Materials System Specification

32-SAMSS-020 Manufacture of Trays and Packing Trays and Packing Process Design Standards Committee Members
Bu Naiyan, Ahmad Saleh, Chairman Dabass, Abdulkarim Abdulaziz, Vice Chairman Ghamdi, Khalid Hamid Ibrahim, Mohammed Abdulrahman Mugim, Salah Mohammed Mutawa, Husain Matouq Naffaa, Mahmoud Youniss Ofi, Saleh Hodaiban Qahtani, Abdullah Melfi Qahtani, Salem Mohummed Roy, Samit Utaibi, Khalid Saiyaf

14 November 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....................................................... 5 Responsibilities.............................................. 5 Proposals....................................................... 6 Tray Design.................................................... 6 Packing Design.............................................. 9 Mechanical Design......................................... 9 Materials....................................................... 12 Tray Fabrication........................................... 14 Tray Installation............................................ 14 Inspection and Testing................................. 16 Marking and Shipping.................................. 17 Drawings, Calculations and Data................. 18

Previous Issue: 9 August 2009 Next Planned Update: 14 November 2014 Page 1 of 18 Primary contact: Al-Dabass Abdulkarim Abdulaziz on 966-3-8735985
CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Trays and Packing Process Design Issue Date: 14 November 2009 Next Planned Update: 14 November 2014

32-SAMSS-020 Manufacture of Trays and Packing

Scope This specification covers the minimum mandatory requirements for the manufacture and installation of new tray systems and inert packing.

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 and 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 SAEP-302 and forward such requests to the Manager, Process and 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 References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

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

Saudi Aramco Engineering Standards SAES-A-007 SAES-A-206 SAES-L-133 SAES-W-010 Hydrotesting Fluids and Lay-up Procedures Positive Material Identification Corrosion Protection Requirements for Pipelines, Piping and Process Equipment Welding Requirements for Pressure Vessels

Saudi Aramco Standard Drawing AD-036981 Tolerances for Pressure Vessels

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Document Responsibility: Trays and Packing Process Design Issue Date: 14 November 2009 Next Planned Update: 14 November 2014

32-SAMSS-020 Manufacture of Trays and Packing

Saudi Aramco Inspection Requirements Form 175-325000 Manufacture of Trays and Packing

Saudi Aramco Forms and Data Sheets NMR-7919-2 9524-ENG 9524-1-ENG 9524-2-ENG 9527-ENG 3.2 Non-material Requirements for Column Trays Process Design Data Sheet-Packing Process Design Data Sheet-Stream Composition Process Design Data Sheet-Trays Pressure Vessel Data Sheet

Industry Codes and Standards American Iron and Steel Institute AISI SG-673 Specification for the Design of Cold Formed Steel Structural Members

American Society of Mechanical Engineers ASME SEC VIII D1 ASME SEC VIII D2 ASME SEC IX Boiler and Pressure Vessel Codes Pressure Vessels, Alternative Rules Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators

International Organizational for Standardization NACE MR0175/ ISO 15156 Petroleum and Natural Gas Industries Materials for use in H2S-Containing Environments in Oil and Gas Production

American Society for Testing and Materials ASTM A36 ASTM A167 Standard Specification for Carbon Structural Steel Standard Specification for Stainless and HeatResisting Chromium-Nickel Steel Plate, Sheet, and Strip Standard Specification for Stainless and HeatResisting Chromium Steel Plate, Sheet, and Strip Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service
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ASTM A176 ASTM A193

Document Responsibility: Trays and Packing Process Design Issue Date: 14 November 2009 Next Planned Update: 14 November 2014

