02-SAMSS-010

Previous Issue: 8 August 2009 Next Planned Update: 7 August 2012

Revised paragraphs are indicated in the right margin Page 1 of 7

Primary contact: Nasri, Nadhir Ibrahim on 966-3-8809603

Copyright©Saudi Aramco 2011. All rights reserved.

Materials System Specification

02-SAMSS-010 9 August 2011

Flanged Insulating Joints/Spools for Cathodic Protection

Document Responsibility: Piping Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2

2 Conflicts and Deviations................................. 2

3 References..................................................... 2

4 Purchase Order Information........................... 3

5 Design............................................................ 4

6 Fabrication..................................................... 5

7 Test and Inspection........................................ 6

8 Marking.......................................................... 7

9 Preparation and Shipment............................. 7

Document Responsibility: Piping Standards Committee 02-SAMSS-010

Issue Date: 9 August 2011

Next Planned Update: 7 August 2012 Flanged Insulating Joints/Spools for Cathodic Protection

Page 2 of 7

1 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).

2 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.

2.2 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.

3 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-H-100 Painting Requirements for Industrial Facilities

SAES-H-101 Approved Protective Coating Systems

SAES-H-200 Storage, Handling, and Installation of Externally

Coated Pipe

http://standards/docs/SAEP/PDF/SAEP-302.pdf

http://standards/docs/SAEP/PDF/SAEP-302.pdf

http://standards/docs/SAMSS/PDF/02-SAMSS-011.pdf

http://standards/docs/SAES/PDF/SAES-H-100.pdf






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Saudi Aramco Inspection Requirements

Form 175-023800 Joints/Spools and Flanges: Integral Insulating for

Cathodic Protection

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B31.3 Process Piping

ASME SEC V Nondestructive Examination

American Society for Testing and Materials

ASTM A53 Standard Specification for Pipe, Steel, Black and

Hot-Dipped, Zinc-Coated, Welded and

Seamless

ASTM A106 Seamless Carbon Steel Pipe for High-

Temperature Service

ASTM A193 Steel Bolting Materials

ASTM A194 Steel Nuts for Bolts

American Petroleum Institute

API SPEC 5L Line Pipe

European Standard

EN-10204/DIN 50049 Inspection Documents for Delivery of Metallic

Products

National Association of Corrosion Engineers / International Standardization

Organization

NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries-

Materials for use in H2S-Containing

Environments in Oil and Gas Production

4 Purchase Order Information

For each flanged insulating joint or spool, the following information shall be specified

in the Purchase Order:

a) Flange rating per ASME B16.5

b) Pipeline material (API-grade), diameter and wall thickness

http://standards/docs/Inspection_Requirements/PDF/175-023800.pdf

http://linkmanager.ihs.com/LinkManagerService/LKMLink.aspx?LinkRefName=NACE+MR0175%2fISO+15156&RefGroupId=30





Page 4 of 7

c) Hydrostatic test pressure

d) Length of insulating liner (if applicable)

e) External Coating

5 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.

5.2 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.

5.3 The pipe pups for insulating joints shall have equal length such that the finished

overall length of the assembled joint is as listed below:

Pipe Size A S M E C L A S S R A T I N G (dia. in inches) 150 300 400 600 900 1500

up to 14 700 mm 700 mm 1000 mm 1000 mm 1000 mm 1000 mm

16 to 24 1000 mm 1000 mm 1200 mm 1500 mm 1500 mm 1500 mm

26 to 36 1500 mm 1500 mm 1800 mm 2000 mm 2000 mm 2000 mm

38 to 48 2000 mm 2200 mm 2200 mm 2500 mm 2800 mm 2800 mm

50 to 60 2500 mm 2800 mm 3000 mm 3000 mm 3200 mm 3200 mm

5.4 Temporary pipe caps shall be welded at each end for the pressure test. These

shall be cut off and the ends rebevelled.

5.5 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 100°C

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.

http://standards/docs/SAMSS/PDF/02-SAMSS-011.pdf




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6 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 NACE MR0175/ISO 15156 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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7 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.

http://standards/docs/Inspection_Requirements/PDF/175-023800.pdf





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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.

8 Marking

The following data shall be painted on the pipe ends:

- Vendor Identification

- Nominal Pipe Diameter

- ASME Rating

- Purchase Order Number

- Item Number

9 Preparation And Shipment

9.1 The joint ends shall be closed with slip-on recessed end caps.

9.2 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 7 August 2007 Editorial revision to transfer of document responsibility from Cathodic Protection to Piping

Standards Committee. Revised the "Next Planned Update". 8 August 2009 Editorial revision to replace cancelled SAES-A-301 with NACE MR0175/ISO 15156. 9 August 2011 Editorial revision to remove the committee members' list.

