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PT. PHE ONW J.

Specification for Pipeline Flanges and Fittings

Revision Log Register

Document Number : PHEONWJ -W-SPE-001 4

Document Title : Specification for Pipeline Flanges and Fittings

Revision :0

PHE ONWJ

Page Date Revision

Reviewer

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Specification for Pipeline Flanges and Fittings

Table of Content

Revision Log Register ................................................................................................................2

Table of Content.........................................................................................................................3

1. Scope ..................................................................................................................................4

2. References .........................................................................................................................4

2.1 Local Regulation and Standards ...............................................................................4

2.2 Company Specification.............................................................................................4

2.3 International Standards and Codes ..........................................................................4

3. Definition of Terms .............................................................................................................5

4. Abbreviations ......................................................................................................................6

5. General Requirement .........................................................................................................6

6. Design.................................................................................................................................6

6.1 Flanges .....................................................................................................................6

6.2 Fittings......................................................................................................................7

6.3 Welding end .............................................................................................................7

7. Manufacturing.....................................................................................................................8

7.1 Manufacturing procedure .........................................................................................8

7.2 Dimensions and tolerances ......................................................................................8

7.3 Workmanship and Visual Inspection ........................................................................8

8. Testing and inspection........................................................................................................8

8.1 Chemical composition ..............................................................................................8

8.2 Mechanical testing ...................................................................................................9

8.3 Non Destructive Testing (NDT) ..............................................................................1 0

8.4 Weldability Testing .................................................................................................1 1

9. Hydrostatic Testing...........................................................................................................1 1

1 0. Inspection Notification......................................................................................................1 1

1 1 . Coating..............................................................................................................................1 2

1 2. Marking.............................................................................................................................1 2

1 3. Preparation for shipment ..................................................................................................1 2

1 4. Documentation .................................................................................................................1 2

Figure 1 : Guide Bar Design for Barred Tees ...........................................................................1 3

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Specification for Pipeline Flanges and Fittings

1.
Scope

This specification covers the minimum requirements for design, manufacturing, testing and

documentation of pipeline flanges and fittings. Flanges and fittings furnished shall meet the

design and environmental conditions as stated in this specification and shall be new, sound,

and free from defects.

2.
References

Design, manufacture, performance and testing shall be in compliance with the following codes

and standard, except where otherwise specified. The following documents shall form an

integral part of this specification:

2.1
Local Regulation and Standards

Decree
Inspection Guidelines for Safety on Facilities,

84.K/38/DJ M/1 998

Equipment and Technology Used in Oil and Gas and

Geothermal Activity

Regulation
Safety Audit to Inspection, Equipment and Technique

06P/0746/M.PE/1 991
used In Oil and Gas Mining and geothermal Activities.

Regulation
Safety for Oil and Gas Pipelines

300.K/38/M.PE/1 997

SNI 3474 Sistem Penyaluran dan Distribusi Pipa Gas

SNI 1 3-3473 Sistem Transportasi Cairan untuk Hidrokarbon, Gas

Petroleum Cair, Amoniak Anhidrous dan Alkohol

SNI 1 3-621 3 Spesifikasi Pipa Alir

The above are listed only as a guide to the applicable Indonesian Acts. CONTRACTOR

shall be responsible for determining all statutory requirements applicable to the scope

of work included in this specification.

2.2
Company Specification

PHEONWJ -W-SPE-0004 Offshore Pipeline Design Basis

PHEONWJ -F-PRC-0007 Standard Practice for Painting on Metal Surface

2.3
International Standards and Codes

ASME B1 6.5 Pipe Flanges and Flanged Fittings NPS ½ through NPS 24

ASME B1 6.9 Factory-Made Wrought Steel Buttwelding Fittings

ASME B1 6.20 Metallic Gaskets for Pipe Flanges - Ring-J oint, Spiral-Wound,

and J acketed

ASME B1 6.25 Buttwelding Ends

ASME B31 .4 Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids

ASME B31 .8 Gas Transmission and Distribution Piping Systems

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Specification for Pipeline Flanges and Fittings