32-SAMSS-020 Manufacture of Trays and Packing

ASTM A194

Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and HighTemperature Service Standard Specification for Stainless and HeatResisting Chromium and Chromium-Nickel Steel Plate, Sheet, and Strip for Fusion-Welded Unfired Pressure Vessel Standard Specification for Stainless and HeatResisting Steel Bars and Shapes Standard Specification for Low and Intermediate Strength Carbon Steel Plates Standard Specification for Pressure Vessel Plates, Carbon Steel, Low-and Intermediate-Tensile Strength Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Standard Specification for Steel Bars, Alloy, Standard Grades Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels Standard Specification for Pressure Vessel Plates, Carbon Steel for Intermediate and High Temperature Services Standard Specification for Pressure Vessel Plates, Carbon Steel for Moderate and Lower Temperature Services Standard Specification for Carbon and Alloy Steel Nuts Standard Specification for Steel Bars, Carbon, Hot-Wrought Special Quality, Mechanical Properties Standard Specification for Nickel-Copper Alloy Plate, Sheet and Strip Standard Specification for Nickel-Copper Alloy Rod, Bar, and Wire

ASTM A240

ASTM A276 ASTM A283 ASTM A285

ASTM A307 ASTM A322 ASTM A479 ASTM A515

ASTM A516

ASTM A563 ASTM A675

ASTM B127 ASTM B164

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Document Responsibility: Trays and Packing Process Design Issue Date: 14 November 2009 Next Planned Update: 14 November 2014

32-SAMSS-020 Manufacture of Trays and Packing

Definitions Major Beam: Beams that extend from wall to wall across the vessel without interruptions. All other beams should be considered minor beams. Tray Assemblies and Systems: Components required for the complete tray installation, including tray decks, downcomers, feed distributors, and tray hardware. Tray Hardware: Components required for assembling tray sections and attaching tray assemblies to a vessel, including clamps, nuts, bolts, washers, and gaskets. Design Engineer: The Engineering Company responsible for specifying on the data sheets the process and mechanical requirements for trays and packing. Packing Manufacturer: The company responsible for the process design and manufacture of inert packing in accordance with this specification. Tray Manufacturer: The company responsible for the process design and manufacture of trays in accordance with this specification. Saudi Aramco Engineer: The General Supervisor of the Downstream Process Engineering Division, Dhahran. Saudi Aramco Inspector: The person or company authorized by the Saudi Aramco Inspection Department to inspect trays and packing to the requirements of this specification.

Responsibilities 5.1 The Design Engineer is responsible for specifying all process design data required for the design of trays and packing, verifying the validity, consistency and completeness of data on the design data sheets, and verifying the process designs of the Tray and Packing Manufacturers. The Tray Manufacturer is responsible for the hydraulic and mechanical design of tray systems, based on the process and mechanical design conditions specified on the data sheets and the requirements of this specification. The tray diameter(s), number of passes, and spacing as specified on the data sheets are preliminary and are to be verified by the Tray Manufacturer with proposal. The Tray Manufacturer shall furnish all tray assemblies, including all component parts such as, but not limited to tray decks, weirs, downcomers, baffles, drawoffs, troughs, seal pans, valves, risers, bubble caps, support beams, and tray hardware.
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5.2

5.3

5.4

Document Responsibility: Trays and Packing Process Design Issue Date: 14 November 2009 Next Planned Update: 14 November 2014

32-SAMSS-020 Manufacture of Trays and Packing

5.5

The Tray Manufacturer is responsible for the mechanical design of all tray supports that are to be welded to the vessel, including but not limited to tray support rings, downcomer support bars, and chairs for support beams. The Vessel Manufacturer is responsible for the supply and installation of all supports that are welded to the vessel, in accordance with the Tray and Packing Manufacturers' drawing. Unless otherwise specified on the purchase order, the Vessel Manufacturer is responsible for the installation of tray assemblies. The Packing Manufacturer is responsible for the hydraulic and mechanical design of packing, based on the process design conditions specified on the data sheets and the requirements of this specification.

5.6

5.7 5.8

Proposals 6.1 6.2 6.3 6.4 The Tray and Packing Manufacturers' proposals shall be based on details for individual vessels and the requirements of this specification. The Tray or Packing Manufacturer may offer alternative designs, but must quote on the base inquiry documents. Proposals shall include a detailed description of any exception to the requirements of this specification. The Tray or Packing Manufacturer shall provide a written guarantee for the length of the warranty period specified in the purchase order or contract documents that the trays or packing shall perform under continuous operation at design conditions specified on the data sheets.

