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PetroChina International Jabung Ltd.

Specification
Flanges

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PetroChina International Jabung Ltd. Specification
Flanges

Table of Contents

Section Title Page

1.0 SCOPE ............................................................................................................ 4


2.0 REFERENCES ................................................................................................ 4
2.1 Project Specification ..................................................................................... 4
2.2 Code and Standard........................................................................................ 4
3.0 CONFLICT ...................................................................................................... 5
4.0 DESIGN........................................................................................................... 5
5.0 MATERIAL ...................................................................................................... 5
5.1 Carbon Steel Flange...................................................................................... 6
5.1.1 Base Material.................................................................................................. 6
5.2 Low Temperature Carbon Steel Flange....................................................... 6
5.2.1 Base Material.................................................................................................. 6
5.3 Stainless Steel Flange .................................................................................. 6
5.3.1 Base Material.................................................................................................. 6
5.4 Duplex Stainless Steel Flange...................................................................... 7
5.4.1 Base Material.................................................................................................. 7
5.4.2 Special requirement for Duplex Flanges ..................................................... 7
5.5 Overlay Welded Flange ................................................................................. 8
5.5.1 Base Material.................................................................................................. 8
5.5.2 Special requirement for Overlay Flanges .................................................... 8
6.0 NOTES ............................................................................................................ 9
7.0 MANUFACTURING ........................................................................................ 9
8.0 SHOP INSPECTION AND TEST .................................................................. 10
9.0 MARKING ..................................................................................................... 10
10.0 STORAGE AND HANDLING ........................................................................ 10

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PetroChina International Jabung Ltd. Specification
Flanges

1.0 SCOPE
This Specification covers the minimum requirements for the material, design
manufacture and certification of flanges use on inline piping for plant piping and
pipeline for Petrochina International Jabung Ltd. (PCI) Betara Complex Development
phase 4 (BCD4) Project.

2.0 REFERENCES
The following applicable section of the latest edition of the code and standards,
including addenda and referenced documents, project’s specification shall form an
integral part of this specification.
Where the requirement of the subject is defined by two or more references, the more
stringent reference shall govern.

2.1 Project Specification


• BCD4-000-44-SPC-4-007-00 Specification for Piping Material Class
Including Commodity Code.
• BCD4-000-44-SPC-4-015-00 Specification for Piping Material Code
And Stamping.
• BCD4-000-44-SPC-4-016-00 Specification for Piping Material Color Coding

2.2 Code and Standard


The following code and standard shall be applied unless otherwise specified.
ASME Code and standard:
• B31.3 Process Piping
• B31.4 Pipeline Transportation System for Hydrocarbon and Other
Liquids
• B31.8 Gas Transportation and Distribution Piping System
ASME Code and standard:
• B16.5 Pipe Flanges and Flanged Fittings.
• B1.20.1 Pipe Thread, General Purpose (Inch).
• B16.25 Butt-welding Ends.
• B16.34 Steel Valves, Flanged, Threaded and Butt-Welding.
• B16.47 Series B Large Diameter Carbon Steel Flanges.
• B36.10M Welded and Seamless Wrought Steel Pipe.
• B36.19M Stainless Steel Pipe.
• B46.1 Surface Texture
ASTM Standard :
• A105 Forgings, Carbon Steel, for Piping Components
• A182 Forged or Rolled Alloy-Steel Pipe Flanges, Forged
Fitting and Valves and Parts for High-Temperature Service

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PetroChina International Jabung Ltd. Specification
Flanges

• A350 Forging, Carbon and Low-Alloy Steel Requiring Notch


Toughness Testing for Piping Components Plate for spectacle
blind or Blind and Spacer
• A240 Heat-Resisting chromium and Chromium-Nickel
Stainless Steel Plate, sheet, and strip for Fusion Welded
unfired Pressure Vessel
• A516 Carbon Steel Plates for Pressure Vessels for Moderate
And Lower Temperature Service
• A694 Carbon and Alloy Steel Forging for Pipe Flanges,
Valves and Parts for High Pressure Transmission Service
MSS Standard :
• SP-25 Standard Marking System for Valves, Fittings, Flanges
And Unions
API Standard :
• API 590 Steel Line Blank for Spectacle Blind

3.0 CONFLICT
If any conflict exists between this specification and other Technical Requirements and
the applicable codes and standards, it shall be submitted in writing to PCI for
resolution.

