Page12 of 28 Specification for Subsea Flange & Fitting

5 DESIGN
5.1 Design Data
Design details and operating conditions for the flanges and fittings are given in the relevant Data Sheets.
Flanges and fittings shall meet the requirements of the design data and shall be compatible for welding
to linepipe. Linepipe shall be supplied in accordance with the specifications.
SUPPLIER shall submit to EPC CONTRACTOR / COMPANY approval details, calculations,
manufacturing drawings and manufacturing procedures covering each flange or fitting to be supplied.
5.2 Flanges
Unless otherwise specified, flanges shall be ring type joint (RTJ ) with octagonal ring metal gaskets and
designed according to ASME VIII, ASME 816.5 and MSS-SP-44.
For proprietary design and non-standard flanges, including swivel ring flanges, SUPPLIER shall submit
dimensional details and calculations to support the design, which shall meet the requirements of ASME
VIII and ASME 816.5 and MSS-SP-44.
The minimum wail thickness of the weld neck shall not be less than that of the matching linepipe. The
maximum wall thickness at the weld neck shall be such that the slope on the outer face of the weld is
not greater than 1:4.
5.3 Bolts, Nuts and Gaskets
Bolts, nuts and gaskets shall be designed to meet the criteria of ASME 816.5 and this Specification.
5.4 Fittings
Fittings, including elbows, wyes and tees, shall be forged, forged and welded or hot formed from
seamless or welded tubular products and designed according to ASME 831 4, ASME 831.8, ASME
816.9 and MSS-SP-75.
The minimum wall thickness at the welding ends of the fittings shall be as specified in Section 6.2.
Unless otherwise specified, tees shall be barred to allow the passage of pigs through the main line.
Pigging guide bars shall be according to Figure 6-1 (All dimension in mm and Minimum thickness of
Guide Bars=12.5mm).
1
Page13 of 28 Specification for Subsea Flange & Fitting

The bars shall be welded parallel to the run-pipe and shall conform to the internal surface of the run-
pipe when the branch connection is equal to or greater than NPS16.
When required, pup pieces shall be welded to the inlet and outlet connections of the fittings Material for
pup pieces will be free-issued by PURCHASER as indicated on the Data Sheets.


Page14 of 28 Specification for Subsea Flange & Fitting


Figure 5-4 Pigging Guide Bar for Tees
5.5 Fabrication Drawings and Design Calculations
SUPPLIER shall prepare and submit for EPC CONTRACTOR / COMPANY approval fabrication
drawings and design calculations (where appropriate) for each type-of flange or fitting to be supplied.
The fabrication drawing shall show all dimensions, tolerances and material specifications. Design
calculations shall show the design to be adequate in accordance with the relevant design standard. EPC
CONTRACTOR / COMPANY approval of fabrication drawings and design calculations shall be
obtained prior to manufacture.










Page15 of 28 Specification for Subsea Flange & Fitting

6 MANUFACTURING REQUIREMENTS
6.1 Manufacturing Procedure Specification (MPS)
SUPPLIER shall submit a detailed MPS for flanges and fittings to EPC CONTRACTOR / COMPANY
for review and approval prior to the start of production. This shall include the following information as
applicable:
Steel making method
Casting practice
Type and grade of starting material, including chemical composition range
Hot forging procedure, if applicable
Details of all forming operations
Heat treatment
Machining
Mechanical testing
Corrosion testing
Inspection and non-destructive testing
Welding procedure specifications and qualifications
Surface finish (internal and external)
Material traceability
Marking, coating and protection procedures
Reference to applicable supplementary requirements e g NACE MR-0175/ISO 15156 sour
service
SUPPLIER shall submit historical data to demonstrate that the proposed MPS will produce fittings
which will meet the requirements of this Specification
Flanges shall not be manufactured from plate, forged blocks or bar.