Tray Design 7.1 General 7.1.1 The Tray Manufacturer shall determine the number of caps or valves required and shall provide the final layout drawings for review and approval by the Design Engineer. Trays are to be designed using bolted sectional construction with sections removable through vessel manways if specifically requested. quick fastening method like lip type connection is acceptable. Bolting connections shall be use to attach downcomer plates and for heavy liquid load trays (e.g., vacuum stripping sections and amine regenerator).

7.1.2

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7.1.3 7.1.4

Draining shall be provided on trays when specified on the data sheets (except blind trays). Draining shall be accomplished by means of opening at the base of outlet weir / inlet weir.. Draining from a blind tray shall be accomplished through a draw-off nozzle and not through weep holes. All draw-off trays shall be designed to establish a seal on the trays at start-up, and hold a seal on the trays to facilitate cooling down of a vessel at shutdown. Draw-off shall be from the inlet of a fractionating tray, or from a blank tray, or from a pan extending across the vessel. All like parts of tray assemblies shall be made interchangeable. Symmetrical tray layouts shall be used wherever possible. Wedge-type trays and cap-type hold-down devices are prohibited. Bubble cap and chimney trays that are used as draw-off trays (partial or total draw-off) shall be seal welded unless accessibility/installation requirements are prevailing. Seal welding is required at all panel to panel, panel to supporting ring, panel to beam and chimney (riser) to panel connections, except at tray man-ways which shall be provided with gaskets. Gasket Material to be specified by the Design Engineer.
Commentary Note: In case seal welding is not possible, special attention shall be given to chimney tray design (e.g,. minimum thickness, gaskets sizing) and special care has to be paid during installation and thermal expansion during operation.

7.1.5

7.1.6 7.1.7 7.1.8 7.1.9

7.2

Bubble Cap Trays 7.2.1 7.2.2 Caps shall be arranged in an equilateral triangular pitch with rows normal to the liquid flow. The distance between the centerline of the outer rows of caps and downcomer inlets or overflow weirs shall be equal to at least the cap diameter plus 25 mm. The minimum distance between the centers of two adjacent caps shall be equal to 1.25 times the cap diameter. The end caps in each row shall lie in a circle with a radius of one cap diameter less than the vessel radius.
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7.2.3 7.2.4

Document Responsibility: Trays and Packing Process Design Issue Date: 14 November 2009 Next Planned Update: 14 November 2014

32-SAMSS-020 Manufacture of Trays and Packing

7.2.5

The type of cap shall be selected to permit a total superficial slot velocity which lies between the following requirements:
14.8 4.2 > V (s) > rho X (V) rho X (V)

(1)

Where: V (s)

= Total superficial slot velocity, m/s

rho (V) = Vapor density, Kgs/m 7.2.6 Caps shall be selected so that net riser area, net reversal area, and net annular area are approximately equal. Depending on the vapor load, the slot area of the caps shall be between 1 and 2 times the cap riser area.

7.3

Sieve Trays 7.3.1 7.3.2 Holes shall have a uniform pitch on triangular spacing. Holes covered by support beams, tray rings, or other internals shall not be included in determining the available hole area. The space taken up by obstructions in the perforated area shall not exceed 10% of the area of the perforated tray sections. Punched trays shall not be thicker than hole diameters. Punched trays shall be installed with the punched side on the underside. Holes shall be at least 100 mm from inlet weirs, unless recessed inlet weirs are used with tops flush with the tray deck. In such cases, holes are permitted within 50 mm of the inlet weir. The last row of holes shall be located at least 100 mm from the outlet weir. No holes shall be located closer than 75 mm from the shell of the vessel.

7.3.3 7.3.4

7.3.5 7.4

Valve Trays 7.4.1 Movable valves shall be supplied with guides and stops, wherein the valve guides and stops are integral with the valve body.
Commentary Note: Rectangular valves are preferred (optional). Rectangular valves shall have strips to prevent valve slipout.

7.4.2

Movable valves shall be supplied with tabs or other projections to provide a clearance of 1.5 mm to 3 mm between the valve and the tray when the valve is in the closed position.

