GS 142-4
GS 142-4
PIPELINE FLANGES
November 1996
Document Title
PIPELINE FLANGES
APPLICABILITY
Regional Applicability: International
This specification covers BP's supplementary requirements for the design, manufacture and
supply of forged steel pipeline flanges for use with linepipe to API 5L Grade B to Grade X 70
inclusive or equivalent grades in ISO 3183.
Its purpose is to clarify the minimum design, testing, inspection and certification requirements
for forged steel pipeline flanges as set out in ISO 7005-1 and ANSI/ASME B 16.5.
AMENDMENTS
Amd Date Page(s) Description
___________________________________________________________________
Section Page
1. INTRODUCTION................................................................................................... 1
1.1 Scope ................................................................................................................ 1
1.2 Quality Assurance................................................................................................ 1
2. DESIGN................................................................................................................... 2
3. MANUFACTURE ................................................................................................... 3
4. MATERIALS .......................................................................................................... 3
4.1 Chemical Composition......................................................................................... 3
4.2 Mechanical Properties.......................................................................................... 4
8. INSPECTION.......................................................................................................... 7
9. CERTIFICATION .................................................................................................. 8
FIGURE 1 ................................................................................................................... 11
CHARPY IMPACT TEST TEMPERATURES ....................................................... 11
FIGURE 2 ................................................................................................................... 12
GS 142-4 PAGE i
PIPELINE FLANGES
SCHEMATIC LONGITUDINAL SECTION OF WELDNECK AND SWIVEL
RING FLANGES ILLUSTRATING THE POSITION OF THE MECHANICAL
TEST SPECIMENS ................................................................................................ 12
FIGURE 3 ................................................................................................................... 13
SCHEMATIC SECTION OF A BLANK FLANGE LOCATION OF
MECHANICAL TEST SPECIMENS...................................................................... 13
APPENDIX A.............................................................................................................. 14
DEFINITIONS AND ABBREVIATIONS .............................................................. 14
APPENDIX B.............................................................................................................. 16
LIST OF REFERENCED DOCUMENTS............................................................... 16
GS 142-4 PAGE ii
PIPELINE FLANGES
FOREWORD
The Introductory volume contains a series of documents that provide an introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular,
the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in the
Introductory volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.
This Guidance for Specification provides BP supplementary requirements for forged steel
pipeline flanges for use with linepipe of API 5L Grade B to Grade X70 and equivalent grades
in ISO 3183 based on BP's knowledge and experience worldwide.
Application
This Guidance for Specification is intended to guide the purchaser in the use or creation of a
fit-for-purpose specification for enquiry or purchasing activity.
This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.
Users are invited to feed back any comments and to detail experiences in the application of
BP RPSE's, to assist in the process of their continuous improvement.
For feedback and further information, please contact Standards Group, BP Engineering or the
Custodian. See Quarterly Status List for contacts.
1.1 Scope
1.1.3 This Specification shall not be applied to general refinery and chemical
plant duties these applications are covered by the supplementary
requirements of BP Group Specification GS142-12 equivalent.
BP GS 136-1 defines the testing required on materials proposed for use in sour
environments.
GS 142-4 PAGE 1
PIPELINE FLANGES
Further suggestions may be found in the BP Group RPSEs Introductory Volume
2. DESIGN
2.1 All flanges shall be made of forged steel. However, for certain
applications and subject to a detailed proposal being submitted by the
manufacturer, consideration may be given to the use of blank flanges
manufactured from rolled plate.
2.2 Welding neck and blank flanges shall be designed as raised face, ring
type joint flanges, in accordance with ISO 7005-1 or other
internationally recognised codes such as ASME/ANSI B16.5 (inch
dimensions), ASME/ANSI B16.47 BS 1560 or MSS SP 44, except as
modified by this Specification.
2.3 The manufacturer's design basis for swivel ring flanges shall be
explained in his offer. The swivel rings shall be secured to their welding
hubs (for example by a thin retaining ring). Apart from this, the flanges
shall be of unwelded construction.