Page16 of 28 Specification for Subsea Flange & Fitting

6.2 Manufacturing Procedure Specification Qualification
Qualification of the MPS shall be carried out in accordance with the requirements of this subsection.
Qualification may be waived at the discretion of PURCHASER, provided SUPPLIER can submit
historical data detailing satisfactory material properties of fittings of the same grade and size as those
specified in the Data Sheets.
When required by PURCHASER, SUPPLIER shall qualify flanges and fittings manufacturing
procedure specifications to demonstrate that the requirements of this Specification can be met.
Requirements for qualification shall be agreed between PURCHASER and SUPPLIER prior to
commencing work. Trial flanges and fittings of each size required in production shall be manufactured
from the same cast of steel as the forgings they represent.
The approval of the manufacturing procedure qualification shall be based on satisfactory inspection,
non-destructive testing, dimensional checks and mechanical testing. Unless otherwise advised, all such
work shall be witnessed by PURCHASER. The manufacturing procedure qualification test results shall
be submitted to PURCHASER for approval.
Prior to mechanical testing, the trial fittings shall be subject to non-destructive testing according to
Section 11 of this Specification.
Any repairs shall be subject to prior approval of PURCHASER, and shall be carried out according to
Section 12 of this Specification.
The location of test samples for mechanical testing shall be as follows:
1. For flanges, test samples shall be taken from the locations specified in Figure 6-2.
2. For tees, samples shall be taken from the tee body and from weld seams. Samples from the tee
body shall be as follows:
Crotch radius areas at the intersection of the branch with the run at the 12 and 3 o'clock positions when
viewed from above
Tee body top centre line of run, clear of crotch Branch clear of crotch
3. For wyes, samples shall be taken from the body and weld seam of prolongations. In addition a
test block shall be produced from the same heat and forming method as the wye to provide
indicative properties of the wye crotch area. Test samples shall be taken from the locations
specified in Figure 6-2 Alternatively, historical test data from the same size and material wye
may be submitted to PURCHASER for review.
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4. For other fittings, location of test samples shall be by agreement with PURCHASER
depending on the type of fitting. However, the location of the test samples shall be such as to
be representative of mechanical properties of the fitting.
Mechanical testing of samples taken from each location shall be in accordance with Section 8 of this
Specification.
All specified non-destructive and destructive tests for flanges and fittings shall be carried out after final
heat treatment.
Commencement of manufacture of production flanges and fittings shall not take place until approval of
qualification test results has been given by PURCHASER

Figure 6-2 Flange Mechanical Test Piece Locations

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Test pieces shall be taken after all heat treatments but may be taken before final machining if above
locations are maintained.
Test pieces shall be taken from three locations equally spaced around the circumference.










Figure 6-3 Wye Test Block Mechanical Test Piece Locations

Page19 of 28 Specification for Subsea Flange & Fitting

6.3 Materials
The flanges and fittings material shall be in accordance with ASTM A694 for forgings. ASTM A860 for
fittings and as follows in this section.
SUPPLIER shall advise PURCHASER of the proposed specification and grade of material to be used
for guide bars in barred tees. Bar material shall be weld able carbon steel with a maximum hardness of
230HV10 Material shall be subject to approval by PURCHASER. All material shall be in accordance
with NACE MR0175/ ISO 15156.
6.3.1 Steel Making
Steel shall be manufactured by a basic oxygen or electric arc furnace process. Fully killed and finished
to fine grain practice.

6.3.2 Chemical Composition
SUPPLIER shall propose a chemical composition for PURCHASER approval as part of the MPS. The
chemical composition of the material shall be such that the finished items meet the specified mechanical
properties. Flanges and weld-end fittings shall meet the requirements of NACE MR0175/ ISO 15156
and shall be suitable for field welding using established welding techniques without significant pre-heat
or the need for post weld heat treatment..
Steel chemistry, based on product analysis shall be subject to the following limitations:
Notes:
Al : N -- 2:1
CE=C+Mn/6+(Cr+Mo+V)/5+(Ni+Cu)/15
Pcm=C+V/10+Mo/15+(Cr+Mn+Cu)/20+Si/30+Ni/ 60+5B
A heat analysis shall be performed on each cast of steel and the results stated on the mill certificate. A
product analysis shall be performed on each forging material cast produced and the results recorded on
the test certificate.
6.3.3 Forging and Hot Forming
Flanges and fittings shall be manufactured by a hot forging process or alternatively hot formed from
tubular products in the case of fittings, in accordance with ASTM A694 or ASTM A860 as appropriate.
Page20 of 28 Specification for Subsea Flange & Fitting

6.3.4 Heat Treatment
All completed fittings shall be subject to heat treatment by normalizing, normalizing and tempering or
quenching and tempering
For welded fittings, the completed fitting shall be stress relieved after welding. The stress relief
temperatures and procedure shall be subject to review and approval by PURCHASER.