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32-SAMSS-020 Manufacture of Trays and Packing

7.4.3 7.4.5

Valve legs and vertical travel stops shall be arranged so that valves cannot work through the tray holes during normal operation. Anti-rotation devices shall be provided to prevent valve spinning, except caged type, axi-symmetrical valve designs.

Packing Design 8.1 The Design Engineer shall provide the following data to Packing Manufacture: 1. 2. 8.2 Bed length(s) and corresponding diameter Equivalent number of theoretical stages

The Packing Manufacturer shall verify the following data based on the information specified on the data sheets and any proprietary data on the packing material: 1. 2. 3. Bed weights Pressure drop across the bed Allowable turndown ratio

8.3 8.4 8.5

The maximum height of a packed section shall be commensurate with the crush strength of the packing material selected. The Packing Manufacturer shall supply supporting data of crush strength to the Design Engineer. The design of packed section shall be such that the packing materials are securely constrained and prevented from migrating in the vessel or into the connecting piping. For random packing materials (raschig rings, berl saddles, etc.), the ratio of the vessel diameter to the diameter of the packing unit shall never be less than 8 to 1 in order to minimize channeling along the walls of a vessel.

8.6

Mechanical Design 9.1 General 9.1.1 Trays shall be mechanically designed to allow for manufacturing tolerances on both the vessel and trays. Allowances shall be made for the vessel shell being out of round as limited by ASME SEC VIII D1 or ASME SEC VIII D2, as applicable.

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32-SAMSS-020 Manufacture of Trays and Packing

9.1.2 9.1.3

Allowances shall be made for differential thermal expansions between the vessel and trays at the design temperature. Provisions shall be made to transfer shear loads, resulting from upset conditions whenever specified in process / mechanical data sheets for the Column in webs at ends of trusses, using clips attached to the vessel shell. All tray parts (except parts welded to the vessel) affected by the dimensions tolerances specified on SASD AD-036981 shall be made adjustable so that when installed, tray assemblies will be within the specified tolerances. The weight of any single section of removable tray assembly except downcomer trusses and inlet panel shall not exceed: 1. 2. 35 Kgs (75 lbs.) for vessels up to and including 1.2 m diameter, and 70 Kgs (150 lbs.) for vessels above 1.2 m diameter.

9.1.4

9.1.5

9.1.6

Each tray shall be provided with one or more manways designed for removal from above and below the tray deck. Whenever possible, the minimum clear opening dimension shall be 380 mm x 460 mm. Tray manways shall be aligned vertically and shall be located to provide access to all sections of the vessel. Unless otherwise specified on the data sheets, the clearance under tray support beams shall be a minimum of 450 mm. If this is not achievable, manways shall be provided on both sides of beams for both tray above and below. It is the responsibility of the Tray Manufacturer to determine the required dimension of tray support rings in accordance with the requirements of paragraph 9.2 and 9.3 of this specification.

9.1.7 9.1.8

9.1.9

9.1.10 All internal piping systems, such as feed and reflux distributors, shall be supported from the vessel shell or head, and not from trays. 9.1.11 Bolts diameter smaller than 10 mm shall not be used. The lengths of miscellaneous assembly bolts shall be grouped by 10-mm increments. The minimum length for bolts is 25 mm for tray panels 9.1.12 Caps shall be designed so that they are removable from above the tray.

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32-SAMSS-020 Manufacture of Trays and Packing

9.1.13 Blind trays shall be seal welded after installation. 9.1.14 Liquid trough gravity distributors shall be self supported by independent beams. 9.2 Loads, Deflections and Allowable Stresses 9.2.1 Maximum allowable stress of of the ultimate tensile strength of the material at the vessel design temperature shall be used to mechanically design Tray assemblies and supports. Corrosion allowance shall not be used for strength purpose. Tray assemblies shall be mechanically designed for a uniform live load using the greater of 0.01 Kgs/cm (20 lbs./ft) or the weight of the tray assembly plus the maximum operating weight of liquid on the tray at the design temperature of the vessel. Tray assemblies shall also be designed for a concentrated load of 114 Kgs (250 lbs.) located at any location on the tray at an ambient temperature of 38C. The maximum allowable stresses for loads at ambient temperatures shall be in accordance with AISI SG-673. For vessels up to 3 m in diameter, the maximum deflection of carbon and alloy steel assembled trays shall not exceed 3 mm. For vessels greater than 3 m in diameter, the maximum deflection of carbon and alloy steel assembled trays shall not exceed 0.1% of the vessel diameter. Support beams and trusses shall not restrict the flow of vapor between tray passes, flow of liquid into downcomers, or personnel accessibility. Elements depth transversal to liquid flow shall be limited to maximum of 20 % tray spacing.

