Materials System Specification

02-SAMSS-005 5 April 2006

Butt Welding Pipe Fittings
Materials and Corrosion Control Standards Committee Members
Anezi, Mohammed Ali, Chairman
Rumaih, Abdullah Mohammad, Vice Chairman
Burgess, Brian Wayne
Cruz, Czar Ivan Tecson
Kermad, Abdelhak
Lobley, Graham Russel
Mehdi, Mauyed Sahib
Moore, Mark Andrew
Niemeyer, Dennis Charles
Sannaa, Muhsen Shobbar
Nabulsi, Khalid Mohammad
Palmer, Robert Eugene
Stark, Gregory Dalton
Tems, Robin Douglas
Abdul Hadi, Abdul Latif Ibrahim
Mugbel, Wajdi Mohammad

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Purchase Order Information........................... 4
5 Design............................................................ 4
6 Materials......................................................... 6
7 Welding.......................................................... 8
8 Heat Treatment.............................................. 9
9 Inspection and Testing................................. 10
10 Product Marking, Coating,
Packing and Documentation................. 12
11 Material Selection and
Testing Subcommittee.......................... 13

Previous Issue: 28 February 2005 Next Planned Update: 1 December 2009

Revised paragraphs are indicated in the right margin Page 1 of 13
Primary contact: Rumaih, Abdullah Mohammad on 966-3-8734398
Copyright©Saudi Aramco 2005. All rights reserved.
Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

1 Scope

1.1 This Specification supplements the requirements of ASME B16.9, ASTM A234
for Grade WPB wrought carbon steel pipe fittings, and MSS SP-75 for high
strength fittings. Normally, it only applies to fittings that are purchased "loose."
This Specification does not apply to fittings installed on equipment that is
engineered, manufactured, and tested prior to delivery to Saudi Aramco unless
specifically invoked in the Purchase Order.

1.2 Cast fittings, stainless steel and corrosion-resistant alloy pipe fittings, and pipe
bends with a radius three times the diameter (3D) or greater are excluded from
the scope of this specification.

1.3 Fittings purchased in accordance with the requirements of this Specification are
deemed to be suitable for wet, sour services without additional testing or
certification.

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
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.

3 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

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

Saudi Aramco Materials System Specification

02-SAMSS-011 Forged Steel Weld Neck Flanges for Low and
Intermediate Temperature Service

Saudi Aramco Inspection Requirements

Form 175-026100 Butt Welding Pipe Fittings

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME B16.9 Factory-made Wrought Steel Butt Welding
Fittings
ASME B16.25 Butt Welding Ends
ASME B16.28 Wrought Steel Butt Welding Short Radius Elbows
and Returns
ASME B16.49 Factory-made Wrought Steel Buttwelding
Induction Bends for Transportation and
Distribution Systems
ASME B31.3 Process Piping
ASME SEC II Specification for Welding Rods, Electrodes, and
Filler Metals
ASME SEC VIII Rules for Construction of Pressure Vessels
ASME SEC IX Qualification Standard for Welding and Brazing
Procedures, Welders, Brazers, and Welding
and Brazing Operators

American Society for Testing and Materials

ASTM A234/A234M Standard Specification for Piping Fittings of
Wrought Carbon Steel and Alloy Steel for
Moderate and Eleveated Temperatures
ASTM A370 Standard Test Methods and Definitions for
Mechanical Testing of Steel Products
ASTM A860/A860M Standard Specification for High-Strength Butt-
Welding Fittings of Wrought High-Strength,
Low-Alloy Steel
ASTM A956 Standard Test Method for Leeb Hardness Testing
of Steel Products

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

ASTM A960 Standard Specification for Common Requirements

for Wrought Steel Piping Fittings
ASTM E165 Standard Test Method for Liquid Penetrant
Examination
ASTM E92 Test Method for Vickers Hardness of Metallic
Materials

American Welding Society

AWS A5.01 Filler Metal Procurement Guidelines
AWS A5.XX Specifications for Welding Filler Metals (Series of
Specifications)

