Materials System Specification

32-SAMSS-009 General Purpose Steam Turbines Compressors, Gears and Steam Turbines Standards Committee Members
Alshaikh, Tariq Hussain, Chairman Khateeb, Eyad Mohammed, Vice Chairman Abbad, Hussain Ali Asiri, Saeed Mohammad Bukhamsin, Sulaiman Ali Hussain, Khaleel Ma'Atug Issa, Mohammad Abdallah Jamea, Khalid Hamad Janbi, Sohail Husain Khogair, Hani Ahmad Khowaiter, Abdul Rahman Othman Muqahwi, Sameer Salim Nguyen, Linh Van Odan, Nabeel Mohammad Sabri, Hasan Abdulrahman

26 January 2009

Saudi Aramco DeskTop Standards

Table of Contents 1 2 5 6 7 8 9 Scope............................................................. 2 Normative References................................... 2 Requirements................................................. 3 Basic Design.................................................. 4 Accessories.................................................... 8 Inspection, Testing and Preparation for Shipment...................... 13 Vendor's Data............................................... 13

Previous Issue: 28 September 2005 Next Planned Update: 26 January 2013 Page 1 of 14 Primary contact: Alshaikh, Tariq Hussain on 966-3-8760121
CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

The following paragraph numbers refer to API STD 611, Fifth Edition, March 2008, which is part of this Specification. The text in each paragraph below is an addition to API STD 611 unless it is noted otherwise (e.g., exception). Paragraph numbers not appearing in API STD 611 are new paragraphs inserted in numerical order. 1 Scope (Modification) This Specification, together with the Data Sheet (2811-ENG or 2811-MENG) and Purchase Order, defines the mandatory requirements for general-purpose steam turbines rated above 220 kW (300 HP). General-purpose steam turbines with lower power rating do not have to meet this specification but shall comply with API STD 611. General-purpose steam turbine driven equipment shall be spared or shall not be critical to plant operation. General-purpose steam turbines shall not be used for any of the following applications (these applications require special-purpose steam turbines): Having a rated power exceeding 3000 kW (4000 HP). Having a maximum continuous speed (MCS) exceeding 6,000 RPM. Having steam conditions exceeding a pressure of 4,800 kPa Gauge (700 psig) and a temperature of 400C (750F). Driving process gas compressors.

Turbines having a rated power exceeding 1,500 kW (2,010 HP) shall be of the multistage design. General-purpose steam turbines shall be supplied by Vendors qualified by experience in manufacturing the units proposed. To qualify, the Vendor or his licensee must have manufactured at least two turbines of comparable speed, power rating and steam inlet conditions. The turbines must have been in continuous service for at least one year and must be performing satisfactorily. Turbines manufactured under a license agreement shall carry the licensors written guarantee. 2 Normative References Material or equipment supplied to this Specification shall also comply with the references listed below: 2.1 Saudi Aramco References Saudi Aramco Inspection Requirements Form 175-320200 Turbines, Steam General or Special Purpose
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Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

Saudi Aramco Standard Drawing AA-036859 Lube Oil Circulation System Piping and Instrument Diagram (P&ID)

Saudi Aramco Forms, Drawings, & Data Sheets 2811-ENG & 2811-M-ENG 2.2 Industry Codes and Standards American Petroleum Institute API STD 611 API STD 671 General-Purpose Steam Turbines for Refinery Service Special-Purpose Couplings for Petroleum, Chemical, and Gas Industry Services Steam Turbine Data Sheet

American Society of Mechanical Engineers ASME SEC VIII ASME B31.3 BPVC Section VIII Rules for Construction of Pressure Vessels Process Piping

American Bearing Manufacturers Association ABMA 7 Shaft and Housing Fits for Metric Radial Ball and Roller Bearings (Except Tapered Roller Bearings) Conforming to Basic Boundary Plan

National Electrical Manufacturers Association NEMA RN 1 Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit Steam Turbines for Mechanical Drive Service

NEMA SM 23 5 Requirements 5.3 Conflicting Requirements

(Exception) Any conflicts between this specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs), codes and forms shall be resolved in writing by the Company or Buyer Representative.