9.2.2

9.2.3

9.2.4

9.2.5

9.3

Minimum Thickness and Corrosion Allowances 9.3.1 The minimum thickness of tray parts, in USS gage, including corrosion allowance shall be in accordance with Table 2, Minimum Thickness of Tray Components.

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Table 2 Minimum Thickness of Tray Components

Tray Basic Material Tray Component Valves Bubble Caps, and Risers Tray Decks, Downcomers Sheets, Weirs and Integral Beams/Trusses. Packing tower material Major Trusses and Beams (Carbon Steel) 10 Ga or 3.5 mm 10 Ga or 3.5 mm 10 Ga or 3.5 mm 6.4 mm (410, 410S, 304, 304S, 316, 316S and Monel) 16 Ga or 1.5 mm 16 Ga or 1.5 mm 14 Ga or 2.0 mm 14 Ga or 2.0 mm 10 Ga or 3.5 mm

9.3.2 9.3.3 9.3.4

The minimum design thickness for tray decks and downcomer sheets shall be not less than 1.5 mm. The minimum thickness of downcomer bars shall be 6.4 mm for carbon steel and 5 mm for alloy steels. Ring supports, downcomer bars, support beams and other tower attachments which are not an integral part of the deck or downcomer sections shall be designed with a minimum of 3 mm corrosion allowance when made of carbon steel, or with a minimum of 1.5 mm total allowance when made of alloy. When a portion of a deck or downcomer including the downcomer trusses is formed into a support member, the support member shall have the same corrosion allowance that is provided for the deck.

9.3.5

10

Materials 10.1 All tray hardware shall be manufactured of the same basic material type as tray deck plates, except for trays with carbon steel deck plates, which shall have 410 stainless steel hardware. Tray parts shall conform to the ASTM material designations corresponding to the basic material types as specified in Table 3, Acceptable Material Specifications.

10.2

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Table 3 Acceptable Material Specifications

Basic Material Type Carbon Steel 12% Chrome Type 304 Stainless Steel Type 316 Stainless Steel Monel Plate, Sheet or Strip A36, A283, A285, A515 or A516 A176 or A240, Types 405 or 410S A167 or A240, Types 304 or 304L A167 or A240, Types 316 or 316L B127 UNS N04400 Bars and Shapes A36, A322 or A675 (Excluding Grade 90) A276 Type 410 A276 Types 304 or 304L or A479 UNS S30400/S30403 A276 Types 316 or 316L or A479 UNS S31600/S31603 B164 UNS N04400 Nuts and Bolts A193 Grade B6 w/ A194 Grade 6 nuts A193 Grade B6 w/ A194 Grade 6 nuts A193 Grade B8 w/ A194 Grade 8 nuts A193 Grade B8M w/ A194 Grade 8M nuts B164 F468, UNS N04400, w/ F467 Grade N04400 nuts or F468 UNS N05500 w/ F467 Grade N05500 nuts

10.3 10.4 10.5 10.6 10.7

All materials for vessels in sour service shall conform to ISO 15156 and SAES-L-133. Materials for tray support rings shall be in accordance with 32-SAMSS-004. The use of non-ASTM materials shall be approved by the Saudi Aramco Engineer. Gasket materials shall be asbestos-free and compatible with the service conditions of the vessel. Entire valve unit, i.e., valves, guides and stops, shall be a minimum of type 410 stainless steel for all new and revamped columns, unless a higher grade material is specified in the data sheet. The entire tray decks, i.e., active areas, blank areas, weirs and downcomers of trays shall be a minimum of type 410 stainless steel for all new and revamped columns, unless another grade material is specified in the data sheet. Carbon steel is not allowed unless required for process reasons (e.g., HF Alkylation) All support parts welded to the column shell, i.e., the tray support rings and the downcomer support bars shall be the same basic material type as the inside wall of the column, unless a higher grade material is specified in the data sheet.

