Tender No.

PLCC/SMPL AUG J18/

Technical Specifications

Chapter -4

Specifications of Carbon Steel Flanges

Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

1.0 Scope
1.1. This Specification shall be used in combination with enclosed “Specific requirement of Project”.
1.2. “Specific requirement of project“ indicates size, rating of flange, quantity, connecting pipe thickness,
connecting pipe material grade, fluid characteristics, any additional tests and requirements, any
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

modification to this specification based on particular project design conditions and requirements.
1.3. This specification defines the technical requirements for the design, materials, manufacturing, testing
and inspection, marking and shipment of forged carbon steel flanges of the welding neck type, blind
flange and Slip on Flanges.
1.4. This specification is applicable only to non-sour service and for onshore crude oil, petroleum products
and LPG service.
1.5. This specification is applicable for flanges of pressure rating 150# to 900#.
1.6. This specification is applicable for flanges from size ½” to 48” with applicable pressure rating as
specified.

2.0 Reference codes and standards

2.1. Unless otherwise specified, requirements of the latest editions of the referenced Codes and Standards
at time of purchase order to be used.
2.2. Reference codes and standards to be used in conjunction with this specification.
2.3. Order of precedence of applicable documents shall be as under:

1. Specific requirement of project (As per Annexure-I)

2. This specification
3. Reference codes and standards
S.No. Reference Description
1. ISO 15590-3 Petroleum and natural gas industries — Induction bends, fittings
and flanges for pipeline transportation systems — Part 3: Flanges
2. ASME B16.25 Butt welding Ends
3. ASME B 16.20 Ring-Joint Gaskets and Grooves for Steel Pipe Flanges
4. ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60
Metric/Inch Standard
5. ASME B 16.5 Pipe flanges and flanged fittings
6. ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and
other Liquids
7. ASME B31.8 Gas Transmission and Distribution Piping Systems

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Technical Specifications

S.No. Reference Description

8. ASME section V
Boiler and Pressure Vessel Code. Non-destructive Examination
9. ASME section VIII
Boiler and Pressure Vessel code - Section VIII: Pressure Vessels
Design
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

10. API 5L Specification for Line pipe

11. MSS SP 44 Steel pipe line flanges
12. ASTM A 370 Test Methods and Definitions for Mechanical testing of Steel
Products
13.
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

ASTM A 388/A Practice for Ultrasonic Examination of Heavy Steel Forgings

388M
14. ASTM A 694/A Specification for Forgings, Carbon and Alloy Steel for Pipe,
694M Flanges, Fittings, Valves and Parts for High – Pressure
Transmission Services
15. ASTM E 10 Test method for Brinell Hardness of Metallic Materials
16. ASTM E 23 Method for Notched Bar Impact Testing of Metallic Materials
17. ASTM E 709 Guide for Practice of Magnetic Particle Examination
18. ISO 148 Charpy impact test (V-notch)
19. AWWA C207 Steel Pipe Flanges for Waterworks Service, Sizes 4 ln. Through
144 In. (100 mm Through 3,600 mm)

3.0 Design:
3.1. Flanges shall comply with the requirements of ASME B16.5/ASME B16.47/MSS SP 44 as indicated in
this specification and as per “specific requirement of project”.
3.2. Pressure-temperature ratings shall be as per MSS SP 44/ISO 15590-3
3.3. Flanges shall be made from forging material meeting the requirements of this specification, applicable
codes and material specification.
3.4. The dimensions of flanges shall be as per ASME B16.5 for NPS ½” to 24” (except 22”), ASME B16.47
Series A/MSS SP-44 for 22” size and from NPS 26” to 36” and ASME B16.47 series B for above 36”.
3.5. Design factor of flanges shall be 0.6 and the flanges are to be guaranteed by vendor for Hydrotest
pressure of 1.5 times the pressure rating.
3.6. Wall thickness of flange weld neck (hub) shall not be less than the connecting pipe thickness indicated
in any case.
3.7. Pipe flanges end thickness and grade shall be selected in such a way that flange meets the design
stress criteria mentioned in Annex-A of MSS-SP-44.
3.8. Nominal bore of WNRF shall be that of the connecting pipeline.
3.9. Bore of slip on flanges shall suit the outside diameter of matching pipe.
3.10. The welding end shall be in accordance with Figure 2 of MSS-SP-44 for wall thickness (of intended
connecting pipe) of 22 mm (0.88 in.) and less. For thicker walls greater than 22, Figure 3 of MSS-SP-
44 to be referred.

