Materials System Specification

02-SAMSS-010 30 March 2005

Flanged Insulating Joints/Spools
for Cathodic Protection
Cathodic Protection Standards Committee Members
Umair, Ahmed A., Chairman
Al-Arfaj, M.A.
Al-Mahrous, H.M.
Al-Mulhem, Tariq A.
Al-Qarashi, A.M.
Al-Rasasi, G.M.
Al-Salman, A.M.
Al-Zubail, S.A.
Barnawi, I.Y.
Bukhamseen, A.A.
Catte, D.R.
Hosawi, M.A.
Khan, N.A.

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....................................... 5
8 Marking.......................................................... 7
9 Preparation and Shipment............................. 7

Previous Issue: 29 May 2002 Next Planned Update: 1 June 2007

Revised paragraphs are indicated in the right margin Page 1 of 7
Document Responsibility: Cathodic Protection 02-SAMSS-010
Issue Date: 30 March 2005 Flanged Insulating Joints/Spools
Next Planned Update: 1 June 2007 for Cathodic Protection

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-A-301 Materials Resistant to Sulfide Stress Corrosion
Cracking
SAES-H-100 Painting Requirements for Industrial Facilities
SAES-H-101 Approved Protective Coating Systems

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Document Responsibility: Cathodic Protection 02-SAMSS-010
Issue Date: 30 March 2005 Flanged Insulating Joints/Spools
Next Planned Update: 1 June 2007 for Cathodic Protection

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

Coated Pipe

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

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
c) Hydrostatic test pressure
d) Length of insulating liner (if applicable)

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Document Responsibility: Cathodic Protection 02-SAMSS-010
Issue Date: 30 March 2005 Flanged Insulating Joints/Spools
Next Planned Update: 1 June 2007 for Cathodic Protection

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.

6 Fabrication

6.1 Welding

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Document Responsibility: Cathodic Protection 02-SAMSS-010
Issue Date: 30 March 2005 Flanged Insulating Joints/Spools
Next Planned Update: 1 June 2007 for Cathodic Protection

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.

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.

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Document Responsibility: Cathodic Protection 02-SAMSS-010
Issue Date: 30 March 2005 Flanged Insulating Joints/Spools
Next Planned Update: 1 June 2007 for Cathodic Protection

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.

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.

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Document Responsibility: Cathodic Protection 02-SAMSS-010
Issue Date: 30 March 2005 Flanged Insulating Joints/Spools
Next Planned Update: 1 June 2007 for Cathodic Protection

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
29 May 2002 Revised the "Next Planned Update". Reaffirmed the contents of the document, and
reissued with no other changes.
30 March 2005 Editorial revision to replace NACE MR0175 with newly approved SAES-A-301.

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