6.4 Welding
For fittings manufactured by forging and welding, all welds shall be made by qualified welders and
welding operators in accordance with approved and qualified welding procedure specifications. All
welds, including longitudinal welds in tees, shall be made according to procedures qualified to the
requirements of ASME IX.
When applicable, welding of PURCHASER supplied pup pieces to fittings shall be in accordance with
API11 04, unless otherwise specified by PURCHASER.
Acceptance criteria, including impact testing, for welding procedure qualification tests shall be as
specified in Section 8 of this specification.
In addition to the requirements of the above clauses of this specification, any change in grade, source of
supply or heat treatment condition shall be considered an essential variable and requires re-qualification
of the welding procedure specification..
All welds on barred tees for guide bars and attaching guide bars to the branch of the tee shall be full
penetration, continuous around the guide bars. The weld procedure shall consist of at least two passes.
Manual metal arc welds shall be made using low hydrogen electrodes which deposit less than 5ml
hydrogen per 100mg of deposited weld metal.
6.5 Weld Neck Bevel
Unless otherwise agreed, welding ends of flanges and fittings shall be supplied with machined standard
30 weld bevels in accordance with API 5L. For wall thickness in excess of 25mm the bevel design
shall be agreed with PURCHASER.
Forged neck test rings shall be supplied to PURCHASER for future field welding procedure
qualification testing when specified. These shall be from the same steel cast and same heat treatment
Page21 of 28 Specification for Subsea Flange & Fitting

batch as the forgings they represent. The forged test rings shall be fully identified and supplied with
weld bevels as specified above. Test rings shall not be less than 500mm long and shall have a CEV
representative of the upper range supplied.




6.6 Bolts, Nuts and Gaskets
Stud bolts shall be manufactured from ASTM A320 Grade L7 for <50mm diameter, or grade L43 for
<100mm diameter material Nuts shall be to ASTM A194, Grade 4/S3 for <50mm diameter or grade 7
for <100mm diameter material. All threads shall be rolled.
Stud bolts and nuts shall be zinc electroplated in accordance with BS 3382 Part 2.
Following electroplating, stud bolts shall be subject to a dehydrogenation heat treatment and PTFE
coating.
Unless otherwise specified, ring joint gaskets for flanges shall satisfy the requirements of ASME 816.5
and ASME B 16 20
Nuts shall be drilled for use of Hydratight stud tensioning equipment.
6.7 Corrosion Resistant Overlay of Flange Sealing Faces
The sealing faces (ring grooves) of flanges and process fluid wetted crevice area of the flange faces of
proprietary compact flange designs, shall be inlaid with nickel alloy, Type 625 to UNS N06625. The
minimum hardness for the sealing surface shall be 250 HV10 SUPPLIER shall provide the proposed
welding procedure specification for overlay welding for PURCHASER approval prior to use.
SUPPLIER shall qualify the welding procedure specification in accordance with ASME IX. At least two
weld layers shall be used and the final machined overlay thickness shall be 3mm minimum, with a
maximum iron content of 5% at the surface (as per ASME IX, Note 2 of Figure QW462.5a). The final
machined overlay shall be subject to 100% dye penetrant inspection, with acceptance criteria to API 6A
1 ISO 10423, Section 7.4.2 2.12, except no porosity shall be permitted.
Unless otherwise agreed with PURCHASER, RT J sealing ring gaskets for flanges with ring grooves
overlaid with UNS N06625 shall be manufactured from nickel alloy, type 825 to UNS N08825. The
hardness of the sealing ring gaskets shall be less than the UNS N06625 overlaid ring groove.
Page22 of 28 Specification for Subsea Flange & Fitting