4.0 DESIGN
Piping components shall as minimum, be designed, manufactured, inspected and
tested in accordance with the ASME B31.3 code, unless otherwise specified in the
individual service class.

5.0 MATERIAL
Material specifications shall conform to the requirements of applicable code and
standard.

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PetroChina International Jabung Ltd. Specification
Flanges

5.1 Carbon Steel Flange

5.1.1 Base Material


The base material shall be in accordance with ASTM A105 and ASTM 694-F52.
The chemical composition (in %) of steel shall conform to the requirement
prescribed below, the percentages indicated are maximum unless indicated :

Chemical ASTM A105 ASTM A694-F52


Carbon (C ) 0.35 0.20
Manganese (Mn) 0.60 – 1.05 0.90 – 1.60
Phosporus (P) 0.035 0.035
Sulphur (S) 0.04 0.025
Silicon (Si) 0.10 – 0.35 0.10 – 0.5
Copper (Cu) 0.40 -
Nickel (Ni) 0.40 -
Chromium (Cr) 0.30 -
Molybdenum (Mo) 0.12 -
The maximum carbon equivalent shall be 0.43.

5.2 Low Temperature Carbon Steel Flange

5.2.1 Base Material


The base material shall be in accordance with ASTM A350 Grade LF2.
The chemical composition (in %) of steel shall conform to the requirement
prescribed below, the percentages indicated are maximum unless indicated:

Chemical ASTM A350-LF2

Carbon (C ) 0.35
Manganese (Mn) 0.60 – 1.35
Phosporus (P) 0.035
Sulphur (S) 0.04
Silicon (Si) 0.15 – 0.35
Nickel (Ni) 0.40
Chromium (Cr) 0.30
Copper 0.40
Molybdenum (Mo) 0.12

The maximum carbon equivalent shall be 0.43.

5.3 Stainless Steel Flange

5.3.1 Base Material


The base material shall be in accordance with ASTM A182 Grade F304L and A182
Grade F316L
The chemical composition (in %) of steel shall conform to the requirement
prescribed below, the percentages indicated are maximum unless indicated :

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PetroChina International Jabung Ltd. Specification
Flanges

ASTM A182
F304L F316L
Chemical
Carbon (C ) 0.035 0.035
Manganese (Mn) 2.00 2.00
Phosporus (P) 0.045 0.045
Sulphur (S) 0.03 0.03
Silicon (Si) 1.00 1.00
Chromium (Cr) 18 – 20 16 – 18
Nickel (Ni) 8 – 13 10 – 15
Molybdenum (Mo) - 2–3
Nitrogen (N) 0.10 0.10

5.4 Duplex Stainless Steel Flanges

5.4.1 Base Material


The base material shall be in accordance with ASTM A182 Grade F51. The
chemical composition (in %) of steel shall conform to the requirement as follows,
the percentages indicated are maximum unless indicated :

Chemical A182-F51

Carbon (C ) 0.030
Manganese (Mn) 2.00
Phosporus (P) 0.030
Sulphur (S) 0.020
Silicon (Si) 1.00
Chromium (Cr) 21– 23
Nickel (Ni) 4.5 – 6.5
Molybdenum (Mo) 2.5 – 3.5
Nitrogen (N) 0.14 (min)

5.4.2 Special requirement for Duplex Flanges


(1) The forging shall be solution annealed followed by water quenching.
(2) The hardness shall be less than 28 HRC (or alternatively 271 HB or 290
HV10) for the base material, HAZ and the weld metal.
(3) Charpy V-notch testing according to ASTM A370 at – 46 OC is required for
the thickness > 6 mm (thickness at the weld neck). The minimum absorbed
energy shall satisfy 45 J average and 35 J single. Reduction factor for
subsize specimens shall be:
7.5 mm – 5/6 and 5 mm –2/3.
(4) The micrographic examination shall be carried out at the same are as
location of specimens for mechanical. The area shall be minimum 10 x 10
mm. The ferrite content shall be determined according to ASTM E 562 or

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PetroChina International Jabung Ltd. Specification
Flanges

equivalent and shall be within 35% to 55%. The microstructure, as


examined at 400X magnification on a suitably etched specimen, shall be
free from intermetallic phases and precipitates.
(5) Impact test, tensile test, hardness test and microstructure examination shall
be carried out for each heat and heat treatment load. A test lot shall not
exceed 2000 kg for forgings with as forged weight < 50 kg, and 5000 kg for
forgings with as forged weight > 50 kg.
(6) Samples for production testing shall realistically reflect the properties in
the actual component.
(7) Dye penetrant testing shall apply 10% of forging above from 2 NPS. The
testing shall be carried out after final machining. Non machined surfaces
shall be pickled prior to the testing. The acceptance criteria shall be ASME
VIII, Division 1, Appendix 8.