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3.11. When the mechanical (specified minimum yield strength) properties of all sections of the flanges are
equal to or higher than those of the pipe to be matched, the hub dimensions to be maintained same
as those indicated in ASME B16.5/ASME B16.47/MSS-SP-44 as applicable.
3.12. When the specified minimum yield strength of any portion of flange is less than that specified for the
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

pipe to be matched, the minimum thickness of the hub at the welding end shall be such that the
product of its thickness times its yield strength shall be at least equal to the product of the specified
nominal wall thickness and minimum specified yield strength of the pipe to be matched in
accordance with MSS-SP-44.
3.13. When the hub thickness at the welding end is greater than the adjoining pipe, the joint design shall be
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

as shown in any of the three sketches in Figure 1 of MSS-SP-44.

3.14. Unless otherwise specified, raised face shall be used for flange rating 150# to 900#.
3.15. Flange facings shall be in accordance with MSS SP 44/ASME B 16.47 and ANSI B 16.5, as applicable.
Flange Facing Finish Imperfections shall not exceed the dimensions shown in Table 11 of MSS SP 44.
Adjacent imperfections shall be separated by a distance of at least four times the permissible radial
projection. Protrusions above the separations are not allowed.
3.16. The surface finish of raised face and flat face of all flanges shall have serrated concentric surface finish
with an average roughness of 3.2 μm (125 μin) to 6.3 μm (250 μin).
3.17. AWWA type flanges shall be as per AWWA C207 Class E with Hub type and to be supplied with flat
face.
3.18. Steel forgings to be used in the manufacture of AWWA flanges and mechanical and chemical
properties shall meet clause 4.1.3.1 of AWWA C207.

4.0 Flange material

4.1. Chemical composition
4.1.1. All flange forged material shall be fully killed and made to fine grain practice.
4.1.2. All flanges shall be normalised irrespective of size and rating. Vendor shall submit the heat treatment
procedure for purchaser’s approval. A record (heat treat chart) shall be maintained of each heat
treatment batch and shall be included in the inspection document.
4.1.3. The final microstructure produced after heat treatment shall be uniform with average grain size of
ASTM 7 or finer as per ASTM E 112.
4.1.4. Manufacturer shall carry out a chemical analysis on each heat of steel used and also on two products
per heat.
4.1.5. Chemical composition of flanges shall be as per Table-4 of ISO 15590-3 with the following changes.
 Nitrogen concentration shall be limited to 0.012% Max.
 V+Nb+Ti shall not exceed 0.15%
 Cr+Mo+Ni+Cu shall not exceed 0.6%.

4.1.6. Maximum Carbon Equivalent shall be 0.43% when calculated with the following formula:
CE = C +MN/ 6 + (Cr+Mo+V)/5 + Cu+Ni)/15

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4.1.7. If any chemical analysis (both raw material and product) fails to meet the requirements stated above,
the whole heat shall be rejected or each individual product shall be fully analysed and all products
failing to meet the requirements shall be rejected.
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

4.2. Material grade

Flange material shall comply with as per the requirements indicated below unless otherwise
specified. Please refer specific requirement of project for connecting pipe thickness and grade.
Material grade for flanges (for crude oil and product pipelines)
Material grade Flange type Pressure rating
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

150# 300# 600# 900#

ASTM A105 WNRF/SORF/BLRF 1/2”-48” 1/2”-18” 1/2”-6” 1/2”-6”

