Materials System Specification

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection Piping Standards Committee Members
Nasri, Nadhir Ibrahim, Chairman Dib, Tony Georges, Vice Chairman Balhareth, Nasser Mohammad Khashab, Jaafar M. Mullen, Marshall Anson Bannai, Nabeel Saad Qahtani, Khalid Daifallah Rumaih, Abdullah Mohammad Lewis, Trevor Dossary, Mohammad Battal Holland, Brad John Teraiki, Abdullah Mohammad Kim, Steve Un Fadley, Gary Lowell Otaibi, Bander Abdulaziz Ramadan, Mousa Sadiq Phan, Howard Cong Mahmoud, Khalid Ahmed

7 August 2007

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 9 Scope............................................................. Conflicts and Deviations................................ References..................................................... Purchase Order Information........................... Design............................................................ Fabrication..................................................... Test and Inspection....................................... Marking.......................................................... Preparation and Shipment............................. 2 2 2 3 4 5 5 7 7

Previous Issue: 30 March 2005

Next Planned Update: 7 August 2012 Page 1 of 7

Primary contact: Nasri, Nadhir Ibrahim on 966-3-8734525 CopyrightSaudi Aramco 2007. All rights reserved.

Document Responsibility: Piping Issue Date: 7 August 2007 Next Planned Update: 7 August 2012

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection

Scope This Specification describes the requirements for carbon steel insulating joints and spools with bolted flanges of any standard pressure rating and pipe diameter. Insulating joints with an internally coated extension are called insulating spools. They are used for pipelines in water or wet hydrocarbon service (Liquid Hydrocarbon with free water in excess of 0.2 volume percent).

Conflicts and Deviations 2.1 Any conflicts between this standard 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. Direct all requests to deviate from this standard 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.

2.2

References Materials or equipment supplied to this specification shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Materials System Specification 02-SAMSS-011 Forged Steel Weld Neck Flanges for Low and Intermediate Temperature Service

Saudi Aramco Engineering Standards SAES-A-301 SAES-H-100 Materials Resistant to Sulfide Stress Corrosion Cracking Painting Requirements for Industrial Facilities

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Document Responsibility: Piping Issue Date: 7 August 2007 Next Planned Update: 7 August 2012

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection

SAES-H-101 SAES-H-200

Approved Protective Coating Systems Storage, Handling, and Installation of Externally Coated Pipe

Saudi Aramco Inspection Requirements Form 175-023800 3.2 Industry Codes and Standards American Society of Mechanical Engineers ASME B16.5 ASME B31.3 ASME SEC V Pipe Flanges and Flanged Fittings Process Piping Nondestructive Examination Joints/Spools and Flanges: Integral Insulating for Cathodic Protection

American Society for Testing and Materials ASTM A53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless Seamless Carbon Steel Pipe for HighTemperature Service Steel Bolting Materials Steel Nuts for Bolts

ASTM A106 ASTM A193 ASTM A194 American Petroleum Institute API SPEC 5L European Standard EN-10204/DIN 50049

Line Pipe

Inspection Documents for Delivery of Metallic Products

Purchase Order Information For each flanged insulating joint or spool, the following information shall be specified in the Purchase Order: a) b) c) Flange rating per ASME B16.5 Pipeline material (API-grade), diameter and wall thickness Hydrostatic test pressure

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Document Responsibility: Piping Issue Date: 7 August 2007 Next Planned Update: 7 August 2012

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection

d) e) 5

Length of insulating liner (if applicable) External Coating

Design 5.1 The insulating joint shall consist of a pair of standard carbon steel pipe flanges in accordance with ASME B16.5 or Saudi Aramco Materials System Specification 02-SAMSS-011, as applicable, welding neck type, raised face, assembled with ASTM A193 Grade B7 stud bolts, ASTM A194 Grade 2H nuts, steel washers, insulating washers, bolt sleeves and gasket, and provided with two butt-welded pipe pups. The pipe pups shall be API SPEC 5L, ASTM A106 or ASTM A53 of the diameter, wall thickness and material grade specified in the Purchase Order, seamless or submerged-arc welded, and beveled on both ends for butt-welding in accordance with ASME B31.3. The buttwelding ends of the flanges shall be prepared in accordance with ASME B16.5 to match the pipe bevel within 1.6 mm at the inside diameter. The pipe pups for insulating joints shall have equal length such that the finished overall length of the assembled joint is as listed below:
A S M E 150 300 700 mm 700 mm 1000 mm 1500 mm 2000 mm 2500 mm 1000 mm 1500 mm 2200 mm 2800 mm C L A S S R A T I N G 400 600 900 1500 1000 mm 1000 mm 1000 mm 1000 mm 1200 mm 1800 mm 2200 mm 3000 mm 1500 mm 2000 mm 2500 mm 3000 mm 1500 mm 2000 mm 2800 mm 3200 mm 1500 mm 2000 mm 2800 mm 3200 mm

5.2

5.3

Pipe Size (dia. in inches) up to 14 16 to 24 26 to 36 38 to 48 50 to 60

5.4 5.5

Temporary pipe caps shall be welded at each end for the pressure test. These shall be cut off and the ends rebevelled. The material of the insulating parts such as filled phenolic laminate shall be resistant to sour water and crude oil containing H2S, sulfur compounds, corrosion inhibitors, bactericides and demulsifiers, up to a temperature of 100C at the required bearing pressure. The insulating gasket and washers shall be 3 mm 0.4 mm thick. The insulating sleeves shall be 1 mm thick and manufactured to close tolerances so as to fit the annulus between stud bolts and flange bolt holes. The bolt size shall be as specified in the applicable flange specification. The parts shall be free of cracks, scratches or broken edges.

