RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

1 of 8

SPECIFICATION

NAME Originator Checked Design Approved Jack Barrington Ed Rios Jack Barrington Jerry DeLaat

DATE April 11, 1989 April 11, 1989 April 11, 1989 April 11, 1989

Rev A
SPECIFICATION FORM

ECN # 3381

Date 8/16/94

Rev D

ECN # SEE ECN

Date 7/15/03
Form #BJT079 Revision 1

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

2 of 8

B C

5133 SEE ECN

3/28/01 10/8/2002

SEE ECN

10/17/03

SPECIFICATION FORM

Form #BJT079 Revision 1

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

3 of 8

1.0

SCOPE 1.1 This specification covers the minimum recommended practice for the field inspection, pressure testing, thread gauging, and identification of STANDARD SERVICE straight joints with nonpressure seal (NPS) union ends, FMC or SPM integral union end straight joints, and FMC or SPM fabricated straight joints.

2.0

GENERAL 2.1 Straight joints shall be inspected, gauged, and tested in strict accordance with the procedures outlined within this specification at intervals not to exceed twelve (12) months. Straight joints not permanently attached to truck, trailer, or skid-mounted unit shall have nonpressure seal union ends. Straight joints used as ground line having line pipe threaded union ends shall be immediately removed from service and destroyed. Each district shall be responsible for the performance of required inspections and tests. Region personnel will assign each straight joint a unique serial number in accordance with Specification No. 40438. Acceptable and unacceptable limits 2.5.1 Straight joints conforming to the requirements of this specification shall be identified in accordance with Section 5.2.4 and returned to service. Straight joints not conforming to the requirements of this specification shall be immediately removed from service. Unacceptable straight joints shall be identified in accordance with Section 2.5.3. Unacceptable components shall be identified by either applying an "X" or other unique symbol with aerosol spray paint of a color contrasting to the equipment paint color, or attachment of a device clearly identifying the item as unacceptable. See Inspection Standard No. 40421 Paragraph 8.0 for additional Identification Requirements.

2.2

2.3 2.4

2.5

2.5.2

2.5.3

3.0

INSPECTION

SPECIFICATION FORM

Form #BJT079 Revision 0

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

4 of 8

3.1 3.2

Prior to a hydrostatic test, all external and internal surfaces, where possible, shall be visually inspected to ensure such surfaces are free of excessive erosion, corrosion, or surface imperfections. Additional inspection points are as follows: 3.2.1 Terminal End Wear (NPS only) Each straight joint NPS terminal end (male and female) shall be inspected using the appropriate tubing I.D. inspection gage in accordance with the inspection method shown on Drawing C-33449. Straight joints having unacceptable terminal ends shall be immediately removed from service with NO other field inspection required. Continuation of inspection (visual, hydrostatic test, etc.) shall be performed only on straight joints whose terminal ends are found to be acceptable within the limits of the gauging practice in the aforementioned inspection. 3.2.2 Female Union Subs ACME threads shall be thoroughly cleaned and visually examined to ensure threads are free of any injurious defects (cracks, chips, etc.). Any sharp edges or burrs shall be removed with a fine flat file to parent metal. The female union sub seal ring seat shall be visually examined to ensure it is free of erosion, corrosion, or other injurious defect. The union sub will be inspected using the appropriate gauge kit according to the gauge kit manufacturers instructions. 3.2.3 Union Sub Seal Ring The union sub seal ring shall be removed and visually examined to ensure it is of the proper type and free of cuts, blemishes, or other injurious defect. If any defect is found, the seal ring shall be replaced. 3.2.4 Male Union Subs The union sub seal face shall be thoroughly cleaned and visually examined to ensure it is free of erosion, corrosion, or other injurious defect. Sharp edges or burrs shall be removed with a fine flat file to parent metal. The union sub will be inspected using the appropriate gauge kit according to the gauge kit manufacturers instructions.

SPECIFICATION FORM

Form #BJT079 Revision 0

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

5 of 8

3.2.5

Wing Nuts The wing nut shall be removed, thoroughly cleaned and visually examined to ensure the threads are free of any injurious defects. Sharp edges or burrs on the body of the wing nut shall be removed with a fine flat file to parent metal only. Rolled over edges or metal fragments on hammer lugs shall be ground smooth. Care must be taken not to grind on the body of the nut. If the nut is found to be gouged or grooved from grinding, it shall be removed from service and discarded. Wing nut hammer lugs having 1/8 or less across the flat at the top of the hammer lug shall also be removed from service and discarded. The retainer segments and retainer ring shall be visually examined to ensure they are free of any injurious defects. The wing nut will be inspected using the appropriate gauge kit according to the gauge kit manufacturers instructions.

3.2.6

Union Gauge Kits P/N 861827 P/N 76111 P/N 854064 P/N 861828 P/N 861829 - 1-1/2 1502 - 2 1502 - 3 1502 - 4 602 - 4 1002

4.0 5.0

RESERVED PRESSURE TEST 5.1 Each straight joint shall be hydrostatic pressure tested to its maximum rated working pressure (see pressure chart) at intervals not to exceed twelve (12) months. Straight joints will be pressure tested individually. Hydrostatic pressure tests shall be performed in accordance with the following procedure:

SPECIFICATION FORM

Form #BJT079 Revision 0

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

6 of 8

5.2

Hydrostatic Test Procedure 5.2.1 Connect a low volume-high pressure hydrostatic test pump. Caution should be exercised to ensure all air is bled prior to start of hydrostatic test from any systems that will contain pressure, that all components used in the pressure test are the proper size and pressure rating, and that the operating temperature is within the component manufacturers recommendations.. 5.2.2 Bring the straight joint to (1) 50% of maximum allowable working pressure, then (2) increase pressure in increments of 10% of working pressure until maximum allowable working pressure is reached. Maximum allowable working pressure shall be held for a minimum of three (3) minutes with no indication of leakage. Upon successful completion of the hydrostatic pressure test, the straight joint and all systems containing pressure must be bled to 0 psi prior to being disassembled. An identification band shall be attached to each component as indicated on the parts checklist. Each band shall be marked, in letters no less than 1/4" in height, with the following: 1. Serial number 2. Date of inspection

5.2.3

5.2.4

6.0

INSPECTION RECORD 6.1 A permanent and progressive record shall be maintained for each straight joint at each district. This record shall contain such information as necessary to record results of successive inspections and tests (i.e. test log, chart recording, ultrasonic test results, etc.). The serial number of each straight joint shall be referenced on all information contained in each individual record.

SPECIFICATION FORM

Form #BJT079 Revision 0

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

7 of 8

SIZE 1 1502 1 -1502 1 1502 2-602 2-1002 2-1502 2-1502 2-2002 2-1502 3-602 3-1002 3-1002 3-1002 3-1502 3-1502 3-2002 3-1502 4-602 4-602 4-602 4-1002 4-1002 4-1002

MANUFACTURER RECOMMENDED ALLOWABLE WALL THICKNESS, NEW AND WORN, FOR STRAIGHT JOINTS WITH NON-PRESSURE SEAL CONNECTIONS NEW MAXIMUM MFG OD NOMINAL MIN. MAX. WORKING NOMINAL WALL WALL ID PRESSURE SPM 2.000 .310 .190 1.620 15,000 Mesa 1.900 .313 .206 1.488 15,000 FMC 2.000 .375 .220 1.560 15,000 FMC FMC SPM Mesa Mesa FMC FMC SPM Mesa FMC SPM Mesa Mesa FMC SPM Mesa FMC SPM Mesa FMC 2.375 2.375 2.375 2.375 2.500 2.375 3.500 3.500 3.500 3.500 3.500 3.500 5.500 3.500 4.500 4.500 4.500 4.500 4.500 4.500 .250 .250 .313 .313 .563 .313 .438 .470 .462 .380 .470 .462 1.250 .440 .310 .313 .313 .440 .440 .500 .122 .195 .220 .257 .351 .257 .179 .220 .259 .287 .320 .378 .772 .378 .180 .205 .210 .290 .334 .338 2.131 1.985 1.935 1.862 1.798 1.862 3.142 3.060 2.982 2.926 2.860 2.744 3.956 2.744 4.140 4.090 4.080 3.920 3.832 3.832 6,000 10,000 15,000 15,000 20,000 15,000 6,000 10,000 10,000 10,000 15,000 15,000 20,000 15,000 6,000 6,000 6,000 10,000 10,000 10,000

SPECIFICATION FORM

Form #BJT079 Revision 0

RESEARCH AND TECHNOLOGY CENTER

11211 FM 2920 Tomball, TX 77375

NUMBER

40204
T itle: Page Revision

Inspection and Testing Procedures for Straight Joints Used in Standard Service

8 of 8

SIZE

MFG

OD NOMINAL 2.375 3.000 2.750 2.500 2.375 3.000 2.750 2.500 2.375 2.500 3.000 2.750 2.500 2.375 2.375 2.500 4.120 3.500 4.120 3.500 4.000 4.120 3.500 5.410 5.380 5.00

NEW NOMINAL WALL .538 .560 * .375 .313 .560 * 375 .313 .380 .560 * .375 .313 .538 .563 .688 .438 .685 .438 .630 .685 .438 1.205 1.118 1.000

MIN. WALL .265 .169 .155 .141 .122 .270 .248 .225 .195 .290 .384 .352 .320 .257 .390 .404 .232 .179 .371 .287 .370 .529 .378 .876 .869 .600

MAX. ID 1.845 2.662 2.440 2.218 2.131 2.460 2.254 2.050 1.985 2.040 2.232 2.046 1.860 1.861 1.595 1.692 3.656 3.142 3.378 2.926 3.260 3.062 2.744 3.658 3.642 3.800

MAXIMUM WORKING PRESSURE 15,000 6,000 6,000 6,000 6,000 10,000 10,000 10,000 10,000 15,000 15,000 15,000 15,000 15,000 20,000 20,000 6,000 6,000 10,000 10,000 15,000 15,000 15,000 20,000 20,000 20,000

1 1502 Integral 2-602 Integral 2-602 Integral 2-602 Integral 2-602 Integral 2-1002 Integral 2-1002 Integral 2-1002 Integral 2-1002 Integral 2-1502 Integral 2-1502 Integral 2-1502 Integral 2-1502 Integral 2-1502 Integral 2-2002 Integral 2-2002 Fabricated 3-602 Integral 3-602 Integral 3-1002 Integral 3-1002 Integral 3-1502 Integral 3-1502 Integral 3-1502 Integral 3-2002 Integral 3-2002 Fabricated 3-2002 Intergral

FMC FMC FMC FMC FMC FMC FMC FMC FMC SPM FMC FMC FMC FMC FMC FMC FMC FMC FMC FMC SPM FMC FMC FMC FMC SPM

Note: SPM figures for 110,000 psi minimum yield material with a 2 : 1 safety factor. Mesa figures for 110,000 psi minimum yield material with a 1.75 : 1 safety factor. * No longer produced by FMC

SPECIFICATION FORM

Form #BJT079 Revision 0