ASME VIII Rules for Construction of Pressure Vessels

ASME IX Welding and Brazing Qualifications

ASNT SNT-TC-1 A Recommended Practice for Qualification and Certification of

Non destructive Testing Personnel

ASTM A275 Standard Test Method for Magnetic Particle Examination of

Steel Forgings

ASTM A370 Standard Test Methods and Definitions for Mechanical

Testing of Steel Products

ASTM A388 Standard Practice for Ultrasonic Examination of Heavy Steel

Forgings

ASTM A694 Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings,

Valves, and Parts for High-Pressure Transmission Service

ASTM A707 Standard Specification for Forged Carbon and Alloy Steel

Flanges for Low-Temperature Service

ASTM A860 Wrought High-Strength Low-Alloy Steel Butt-Welding

Fittings

ASTM E1 1 2 Test Methods for Determining Average Grain Size

ASTM E1 290 Test Method for Crack-Tip Opening Displacement (CTOD)

Fracture Toughness Measurement

ISO 1 5590-2 Induction bends, fittings and flanges for pipeline

transportation systems, Part 2: fittings

ISO 1 5590-3 Induction bends, fittings and flanges for pipeline

transportation systems, Part 3: flanges

ISO 31 83/API 5L Specification for Line Pipe

ISO 1 51 56-2 Materials for use in H2S-containing environments in oil and

gas production—Part 2: Cracking-resistant carbon and low

alloy steels, and the use of cast irons

MSS SP 25 Standard Marking System for Valves, Fittings, Flanges and

Unions

MSS SP 44 Steel Pipeline Flanges

MSS SP 75 Specification for High Test Wrought Butt Welding Fittings

The CONTRACTOR shall have readily available for use, at the request of the COMPANY

latest editions of all the Codes, Specifications and Standards necessary for the

execution of the work at the work site.

3.
Definition of Terms

COMPANY PT.Pertamina Hulu Energi ONWJ .

CONTRACTOR The party that carries out all or part of the design, engineering,

procurement, construction, commissioning or management of a

project. The COMPANY may undertake all or part of the duties of

the CONTRACTOR.

VENDOR The party that manufacturers or supplies equipment and/or

services to perform the duties specified by the CONTRACTOR.

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Specification for Pipeline Flanges and Fittings

4.
Abbreviations

CEIIW Carbon equivalent-International Institute of Welding

CTOD Crack tip opening displacement

HIC Hydrogen-induced cracking

MT Magnetic particle testing

NDT Non-destructive testing

PWHT Post weld heat treatment

SSC Sulfide stress-cracking

UT Ultrasonic testing

5.
General Requirement

The purchase order will indicate:

•
Size, pressure rating, and steel grade

•
minimum wall thickness and bore size for the matching pipe

•
other identification (e.g non-sour service or sour-service conditions, flange facing for

flanges)

If applicable, the purchase order will specify the following additional information:

•
minimum and maximum design temperatures

•
special dimensional requirements

•
requirements for supplementary inspection and testing

•
pipeline-design standard or design factors (e.g. for anchor and swivel flanges)

•
pipeline operating conditions

•
mechanical property requirements at the maximum design temperature

•
requirements for gauging and measurements of dimensions (required for fittings)

•
requirements for proof, burst, or hydrostatic testing

•
coating or painting requirements

•
hold-points for witness and approval

•
marking requirements if different from this specification

•
packaging and shipping instructions

•
third-party inspection

•
requirements for format and additional content of the inspection document

•
whether testing of welding procedures, welders, or welding operators specific to the

order is required

•
whether approval of the MPS is to be by review of previous production data or by testing

•
Surface hardness testing (see Section 8.2.4)

•
HIC testing (for sour-service)

•
SSC testing (for sour-service)

•
CTOD testing for fittings (for sour-service)

•
UT for fittings body (see Section 8.3.3.3)

6.
Design

6.1
Flanges

Flanges shall be forged, weldneck and either raised face or ring joint type as indicated in

purchase requirement. Flange face dimensions shall as per ASME B1 6.5 for sizes up to

and including DN 600 (NPS 24), except DN 550 (NPS 22) as per MSS-SP-44, and as per

ASME B1 6.47 Series A for DN 650 (NPS 26) and larger sizes. Flange face finish shall be

serrated or smooth as indicated in the purchase requirement. Smooth finish when

specified shall be in a roughness Ra 3.2 - 6.3 micrometers (1 25 - 250 microinch) AARH.