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Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

Basic Design 6.1 6.1.3 General Turbines having a rated power exceeding 1,500 kW (2,000 HP) shall be of the multistage design and shall have a minimum isentropic efficiency of 75% at rated speed and normal steam conditions. If seawater cooling is to be used, an inlet design temperature of 35C (95F) shall be used. (Exception) Equipment sound pressure levels for each new piece of equipment or integrated unit shall not exceed 85 dB(A) at a distance of one meter. Control of the sound pressure to meet these requirements shall be the sole responsibility of the Vendor. Unless otherwise specified on the datasheets, the equipment will be installed outdoors in a desert area, with relative humidity from zero to 100% and ambient temperatures from 1C to 50C (32F to 120F). Metal temperature can reach 70C (158F) when exposed to direct solar radiation. Additionally, equipment which is not enclosed or hermetically sealed but is located offshore or near-shore (as specified on the datasheet) shall be protected against failure due to windborne seawater spray and the accumulation of wetted salt (NaCl). 6.1.17 Hand operated nozzle control valves shall be provided. Governor control shall be stable for any combination of steam conditions and hand controlled nozzle valve positions from no load to rated load. Pressure Casings (Modification) Pressure containing parts, including flanges and valves, shall not be made of Cast Iron. 6.3.5 6.3.6 6.3.8.5 6.3.9 Axially split casing shall be designed to permit inspection and replacement of the bearings without removal of the upper casing half. (Exception) Turbines shall be axially split between bearings design mounted horizontally. Radially split casing designs shall not be used. (Modification) Minimum spot face diameter shall be twice the size of the bolt hole. Drain connections shall be piped individually to open atmospheric drain lines and flanged stainless steel shut-off valves shall be provided. Drains
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6.1.11 6.1.12

6.1.14

6.3

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

shall not be manifolded and shall terminate with flanges outside insulation. 6.3.18 6.4 6.4.1 Vertical jackscrews shall be provided. Casing Appurtenances All turbines shall be protected against a closed exhaust valve by a Buyer supplied relief valve in the exhaust piping between the turbine exhaust flange and the block valve. The turbine Vendor shall advise the steam flow rate for this valve based on minimum inlet steam conditions and maximum exhaust pressure at the turbine rated power. Rotating Elements Rotors Metal plating/coating of the disc bore or shaft under the wheel is not allowed. Axial disc movement shall be positively prevented by providing a shaft shoulder or equivalent in the rotor design. Blading For all blading, the blade Goodman Factor shall not be less than 3.0. Blades shall be one-piece design incorporating any spacing required between adjacent blades as an integral part of the blade design. No spacers, crush pins, or other packing pieces are acceptable. Seals (Exception) Non-Contacting mechanical seals shall be provided for all applications. The seal design shall be of the self-cleaning face type. Carbon ring type sealing is not acceptable. Sealing steam pressure shall be automatically controlled for multistage turbines. Dynamics Lateral Analysis Calculations and supporting test data shall be provided for all multistage turbines. Vibration and Balancing (Clarification) For multi-stage turbines, each bladed disc shall be
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6.7 6.7.1 6.7.1.2

6.7.3 6.7.3.1 6.7.3.3

6.8 6.8.1

6.8.6 6.9 6.9.2 6.9.2.3 6.9.4 6.9.4.1

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

dynamically balanced prior to being assembled on the shaft. 6.9.4.2 6.9.4.8 Single stage turbine rotors may be fully assembled and then balanced. (Exception) The total combined electrical and mechanical runout for areas to be observed by shaft relative displacement sensors shall not exceed: 9 micrometers (0.35 mils) for rated shaft speeds up to 3,600 RPM 6.35 micrometers (0.25 mils) for rated shaft speeds exceeding 3,600 RPM 6.10 6.10.1.2 6.10.2.1 Bearings and Bearing Housings (Exception) Multistage turbines shall be provided with hydrodynamic thrust and radial bearings. (Modification) Anti-friction thrust bearings are not required to meet the housing fit requirements of ABMA 7, provided that rotation of the bearing outer race is positively prevented and the locking arrangement design has been proven in service conditions at least as severe as those specified. Bearing Housings (Modification) The ambient temperature ranges from 1C to 50C (32F to 120F). For hydrodynamic thrust and radial bearings, the metal temperature shall not exceed 105C (220F) at the loaded area, based on a maximum oil inlet temperature of 60C (140F). The oil inlet temperature shall be taken as 60C (140F) for all lube oil systems using air coolers, and 50C (122F) for lube oil systems using water cooling. The bearing oil outlet temperature shall not exceed 88C (190F). The wobble plate minimum thickness shall be 3/8 inch. Oil Mist Lubrication (Exception) Oil mist lubrication shall not be applied. 6.11 6.11.2 6.11.3 Lubrication If a forced feed lubrication system is not provided, a circulating oil system shall be supplied. The circulating lubrication oil system shall comply with Saudi Aramco Standard Drawing AA-036859. Two identical lube oil pumps shall be provided. An oil disk shall be supplied for backup lubrication.
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6.10.4 6.10.4.1.4

