304121 pve fd pl spc 001 draft (comment by pvpipe) (1)

PETROVIETNAM GAS CORPORATION

CA MAU GPP PROJECT MANAGEMENT BOAD

PROJECT CA MAU GAS PROCESSING PLANT

PACKAGE LOOP PIPELINE

STAGE FRONT-END ENGINEERING DESIGN

SPECIFICATIONS FOR LINEPIPE

A1 08/01/15 Issued for IDC LHD VXH TĐK

Rev Date Description Prepared Checked PM PVE

PETROVIETNAM ENGINEERING

J.S.C

Document No: 304121-PVE-FD-PL-SPC-001

Number of pages: 54

(Including this cover)

CA MAU GAS PROCESSING PLANT PROJECT PACKAGE: LOOP PIPELINE


Doc. No.: 304121-PVE-FD-PL-SPC-001 Rev.: A1 /35

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................... 5

1.1. Project Overview ..................................................................................... 5

1.2. Purpose and Document ........................................................................... 6

1.3. Abbreviations and Definition ..................................................................... 6

1.3.1. Definition ............................................................................................... 6

1.3.2. Abbreviations ......................................................................................... 7

1.4. Codes and Standards ............................................................................... 9

1.5. Order of Precedence .............................................................................. 10

2. QUALITY ASSURANCE SYSTEM ...................................................... 11

3. GENERAL REQUIREMENTS ............................................................. 11

4. MANUFACTURER OBLIGATIONS .................................................... 12

5. MANUFACTURING AND FABRICATION REQUIREMENTS ................ 14

5.1. General Requirements ........................................................................... 14

5.2. Manufacturing Procedure ....................................................................... 14

5.2.1. Changes to the Manufacturing Procedure ................................................ 15

5.2.2. Steel Making ......................................................................................... 15

5.2.3. Rolling Technique – Heat Treatment ....................................................... 15

5.2.4. Process of Pipe Manufacture .................................................................. 16

5.3. Welding ................................................................................................ 16

5.3.1. Welding Processes ................................................................................ 16

5.3.2. Welding Consumables ........................................................................... 17

5.3.3. Welding Procedure Qualifications ........................................................... 17

5.3.4. Welder Qualification .............................................................................. 18

6. CHEMICAL PROPERTIES ................................................................. 18

7. MECHANICAL TESTING .................................................................. 20

7.1. Test Frequency ..................................................................................... 20

7.2. Tensile Test .......................................................................................... 20

7.3. Toughness Test .................................................................................... 21




7.3.1. General ................................................................................................ 21

7.3.2. Test Temperature ................................................................................. 21

7.3.3. Charpy V-Notch Energy Requirements .................................................... 21

7.3.4. Fracture Arrest ..................................................................................... 22

7.4. Drop Weight Tear Test .......................................................................... 22

7.5. Marco/Hardness Tests ........................................................................... 22

7.6. Micrography.......................................................................................... 23

8. DIMENSIONAL REQUIREMENTS ..................................................... 23

8.1. Diameter .............................................................................................. 23

8.1.1. Body .................................................................................................... 23

8.1.2. Ends .................................................................................................... 24

8.2. Wall Thickness ...................................................................................... 24

8.3. Length ................................................................................................. 24

8.4. Straightness ......................................................................................... 24

8.5. Squareness of Pipe Ends ........................................................................ 24

8.6. Pipe End Preparation ............................................................................. 25

8.7. Jointers ................................................................................................ 25

8.8. Bulges, Dents and Flat Areas .................................................................. 25

8.9. Misalignment of Plate Edges ................................................................... 25

9. HYDROSTATIC TESTING ................................................................. 25

10. INSPECTION ................................................................................... 25

10.1. General ................................................................................................ 25

10.2. Visual Inspection/Workmanship .............................................................. 26

11. NON-DESTRUCTIVE TESTING ......................................................... 27

11.1. Procedures ........................................................................................... 27

11.2. Personnel ............................................................................................. 28