The surface finish of RTJ groove shall not exceed 1 .6 micrometers (63 microinch)

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Specification for Pipeline Flanges and Fittings

roughness. Imperfections in the flange facing finish shall not exceed the dimensions

shown in the Table 3 of ANSI B1 6.5 (Table II-3 of Mandatory Appendix II). A distance of

at least four times the maximum radial projection shall separate adjacent imperfections.

Swivel-ring flanges shall be designed and calculations shall be made in accordance with

ASME Section VIII Division 1 . A fully dimensioned drawing shall be submitted to

COMPANY for approval prior to manufacturing. Swivel-ring flanges should have RTJ -

groove-sealing faces.

The R or RX series ring gaskets shall fully comply with ASME B1 6.20. Gasket material

shall be as a minimum of AISI 31 6 stainless steel, octagonal type and the hardness shall

be less than the mating flange faces.

Blind flanges shall be designed to match the dimensions of the intended flanges.

Anchor flanges shall be designed in accordance with ASME B31 .3 or equivalent.

Stud bolts and nuts shall be in accordance applicable standards. All bolting and nuts

exposed to the sea water environment shall be coated with PTFE or shall be plated with

zinc as per ASTM B633 Type II SC3. If required, bolts length shall be sufficient to allow

use of hydraulic tensioners (Hydratight or equivalent), nuts shall be drilled on each face

for the use of a “tommy bar” for tightening with the hydraulic tensioners.

6.2
Fittings

Fittings mean elbow (if applicable), cap, tee, extruded header, reducer, transition

section.

Dimensions of fittings shall be in accordance with MSS SP-75 and, for nominal sizes

less than DN 400 (NPS 1 6), ASME B1 6.9.

Fittings body shall be forged, seamless and designed to comply with ASME B31 .8.

The capability of the fitting to withstand internal pressure shall equal or exceed that of

the matching pipe. The verification of the capability shall be made by calculation and/or

proof testing and shall be available for review and approval by COMPANY. If the SMYS

of the fitting material is less than that of the matching pipe, the minimum thickness of

the fitting end shall be increased such that the product of its thickness times its SMYS

shall at least equal the product of the specified wall thickness and the SMYS of the

matching pipe, in accordance with MSS SP-75.

The internal diameter of fittings body shall be no smaller than that of the matching pipe

to assure that the fittings do not interfere with the passage cleaning pigs.

The design and welding for the attachment of guide bars of barred tees shall be in

accordance with Figure 1 . VENDOR shall submit fabrication drawings of barred tees for

COMPANY approval.

6.3
Welding end

Welding end shall conform to either ASME B31 .4 Figure 434.8.6(a) or ASME B31 .8

Figures I-4/I-5. In the case of a heavy-wall thickness, the outside profile may be tapered

at 30° and then to 45° as illustrated in ASME B1 6.25 Figure 1 . The purchase order will

specify the outside diameter, wall thickness, and whether cladding has been applied.

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Specification for Pipeline Flanges and Fittings

7.
Manufacturing

7.1
Manufacturing procedure

Steel shall be fully killed and made to fine grain practice. All forming operations shall be

performed in accordance with the MPS (manufacturing procedure specification).

Materials shall be heat treated by normalizing, quenching, and tempering or stress

relieving. Heat treatment shall be performed in accordance with ASTM A860 for fittings

and ASTM A694 for flanges. If quench and tempering is used as a heat treatment, the

minimum tempering temperature shall be 650°C. A record shall be maintained of each

heat treatment and shall be included in the inspection document.

