Product Specifications - ITL

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Plot # 37-39, Sector4, Export Processing Zone
Chittagong – 4223, BANGLADESH
PRODUCT SPECIFICATIONS FOR COPPER-

NICKEL FITTINGS AND FLANGES
Revision: 01
Intercontinental PRODUCT SPECIFICATIONS – COPPER-NICKEL
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1. Introduction
This document is designed to specify technical requirements and outlining boundaries,

parameters for manufacturing of 90/10 and 70/30 Copper-Nickel pipe fittings and flanges as
per major international standards.
2. Reference Standards
Following international standards are followed in manufacturing Copper-Nickel fittings and

flanges.
 EEMUA 234 : 2015 (Supersedes EEMUA 144, 145, 146:1987)

 DIN 86103 : 1996
 DIN 86037 : 2017
 DIN 86087 : 2008
 DIN 86088 : 2013
 DIN 86089 : 2008
 DIN 86090 : 2008
 DIN 28011 : 2012
 ASME B16.5 : 2017
 ASME B16.9 : 2012
 ASME B16.11 : 2016
 ASME B16.48 : 2015
 MSS SP 43 : 2013
 MSS SP 95 : 2014
 MSS SP 97 : 2012
 BS 4504-3.3 : 1989
 BS EN 1092-3 : 2003
3. Base Materials for Manufacturing
Materials in the following forms are used as raw materials for manufacturing Copper-Nickel
fittings and flanges.
 Seamless Copper-Nickel pipes in annealed condition

 Rolled Copper-Nickel plates in annealed condition
 Round or hexagonal extruded and drawn solid rods of Copper-Nickel in annealed
condition
 Solid forgings of Copper-Nickel in annealed condition.
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Following international standards are followed as a basis of selection of raw materials for
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manufacturing.
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EEMUA 234 7060X, DIN 86019 WL 2.1972, ASTM/ASME B/SB 151, 466 C70600, C71500, DEF
STAN 878 Annex C & D, NES 779 CW352H, MIL-T-16420K Alloy 706 and 715, etc.
Chemical composition, mechanical properties and physical properties of start materials shall
conform to requirements set out in relevant manufacturing and materials standards.
Raw material supplier mill shall carry out all required non-destructive and destructive tests
as per relevant standards to prove conformity and integrity of the incoming raw materials
and report the same in the mill test certificate EN 10204 3.1.
4. Manufacturing Methods
4.1 Butt Weld Fittings
Butt weld fittings shall be manufactured from seamless pipes or rolled plates.
Manufacturing shall be done by cold forming or hot forming followed by annealing,
machining and surface finishing.
The dimensions and tolerances of butt weld fittings shall conform to requirements set out in
relevant standards.
The chemical composition and mechanical properties of butt weld fittings shall conform to
requirements set out in relevant standards.
4.2 Socket Weld & Threaded Fittings
The fittings shall be manufactured by hot forging or cold forging as set out in relevant
standard followed by annealing, machining and surface finishing. Straight fittings like
coupling, unions, etc. may also be machined directly from bar stock or forged stock.
The dimensions and tolerances of socket weld and threaded fittings shall conform to
The chemical composition and mechanical properties of socket weld and threaded fittings
shall conform to requirements set out in relevant standards.
4.3 Flanges
The flanges shall be manufactured by hot forging or cold forging as set out in relevant
standard followed by annealing, machining and surface finishing.
The dimensions and tolerances of flanges shall conform to requirements set out in relevant
standards.
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The chemical composition and mechanical properties of flanges shall conform to

5. Scope & Design Basis
Copper-Nickel fittings and flanges specified here as per EEMUA 234, DIN are basically
suitable for Maximum Allowable Working Pressure (MAWP) of 10/14/16 Bar and 20 Bar at
750 C and 380 C temperature respectively. ASME/ANSI grade flanges specified here are 150#
and 300# class. ANSI socket weld, threaded fittings are for 3000# class. Fittings and flanges
of higher class are also available as per customer’s requirements.
Flange thickness in the relevant standards (EEMUA, ASME) have been derived following
ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, Appendix 2 and design stress of
68.6 N/mm2 have been used.
A design feature of self-reinforced branch connections (O Lets) shall include the additional
compensatory reinforcement necessary to comply with the requirements of Section 304.3
(Branch Connections) in ASME B31.3:2014 “Process Piping”. For details of calculations
please contact with us.
6. Dimensions, Weights & Tolerances
Dimensions and approximate weights of our core Copper-Nickel fitting and flange products
as per major international standard are shown in following pages.
For tolerances, please refer to relevant standards.
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900 (Long Radius) 450 (Long Radius) Tee
Forged Socket Weld Elbow, Tee

Dimensions to EEMUA 234
Pipe D1 D2 D3 C J E E A
Outside Socket Fitting Socket Socket Centre to Centre to Centre to
Diameter (mm) Size Bore Wall Depth Socket Socket End Tee
(mm) (mm) (mm) (mm) (mm) 90 Deg 45 Deg (mm)
(mm) (mm)
16.121/
16 23 12 3.2 10 30 12 22
16.070
25.131/
25 32 21 3.2 13 37.5 15.5 27
25.080
30.131/
30 37 25 3.2 13 45 18.6 34
30.080
38.146/
38 45 33 3.2 13 57 23.6 37
38.095
44.646/
44.5 52 39.5 3.2 13 66.8 27.6 42
44.595
57.276/
57 65 52 3.2 16 85.5 35.3 47
57.225
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Forged Capillary Elbow, Tee

