supported by adjustable hinges or an adjustable davit. The direction of view for determination of the hinge position for horizontal traps is from the closure end of the trap. The hinge position shall be on the left-hand side, unless specified otherwise in the Purchase Order.

6.6.4

Hinge or davit position for vertical traps shall be as indicated on the applicable standard drawing or design drawing.

6.6.5

The required clearance area for the door shall be indicated by the Vendor on the approved drawing.

6.6.6

Threaded type closures shall be provided with lubrication injection nipples where large friction areas are present. All closures shall require no maintenance other than lubrication of seals.

6.6.7

Closure seals Page 7 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

-

Vendor shall specify proposed seal type, dimensions and material at time of quotation and prior to fabrication.

-

Closure seals shall be Chevron type or equivalent self-energizing seal type.

-

O-ring seals having a groove configuration or other design to prevent O-ring slipping during the door closure are acceptable alternates. Oring seals shall be submitted for prior review and approval by the Chairman of Piping Standards Committee.

6.6.8

Closures for installation on vertical scraper traps shall be suitably balanced by counterweights where necessary, to limit lifting weight in normal operation to 45 kg (100 lb) maximum. Other means may be provided for convenient operation subject to prior approval from the Chairman of Piping Standards Committee.

6.6.9

Large size closures will require mechanical assistance to break the seal when opening the door and compress the seal when closing the door. All required tools shall be included in the delivery and suitable attachment lugs for the tools shall be provided where necessary.

6.6.10 Closure Safety: The closure locking mechanism shall be provided with a pressure warning safety interlock device which must be opened before the closure mechanism can be unlocked. Closing of the pressure warning safety interlock shall not be possible until the closure locking mechanism is fully engaged and locked. The non-bleed type of pressure warning device is preferred in toxic or sour fluid service. 6.7

Supports 6.7.1

General Supports for horizontal scraper traps shall be of a sliding type. Support dimensions are given in the drawing specified in the Purchase Order or in the design drawing of the scraper trap attached with the Purchase Order.

6.7.2

Design The following loads shall be used for the design calculations: Vertical load = 2 x mass of trap filled with water Axial load

= 2 x mass of trap filled with water x friction factor

(Friction factor steel to steel = 0.4 for this calculation.)

Page 8 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

Low friction, non-corrosive sliding material may be used with proper designs to prevent entry of sand and to assure even load distribution. 7

Material 7.1

General 7.1.1

Materials supplied by the Vendor for piping elements or structural attachments shall conform to the requirements of the applicable code and shall be traceable to mill certificates. Material selection may be further limited in this specification or in the Purchase Order. Used or reclaimed materials or materials of unknown specification are not permitted. Material test reports (MTR's) shall meet EN-10204, type 3.1.B inspection certificate.

7.1.2

7.2

For carbon steel with minimum design temperatures below minus 18°C and for non-carbon steel, the material specifications and requirements shall be specified in the Purchase Order.

Pipe Material Pipe material shall be seamless or SAW pipe, API SPEC 5L Grade B through X60, or ASTM A106 Grade B. For sour service, pipes shall be seamless or in accordance with 01-SAMSS-016.

7.3

Plate Material a)

Sour Service Plate materials used for pressure containing parts shall be ASTM A516, ASTM A537 CL1, ASTM A537 CL2 or ASTM A662. The plate material shall be qualified per 01-SAMSS-016.

b)

Non-Sour Service Plate materials used for pressure containing parts shall be ASTM A515, ASTM A516, ASTM A537 CL1, ASTM A537 CL2, or ASTM A662.

7.4

Fittings Butt welding pipe fittings for sour service shall be in accordance with 02-SAMSS-005, or NACE MR0175-2002 & TM0284.

7.5

Flanges Page 9 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

Flanges for sour service shall be in accordance with NACE MR0175-2002 and TM0284. 7.6

Castings Cast carbon steel materials shall be equivalent to ASTM A216 grade WCB or better.

7.7

Structural Steel Structural steel used for non pressure containing parts shall be equivalent to ASTM A36, S-1 or better.

8

Fabrication 8.1

Flange bolt holes shall straddle the vertical and horizontal centerlines unless orientation is given on the scraper trap drawing.