5.5 Overlay Welded Flanges

5.5.1 Base Material


The base material shall be in accordance with ASTM A105, overlay layer shall be in
accordance with ASTM A240-316L. The chemical composition (in %) of steel shall
conform to the requirement as follows, the percentages indicated are maximum
unless indicated :
Chemical A105 A240-316L

Carbon (C ) 0.35 0.03


Manganese (Mn) 0.60 - 1.05 2.00
Phosporus (P) 0.035 0.045
Sulphur (S) 0.040 0.03
Silicon (Si) 0.10 – 0.35 0.75
Copper 0.40 -
Nickel (Ni) 0.40 10 – 14
Chromium (Cr) 0.30 16 – 18
Molybdenum (Mo) 0.12 2–3

The maximum carbon equivalent shall be 0.43.

5.5.2 Special requirement for Overlay Flanges


(1) Flange shall be A105 base material with minimum 2.5 mm A240-316L SS
welded overlay. Vendor shall verify dimension so that finish dimension such
as raised face diameter shall conform to ASME B16.5 or B16.47-B
(2) Weld overlay shall be a minimum of two passes. Weld overlay shall be
undertaken in accordance with an approved WPS. Weld overlay shall be
100% DPI.
(3) Supplier shall demonstrate mechanical properties of the carbon steel forging
following weld overlay.
(4) Chemical composition of weld overlay shall meet the requirements of UNS
S31603 0.5 mm below the surface.

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PetroChina International Jabung Ltd. Specification
Flanges

6.0 NOTES
(1) Material Certificate
Material certificate shall be supplied for all materials; Carbon, Alloy, Stainless
Steel and others.
The certificate shall include chemical analysis, Mechanical Properties, heat
treatment and other test required per the applicable material standard as well
as calibration record of equipment used.
(2) Material Description
Material description shown in Piping Material Class or other material lists
generally are simplified description, and for full description shall refer to
Commodity Code list of Doc. No. BCD4-000-44-SPC-4-007-00 ”Specification
for Piping Material Class Including Commodity Code”.
(3) Flange for non metallic piping and for mating to cast iron elements or mating to
nozzle equipment with flat face surface shall be flat faced and use with full face
gaskets.
(4) ASME Class 150 through 1500 flanges shall be raised face and shall be in
accordance with the standard specified in paragraph 6 item (1) and (2).
(5) Unit to be used for flange’s size shall be inch, other dimensions shall be
converted to millimeter (mm) when Vendor submits drawing, by multiplying with
the following factor: 1 inch = 25.4 millimeter

7.0 MANUFACTURING
(1) Outside diameters and wall thicknesses on mating pipes shall be in
conformance with ASME B36.10M or B36.19M, either one depending on the
schedule or material type. The outside diameter not specified in the standard
shall be corresponding to the nominal pipe size.
(2) Dimensions, pressure rating bolting and facing of all flanges shall be in
accordance with the following standard:
• NPS 24” and smaller: ASME B16.5
• NPS 26” and larger: ASME B16.47B.
(3) Dimensional tolerances on flanges shall be within the limit specified in
applicable ASME standard.
(4) Threaded ends shall have NPT internal taper pipe thread conforming to ASME
B1.20.1.
(5) Galvanized flanges shall be coated with zinc by hot-dip process in
conformance with ASTM A153.
(6) Beveled ends shall conform to details shown on Figure 2a for thickness 22
millimeters and smaller, and Figure 3a for thickness greater than 22 millimeters
in ASME B16.25.
(7) The flange facing shall be serrated finished and generated either concentrically
or as a continuous spiral groove by a round nosed tool, with a roughness
shown in the following table that defines the acceptable ranges of contact
surface finishes for each gasket. The surface finishes are specified AARH
(Arithmetical Average Roughness Height).