Compressed Gas Association

CGA G6.2 Specification for Carbon Dioxide
CGA G11.1 Specification for Argon

Manufacturers Standardization Society

MSS SP-75 Specification for High Test Wrought Butt-Welding
Fittings

4 Purchase Order Information

The following information shall be included in the Purchase Order:

a) Type of fitting
b) Nominal size of fitting
c) Grade or specified minimum yield strength of fitting material
d) Nominal size, wall thickness or schedule and end details of pipe to be matched
e) Material specification of matching pipe
f) Wall thickness of lap-joint stubs; if applicable
g) Additional material and testing requirements; if applicable
h) Charpy impact testing requirements, if applicable
i) Export packing, marking, and shipping details

5 Design

5.1 Pressure Rating

5.1.1 Design and pressure rating of ASTM A234 Grade WPB fittings shall be

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

established by proof testing per ASME B16.9 Section 9 or by

mathematical stress analysis per ASME B31.3 Para. 304.7.2(d).

5.1.2 Design and pressure rating of MSS SP-75 fittings shall be in accordance
with that specification. In addition, for elbows larger than NPS 16, the
wall thickness shall comply with ASME B31.3 Para. 304.2.1 or ASME
B16.49 Para. 2.2. The thickness of the remainder of the fitting may be
increased to equal the required thickness of the intrados (inner radius or
"crotch").

5.2 Main Dimensions

The pipe fittings covered by this specification shall have dimensions as specified
in ASME B16.9, ASME B16.28 or MSS SP-75 as applicable.

Any exceptions shall be indicated in the Purchase Order.

5.3 Circumferential Welds

Circumferential welds are not allowed except to attach extensions such as those
mentioned in Para. 5.4 and straight tangent ends that are specified in the
purchase order. Circumferential welds are never allowed in the crotch area of
fittings.

5.4 Tees and Reducing Tees

The branch outlet of tees shall be extruded or forged to the run and shall have a
smoothly curved transition between run and branch. Welded-on branch
connections (set-on or stub-in) are prohibited. However, lengthening of an
extruded outlet by means of a circumferential weld in the cylindrical part of the
branch will be permitted.

When tees are fabricated from plate, the weld seams shall be parallel to the axes
of the run and the branch.

5.5 Reducers

Concentric and eccentric reducers shall have smoothly curved wrought

transitions and parallel ends (ASME shape) unless a conical shape has been
specified in the Purchase Order.

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

ASME shape reducers not listed in ASME B16.9 or MSS SP-75 shall be

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

designed in accordance with ASME B31.3, paragraph 304.6 for a design

pressure permitted by the matching pipe.

Conical reducers are only permitted when so specified in the Purchase Order.
The included angle shall not exceed 12 degrees.
Exception:

An included angle of maximum 15 degrees is allowed when the reducer is

concentric, has two cylindrical ends with a minimum length of 50 mm, and
smoothly finished circumferential welds.

5.6 Lap-Joint Flange Stub Ends

The wall thickness of stub ends for lap-joint flanges shall be as specified in the
Purchase Order and the welding end prepared by internal taper boring to match
the specified pipe. Lap-joint flange stub ends (weld ends) for sizes larger than
NPS 24 are covered by 02-SAMSS-011 and related standard drawings.

5.7 Special Designs

Special designs, such as nonstandard shapes and dimensions, will be considered

when the Vendor can prove that similar fittings have been successfully tested by
means of an actual bursting test in accordance with ASME B16.9 or MSS SP-
75. The design shall be approved in writing by the Saudi Aramco Consulting
Services Department.

5.8 Butt Welding Ends

Unless otherwise specified in the Purchase Order, the butt welding ends shall be
in accordance with the requirements of ASME B16.25 and match the beveled
end of the pipe specified in the Purchase Order.

6 Materials

6.1 General

Boron content shall be shown in the heat analysis or product analysis and shall
not exceed 0.0005%.

6.2 Grade WPB Fittings

6.2.1 Material shall conform to the requirements of ASTM A234/A234M

Grade WPB, including ASTM A960 Supplementary Requirements S50
"Product Analysis", S51 "Tension Test" and S57 "Hardness Test".

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

Note:

For Supplementary Requirement S50, a heat analysis may be substituted

for the product analysis except for welding material.