6.10.4.1.5

6.10.4.4.8 6.10.4.3

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

6.11.4

The required oil is ISO VG 46. Other oils may be used only during shop testing provided that the temperature is adjusted to reach a viscosity equal to the lowest at site conditions. The complete lube oil system shall be fabricated from AISI-316 stainless steel. Valves may be carbon steel with stainless steel trim. Water cooled heat exchangers shall be of shell-tube design, and shall be limited to the following materials: Bronze, Admiralty Brass, or Stainless Steel. Dual 10 micron filters are required. Materials General Ductile iron is not acceptable for pressure parts Cast blades are not acceptable. For services where saturated inlet steam is used, AISI 400 series or precipitation hardened stainless steel shall be used for blading, nozzles, support rings and wheels (except for integral rotor wheels). Welding All weld repair procedures, including the welding procedure specifications (WPS), together with supporting documentation shall be submitted through the Company or Buyer. All major repairs shall be documented. The documentation shall include the following: a) b) c) d) e) Extent of the repair; Location; Size; The WPS to be used to effect the repair; Detailed photographs of the defect: 1) 2) Prior to any preparatory work; After preparation but prior to the actual repair.

6.11.6

6.12 6.12.1 6.12.1.3 6.12.1.4

6.12.4 6.12.4.4

If the location of the defect cannot be clearly defined by photographic means, the location shall be indicated on a sketch or drawing of the affected component.

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Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

The repaired part shall be presented for inspection by the Company or Buyer's Representative within two weeks after completion of the repair. Reports as required by ASME SEC VIII shall be made available to the Buyer. The Buyer may require additional non-destructive examinations to verify the acceptability of the repair. Such additional requirements shall then be subject to mutual agreement between the Coordinator, Materials Engineering & Corrosion Control Division, Consulting Services Department, Saudi Aramco and the Vendor. 6.13 6.13.1 Nameplates and Rotation Arrows Nameplate data shall be permanently etched, stamped or embossed into the metal surface. Printing or painting data onto the nameplate is not permitted. The nameplate shall be in English.

Accessories 7.2 7.2.2 Couplings and Guards Metallic disc-pack or diaphragm type spacer couplings shall be supplied on all turbines by the vendor responsible for the train. Lubricated couplings are not acceptable. Couplings shall be designed to withstand cold start-up and slow roll misalignment. Couplings shall be capable of absorbing twice the maximum axial thermal growth. The coupling spacer shall be a minimum of 12 inch Between Shaft Ends (BSE) to permit removal of the coupling hubs without removal of the rotating elements or movement of the machines. Shaft Coupling shall be continuously rated at a minimum of 2.0 x turbine design rated torque. Couplings for steam turbines rated at 1500 kW and above shall comply with API STD 671. (Modification) Coupling guard shall be of non-sparking material. Mounting Plates Baseplate Baseplate design shall be such that no stationary liquid pools will form on the surface. The baseplate shall be provided with decking welded to the peripheral and cross members. All walk areas shall be provided with non-slip surfacing.

7.2.6 7.2.11 7.3 7.3.2 7.3.2.2 7.3.2.4

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Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

7.4 7.4.1 7.4.1.1

Controls and Instrumentation General The use of Intrinsic Safety as a protection method is required for all instruments located within Class I, Zone 0 areas. In other electrical hazardous areas (Class I, Zone 1 and Zone 2), I.S. systems shall only be used where other methods of protection are impractical. Only equipment, apparatus or devices that have been certified, labeled or listed as intrinsically safe (I.S.) by a third party testing laboratory shall be used or installed. The intrinsically safe instrument enclosure shall be sealed to provide adequate ingress protection (NEMA 4X) or IP-65. Terminals installed outside the control panel shall be installed in terminal boxes.