ASTM A694 F52 WNRF/BLRF - 20”-28” 8”-14” -

ASTM A694 F60/F65/F70# WNRF/BLRF - 30”-48” 16”-36” 8”-24”

Material grade for flanges (for LPG piping)

Material grade Flange type Pressure rating

300# 600#

ASTM A350 LF2 Cl2 WNRF/BLRF 1/2”-6” 1/2”-6”

ASTM A105 WNRF/BLRF 8”-16” -

ASTM A694 F52 WNRF/BLRF 18”-24” 8”-10”

ASTM A694 F60/F65/F70# WNRF/BLRF - 12”-24”

Note:
1. # - If flange material SMYS is less than connecting pipe SMYS, then clause 3.10 & 3.11 to be followed.
2. For 8” size, if low temperature is specified, then ASTM A350 LF2 to be selected.

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5.0 Manufacturing & Dimensional requirements

Manufacturing & Dimensional requirements of flanges shall be as per following:
Details Up to 20” & 24” 22” & 26” to 36” > 36” (only for 150# and
300#)
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

For WNRF & BLRF Flange

a Manufacturing & ANSI B 16.5 / ANSI B 16.47 Series A / ASME B16.47 Series B
Dimension MSS SP 44 (12”-24”) MSS SP 44
For SORF Flanges (for 150# only)
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

b Manufacturing, ANSI B 16.5 AWWA C207 Class E AWWA C207 Class E

Dimensions

6.0 Inspection and testing:

6.1. General instruction
6.1.1. Test pieces shall be prepared in accordance with ISO 377. If thermal cutting has been used to remove
samples, the full extent of the heat-affected region shall be removed during the preparation of the
test pieces.
6.1.2. Mechanical testing samples shall consist of sacrificial forging. The testing of separately forged bars
should not be permitted. All inspection and testing cost shall be included in cost of flange itself.
6.2. Summary of testing, inspection and extent of testing:

S.No. Tests Sample frequency Inspection

1 Heat analysis One per heat Review
(raw material)
2 Product analysis Two per heat 100% Witness

3 Tensile testing, Impact One per heat/lot/each heat treatment 100% Witness
testing, Hardness and batch
Metallography
4 Visual inspection For all flanges 100% witness
5 Ultrasonic Testing of weld For all flanges 100% witness
ends for lamination
cracks/other defects up to a
width of 50 mm from weld
end
6 Physical and Dimensional 150# & 20% or min. 2 nos. 100% witness
Check 300# whichever is higher for
sizes ≤16”
100% for sizes ≥ 18”
600# 100%
900# 100%

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Note:
a) If fittings are made in different lots, then destructive testing to be carried out for each heat under
each lot and each heat treatment batch.
b) All samples drawn for testing to be witnessed by TPI and/or IOCL.
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

c) If order quantity is less than 2, minimum 1 no. to be witnessed.

d) Flanges inspected by TPI and/or IOCL shall be clearly identified by marking
e) Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests as per this
specification at Manufacturer’s works prior to shipment. Manufacturer shall provide reasonable
notice of time and shall provide, without charge, reasonable access and facilities required for
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

inspection to purchaser’s inspector.

6.3. Tensile testing:

6.3.1. Tensile tests shall be carried out in accordance with ASTM A 370.
6.3.2. Sample orientation of tensile test is as per ISO 15590-3.
6.3.3. For weld-neck flanges:

Note: Marking 1- Welding neck flange, Marking 2- Longitudinal tensile specimen.

6.3.4. For Blind flanges:

Note: Marking 3- Blind flange, 4- Transverse tensile specimen.

6.3.5. Tensile properties of sample tested shall meet values as per material specification grade indicated viz.
ASTM 105/ASTM A694 w.r.t yield strength, ultimate strength, elongation.