6.2.2 High strength starting stock shall not be used for Grade WPB fittings
without prior, written permission from the CSD. In no case shall the
actual yield strength of the finished fittings exceed 440 MPa (63,817
psi). All other requirements for WPB fittings shall be met.

6.2.3 The carbon equivalent shall not exceed 0.42% when calculated according
to the formula:

Mn (Cr + Mo + V) ( Ni + Cu)
CE (IIW) = C + + + (1)
6 5 15

6.3 High Strength Fittings (≥ 42,000 psi specified minimum yield strength)

6.3.1 With the exception of the chemical composition requirements in

paragraph 6.3.2 below, the high strength material shall conform to the
requirements of MSS SP-75, including Supplementary Requirements
SR-4 (hardness and nickel content limitations, except parent metal nickel
shall be limited per paragraph 6.3.2 below), SR-5 (actual yield strength
limitation), and SR-10 (more restrictive chemical requirements and
carbon equivalent).

6.3.2 Chemical composition shall be in accordance with the requirements of

ASTM A860/A860M, Paragraph 7.

6.4 The vendor shall provide a certified material test report listing the actual results
of the chemical analysis, mechanical properties, notch toughness properties, heat
treatment, nondestructive examination, and any special tests required by the
Purchase Order.

6.5 For Sour service, the following additional requirements are applicable for
welded fittings fabricated from plate or strip:

6.5.1 The steel shall be vacuum degassed.

6.5.2 The maximum sulfur shall be 0.002%. Sulfur content up to and

including 0.005% is acceptable if the steel is calcium treated for
inclusion shape control. Typical calcium content is between one and
three times the sulfur content.

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

7 Welding

7.1 General

7.1.1 Complete Welding Procedure Specifications (WPS's) and Procedure

Qualification Records (PQR's) shall be made available for review by the
Saudi Aramco inspector.

7.1.2 All Welding Procedure Specifications (WPS's) and Procedure

Qualification Records (PQR's) shall be written in English and conform to
the applicable Code.

7.2 Processes

7.2.1 The following processes are approved for use:

• Shielded Metal Arc Welding (SMAW)
• Gas Tungsten Arc Welding (GTAW)
• Submerged Arc Welding (SAW)
• Gas Metal Arc Welding (GMAW) - Short Circuiting transfer shall
not be used.
• Flux Core Arc Welding (FCAW) - Shall not be used for the root pass
on one sided groove welds.

7.2.2 Automatic welding without the addition of filler material is not

permitted.

7.3 Welding Consumables

7.3.1 Electrodes, filler wires, and fluxes shall conform to the requirements of
the BPV, ASME SEC II, Part C, identical to the AWS A5.XX
specification series. Other consumables may be used only with the
specific approval of Saudi Aramco.

7.3.2 Properly conditioned low-hydrogen electrodes shall be used for all

fittings when the wall thickness exceeds 13 mm.

7.3.3 A change in filler metal deposit chemistry from A-No. 1 of BPV, ASME
SEC IX to A-No. 2 and vice-versa is not permitted without
requalification.

7.3.4 Active Submerged Arc Welding fluxes shall not be used.

7.3.5 Shielding gases shall conform to the appropriate Compressed Gas

Association (CGA) specification(s).

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

7.4 Welding Procedure Qualifications

7.4.1 General

For any SAW flux, GMAW electrode, or FCAW electrode used for
procedures which require Charpy Impact testing and all FCAW
electrodes for fittings shall be restricted to the specific brand, type and
maximum size as used for the PQR. The brand name and type of flux or
electrode shall be specified on both the WPS and PQR.

7.4.2 Hardness Testing

Hardness traverses conducted in accordance with ASTM E92 shall be

made on a full-thickness, transverse cross-section of the weld that has
been mounted, polished to metallographic quality, and etched. Two
traverses shall be made. One shall be within 1.0 mm from the O.D.
surface and one within 1.0 mm from the I.D. surface. Each traverse shall
consist of at least two hardness indentations in each of the following
locations:
a) weld metal
b) heat affected zone on each side of the weld and
c) parent metal on each side of the weld.