7.4.1.4

Conduits used for routing cables shall be closed, threaded, hot-dip galvanized, rigid steel. Certified, liquid-tight flexible conduits suitable for the area classification may be used only between the rigid conduit and terminal head to tolerate vibration. Conduit fittings shall be steel, cast iron or malleable iron, and hot dip galvanized or zinc electroplated. Nickelplated brass conduit fittings are also acceptable. Additionally, for offshore or nearshore installations, the conduit and fittings shall be PVC coated per NEMA RN 1 (minimum thickness of PVC: 40 mils). As an alternative to the rigid conduits mentioned above, armored cables routed on stainless steel cable trays, with SS covers, may be used. The armored cables shall be suitable for the area classification and shall be terminated using EExd glands with barrier seal at each end. The armored cable shall be individually routed on the trays not bunched or joined to adjacent cables. The cable trays supporting the armored cable shall be elevated from the skid base plate and shall not be supported by any on-skid piping. The cable trays shall not be routed underneath or across the top of the turbine and clear maintenance access shall be provided

7.4.2 7.4.2.1.4 7.4.2.2

Governing Control Systems (Modification) NEMA SM 23, Class D programmable digital electronic governors shall be provided for all turbines. Electronic governors for general-purpose steam turbines shall be of the simplex type. Governor actuators shall be of the pneumatic piston type

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Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

only, acting directly on the throttle valve, with no linkages. The governor shall be installed at a maximum distance of 4 meter from the turbine. Loss of electrical power to the governor or emergency trip device, shall lead to an automatic trip. Loss of governor signal shall close the governor valve. For turbines required to start automatically, electronic governors having acceleration rate control shall be provided. Governors shall be suitable for outdoor installation and shall be provided with a sunshade. The maximum distance from a turbine to a governor will depend on the type of instrumentation. For passive pickups and transducers, the distance shall be limited to 75% of the maximum distance providing satisfactory operation of the control system. Longer distances shall require active pickups and transducers (with power supply or modulated current transducers). The combination of the magnetic speed pickup and the multi-toothed surface shall produce sufficient signal at 5 00 rpm and above such that the speed pickup fail-safe override feature of electronic governors can be deactivated. A combined, total train control system that provides control for the turbine and the driven equipment is also acceptable. 7.4.2.2.10 Electronic governor shall be capable to control turbine starting from a minimum of 20% design speed up to the Maximum Continuous Speed (MCS). The electronic governor shall be capable of increasing turbine speed beyond the maximum governor control range for testing the overspeed trip. Overspeed Shutdown System A single valve to be used for Trip and Throttle functions is not acceptable. An air operated globe type trip valve with spring return shall be supplied, and designed for steam service with fail-closed design. The trip valve trim shall be of hardened stainless steel. Mechanical linkages to the turbine are not acceptable. The valve shall trip fully closed within 0.5 seconds maximum. Trip shall be through a minimum of two solenoid operated pneumatic-valves set at fail-safe mode, with one out of two trip action. Solenoid valves to have, H-rated coils and Viton or Teflon soft seating. The trip valve pneumatic actuator shall be of the piston-cylinder type, and shall be equipped with a separate hand lever, with red color handle, for manual trip. The turbine shall be equipped with two independent overspeed trip devices; one is taken from the governor and the other is a simplex
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7.4.2.3 7.4.2.3.1