10.8

10.9

10.10 Gravity liquid distributors shall be a minimum of type 410 stainless steel for all new and revamped columns, unless a higher grade material is specified in the data sheet. Gravity Liquid distributors shall be the same basic material type as the packing bed located below.
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32-SAMSS-020 Manufacture of Trays and Packing

Internal feed pipe liquid distributors shall be made the same basic vessel material. For wet sour gas systems shall be minimum seamless or HIC resistant carbon steel unless a higher grade material is required and specified in the data sheet.

10.11 For existing columns, carbon steel valve units, tray decks, and/or liquid distributors (such as detailed in clauses 10.7, 10.8 and 10.9 respectively) may be replaced in kind, providing no corrosion reported by inspection, the service and operating conditions remain unchanged, and the specifications remain as per the original data sheet(s). 10.12 The material of packing (random, structured, or grids) shall be a minimum of type 410 stainless steel for all new and revamped columns, unless a higher grade material is specified by Design Engineer and approved by Saudi Aramco Engineer. 10.13 Material identification of all non-carbon steel materials shall be in accordance with SAES-A-206. 10.14 An isolation material (Gasket) between dissimilar materials is required to avoid severe galvanic interaction ONLY in services where the bulk fluid is water (e.g., Desalination & De-aerators columns). 11 Tray Fabrication 11.1 11.2 The surface of fabricated parts shall be free from scale, dents and defects. Burrs shall be removed from all perforated areas and edges of tray sections. Burrs on sheared edges are acceptable.

12

Tray Installation 12.1 General 12.1.1 All tray support rings and other attachments required for supporting trays shall be welded to the vessel shell. The welding of tray subassemblies and tray decks to tray supports is prohibited. 12.1.2 All segments of valve trays that contain valves shall be installed after the vessel has been hydrotested, thoroughly dried, and cleaned. 12.1.3 Vessel circumferential seams shall not be covered by the tray or tray support installations.

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12.1.4 Trays are to be installed in accordance with the acceptable tolerances as per SASD AD-036981 and the Tray Manufacturer's Drawings. 12.1.5 All tray and distributor support clips shall be welded to the vessel prior to any postweld heat treatment and prior to hydrostatic testing. 12.1.6 Tray bolts shall be tightened, using a calibrated torque wrench, to the Tray Manufacturer's instructions and engaged to the full depth of the nuts. 12.2 Welding 12.2.1 Welding of Shell Attachments 1. The welding of tray supports and all attachments to vessel shells is the responsibility of the Vessel Manufacturer and shall conform to SAES-W-010. All attachments to vessel shells shall be fully welded on all sides. Skip welding is not permitted. All welding to vessel shells shall be completed prior to post weld heat treatment and prior to the hydrostatic testing of a vessel.

2. 3.

12.2.2 Welding of Other Attachments 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 process requires 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. All WPSs, PQRs and Weld Maps shall be submitted for approval to the Saudi Aramco Engineer prior to the start of the job. All WPSs, PQRs and weld maps shall be available at the work site for review at any time. All full-penetration groove welds shall be welded from both sides. Single-sided groove welds are not permitted unless approved by

4. 5.

6.

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the Saudi Aramco Engineer. Double-sided welds shall be ground or gouged to sound metal prior to welding the second side. 7. Thermally cut or gouged surfaces of all material shall be ground to bright (un-oxidized) material prior to welding.