Only Vickers 5 kg or 10 kg hardness testers shall be used. Hardness of

base metal, HAZ, and weld metal shall not exceed 207 HV for Grade B
fittings and 250 HV for high strength fittings.

7.5 Repairs

7.5.1 Cracks shall be repaired only if approved by the Saudi Aramco inspector.

7.5.2 Unsuccessful weld repairs after the second attempt shall be completely
cut out and replaced.

8 Heat Treatment

Heat treatment after all forming and welding processes are completed is required for all
fittings.

8.1 All Grade WPB fittings supplied in accordance with this specification shall be
normalized as defined in ASTM A234. All high strength fittings shall be
normalized, normalized and tempered, or quenched and tempered as defined in
MSS SP-75. Stress relief heat treatments are not acceptable, even if permitted in
ASTM A234/A234M or in MSS SP-75.

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

8.2 Seamless Grade WPB fittings for which the final forming operation is
completed at a temperature above 620°C and below 980°C need not be
subsequently heat treated provided they are cooled in still air.

8.3 Hot formed high strength fittings shall be cooled below the lower critical
temperature prior to heat treatment.

9 Inspection and Testing

9.1 General

The fittings are subject to inspection by the Saudi Aramco Inspection

Representative per Saudi Aramco Inspection Requirement Form 175-026100
attached to the Purchase Order.

9.2 Visual Examination and Dimensional Check

General appearance, workmanship and fit-up shall be acceptable in accordance

with ASME B31.3 Para. 344.2. Weld surfaces shall show a smooth contour.
Dimensions of the fitting shall be checked against ASME B16.9, MSS SP-75 or
approved Vendor's Drawings.

9.3 Dye Penetrant or Magnetic Particle Testing

All butt weld ends shall be tested using one of the following methods:
• dye penetrant (color contrast penetrant) in accordance with ASTM E165.
Acceptance criteria shall be per "Boiler & Pressure Vessel Code," ASME
SEC VIII D1, Appendix 8.
• magnetic particle tested in accordance with ASME SEC VIII D1, Appendix 6.

9.4 Radiography

All welds in fabricated fittings shall be 100 percent radiographed in accordance

with "Boiler and Pressure Vessel Code," ASME SEC VIII D1, paragraph UW-51.

9.5 Production Hardness Tests

9.5.1 Hardness tests shall be conducted on a minimum of 20% of seamless

fittings forged at temperatures above 620°C and 100% of seamless
fittings forged at 620°C or lower. Hardness tests shall be conducted on
100% of all welded construction fittings regardless of forging
temperature.

9.5.2 Hardness testing shall be conducted using either a bench-top hardness

tester calibrated to ASTM (or equivalent) standard hardness test blocks

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

or a portable hardness tester that has been approved in writing by Saudi

Aramco. To be approved, the portable hardness tester must be
demonstrated to give repeatable results within 10% of those obtained
with the calibrated bench-top hardness tester on fittings similar to the
production fittings. If the difference in readings between the portable
and bench-top testers exceeds 5%, the hardness acceptance criterion shall
be adjusted (lowered) by the maximum amount of the difference (for
example, lowered by 6%, 8%, or 10%). The calibrations must be
certified by an independent, third-party agency or by the Saudi Aramco
Inspection representative.

9.5.3 A minimum of three hardness indentations shall be made on the parent

metal of each fitting, with the test locations spaced evenly across the
piece being tested. (For fittings 2-inch and smaller, only two
indentations are required.) For welded fittings, an additional three
hardness indentations shall be made, evenly spaced, along the weld.
Where accessible, the weld metal hardnesses should be measured on the
I.D. surface of the fittings.

9.5.3.1 If any single indentation exceeds the allowable hardness limit,

two additional hardness indentations shall be taken within 25
mm of it, and the three hardness values shall be averaged. If
the average exceeds the allowable limit, the fitting shall be
rejected, and all the other fittings from the same heat shall be
100% hardness tested, even if not otherwise required in
paragraph 9.5.1.