Flanges shall not be machined from bars.

Fittings ends shall be made from fusion-welded with filler metal or seamless tubular

products. High-frequency welded (HFW) and helical-seam submerged-arc welding

(SAWH) pipes shall not be used. All welds shall have complete penetration. Fittings

body shall be made from seamless tubular products and shall not contain girth welds.

Welding and repair welding of fittings shall be performed in accordance with

procedures qualified in accordance with ASME IX or equivalent. Welders and welding

operators shall be qualified in accordance with ASME IX or equivalent.

7.2
Dimensions and tolerances

Dimensions and tolerances shall be in accordance with the applicable standard.

7.3
Workmanship and Visual Inspection

Product shall be free from dents with sharp bottom gouges or dents exceeding 3 mm in

depth. The depth of a gouge or dent shall be measured as the maximum distance

between the contour of the gouge or dent and the normal contour.

Surfaces shall be finished so that surface imperfections can be detected by visual

inspection. Hard spots, laps, flats, tears, pulls and similar defects are not permitted.

Weld repairs to the body of product are not permitted.

All dressable surface defects shall be dressed out by grinding. Grinding shall be carried

out in such a way that the dressed area blends in smoothly with the contour of the

pipe. Complete removal of defects shall be verified by local visual inspection, aided if

necessary by suitable NDT methods.

8.
Testing and inspection

8.1
Chemical composition

The chemical composition of the steel used in the manufacture shall comply with the

applicable material standards. The carbon equivalent of carbon steel welding ends shall

not exceed 0.42% as calculated by the CEIIW with mass fraction of carbon not exceed

0.1 8% and sulphur not exceed 0.01 0% for non-sour service or not exceed 0,003% for

sour service. Weld ends shall be field weld able to the intended matching pipe to which

it is welded as far as possible without the need of PWHT.

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Specification for Pipeline Flanges and Fittings

A product analysis shall be made for each heat of steel and shall comply with the

applicable material standards. Rare earth metal additions are not permitted unless

approved by COMPANY in writing based on technical data presented on their

performance effect.

8.2
Mechanical testing

In general, all testing shall be carried out fully in accordance with this specification.

Manufacturer standard test protocol shall be acceptable provided it is no less stringent

than specified in this specification.

8.2.1
Tensile testing

Tensile testing and acceptance criteria shall be in accordance with ASTM A370

or equivalent.

8.2.2
Charpy V-notch impact testing

Charpy V-notch impact testing and acceptance criteria shall be in accordance

with ASTM A860 or equivalent.

In no case shall the test temperature exceed 0 °C. For pipeline with a minimum

design temperature lower than 0 °C, test temperature shall be below 1 0 °C of

design temperature for wall thickness up to and including 20mm, and below

20 °C of design temperature for wall thickness greater than 20mm.

COMPANY shall have the right to order retest if there is reason to believe that:

• The failure of a specimen to show the minimum impact value required is due

to some fault in its preparation or testing.

• The test has not provided a true indication of the notch ductility of the

material.

8.2.3
Through-thickness hardness testing

Through-thickness hardness testing shall in accordance with ASTM A370 or

equivalent. No hardness reading shall exceed 300 HV 1 0 for non-sour service and

250 HV1 0 for sour service condition.

8.2.4
Surface hardness testing

If surface hardness testing is specified by the purchase requirement in addition

to the through-thickness hardness testing, test procedures and acceptance

criteria shall be in accordance with ASTM A370 or equivalent.

Ten hardness tests shall be performed. Location of hardness tests shall be

approved by COMPANY prior to testing. Hardness testing equipment shall be

approved in advance by COMPANY. Material shall be tested while lying flat or

supported on stands. No hardness reading shall exceed 300 HV 1 0 for non-sour

service and 250 HV1 0 for sour service condition.

8.2.5
Metallographic examination

Grain-size of the specimens for through-thickness hardness testing shall be

examined, prior to hardness testing, in accordance with ASTM E1 1 2 or

equivalent. An average grain-size number shall be of 7 or finer.