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6.4. Charpy V-notch impact test:

6.4.1. Charpy V-notch test pieces shall be prepared in accordance with ASTM A 370/ ISO 148-1 with the axis
of the notch perpendicular to the flange surface.
6.4.2. The orientation and size of the test pieces shall be as follows:
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

6.4.2.1. Actual location of specimen shall be that nearest to the welded end from which 10 mm × 10 mm
Charpy specimens can be taken.
6.4.2.2. If transverse specimen of 10 mm is not possible, then sub-size specimen can be taken.
6.4.2.3. If transverse test pieces with a minimum width of 5 mm are not possible, longitudinal test pieces with
the greatest possible width between 10 mm and 5 mm shall be used.
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

6.4.3. % shear area at the fracture surface to be reported.

6.4.4. Each set of impact tests shall consist of three adjacent test pieces.
6.4.5. The impact test temperature shall be 0°C for petroleum and crude oil service and -29°C for LPG
service. For low temperature carbon steel material, impact energy and testing temperature shall be
as per respective material grade specification.
6.4.6. Min. average and min. individual value for transverse direction shall meet the following requirements.
Material grade Min. Average Value (J) Min. individual value (J)
ASTM A105 27 22
F52 (360) 36 30
F60 (415) 42 35
F65 (450) 45 38
F70 (485) 50 40
6.4.7. The minimum average and individual Charpy V-notch values when testing test pieces taken in the
longitudinal direction shall be at least 1.5 times the values stated for transverse test pieces.

6.5. Hardness requirements

6.5.1. Three through thickness macro sections shall be taken at 120 º intervals from the hub and ring of the
test flange.
6.5.2. Three hardness traverses shall be made on each macro section as follows:
 1.5±0.5 mm from the outer surface
 Mid-thickness
 1.5±0.5 mm from the inner surface
6.5.3. Each traverse shall consist of five indents.
6.5.4. No hardness reading shall exceed 248 HV10

6.6. Non destructive testing:

Flanges shall be subject to the following inspection:
6.6.1. Ultrasonic inspection as specified - Ultrasonic testing shall be carried out in accordance with ASME V
or ASTM A 388/A 388M.

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 The final 50 mm of weld end of the flange shall be UT inspected for the detection of laminar
imperfections in accordance with ISO 11496. The reference standard shall be a flat bottom
hole.
6.6.2. The bevel faces shall be machined and shall be free from cracks, laminations, notches, scores, pits etc.
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

6.6.3. 100% visual inspection of internal and external surfaces- Forgings shall comply with the workmanship,
finish and appearance requirements of ASTM A 694/ASTM A105.
6.6.4. Final NDT shall be carried out after heat treatment with the forging in the finish-machined condition.
6.7. Hydrostatic testing
Hydrostatic testing of flanges is not required unless otherwise specified. Flanged joints may be
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

subjected to system hydrostatic tests at a pressure limited to 1,5 times the pressure rating. The
manufacturer shall certify and guarantee that the flange can withstand the hydrostatic test
pressures.
6.8. Dimensional requirements:
6.8.1. WNRF and Blind Flanges shall be machined according to the dimensions of ASME B16.5 for sizes up to
24” (except 22”), as per MSS SP 44/ASME B 16.47 series A for sizes 22” and above 24” to 36” and as
per ASME B16.47 series B for sizes above 36”.
6.8.2. For slip on flanges, dimensions shall be as per ASME B 16.5 for sizes up to 24” and as per AWWA C207
Class E (275PSI) hub type for size above 24”.
6.8.3. If flange material SMYS is less than connecting pipe SMYS, then clause 3.10 & 3.11 to be followed.

6.9. Tolerance:
Tolerances shall be as per ASME B 16.5 for sizes ≤ 10” and as per MSS-SP-44 for sizes > 10”

6.10. Repair of defects

Minor surface defects on flanges shall be ground out leaving a smooth gradual profile provided
that the wall thickness is not reduced below the tolerances specified. Any ground areas (except
for cosmetic grinding) shall be examined by ultrasonic Inspection. Forgings containing larger
defects shall be rejected. Repair welding of forgings is not allowed.