9.5.3.2 The difference between the highest and lowest hardness

readings in the parent metal shall not exceed 20 HB. In
addition, for welded fittings, the difference between the highest
and lowest hardness readings in the weld metal shall not
exceed 20 HB. If the difference exceeds 20 HB for either the
parent metal or the weld metal hardness values, the fittings
shall be rejected, and all other fittings from the same heat shall
be 100% hardness tested, even if not otherwise required in
paragraph 9.5.1. For the purpose of determining the spread of
HB readings, a set of three indentations at the same location
may be substituted for any single reading and the average of
the three used instead of the single reading.

9.5.3.3 At the manufacturer's option, all fittings that have failed the
hardness test requirements in paragraphs 9.5.3.1 and/or 9.5.3.2
can be re-normalized and hardness tested again. Fittings that
pass the hardness test requirements and the strength

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

requirements after re-normalizing may be accepted. Fittings

that fail a second time shall be permanently rejected.

9.5.4 If a portable hardness tester of the Leeb (rebound) type is used, its
application shall be in accordance with ASTM A956.

9.6 Charpy Impact Testing

9.6.1 Charpy impact testing requirements for fittings in Grades WPHY-42 and
higher strength are given in MSS SP-75. Grade WPB fittings do not
require impact testing unless specified in the Purchase Order.

9.6.2 For welded fittings, testing shall be performed on the base metal, heat-
affected zone, and the weld metal. The weld metal and heat-affected
zone impact test specimens shall be transverse to the weld axis.

9.6.3 Impact test procedures and apparatus shall conform to the applicable
paragraphs of ASTM A370.

9.6.4 The test temperature and the minimum Charpy energy requirements shall
be specified in the Purchase Order if different from the requirements in
Para. 9.6.1.

10 Product Marking, Coating, Packing and Documentation

10.1 Fittings per ASTM A234/A234M WPB shall be marked in accordance with
ASME B16.9, paragraph 4.

10.2 Fittings per MSS SP-75 shall be marked per MSS SP-75, paragraph 17. In
addition, the carbon equivalent shall also be marked on the O.D. of the fitting.

10.3 After inspection by Saudi Aramco's Inspection Representative, unless otherwise

specified in the Purchase Order, fittings shall be supplied with a protective
coating that does not hide markings or surface defects. This temporary coating,
combined with appropriate packing, must protect against corrosion during ocean
shipment. The coating shall be hard and dry. It can be either a clear coating or a
thin opaque coating. Except for clear coatings, the maximum dry film thickness
shall be 0.076 mm. The fitting's normal stamped markings must be readable.

10.4 The welding ends shall be coated with an aluminum-flake weldable primer
("Deoxaluminite" or "Bloxide" or other brand approved by Saudi Aramco
Consulting Services Department) or a coating that is easily strippable and does
not leave a residue that interferes with welding. The maximum dry film
thickness of a weldable coating shall not exceed 0.050 mm. A welding end
strippable coating is allowed to be any thickness. Examples of strippable

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Document Responsibility: Materials and Corrosion Control 02-SAMSS-005
Issue Date: 5 April 2006
Next Planned Update: 1 December 2009 Butt Welding Pipe Fittings

coatings include high-build vinyl, urethane, PVC, or strippable tape applied

before a coating.

10.5 All fittings must be protected from mechanical damage. Welding ends must be
protected with suitable wood, plastic, or metal covers. Fittings must be
packaged in steel-banded wooden crates or secured to skids.
Note:

If fittings up through 6-inch size are securely packaged in the wooden crates so
that they cannot shift during shipment and damage the welding bevels, the
separate covers are not required.

10.6 The results of all tests required in this Specification shall be reported. The
reporting documentation shall be in the English language and three copies shall
be provided.

11 Material Selection and Testing Subcommittee

Graham Lobley Coordinator

Stan Jones Member
Muhsen Al-Sannaa Member
Mauyed Mehdi Member
Khalid Al-Nabulsi Member
Abdulmajid Al-Ismail Member
Robin Tems Member
Abdelhak Kermad Member
Brian Burgess Member
Gregory Stark Member
Abdullah Al-Rumaih Member
Wajdi Al-Mugbel Member

Revision Summary
28 February 2005 Editorial revision to affirm the contents, update the referenced paragraphs and committee
list, and changed the "Next Planned Update."
5 April 2006 Minor revision.

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