8.2.6
HIC testing

If HIC testing is specified by the purchase requirement, test procedures and

acceptance criteria shall be in accordance with ISO 1 51 56-2 or equivalent.

8.2.7
SSC testing

If SSC testing is specified by the purchase requirement, test procedures and

acceptance criteria shall be in accordance with ISO 1 51 56-2 or equivalent.

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Specification for Pipeline Flanges and Fittings

8.2.8
CTOD testing

If CTOD testing is specified by the purchase requirement, test procedures and

acceptance criteria shall be in accordance with ASTM E1 290 or equivalent.

8.2.9
PWHT for fittings

If PWHT for fittings is required, additional testing may be requested to

demonstrate that the mechanical properties of the fitting are also achieved after

PWHT. Testing and inspection shall be carried out on the fitting after final heat

treatment.

8.2.1 0
Guided weld bend testing for fittings

Guided weld bend testing for fittings shall be in accordance with ASTM A370 or

equivalent.

8.3
Non Destructive Testing (NDT)

8.3.1
Procedures and personnel

All NDT shall be conducted in accordance with NDT procedures.

All personnel performing NDE shall be qualified and certified in accordance with

ASNT SNT-TC-1 A or equivalent to the appropriate level of competence. The

minimum level of competence for NDT shall be NDT level 2.

8.3.2
Radiographic testing

Weld seams shall be subjected to RT in accordance with ASTM E94 or

equivalent. Instead of radiographic examination, ultrasonic examination may be

substituted with COMPANY approval.

8.3.3
Ultrasonic testing

8.3.3.1 Base pipe for fittings

Pipe for fittings shall be volumetrically examined over the complete surface

area by UT in accordance with ISO 31 83/API 5L.

8.3.3.2 Weld-ends of flanges and fittings

A 50 mm wide band at each end shall be inspected for laminar imperfections

by UT in accordance with ASTM A435 or equivalent. This 50 mm band shall

extend from the intersection of the weld bevel and the outside diameter

back along the body material. No indications will be permitted on bevelled

ends. All indications shall be removed by cutting back or grinding and subject

to re-examination.

8.3.3.3 Fittings body

If specified by the purchase requirement, in addition to Section 8.3.4.1 , UT

shall be carried out on the finished product in accordance with ASTM A388

utilizing a 3mm flat-bottom hole reference standard for the compression

wave examination and a 60º V-notch for the shear wave examination.

a) Compression wave examination

Any indication which has signal amplitude equal to or greater than the

signal received from a 3mm flat-bottom hole shall be cause for rejection.

Multiple indications with an amplitude exceeding 50% of that from the

calibration hole, accompanied by a loss of back reflection exceeding

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Specification for Pipeline Flanges and Fittings

50% shall also be cause for rejection. Any indication that results in a

complete loss of back wall echo shall be cause for rejection.

b) Shear wave examination

Any indication which has a signal amplitude equal to or exceeding the

signal amplitude obtained from a rectangular or 60º V-notch having a

depth not greater than 3% of the nominal wall thickness shall be cause

for rejection.

8.3.4
Magnetic particle testing

8.3.4.1 Flanges and fittings body

All accessible surfaces of the finished product after heat treatment and final

machining shall be MT-inspected in accordance with ASTM A275 or

equivalent. The wet AC yoke method shall be used. The acceptance criteria

are:

• no cracks, linear defects and laminations

• the size of individual pore not exceeds 1 .5mm

• the aggregate length of cluster porosity in any continuous 250 mm

length not exceeds 6 mm

• no indications will be permitted on bevelled ends. All indications shall be

removed by cutting back or grinding and subject to re-examination.

8.3.4.2 Guide bar attachment welds of fittings

Guide bar attachment welds shall be subjected to MT in accordance with

ASTM E709 or equivalent.

8.3.5
Residual magnetism of fittings

The residual magnetic flux density at the fitting ends shall not exceed 3 mT.