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Document Responsibility: Piping Issue Date: 7 August 2007 Next Planned Update: 7 August 2012

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection

Fabrication 6.1 Welding All welding shall be in accordance with ASME B31.3, including consumable welding materials, end preparation and fit-up, qualification of procedure and welders, preheating and heat treatment, if required, and limitations on imperfections based on B31.3 "normal service" category. The pipe to flange weld shall be a full penetration butt weld without backing ring. The inside of the weld of the spool which is to be lined, shall be ground smooth. All welding and materials shall comply with SAES-A-301 for sour service applications. 6.2 Internal Coating The bore of the long pipe part of insulating spools shall be internally coated before assembly of the joint. The coating shall be continuous, extending in the bore of the flange and on the raised face. The interior surface shall be prepared in accordance with APCS-2A and SAES-H-101. Sharp corners shall be rounded by grinding prior to blast cleaning. The coating shall be an epoxy in accordance with APCS-2A, except that no holidays are permitted and the maximum dry film thickness may be exceeded to achieve a holiday-free coating. 6.3 External Coating The exterior surfaces of the welded parts shall be coated with APCS-104 or 113 and holiday tested per SAES-H-200, Paragraph 7, before being bolted together with the coating specified in the purchase order. 6.4 Bolting The finished parts shall be bolted together with insulating sleeves around each bolt, insulating washers and steel washers on both sides and an insulating gasket with elastomeric seals on both sides. The bolts shall be torqued evenly as required to ensure a tight joint at all pressures up to the specified test pressure. The insulating parts shall provide complete electrical insulation between the adjoining metal parts. 6.5 Finish After successful completion of the hydrostatic test and all inspection, the open space between the flanges around the bolts shall be filled with a non-setting dielectric sealant.

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Document Responsibility: Piping Issue Date: 7 August 2007 Next Planned Update: 7 August 2012

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection

Test and Inspection 7.1 General The joints and spools shall be subject to inspection by Buyer's Inspector, per Saudi Aramco Form 175-023800 attached to the Purchase Order. 7.2 Radiographic Requirements All welds shall be 100% radiographed. Radiographic technique and sensitivity shall meet the requirements of the ASME SEC V. Interpretation and acceptance shall be in accordance with ASME B31.3 "normal service" category. 7.3 Hydrostatic Test A hydrostatic test shall be performed on each insulating joint or spool at the specified hydrostatic test pressure in accordance with ASME B16.5. The full test pressure shall be maintained for not less than two hours. During the test, the joint shall be in an unrestrained condition. 7.4 Dielectric Test and Megger Test Each insulating joint or spool shall be megger tested with 1000 V DC. Minimum resistance shall be 60 megohms. Resistance test shall be performed between the bolts and the flange. Each insulating joint or spool shall also be dielectric tested at 5000 V AC for 1 minute. Maximum allowable leakage is 5 milliamperes on sizes up to 28-inch nominal pipe size and 8 milliamperes on sizes 30-inch and larger nominal pipe size. 7.5 Holiday Tests Insulating spools shall undergo holiday detection of the internal coating per SAES-H-100, Paragraph 8.2.6, after completion of the hydrostatic test. No holidays are permitted. 7.6 Visual Inspection and Dimensional Check 7.6.1 Visual inspection of all parts prior to assembly of the insulating joint will be done by the Vendor. Visual inspection of the finished insulating joint is to be carried out by the Buyer's Representative. General appearance shall show good workmanship.

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Document Responsibility: Piping Issue Date: 7 August 2007 Next Planned Update: 7 August 2012

02-SAMSS-010 Flanged Insulating Joints/Spools for Cathodic Protection

7.6.2

Dimensions of the insulating joint or spool shall be checked against the Specification, Purchase Order description and/or approved Vendor Drawings. The overall length tolerance is 10 mm.

7.7

Certification All material and test certificates for the above testing and inspection shall meet EN-10204/DIN 50049 and be submitted to the Buyer prior to shipment.

Marking The following data shall be painted on the pipe ends: Vendor Identification Nominal Pipe Diameter ASME Rating Purchase Order Number Item Number

Preparation and Shipment 9.1 9.2 The joint ends shall be closed with slip-on recessed end caps. The insulating joint shall be strapped individually on skid-mounted cradles and be enclosed in a crate, in accordance with the Saudi Aramco packing specification.
Revision Summary Editorial revision to transfer of document responsibility from Cathodic Protection to Piping Standards Committee. Revised the "Next Planned Update".

7 August 2007

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