7 MECHANICAL TESTING
Tests shall be carried out on a production flange or fitting or on forged rings or prolongations of
sufficient size for all required mechanical test pieces to be removed. Tests shall be carried out on base
metal and fabrication welds as appropriate. Source/location of material for mechanical testing shall be
subject to agreement between SUPPLIER and PURCHASER.
Mechanical tests shall be carried out on material from each steel heat, material grade, heat treatment
batch and flange or fitting size, unless otherwise agreed with PURCHASER Tests shall be performed on
material in the final heat treated condition.
7.1 Tensile Tests
Tensile testing shall be performed in accordance with ASTM A370.
One transverse and one longitudinal tensile test shall be taken from the base metal. For fabrication
welds, one transverse weld tensile and one all-weld tensile test shall be made.
Tensile tests shall meet the requirements for the appropriate material grade specified in the datasheet, in
both longitudinal and transverse directions.
The yield-tensile ratio shall not exceed 0.90.
7.2 Impact Tests
Charpy V-notch impact tests shall be performed in accordance with ASTM A370, and shall be carried
out at -10-C Acceptance criteria shall be 30J minimum, and 36J minimum for average of 3no
specimens.
For base material, all specimens shall be taken transverse to the direction of grain flow and with the
notch perpendicular to the surface. For welds; specimens transverse to the weld shall be taken from the
weld metal, fusion line +2mm and fusion line +5mm and notched as for base material specimens.
Page23 of 28 Specification for Subsea Flange & Fitting

Where standard size impact specimens cannot be made (10mm x 10mm), sub-size specimens may be
used.

7.3 Hardness Tests
Vickers hardness tests shall be carried out according to BS 427 Part 1 on each production flange or
fitting.
Location of hardness tests in parent material shall be proposed by SUPPLIER, depending on the type of
flange or fitting and shall be subject to agreement by PURCHASER. For fabrication welds, three
complete traverses of the weld zone shall be made on a section from each weld seam. The positions of
the hardness indentations shall be as shown in Figure 7-3 below. Hardness shall be in accordance with
NACE MR 0175/ISO15156. The maximum hardness values shall be 250 HV10 in weld metal and HAI,
and 220HV10 in the parent material.

Figure 7-3 Position of Hardness Testing Indentations

7.4 Retests
If any test piece fails to meet the specified requirements, two additional specimens may be taken. If
either of the tests fails to meet specified requirements, the flange or fitting or batch of flanges or fittings
represented by the test shall be deemed to have failed the test and shall be rejected. Alternatively, and
with the prior approval of PURCHASER, SUPPLIER may reheat treat the forgings and repeat all
prescribed mechanical tests. Such repeated treatment may be carried out no more than twice.
Page24 of 28 Specification for Subsea Flange & Fitting



8 CORROSION TESTING
Tubular materials used in the manufacture of fittings shall be subject to Hydrogen lnduced Cracking
testing. HIC or stepwise cracking testing shall be performed in accordance with NACE TM0284, using
test solution A. The test specimens shall not be flattened. The acceptance criteria shall be as follows:
Crack Length Ratio Crack CLR - 15%
Thickness Ratio Crack
CTR * 3%, with no transverse cracking greater than 0 1
mm
Surface Ratio CSR s 1.5%

9 HYDROSTATIC TESTING OF WELDED FITTINGS
Hydrostatic testing of completed welded fittings shall not be required provided SUPPLIER can
demonstrate by calculation to the satisfaction of PURCHASER that fittings are capable of withstanding
a hydrostatic test pressure according to MSS-SP-75.
10 INSPECTION AND NON-DESTRUCTIVE TESTING
Non-destructive testing shall be carried out after all processing and heat treatment in accordance with
procedures approved by PURCHASER.
All non-destructive testing personnel shall be qualified to ASNT-TC-1A Level 2 or agreed equivalent
for the test method for which they are employed.
10.1 Visual Inspection
Completed flanges and fittings shall be 100% visually inspected to ensure freedom from surface defects
and to ensure compliance with dimensional tolerances as detailed in Section 13.
10.2 Magnetic Particle Examination
Magnetic particle examination shall be performed over the entire inner and outer surfaces of flanges and
fittings, including all weld seams This shall also include guide bar welds in the case of barred tees and
all weld bevels,
Page25 of 28 Specification for Subsea Flange & Fitting

