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Title32-SAMSS-022
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Page 1

Previous Issue: 29 March, 2000 Next Planned Update: 1 July, 2007
Revised paragraphs are indicated in the right margin Page 1 of 11


Materials System Specification
32-SAMSS-022 30 June, 2002

Manufacture of Components for Flare Systems

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
























Saudi Aramco DeskTop Standards

Table of Contents

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

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Document Responsibility: Flare Systems Design
Issue Date: 30 June, 2002 32-SAMSS-022
Next Planned Update: 1 July, 2007 Manufacture of Components for Flare Systems



Page 2 of 11

1 Scope

1.1 This specification covers the minimum mandatory requirements for the design,
fabrication, materials, and inspection of new flare systems and includes: flare
stacks, flare tips, dry gas seals, liquid-seals, and flare knockout drums.

1.2 This specification does not include requirements for incinerators, or equipment
used for the burning of combustibles on ships.

1.3 This specification does not prohibit the use of vendor proprietary designs
required for flare systems.

2 Conflicts and Deviations

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

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, Process & Control Systems
Department of Saudi Aramco, Dhahran.

3 References

Materials or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.

3.1 Saudi Aramco Documents

Saudi Aramco Engineering Procedure

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

Saudi Aramco Engineering Standards

SAES-N-100 Refractory Systems

SAES-N-110 Installation Requirements, Castable Refractories

Saudi Aramco Materials System Specification

32-SAMSS-004 Manufacture of Pressure Vessels

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Document Responsibility: Flare Systems Design
Issue Date: 30 June, 2002 32-SAMSS-022
Next Planned Update: 1 July, 2007 Manufacture of Components for Flare Systems



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Flare Tip Assembly: Includes the barrel, steam piping, pilots, nozzles, ignitors and
jets.

Flare Manufacturer: The company responsible for the manufacture of complete flare
systems, or components of flare systems, in accordance with this specification.

Flare System: Includes all piping, valves, pressure vessels and devices downstream of
relief/depressuring outlet block valves, to and including flare tip(s).

Flash Back Protection System: A system to prevent a flame front from traveling back
to the upstream piping and equipment. Normally flash back is caused when air
(oxygen) is inadvertently introduced into the flare system.

Liquid Seal Drum: A horizontal or vertical vessel in which a liquid (usually water)
level is used to maintain a positive pressure in the relief system upstream of the seal
drum, under conditions of no flow. Also used for staging between flares or a flare gas
recovery system and a flare.

Main Flare Knockout Drum: A vessel, located in either a main flare header or at the
base of a flare stack, which removes liquids that condense in or are carried over into the
flare system.

Maximum Continuous Flow: A flow which may be continuous for periods from a few
minutes to days or weeks. An example is flaring associated gas. (The maximum
continuous flow in a unit relief header, in a multi-unit plant, may not be the flow that
contributes to the maximum continuous flow in the main flare header).

Maximum Instantaneous Flow: This flow is due to depressurization and/or an
emergency relief. It is the maximum sum of the loads resulting from any single
contingency considered for emergency relief and/or emergency shutdown requiring
depressurization, and the plant(s) or unit(s) feed gas flow associated with that relief or
shutdown situation.

Multitip Multistage Flare: A flare made up of a number of stages, where each stage
usually has more than one tip. The tips are of proprietary designs and are designed to
burn smokeless and with low radiation due to the high velocity flow from each tip. It is
usually staged by means of control valves and rupture devices (as a safety backup to
each control valve). It may be elevated or low level.

Normal Continuous Flow: The flow due to combustible purge gas and other small
continuous sources and normal venting.

Pipe Type Flare Tip: A flare tip which is constructed from a pipe or thin-walled
hollow cylinder with addition of pilots and flame retention devices for flame stability.
The flare gas passes through the tip.

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Document Responsibility: Flare Systems Design
Issue Date: 30 June, 2002 32-SAMSS-022
Next Planned Update: 1 July, 2007 Manufacture of Components for Flare Systems



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Saudi Aramco Engineer: The Supervisor of the Flare & Relief Systems Unit,
Downstream Process Engineering Division of P&CSD, Dhahran.