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PetroChina International Jabung Ltd. Specification
Flanges

Allowable Allowable
Gasket Type Minimum Maximum

• Sheet Gasket (where allowed) 125 250


• Spiral wound 125 250
Note: All dimensions above are in micro-inches.
(8) No circumferential or longitudinal weld is permitted.
(9) Weld Neck flange shall be used for size NPS 2” and larger in all services and
for size NPS 1-1/2” and smaller use Socket Weld type, except for the
following;
• For Instrument Air, small bore piping (NPS 2” and smaller) use galvanized
threaded flanges, for NPS 3” and larger use Weld Neck flanges.

8.0 SHOP INSPECTION AND TEST


(1) Shop inspection and test shall be carried out in conformance with the
requirements of applicable ASME and ASTM standard.
(2) PCI, Contractor and their designated inspection agency have the right to inspect
and witness test at Vendor’s premises to ensure confirming with the
requirements in accordance with the approved Shop Inspection and Test Plan.
(3) Alloy elements check (PMI examination) by metascope or other equipment shall
be required for Alloy flanges.
(4) ASTM A350–LF2 flanges shall be subjected to impact test at -46oC in
conformance with ASTM standard.

9.0 MARKING
(1) Each flange shall be legibly and conspicuously marked in conformance with the
requirements of applicable ASME / ASTM standard, and MSS Standard.
Marking on flanges in size NPS 26” and larger shall be in conformance with
MSS SP-25.
(2) Piping commodity code shall be marked on each flange in conformance with
Doc. No. BCD4-000-44-SPC-4-015-00 “Specification for Piping Material Code
and Stamping”.
(3) Color Coding shall be provided on each flange in conformance with Doc. No.
BCD4-000-44-SPC-4-016-00 “Specification for Piping Material Color Coding”.
(4) Paint or ink for color coding of stainless steel flanges shall not contain any
harmful metal or metal salts, such as zinc, lead or copper which causes
corrosive attack on heating. Chloride shall not also be contained.
(5) Marking shall be stamped by low stress method.

10.0 STORAGE AND HANDLING


The followings are minimum requirement for protection of flange materials. The flange
shall be prepared in such manner as to provide suitable protection during
transportation and storage, and the requirement for protection shall not be limited by
the followings.

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PetroChina International Jabung Ltd. Specification
Flanges

(1) Flanges shall be protected from rust, corrosion, and mechanical damage during
transportation, shipment, and storage.
(2) Flanges shall be dry, clean, and free from moisture, dirt, and loose foreign
materials of any kind.
(3) Exterior surface on each flange shall be coated with rust preventive except for
galvanized flanges.
(4) Rust preventive on Carbon Steel flange’s face shall be of grease type.
(5) Rust preventive on machined surfaces to be welded shall be easily removable
with a petroleum solvent, or not harmful to welding.
(6) Each end of flange shall be protected with the following materials:
Threaded end : Plastic Plug
Socked Welding end : Vendor’s Recommendation
Slip-on end : - ditto -
Beveled end : Wood, metal or plastic cover
Flange face : - ditto -
(7) End protectors to be used on flange face shall not be smaller than the outside
diameter of the flange face.
(8) Steel protectors to be used on galvanized flanges shall be galvanized
(9) End protectors to be used on the beveled end shall be securely and tightly
attached with belt or wire.
(10) Packing and securing shall be designed to offer adequate protection against
method of transport (inland and overland) until delivery at job site and storage
area. Packing shall refer to Section 4.8 of BCD3-000-50-PCD-4-007-00 Rev 0
“Packing and Marking Procedure”.
(11) All flanges shall not be laid direct to the ground. The wooden base is required,
with sufficient width and length to prevent direct contact flanges to the ground,
and to store flange in the warehouse. The storage classification and instruction
shall refer to BCD3-000-60-PCD-4-018-00 Rev 0 “Procedure Field Material
Handling for Warehouse”
(12) Duplex or Stainless Steel flanges shall be stored separately from other steel
flanges and steel materials to avoid receiving rust. Protective plastic, wood, or
carpet strips can be used to prevent contact between those steel and to protect
from rainwater.
(13) Care should be taken to prevent damage to the overlaid surface flange,
especially when using clamps and hooks.

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