7.0 Marking
7.1. Marking shall be such that complete traceability is demonstrated in all stages of manufacture.
7.2. Each flange shall be clearly identified on the outside rim using the following marking
7.3. Each flange shall be marked as a minimum with the following information:
1. Company’s name/logo/trade mark
2. DN / NPS
3. Wall thickness/pipe schedule
4. Class
5. Serial no. and Heat number
6. Purchase order No.
7. Material grade of forging

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8. TPI witnessed mark on flange tested.

8.0 Handling, storage and packing
Manufacturer shall ensure that all finished flanges are handled and stored in such a manner so
as to preserve the machined faces and general surface condition of the forging. The
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

manufacturer shall ensure that all flanges are adequately protected against corrosion during
transportation and storage by applying proper rust protective coating.

Manufacturer shall take suitable corrective action if damage is observed by the

Inspector/IOCL site representative due to inadequate handling or storage conditions.
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

9.0 Documentation
9.1. During bid submission
- Confirmation on Specific requirement of project (As per Annexure-I)
- Supporting documents as per BQC indicated in Annexure-II
- Confirmation on Standard Quality assurance procedure (As per Annexure-III)
- Compliance letter from the flange manufacturer that the flanges shall be manufactured as per
the furnished specification.
9.2. After purchase order
- Confirmation on Standard Quality assurance procedure (As per Annexure-III)
- Sketch showing test specimen location for each test for the size of flange proposed under
each heat.
- Manufacturing drawing of steel flange for each size and rating with tolerance where SMYS of
flange ≤ SMYS of connecting pipe.
9.3. At the time of Despatch for each lot
- List of flanges produced – size and rating, quantity, heat no.
- Manufacturer test/Mill certificate to signify compliance with specification.
- Raw material test certificate from original steel manufacturer
- Duly witnessed/reviewed documents, as applicable, as per QAP from TPI.
- Record of Heat treatment with graph, date of heat treatment for all size and rating along with
Heat no.
- All Mechanical, chemical test, Hardness, impact, NDT test reports and certificates
- Dimensional inspection test reports.
- All other documents as indicated in QAP.
- The flange shall be guaranteed by the vendor against defective materials, poor workmanship,
improper design and failure in normal usage within 18 months from the date of supply.
- The supplied flanges shall be guaranteed for withstanding hydrostatic testing along with the
piping system at a pressure of 1.5 times the pressure rating specified in the summary of
requirement.
Note: QAP for Carbon Steel Flanges is attached as Annexure – IIB-2A

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Note: The indicative thickness is for the connecting pipe thickness

Sl.NO Nom. Size Connecting pipe

(Inch)
Document / Drawing and the design it covers are property of INDIAN OIL CORPORATION LIMITED. They are merely loaned and on the borrower’s express agreement that they will not

1 14 14 " OD x 0.375" WT API 5L X60 PSL 2 PIPE

2 12 12.75" OD x 0.375" WT API 5L X60 PSL 2 PIPE
3 12 12.75" OD x 0.375" WT API 5L Gr B PSL 2 PIPE
4 10 10.75" OD x 0.365" WT API 5L x 52 PSL 2 PIPE
be reproduced, copied, loaned, exhibited, not used except in the limited way and private use permitted by any written consent given by the lender to the borrower.

5 10 10.75" OD x 0.365" WT API 5L Gr B PSL 2 PIPE

6 8 8.625" OD x 0.375" WT API 5L x 52 PSL 2 PIPE
7 8 8.625" OD x 0.322" WT API 5L Gr B PSL 2 PIPE
8 6 6.625" OD x 0.280" ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
9 4 4.5" OD x 0.237"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
10 3 3.5" OD x 0.216"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
11 2 2.375" OD x 0.218"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
12 1.5 1.315" OD x 0.179" WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe

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