* 2.4 Unless the outside diameter at the weld bevel is increased, and a
reduction in strength at the hub extension is then approved by BP, the
minimum tensile properties there shall match those of the designated
linepipe. Where a reduction in the strength level is agreed the revised
minimum value shall be specified in the Purchase Order together with
any revision to the notch ductility requirements of 4.2. Tensile
properties of blank flanges shall be compatible with their mating
pipeline flanges and meet the requirements of the design standard, while
those of swivel rings shall meet the manufacturer's design strength,
subject to approval by the BP Materials Engineer.
2.5 The internal diameter (bore) of the flange is defined by the pipeline data
sheet, and shall have a tolerance of +/- 1.5mm (1/16 in).
This restriction on internal bore dimension for flanges corresponds to that specified
for linepipe.
2.7 The weld bevel angle shall be 30 degrees plus 5 degrees, minus 0
degrees for thicknesses up to 20mm. Above this thickness details of
any alternative end bevel preparation will be provided in the Purchase
Order.
GS 142-4 PAGE 2
PIPELINE FLANGES
2.8 The weld bevel root face shall be 1.5 +/- 0.5 mm (1/16 in +/-.020 in).
3. MANUFACTURE
3.1 The steel shall be made by the electric furnace or basic oxygen process,
and shall be fully killed and of fine grain size.
3.2 The cast material shall be hot forged to bring it as close as is practicable
to the final shape and size. All parts shall undergo a reduction of at
least 2:1 during the forging process.
4. MATERIALS
where,
GS 142-4 PAGE 3
PIPELINE FLANGES
CEV = C + Mn + Cr + Mo + V + Ni + Cu
6 5 15
4.1.2 The analysis shall be determined both on each heat of steel used, and
also on a broken mechanical test piece from each heat.
4.1.3 Other elements shall not be added to the steel without the approval of
the BP Materials Engineer.
4.1.4 If any part of the product analyses fails to meet the requirements of
4.1.1, the whole heat shall be rejected or each individual item shall be
fully analysed and all items failing to meet the requirements shall be
rejected.
4.2.1 The following mechanical tests shall be carried out on one flange of
each type on every heat (or heat treatment lot if this occurs more
frequently) which has been subject to all forming and heat treatment
operations.
4.2.4 Unless stated otherwise on the Pipeline Data Sheet, the minimum
acceptable Charpy toughness shall be an average, from three specimens,
of 50J, with no individual value below 40J. The test temperature shall
be established from Figure 1, using the wall thickness of the matching
linepipe. The test temperature shall not be greater than the minimum
design temperature. The yield strength, tensile strength, reduction of
area and elongation shall be measured and the results shall comply with
2.3.
GS 142-4 PAGE 4
PIPELINE FLANGES
4.2.5 On each flange selected for mechanical testing, hardness tests shall be
carried out at 0.1 diameter intervals in a longitudinal direction along
both the internal and external surfaces using a portable instrument
approved by BP. In addition macro-sections shall be cut from each end
of weld neck and swivel flanges and the hardness measured through the
material thickness using a Rockwell or Vickers testing machine. The
hardness shall not exceed 248 HV10 where service is sour, or 300
HV10 where service is non-sour.
4.2.7 For flanges in sour service BP may specify additional testing based on
BP GS 136-1. BP will confirm testing frequency and acceptance
criteria prior to contract.
4.2.8 BP will permit a retest only if there is reason to believe that failure was
due to some fault in preparation or testing, and was not representative
of the test sample
The manufacturer may re-heat-treat the batch (including the original test flange) if
he believes that subsequent tests will succeed in meeting the requirements.
5.1 Gaskets shall be ring type, of soft iron, with a maximum Brinell
hardness of 90 conforming to ANSI B 16.20 as required by BP Group
Specification GS142-7.
5.2 All stud bolts and nuts shall meet the general requirements of BP GS
142-9 and shall be threaded full length. The minimum length of point
shall be:
5.3 For minimum design temperatures down to -20 C (-4 F) studbolts shall
be to BS 4882 (or ASTM A193) Grade B7 and hexagon nuts to BS
4882 (or ASTM A194) grade 2H. Where design temperature is below -
20°C the requirements of BP Group Specification GS142-9 shall apply.