13

Inspection and Testing 13.1 Tray Manufacturers Shop 13.1.1 Tray materials and hardware are subject to shop inspection by the Saudi Aramco Inspector, in accordance with Saudi Aramco Inspection Requirements Form 175-325000. 13.1.2 One complete tray assembly of each type and size for each vessel being manufactured shall be fully assembled and inspected at the Tray Manufacturer shop for conformance to the requirements of this specification. For symmetrical internal configuration (e.g., multipass trays) only half tray can be assembled and inspected. 13.2 After Tray Installation 13.2.1 After installation, all trays shall be visually inspected for conformance to the Tray Manufacturer's drawings and installation tolerances. 13.2.2 Bubble cap and valve trays are to be inspected by using a strong light. Any open seams, holes or gaps, which exceed 6 mm, shall be closed by non-asbestos gaskets and bolt tightening. Openings less than 6 mm shall be repaired by bolt tightening or gaskets. 13.2.3 Water used for leakage testing shall not contain more than 50-PPM chlorides in accordance with SAES-A-007. 13.2.4 The addition of gaskets and/or rope is to be regarded as the last course of action to be taken to seal trays. 13.2.5 Materials for gaskets and rope must be compatible with the design conditions of the vessel and chemically resistant to the service. 13.3 Leakage Test 13.3.1 Leakage test shall be performed, in the presence of the manufacturer, on trays after installation in the erected vessel as follows: Blind and draw-off Trays (including those as described by paragraph 7.1.9 of this specification).
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a) b)

All tray assemblies shall be thoroughly cleaned. Trays provided with man-ways shall be filled with water to the overflow weir or chimney height, as applicable. The level shall not drop by more than 25 mm after 1 hour and 15 minutes. If the actual leakage rate exceeds this, gaskets shall be added or the tray replaced and re-tested. All tray assemblies with no man-ways shall have no leakage. After testing, the tray assembly shall be thoroughly dried.

d)

13.3.2 If the actual leakage rate exceeds this, gaskets shall be added or the tray replaced and re-tested. 13.3.3 After testing, all plugs are to be removed and the tray assembly thoroughly dried. 13.3.4 No leakage test is required for sieve, valves and cartridge trays. 14 Marking and Shipping 14.1 Marking 14.1.1 Each tray or packing material part segment shall be piece marked with part number in the part-list as shown on the Tray/Packing Manufacturer's drawings. 14.1.2 The marking shall be done with water-insoluble material that contains no harmful substances that would attack or harmfully affect the material at ambient or elevated temperatures. The marking material shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, or other halogens. 14.1.3 Tray deck sections shall also be marked with the tray number on the underside using metal stencils. 14.1.4 Tray hardware shall be packaged separately from the main tray segments and marked with adequate identification. 14.2 Shipping 14.2.1 Tray and Packing components shall be properly packaged to prevent damage during shipping. 14.2.2 Carbon steel trays and components shall be protected with a rust inhibitor. The rust inhibitor must be easily removable.

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32-SAMSS-020 Manufacture of Trays and Packing

14.2.3 The Tray Manufacturer shall provide the type of inhibitor, and procedures for the removal of inhibitor with proposal. 14.2.4 All stainless steel components shall be protected from salt water and spray when shipped is by ocean freight. 14.2.5 All packages shall be marked with the order number, vessel equipment number and tray number. 14.2.6 Tray parts and tray hardware for different tray designs shall not be intermixed. 14.2.7 Copies of parts lists, assembly drawings and installation instructions shall be included with the shipment. 14.2.8 The manufacturer shall provide the following supplementary material hardware to compensate for installation losses and shall be the greater of the following: 1. 2. 3. 4. 5. 15 Bolts, nuts and washers, 10% or 10 of each size Tray clamps, 5% or 5 of each size and type Gaskets, 20% Floating Valves 5 % Random Packing 10 %

Drawings, Calculations and Data 15.1 15.2 The Tray Manufacturer shall prepare drawings, calculations, and data in accordance with Form NMR-7919-2, Non-material Requirements. Drawings and calculations, which are approved by the Design Engineer, shall not relieve the Tray Manufacturer of the Tray Manufacturer's responsibilities to comply with this specification. The following technical data shall be provided by the Packing Manufacturer, for review and approval: 1. 2. Complete rating data including, liquid/vapor loading, and hydraulic parameters Installation instructions
Revision Summary Major revision.

15.3

14 November 2009

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