8.4
Weldability Testing

The steel used to manufacture weld-ends product shall suitable to weld to the intended

matching pipe which it is welded. COMPANY may require Manufacturer to

demonstrate the weldability by test using steel furnished. Weldability test is not

required as long as Manufacturer provide (to the satisfaction of COMPANY) a

comprehensive documentation to support the weldability of the steel furnished, such as

in-house laboratory tests, weldability test results from previous orders, welding

recommendations, etc.

9.
Hydrostatic Testing

Manufacturer shall demonstrate to the satisfaction of COMPANY that the product (except

flanges) is properly designed to withstand a field hydrostatic testing. Satisfactory design can

be demonstrated by either established mathematical analysis or a bursting strength proof test.

1 0. Inspection and Notification

Whether COMPANY will inspect the product and witness the required tests shall be indicated

on the purchase order and confirmed or waived at the time product is offered for final

inspection. Notification thereof shall reach COMPANY at least two working weeks before the

testing is scheduled.

Reasonable access shall be allowed to COMPANY’s representative as well as to

representative of authorized inspection/testing agency.

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Specification for Pipeline Flanges and Fittings

COMPANY shall have the right of unrestricted access to inspect all materials and the

manufacture and fabrication of all items concerned with the work. COMPANY shall also have

free access at all times to any part of the manufacturer facilities being used for manufacturing

and storage.

1 1 . Coating

Coating shall be in accordance with PHEONWJ -F-PRC-0007 (Site Technical Practices for

Painting on Metal Surfaces). In addition to the corrosion resistant paint, entire product surface

shall be provided with suitable antifouling coating to overcome rapid growth of fouling

organisms/marine growth during the operational life of the valve.

Machined faces shall be protected with a corrosion inhibitor, which may be easily removed on

site. Precaution shall be taken to prevent the ingress of moisture and dust.

1 2. Marking

Each product shall be identified with the marking requirements in accordance with applicable

standard (e.g. MSS-SP-25, MSS-SP-75).

For flanges, in addition to the markings, the heat reference shall be die-stamped on the

external surface, using low-stress 1 0 mm rounded or interrupted dot stamps. Smaller stamps

may be required on small sized flanges due to space limitations. Identification markings shall

not be stencilled or painted on the weld preparation or the raised face or RTJ groove.

For fittings, markings shall be made with indelible paint on the inside surface or, if it is not

possible to mark on the inside surface (i.e. for smaller diameter fittings), on the outside. For

fittings of DN 1 00 (NPS 4) and larger, markings shall be executed in block capitals of minimum

height of 1 9 mm. For smaller fittings, the character height shall be appropriate. Identification

markings shall not be applied on weld bevels. For fittings designed with a lower SMYS than

the matching pipe, both the fitting designation and the intended matching pipe grade shall be

marked.

1 3. Preparation for shipment

Flange and fitting ends shall be capped to protect ends during shipment and storage. The

protective covers shall be wood, wood fiber, plastic, or metal and shall be securely attached

to the flange and fitting ends by bolting, steel straps, steel clips, or suitable friction locking

devices. Covers shall be of such design that the flanges and fittings cannot be installed

without removal of the protective cover. All packages shall be numbered. Fittings shall be

palletized for protection during shipping. Shipping of product shall be as per applicable

instructions on Purchase Order. Manufacturer shall obtain an unconditional inspection release

from COMPANY as applicable, prior to any shipment.

1 4. Documentation

Manufacturer shall provide COMPANY a Manufacturing Data Record (MDR) compliance with

the requirements of the purchase order. The document shall be written in English.

International system of units (SI) shall be adopted. The MDR content shall be as a minimum

as follows:

• purchase order scope of supply and variation to purchase order

• all approved queries and concessions

• inspection documents (e.g. official certificates of mechanical test results, records of

heat treatments, dimensional inspection reports, NDT, masses, etc.)

• list of flanges or fittings produced, identification and heat numbers

• original steel maker’ s or forger’ s certificates

• manufacturing procedure specification and qualification

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Specification for Pipeline Flanges and Fittings

Figure 1 : Guide Bar Design for Barred Tees

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