GS 142-4 PAGE 5
PIPELINE FLANGES
When specified on the order, the nuts shall be drilled to suit bolt
tensioning equipment.
6. NON-DESTRUCTIVE TESTING
* 6.2 All NDT shall be carried out after final heat treatment using procedures
approved by BP.
6.3 All surfaces of each flange shall be visually examined for defects and
shall satisfy the requirements of ASTM A 694. Illumination greater
than 500 lux shall be required to enable proper inspection.
6.4 The neck of each flange shall be examined for laminations and other
defects within 4t of the weld bevel, where 't' is the nominal thickness at
the weld bevel, by ultrasonic testing in accordance with ISO 11496 or
ASME V.
6.5 Planar defects of any size, pores or inclusions larger than 5 mm (3/16
in) in their greatest dimension and laminations exceeding 50mm2 are
unacceptable.
6.6 After final machining, each flange shall be examined for surface defects
by wet magnetic particle inspection in accordance with BS 6072 or
ASTM E 709.
6.7 Surface defects which do not encroach on the specified dimensions shall
be removed by grinding or further machining. Grinding or machining
below minimum thickness shall be cause for rejection.
6.9 Hardness tests shall be performed on the internal and external surfaces
of each flange at approximate 0.1 diameter intervals along its length
GS 142-4 PAGE 6
PIPELINE FLANGES
using a portable instrument approved by BP e.g. EQUOTIP. Values
shall not exceed those stated in 4.2.3.
6.10 For swivel ring flanges, the weld between the retaining ring and the hub
shall be subject to wet magnetic particle inspection in accordance with
BS 6072 or ASTM E 709.
6.11 Dimensional tolerances, in accordance with 2.0, 12.2 and the approved
drawings, shall be verified for each flange.
7. HYDROSTATIC TEST
* When the flanges have been installed they may be required to undergo a field
hydrostatic test. BP will specify the pressure prior to contract. The manufacturer will
be required to provide a warranty for all flanges supplied to this Specification at all
pressures up to and including that advised for the field test following installation.
8. INSPECTION
(d) To witness all mechanical tests and confirm that all heat
treatment and residual defects are within agreed limits, that the
chemical analysis is within the agreed range.
(e) To check that surfaces of the flanges are clean and free from
damage, that swivel rings and their welding hubs are machined
smooth (and with sufficient free play so that the swivel rings can
rotate freely), and that all items are correctly marked by
stamping on the outer machined ring of the flange (using low
stress stamps).
(f) To check that all flanges have the same external dimensions and
bolt hole positions, so that flanges can be mated with (and
bolted to) any other flange of the same size, that stud bolt
threads are free from burrs and that the nuts run freely along the
full thread length when turned by hand.
GS 142-4 PAGE 7
PIPELINE FLANGES
(g) To investigate swivel ring flange design, the first swivel flange
assembly shall be bolted to a blank flange (prior to attachment
of the swivel retaining ring) and full field loading applied to the
bolts. The assembly shall then be dismantled and the swivel ring
and hub inspected by wet magnetic particle inspection, and a full
dimension re-inspection carried out. Any defects found, and any
dimensions out with the agreed tolerance range (other than
those of the ring groove)will be cause for rejection.
9. CERTIFICATION
* 9.1 The original steel makers certificates shall be supplied for each heat of
steel used.
The flange manufacturer shall prepare a test certificate for each heat of
steel used for each type of forging (or each heat treatment lot where
more than one lot is made from the same heat). This shall show the
heat number, the steelmaking process, the heat and product analysis, the
heat treatment and the mechanical properties as determined from the
test pieces from that heat or lot. The certificate shall identify by
reference number, all flanges covered and shall be subject to approval
by the BP Materials Engineer.
9.2 The manufacturer shall ensure that all documents related to this
Specification and the purchase order are collated, indexed and retained
for subsequent presentation to BP.
GS 142-4 PAGE 8
PIPELINE FLANGES
The documentation shall be presented in data folders in chronological
order, edited into sections and clearly indexed for ease of recovery and
traceability.
10.1 The flange reference number and class rating shall be stamped on the
periphery of each flange, and of each swivel ring flange hub using low
stress stamps.