8.2

Welding and Heat Treatment Except modified otherwise, welding and heat treatment shall conform to: SAES-W-011 for scraper traps designed to ASME B31.3 SAES-W-012 for scraper traps designed to ASME B31.4 or ASME B31.8.

9

Coatings 9.1

Internal Coating or Lining When specified in the Purchase Order internal coating or lining shall be applied in accordance with SAES-H-001.

9.2

External Coating The exterior of scraper traps shall be supplied and coated in accordance with SAES-H-101, APCS-1B or as specified in the purchase order.

10

Quality Requirements 10.1

The Vendor shall maintain a Quality Program as approved by the Buyer and shall make available for the Buyer's review a written description or check list which explains what documents and what procedures will be used to produce items to meet Saudi Aramco Materials System Specification.

Page 10 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

10.2

The items manufactured to this specification are subject to verification by the Buyer inspection representative in accordance with SA 175-026800 and SA 175-091900 attached with the Purchase Order.

10.3

Acceptance Criteria All butt welds shall be 100% radiographed in accordance with the requirements of ASME SEC VIII D1, Appendix 4. All other full penetration groove welds shall be inspected by magnetic particle testing (MT) in accordance with the requirements of ASME SEC VIII D1 Appendix 6. A hydrostatic pressure test shall be applied for not less than one hour at a pressure which causes a hoop stress of 90% of SMYS in the shell or at the applicable test pressure listed in ASME B16.5, whichever is lower.

11

Documentation 11.1

Calculations and Drawings The Vendor shall submit 3 sets of calculations and drawings for the Buyer representative's approval at least 4 weeks prior to fabrication of the scraper traps to indicate compliance with paragraphs 5.1 and 5.2.

11.2

Final Documents Unless otherwise specified in the Purchase Order, the Vendor shall forward to the Buyer as part of the order three copies of the following documents, as applicable, after acceptance of the material by the Buyer's Inspector:

12

a)

Certified Drawing(s)

b)

Calculations

c)

Works Certificate

d)

Welding procedures

e)

NDE records including hardness testing

f)

Heat treatment records

Export Packing, Marking, and Shipping Export packing, marking, and shipping shall be in accordance with the Purchase Requisition/Purchase Order. 12.1

Manufacturer's Nameplate Page 11 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

A nameplate of 1.5 mm minimum thickness, stainless steel or monel shall be attached securely with stainless steel or monel fasteners on a support continuously welded to the scraper trap. The location shall be such that the nameplate data can be read from the normal position near the closure. The nameplate shall be marked by raised letters or by die stamping. As a minimum requirement the nameplate shall include the manufacturer's name and location, Purchase Order number, serial number, maximum allowable operating pressure, sour or non-sour service, hydrostatic test pressure, design code, date of manufacture, and empty weight. 12.2

Preparation for Shipment Flange facings shall be protected during shipment. Welding bosses shall be fitted with threaded steel bar stock plugs. All plugs shall be given a graphite and lubricating oil paste coating before installation. Wooden plugs shall not be used. Scraper traps shall be stencil marked with Saudi Aramco Purchase Order number, item number, nominal line size and pressure class rating.

30 November, 2004

Revision Summary Minor revision to Section 3.1, adding requirement to use RVL approved scraper door manufacturers in paragraph 6.6.1, adding branch connection chart to paragraph 6.3.1 and improving clarity of various paragraphs (5.1, 6.6.2, 6.6.7). Revised the "Next Planned Update."

Page 12 of 13

Document Responsibility: Piping Issue Date: 30 November, 2004 Next Planned Update: 1 December, 2009

02-SAMSS-009 Design and Fabrication of Scraper Traps

Appendix – A: Branch Connections Chart 60 56 48 42 40

Region-2

36

B R A N C H

Region-1

30 24 20 18

Region-3

16

SI Z E

14 12 10 8 6

Region-4

4 3 2 1.5 1.0

Region-5

.75 0.5 60

56

48

42

40

36

30

24

20

18

16

14

12

10

8

6

4

3

2

1.5

1

0.75

0.5

HEADER SIZE LEGEND Region-1: Equal Tee Region-2: Reducing Tee Region-3: Reducing Tee or Branch weld with reinforcing pad or full encirclement sleeve Region-4: Weldolet or branch weld with reinforcing pad Region-5: Weldolet, Sockolet, Threadolet or Welding boss per SASD AE-036175 and AE-036643

Page 13 of 13