Unit Knockout Drum: A vessel, located in a unit or close to the boundaries of a unit
which retains liquid carryover and/or condensate discharged from a unit relief header
and discharges the vapor to a main flare header.

5 Responsibilities

5.1 The Design Engineer is responsible for specifying the process and mechanical
design requirements and completing the data sheets.

5.2 The Flare Manufacturer is responsible for the design (process systems,
mechanical and structural), supply of materials, fabrication, non-destructive
testing, and preparation for shipment of flare stacks, flare tips, liquid-seals, and
knockout drums in accordance with the completed data sheets and this
specification.

6 Proposals

6.1 General

6.1.1 The Flare Manufacturer's proposal shall be based on details as outlined
on the data sheets.

6.1.2 The Flare Manufacturer may offer an alternative design, but must quote
on the base inquiry documents.

6.1.3 The Flare Manufacturer's proposal shall include a detailed description of
any exception to the requirements of this specification.

6.2 Detailed Requirements

The Flare Manufacturer is to supply the following information with the
proposal. This information is necessary and will be used to complete the
technical evaluation of the quotation. The quotation will be technically
unacceptable if any of the information required is not included.

(1) Completed data sheets

(2) A list of users operating flares of the same design and under similar
operating conditions

(3) Steam pressure and flow required for all specified flaring scenarios

(4) Dimensional drawing(s) showing internals of seal drums

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Document Responsibility: Flare Systems Design
Issue Date: 30 June, 2002 32-SAMSS-022
Next Planned Update: 1 July, 2007 Manufacture of Components for Flare Systems



Page 10 of 11

8.4 Materials for knockout drums and liquid-seals shall be in accordance with
32-SAMSS-004.

Commentary Note:

With reference to 32-SAMSS-004, the materials for knockout drum and seal
drum shells and heads may be SA285 Grade C or SA283 Grade C.

9 Welding

9.1 Flare stacks shall be welded in accordance with ASME B31.3.

9.2 Flare tip barrels shall be welded in accordance with the following:

(1) All welding procedures and welders shall be qualified in accordance with
ASME SEC IX.

(2) Approved processes are SMAW and GTAW. Any other processes require
the approval of the Saudi Aramco Engineer.

(3) 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.

(4) A weld map shall be prepared to indicate which welding procedure will be
used for each weld joint.

(5) WPS's, PQR's and weld maps shall be submitted for approval to the Saudi
Aramco Inspector prior to the start of fabrication. All WPS's, PQR's and
weld maps shall be available at the work site for review at any time.

(6) Circumferential and longitudinal butt welds of flare tip barrels shall be full
penetration. Use of backing rings or strips are prohibited.

(7) All full penetration groove welds shall be welded from both sides. Single-
sided groove welds are not permitted unless approved by the Saudi
Aramco Engineer. Double-sided welds shall be ground or gouged to
sound metal prior to welding the second side.

10 Fabrication

10.1 General

10.1.1 Fabrication of flare stacks and flare tip barrels shall be in accordance
with ASME B31.3 and the following:

(1) Longitudinal butt welds shall be 5% randomly radiographed.

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Document Responsibility: Flare Systems Design
Issue Date: 30 June, 2002 32-SAMSS-022
Next Planned Update: 1 July, 2007 Manufacture of Components for Flare Systems



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(2) All welds on flare tip barrels shall be visually examined and
penetrant tested over their entire length.

(3) All butt and fillet welds on flare tip barrels and flare stacks shall
be 100% visually examined and 100% dye penetrant examined.

10.1.2 Fabrication of steam piping shall be in accordance with ASME B31.3
with all butt fully radiographed.

10.1.3 Fabrication of knockout and liquid-seal drums shall be in accordance
with 32-SAMSS-004.

10.2 Refractory

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

11 Inspection

11.1 The Responsibility for inspection rests with the Flare Manufacturer in
accordance with the applicable Code and the requirements of this specification.

11.2 Flare tips are subject to verification by the Saudi Aramco Inspector in
accordance with Saudi Aramco Inspection Requirements Form 175-326700.



Revision Summary
30 June, 2002 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued

with minor changes.

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