Materials System Specification

02-SAMSS-005 Butt Welding Pipe Fittings Materials and Corrosion Control Standards Committee Members
Anezi, Mohammed Ali, Chairman Rumaih, Abdullah Mohammad, Vice Chairman Abdul Hadi, Abdul Latif Ibrahim Bannai, Nabeel Saad Buraiki, Iyad Abdulrazzak Burgess, Brian Wayne Cruz, Czar Ivan Tecson Kermad, Abdelhak Lobley, Graham Russel Mehdi, Mauyed Sahib Moore, Mark Andrew Mugbel, Wajdi Mohammad Nasri, Nadhir Ibrahim Niemeyer, Dennis Charles Nuaim, Tareq Abdulaziz Omari, Ahmad Saleh Rao, Sanyasi Tems, Robin Douglas

3 July 2007

Saudi Aramco DeskTop Standards

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

Previous Issue: 5 April 2006

Next Planned Update: 1 December 2009 Page 1 of 13

Primary contact: Anezi, Mohammed Ali on 966-3-8746122 CopyrightSaudi Aramco 2007. All rights reserved.

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

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

1.2

1.3

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. 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.

2.2

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 Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 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 3.2 Industry Codes and Standards American Society of Mechanical Engineers ASME B16.9 ASME B16.25 ASME B16.28 ASME B16.49 Factory-made Wrought Steel Butt Welding Fittings Butt Welding Ends Wrought Steel Butt Welding Short Radius Elbows and Returns Factory-made Wrought Steel Buttwelding Induction Bends for Transportation and Distribution Systems Process Piping Specification for Welding Rods, Electrodes, and Filler Metals Rules for Construction of Pressure Vessels Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators Butt Welding Pipe Fittings

ASME B31.3 ASME SEC II ASME SEC VIII ASME SEC IX

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 Standard Test Methods and Definitions for Mechanical Testing of Steel Products Standard Specification for High-Strength ButtWelding Fittings of Wrought High-Strength, Low-Alloy Steel Standard Test Method for Leeb Hardness Testing of Steel Products

ASTM A370 ASTM A860/A860M

ASTM A956

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

ASTM A960 ASTM E165 ASTM E92 American Welding Society AWS A5.01 AWS A5.XX Compressed Gas Association CGA G6.2 CGA G11.1

Standard Specification for Common Requirements for Wrought Steel Piping Fittings Standard Test Method for Liquid Penetrant Examination Test Method for Vickers Hardness of Metallic Materials

Filler Metal Procurement Guidelines Specifications for Welding Filler Metals (Series of Specifications)

Specification for Carbon Dioxide Specification for Argon

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

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

Design 5.1 Pressure Rating

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

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

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

ASME shape reducers not listed in ASME B16.9 or MSS SP-75 shall be 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 SP75. 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.

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 Issue Date: 3 July 2007 Next Planned Update: 1 December 2009 Note:

02-SAMSS-005 Butt Welding Pipe Fittings

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. The carbon equivalent shall not exceed 0.42% when calculated according to the formula: CE (IIW) = C + Mn (Cr + Mo + V) ( Ni + Cu) + + 6 5 15 (1)

6.2.3

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). Chemical composition shall be in accordance with the requirements of ASTM A860/A860M, Paragraph 7.

6.3.2 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. For Sour service, the following additional requirements are applicable for welded fittings fabricated from plate or strip: 6.5.1 6.5.2 The steel shall be vacuum degassed. 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.

6.5

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

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. All Welding Procedure Specifications (WPS's) and Procedure Qualification Records (PQR's) shall be written in English and conform to the applicable Code.

7.1.2

7.2

Processes 7.2.1 The following processes are approved for use: 7.2.2 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.

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. Properly conditioned low-hydrogen electrodes shall be used for all fittings when the wall thickness exceeds 13 mm. 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. Active Submerged Arc Welding fluxes shall not be used.

7.3.2 7.3.3

7.3.4

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

7.3.5 7.4

Shielding gases shall conform to the appropriate Compressed Gas Association (CGA) specification(s).

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) b) c) weld metal heat affected zone on each side of the weld and 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 7.5.2 Cracks shall be repaired only if approved by the Saudi Aramco inspector. Unsuccessful weld repairs after the second attempt shall be completely cut out and replaced.

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
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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

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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. 8.2 Seamless Grade WPB fittings for which the final forming operation is completed at a temperature above 620C and below 980C need not be subsequently heat treated provided they are cooled in still air. Hot formed high strength fittings shall be cooled below the lower critical temperature prior to heat treatment.

8.3

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 620C and 100% of seamless fittings forged at 620C or lower. Hardness tests shall be conducted on

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

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 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. 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. 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.
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9.5.3

9.5.3.2

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

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 requirements after re-normalizing may be accepted. Fittings that fail a second time shall be permanently rejected.

9.5.4 9.6

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

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. For welded fittings, testing shall be performed on the base metal, heataffected zone, and the weld metal. The weld metal and heat-affected zone impact test specimens shall be transverse to the weld axis. Impact test procedures and apparatus shall conform to the applicable paragraphs of ASTM A370. 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.

9.6.2

9.6.3 9.6.4

10

Product Marking, Coating, Packing and Documentation 10.1 10.2 10.3 Fittings per ASTM A234/A234M WPB shall be marked in accordance with ASME B16.9, paragraph 4. 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. 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. The welding ends shall be coated with an aluminum-flake weldable primer ("Deoxaluminite" or "Bloxide" or other brand approved by Saudi Aramco
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10.4

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 December 2009

02-SAMSS-005 Butt Welding Pipe Fittings

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 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.
Revision Summary Editorial revision to affirm the contents, update the referenced paragraphs and committee list, and changed the "Next Planned Update." Minor revision. Editorial revision to delete Section 11.

28 February 2005 5 April 2006 3 July 2007

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