10.2 All surfaces other than those which have been freshly machined shall be
blast cleaned to Sa 2 1/2 or better as defined by ISO Standard 8501-1.
Except for surfaces to be greased and surfaces within 25 mm (1 in) of
the weld bevel, all surfaces shall be coated with epoxy primer to a dry
film thickness of 50 microns (0.002 in).
10.3 Flange faces and swivel ring and hub bearing surfaces shall be given a
protective coat of grease. The flanges shall be packed in such a way
that the faces are protected from mechanical damage.
10.4 Protection, labelling and packing shall comply with the requirements
specified in the Purchase Order. All nuts and studbolts shall be coated
with a protective film of oil. The studbolts shall be individually packed
in cardboard cartons; nuts may be loose-packed in cardboard cartons.
GS 142-4 PAGE 9
PIPELINE FLANGES
11.6 Proposals for warranty in the event of flange failure during field
hydrostatic test.
11.7 Any items which are to be produced by sub-contractors, and the name
of the sub-contractor proposed for each item.
12.1 BP will specify whether the fitting will operate in sour or non-sour
service.
12.2 The manufacturer shall supply his design calculations and shop
drawings for the flanges, and his proposals for protection during
shipment.
GS 142-4 PAGE 10
PIPELINE FLANGES
FIGURE 1
GS 142-4 PAGE 11
PIPELINE FLANGES
LONGITUDINAL AND TRANSVERSE TENSILE
SPECIMENS SHALL BE CENTRED AT THE SAME
LOCATION AS THE CHARPY SPECIMENS
30deg
+5
-0
1.5mm
+ / - 0.5mm
30deg
+5
-0
1.5mm
+ / - 0.5mm
FIGURE 2
GS 142-4 PAGE 12
PIPELINE FLANGES
CHARPY SPECIMENS TO BE
NOTCHED THROUGH THICKNESS
TENSILE SPECIMENS
FIGURE 3
GS 142-4 PAGE 13
PIPELINE FLANGES
APPENDIX A
Definitions
GS 142-4 PAGE 14
PIPELINE FLANGES
quality system: the organisation structure, responsibilities, activities, resources
and events that together provide organised procedures and
methods of implementation to ensure the capability of the
organisation to meet quality requirements.
Abbreviations
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
BS British Standard
HAZ Heat Affected Zone
HV Vickers Hardness
MSS Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.
NDT Non-Destructive Testing
SI Systeme International d'Unites
ISO International Standards Organisation
GS 142-4 PAGE 15
PIPELINE FLANGES
APPENDIX B
A reference invokes the latest published issue or amendment issue unless stated
[Link] standards may be replaced by equivalent standards that are
internationally or otherwise recognised provided that it can be shown to the satisfaction of the
purchaser's professional engineer that they meet or exceed the requirements of the referenced
standards.
BS 1560 Circular flanges for pipes, valves and fittings (Class designated) Section
3.1 Specification for steel flanges.
BS 1706 Electroplated Coatings of Cadmium and Zinc on Iron and Steel.
BS 4882 Bolting for Flanges and Pressure Containing Purposes.
BS EN ISO 9001 Quality Systems. Model for quality assurance in design, development,
production, installation and servicing.
BS EN ISO 9002 Quality Systems. Model for quality assurance in production, installation
and servicing.
BS EN ISO 9003 Quality Systems. Model for quality assurance in final inspection and
test.
BS 5750: PART 4 Guide to Use of BS EN ISO 9002.
BS 6072 Method for Magnetic Particle Flaw Detection
ASTM A193 Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature
Service
ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-
Temperature Services
ASTM A 370 Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
ASTM A 694 Forgings, Carbon and Alloy Steel, for flanges, fittings, valves and parts
for high-pressure transmission.
GS 142-4 PAGE 16
PIPELINE FLANGES
ISO 8501-1 Preparation of steel substrates
ISO 11496 Seamless and Welded Steel Tube for Pressure Purposes - Ultrasonic
Testing of Tube Ends for the Detection of Laminar Imperfections
GS 142-4 PAGE 17
PIPELINE FLANGES