Magnetic particle examination shall be to ASME V Article 7 or PURCHASER agreed equivalent.
Acceptance criteria shall be according to ASME VIII Division 1, Appendix 6 except that indications
interpreted as cracks or other linear defects are unacceptable, regardless of length.
10.3 Ultrasonic Examination
Flanges and fittings shall be subject to 100% ultrasonic examination, including welds if applicable,
according to ASME V, Article 5, or PURCHASER agreed equivalent.
Where ultrasonic testing is not practical, 100% radiography test may be used in accordance with ASME
V Article 2. Acceptance shall then be in accordance with ASME VIII Division 1, Appendix 4.
Acceptance criteria shall be established by the method defined in ASTM A388 and shall be agreed
between SUPPLIER and PURCHASER.
11 REPAIR OF DEFECTS
No repair shall proceed without the approval of PURCHASER. Repairs by welding shall not be
permitted on parent material of flanges and fittings.
11.1 Surface Repairs
Surface defects such as slivers, sharp notches, gouges, scores, pits and machinery marts may be
removed by grinding or machining, provided the section thickness is maintained within specified
tolerances.
The machined or ground area shall be prepared so as to ensure a smooth transition with the surrounding
surface, with no sharp notches or contours.
The repaired area shall be fully examined by magnetic particle inspection to ensure freedom from
defects. If the section/wall thickness is reduced below the minimum section/wall thickness the forging
shall be rejected.
11.2 Weld Repair of Welded Fittings
Weld repair of defective welds in welded fittings shall be permitted using qualified weld repair
procedures approved by PURCHASER. Weld repair procedures shall be qualified according to Section
7.4 of this Specification. Completed weld repairs shall be subject to non-destructive examination, after
stress relief, in accordance with Section 11 of this Specification.
Page26 of 28 Specification for Subsea Flange & Fitting

12 DIMENSIONS
12.1 Flange Dimensions
Flange dimensions and tolerances shall be in accordance with ASME 8165 and MSSSP-44 and as
detailed on the Data Sheets.
12.2 Fitting Dimensions
The dimensions and tolerances of forged and forged welded fittings shall be in accordance with
ASME 816.9 and MSS-SP-75 and as detailed in the Data Sheets.
13 MARKING, COATING AND PROTECTION
13.1 Marking
Flanges and fittings shall be marked according to the minimum requirements of ASTM A694 or
ASTM A860 as appropriate.
A minimum, each item shall be hard stamped on the periphery using low-stress dies:
COMPANY'S name
Manufacturer's name
Unique fitting identification number and tag no
Heat number
Material grade
Purchase order and item number
Pressure rating
Matching nominal pipe diameter
Matching nominal pipe wall thickness
13.2 Coating
Components shall be delivered bare with no loose mill scale, foreign matter or oil.

13.3 Protection
SUPPLIER shall develop a fully detailed packing, handling and storage procedure for PURCHASER
Approval. Components shall be supplied with temporary protective coating for storage and
Page27 of 28 Specification for Subsea Flange & Fitting

transportation. The applied coating shall be in accordance with manufacturers standard, and shall be
submitted for approval.
Flange faces shall be protected by grease prior to packing and shall be protected by bolting mating
flanges together or by the use of wooden disks. Weld bevel ends shall be fitted with caps to protect
against damage.
14 DOCUMENTATION
14.1 Material
Materials shall be supplied with certification in accordance with BS EN 10204 3.1 B.
14.2 Certification and Documents
Certification and documents shall be supplied to PURCHASER in the form of a Data Book, which
shall contain all specified information. This shall include, but not be limited to, the following:
PURCHASER'S name and requisition number
Description of product (including pressure-temperature rating), dimensions and quantity
including fabrication drawings and design calculations
Heat treatment details and furnace charts for each product
Mill test certificates, showing both chemical check for ladle and product analyses and
mechanical properties of the finished products
Heat treatment details and furnace charts for each product
Manufacturing procedure specifications
NDT test reports for all items, including repairs
Hydrostatic test results (if applicable)
Dimensional control checks
Weight
Welding procedure specifications and qualifications (if applicable)
Welder qualification certificates (if applicable)
NDT operator qualification certificates
SUPPLIER'S BS EN 10204 318 certificates
PURCHASER release notes,
Equipment calibration certificates