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

electronic overspeed trip. Shaft mounted mechanical overspeed trip mechanisms are not acceptable. A total of four speed pickups shall be used; two dedicated for overspeed and two dedicated for the electronic governor. The loss of one of the two overspeed pickups output signals shall trip the turbine. 7.4.3 7.4.3.2 Instrument and Control Panels The local panel enclosures shall be NEMA Type 4X or IP-65 (galvanized and/or painted or coated carbon steel sheet metal enclosures are not permitted), hardware shall be Type 300 Series stainless steel, and the nameplates shall be attached to the cabinets using stainless steel screws. The vibration monitor and readout instruments shall be remotely mounted, unless otherwise specified. An interface must be provided to enable data transfer between any control, alarm or trip function of the panel and the central control room or DCS system. Instrumentation Tachometers Electronic governor shaft speed display shall be used in lieu of the tachometers. 7.4.4.3 7.4.4.3.1 Vibration, Axial Position and Temperature Detectors The vibration instrumentation for steam turbines shall be as follows: 1. Turbines equipped with anti-friction radial bearings and rated above 220 kW (300 HP) shall be provided with one seismic vibration transducer reading velocity on each bearing housing in radial direction. Turbines equipped with hydrodynamic radial and anti-friction thrust bearings and rated from 220 kW (300 HP) to 746 kW (1,000 HP) shall be provided with one seismic vibration transducer reading velocity on each bearing housing in radial direction. Turbines equipped with hydrodynamic radial and anti-friction thrust bearings and rated in excess of 746 kW (1,000 HP) shall be provided with the following: a) b) Two non-contacting vibration probes in each radial bearing housing, One seismic vibration transducer reading velocity mounted on the thrust bearing housing in radial direction,
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7.4.4 7.4.4.2

2.

3.

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

c) 4.

One key phasor probe, to measure shaft speed, on the driver shaft.

All turbines equipped with hydrodynamic radial and thrust bearings shall be provided with the following: a) b) c) Two non-contacting vibration probes in each radial bearing housing, One-even-per-revolution probe, Two axial position probes.

7.4.4.3.2

Turbines of 1000 HP and above, equipped with hydrodynamic radial bearings shall be provided with one embedded or tip-sensitive resistance temperature detector in each bearing. If a hydrodynamic thrust bearing is furnished, one embedded tip-sensitive resistance temperature detector shall be provided on each the active and inactive sides of the bearing. Pressure Gauges All pressure Gauges shall be liquid filled and shall be mounted on a local gauge board. Flow Indicators A sight glass in the oil drain return line for each bearing housing shall be provided. Alarms and Shutdowns Sentinel valves shall not be furnished. Piping and Appurtenances General Pipe bends shall have a surface free of cracks and buckles. Flattening of the cross section of bends shall not exceed 5% of the nominal pipe diameter. Bending procedures and required heat treatment shall be in accordance with ASME B31.3. Mitre fittings such as mitre elbows and mitre bends require the approval of the Compressors, Gears and Steam Turbines Standards Committee Chairman. Oil Piping (Modification) All oil piping, tubing and reservoirs/tanks shall be 316L Stainless Steel.
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7.4.4.7 7.4.4.7.2 7.4.4.10 7.4.4.10.1 7.4.5 7.4.5.2 7.5 7.5.1 7.5.1.5

7.5.2 7.5.2.3

Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

32-SAMSS-009 General Purpose Steam Turbines

Inspection, Testing and Preparation for Shipment 8.1 8.1.1 8.2 8.2.1 8.2.1.1 8.2.2.1.1 General Inspection and testing shall be performed as indicated on the turbine Data Sheet and the referenced Inspection Form 175-320200. Inspection General Material test reports stating material type, chemistry and mechanical properties shall be provided for rotating and stationary blades. Steel castings shall be 100% radiographed when the proposed foundry has never cast an identical casing. The radiographic examination of the casting shall be made after rough machining of the casing. Testing General Requirements for documentation and witnessing of tests shall be as specified on the turbine Data Sheet and the Form 175-320200.

8.3 8.3.1 8.3.1.1

Vendor's Data 9.2 9.2.1 Proposals General All deviations clarification from this Specification shall be separately listed by the Vendor in his bid quotation and shall refer to the relevant paragraph numbers. 9.2.4 Curves The vendor shall provide steam flow versus power performance curve(s) for all conditions. 9.3 9.3.5 9.3.5.1 Contract Data Installation, Operation, Maintenance and Technical Data Manuals General Manuals in searchable and printable electronic format, without copy right
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Document Responsibility: Compressors, Gears and Steam Turbines Issue Date: 26 January 2009 Next Planned Update: 26 January 2013

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protection, shall be provided.

26 January 2009

Revision Summary Major revision.

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