Dimensions to EEMUA 234
Pipe D1 D2 D3 C J E E E
Outside Socket Fitting Socket Socket Centre to Centre to Centre to
Diameter (mm) Size Bore Wall Depth Socket Socket End Tee
(mm) (mm) (mm) (mm) (mm) 90 Deg 45 Deg (mm)
(mm) (mm)
16.121/
16 23 12 3.2 10 22 19 22
16.070
25.131/
25 32 21 3.2 13 27 23 27
25.080
30.131/
30 37 25 3.2 13 34 27 34
30.080
38.146/
38 45 33 3.2 13 37 29 37
38.095
44.646/
44.5 52 39.5 3.2 13 42 32 42
44.595
57.276/
57 65 52 3.2 16 47 36 47
57.225
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6.1 Preparation of welding end for butt weld fittings and weld neck flanges
As per ASME B16.9

For wall thickness less than 3 mm, the weld bevel may be omitted.
6.2 Welding dimensions required for socket welding fittings 39

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6.3 Crotch Thickness of Butt Weld Tee
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6.4 Intrados thickness of long radius butt weld elbow
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7. Inspection & Testing
Inspection, testing and verification shall be done as per company’s standard Quality
Assurance Plan (QAP) or as per any special QAP agreed between the purchaser and ITL.
7.1 Inspection of Butt Weld Fittings
Fittings shall be dimensionally correct as per dimensions and tolerances given in the
relevant standard. Fittings shall be visually clean, smooth and free from defects greater than
0.5 mm in depth, irregularities, scale or deposits. And shall be free from deleterious films in
the bore. No repair weld shall be done on the fittings.
Special attention to be given to following aspects (angularity, off plane & ovality) of butt
weld fittings and maximum deviation shall not exceed the limit set out in relevant standard.
7.2 Inspection of Socket Weld, Threaded Fittings & Flanges
Fittings and flanges shall be dimensionally correct as per dimensions and tolerances given in
the relevant standard. Fittings and flanges shall be visually clean, smooth and free from
defects greater than 0.5 mm in depth, irregularities, scale or deposits. And shall be free from
deleterious films in the bore. No repair weld shall be done on the fittings.
Socket & Thread Gaging: Socket and thread dimensions and thread profiles shall be verified
by properly calibrated plug and thread gauges respectively. Threaded fittings and flanges
listed in this “Product Specifications” represent threads as per ASME B1.20.1 (NPT), ISO 228
(BSPP) and ISO 7/1 (BSPT). Threads of other specifications are available on request.
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7.3 Testing of Fittings and Flanges
Hydrostatic testing of wrought fittings, forged fittings and flanges are not required as per
the relevant standards according to which these are manufactured. However fittings and
flanges shall be capable of withstanding, without leakage or impairment of serviceability, a
hydrostatic test pressure required by the applicable piping code for seamless pipe of
material equivalent to the fittings and flanges material, and of the size and wall thickness
the fitting/flange marking identifies.
Hardness check of all the fittings and flanges shall be done and recorded.
Butt weld fittings specified here do not require any further testing as per the relevant
standards provided they are manufactured from seamless pipes of material equivalent to
the fittings in grade. Size and thickness.
Final solution annealing/heat treatment data for all fittings and flanges shall be monitored
and recorded.
Mechanical properties of flanges shall be determined by tensile testing. Test coupon shall be
selected in accordance with Table 20 of BS EN 12420. Testing shall be done in accordance
with ASTM A370 or BS EN 10002. Test sample shall be prepared as per instructions given in
following Appendix A.
Chemical analysis of flanges shall be done by selecting one sample from each cast.
Apart from tests described above, following additional test can be arranged as per
requirements of the purchaser.
 Dye Penetration , Hydrostatic Testing, Microstructure analysis, Charpy Impact

Testing, RT, Eddy Current, MP and UT, Corrosion Testing
8. Marking & Packing
All fittings and flanges shall be individually and permanently marked and identified by clear
legible printing by laser / ink jet / electro-chemical etching or as per customer’s
requirements. Minimum information to be provided are; Manufacturer’s Mark, Standard,
Material Grade, Size, Wall Thickness, Pressure Rating, Cast/Heat/Batch no. and any other
information required by customer.
Packing should be suitable for sea or air transportation without causing any damage to the
goods.
9. Certifications
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Mill certificate as per EN 10204 3.1 shall be issued as mandatory requirements for each
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batch of fittings and flanges confirming compliance with product requirements.

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Appendix A
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Appendix B:
Typical Chemical Composition & Mechanical Properties of 90/10 Copper-Nickel Fittings and
Flanges. (Example given here is as per EEMUA 234.
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Intercontinental

PRODUCT SPECIFICATIONS FOR COPPER-

This document is designed to specify technical requirements and outlining boundaries,

Following international standards are followed in manufacturing Copper-Nickel fittings and

 EEMUA 234 : 2015 (Supersedes EEMUA 144, 145, 146:1987)

3. Base Materials for Manufacturing

 Seamless Copper-Nickel pipes in annealed condition

4.1 Butt Weld Fittings

4.2 Socket Weld & Threaded Fittings

The chemical composition and mechanical properties of flanges shall conform to

5. Scope & Design Basis

6. Dimensions, Weights & Tolerances

For tolerances, please refer to relevant standards.

900 (Long Radius) 450 (Long Radius) Tee

Forged Socket Weld Elbow, Tee

Forged Capillary Elbow, Tee

As per ASME B16.9

6.2 Welding dimensions required for socket welding fittings 39

6.3 Crotch Thickness of Butt Weld Tee

6.4 Intrados thickness of long radius butt weld elbow

7. Inspection & Testing

7.1 Inspection of Butt Weld Fittings

7.2 Inspection of Socket Weld, Threaded Fittings & Flanges

7.3 Testing of Fittings and Flanges

 Dye Penetration , Hydrostatic Testing, Microstructure analysis, Charpy Impact

8. Marking & Packing

batch of fittings and flanges confirming compliance with product requirements.

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