11.3. Examination of Plates ............................................................................ 28

11.3.1. Edges .................................................................................................. 28

11.3.2. Body .................................................................................................... 28




11.4. Examination of Pipe ............................................................................... 28

11.4.1. Ultrasonic Examination .......................................................................... 28

11.4.2. Radiographic Examination ...................................................................... 29

11.4.3. Magnetic Particle Inspection (MPI) ......................................................... 29

11.5. Acceptance Limits ................................................................................. 30

11.5.1. Ultrasonic Examination .......................................................................... 30

11.5.2. Radiography ......................................................................................... 30

11.5.3. Magnetic Particle Inpsection .................................................................. 30

12. REPAIRS ......................................................................................... 30

12.1. Repairs: Body of Pipe ............................................................................ 30

12.2. Repairs: Welded Seam of Pipe ................................................................ 31

13. MARKING AND TRACEABILITY ....................................................... 31

14. PROTECTION OF PIPE ENDS .......................................................... 33

15. HANDLING AND STORAGE OF PIPE ................................................ 33

16. RECORDS, TEST REPORTS AND ADDITIONAL INFORMATION ....... 34

17. APPENDICES .................................................................................. 35




1. INTRODUCTION

1.1. Project Overview

The region currently receives natural gas from Block PM3 in Commercial Arrangement Area (CAA) in the overlapping Vietnamese and Malaysia area of the Gulf of Thailand, which feed the gas fired power plants and the fertilizer plant at Ca Mau province in Vietnam. Nature gas is transported by PM3-CM pipeline system, which was designed to transport a maximum of 2 billion standard cubic meters natural gas per year. In future, additional gas production from Block B&52 is planned.

Ca Mau Gas Processing Plant Project (PROJECT) was approved by Vietnam Oil & Gas Group (Petrovietnam) in 2011 to recover LPG and condensate from existing Block PM3 gas production and future Block B&52 gas production. Feed gas from Block B&52 has been delaying, so PROJECT was adjusted basing on Block PM3 as only feed gas source for process train-1. However, PROJECT shall be designed to cover or/and meet the requirement of upgrade when adding Block B&52 gas source (additional flow rate approximate 16.28 MMSCMD).

GPP will extract NGL from only Block PM3 gas production and produce: LPG, condensate and residue gas. The liquid product (LPG and condensate) will be stored in spheres/tanks at Terminal next to GPP and will be exported by truck and barge via a new jetty at the existing port of Ca Mau 1 Power Plant. The residue gas shall be sent back to the existing Gas Distribution Station (GDS) and subsequently delivery to the existing consumers including the power and fertilizer plants.

Gas consumption for future GPP and the booster compressor system (belong to PROJECT) at Mui Tram Land Fall Station (LFS) is approximately 1 MMSCMD by feed gas heating value (including fuel gas). Hence, to ensure gas supply to power and fertilizer plants, the needing new loop pipeline for PM3-CM to upgrade capacity of the existing pipeline. In order to safely and stably operate the system, it's needed to have an additional compressor package installed in LFS simultaneously with installing loop pipeline.

PROJECT shall include some packages:

- Package-1 – Gas processing plant, terminal and export facilities, consist of following:

+ Process units at GPP;

+ Terminal: to storage the liquid products (LPG and condensate);




+ Export pipelines: to transport liquid products from terminal to jetty, including but not limited following: pipelines, pig launcher/receiver system;

+ Jetty: to export liquid product;

+ Utility systems;

+ Electrical system;

+ Instrument & control system;

+ Civil/Structure;

+ By-pass system;

+ Interface/Tie-in.

- Package-2 – Loop pipeline to upgrade capacity of the existing PM3-CM pipeline to 6.95 MMSCMD, consist of following:

+ Loop pipeline;

+ Associated equipment;

+ Interface/tie-in;

- Package-3 – Additional compressor package at Mui Tram LFS, consist of following:

+ Additional compressor package;

+ Modified/Added facilities (at Mui Tram LFS and Ca Mau GDS) due to upgrade capacity of the PM3-CM pipeline system.

+ Interface/Tie-in.

1.2. Purpose and Document

This specification defines the minimum technical requirements for the manufacture and supply of the line pipe for the 28” new loop pipeline for PM3-CM pipeline. The line pipes to be used for the offshore pipeline shall be produced by the Longitudinal Submerged Arc Welded Welding (LSAW).

1.3. Abbreviations and Definition

1.3.1. Definition

CLIENT Petrovietnam Gas Joint Stock Corporation (PVGAS)

REPRESENTATIVE of CLIENT Ca Mau GPP Project Management Board (CMGPMB)




PVE/CONTRACTOR Petrovietnam Engineering Consultancy J.S.C (PVE)

PROJECT Ca Mau Gas Processing Plant Project Package: Loop Pipeline

INSPECTOR Authorized CLIENT/CONTRACTOR representative or third party inspection agency engaged to carry out an inspection (s), as further defined in this document.

MANUFACTURER Entity responsible for supply and manufacture of line pipe.

WORKS All activities of manufacture and supply of linepipe for the 28” new loop pipeline.

ITT Documents Invitation to Tender documents for bidding of manufacture and supply of line pipes.

MR Documents Material Requisition documents of line pipes

Within the context of this specification, the following words shall have the meanings stated below:

“agreement” Unless otherwise indicated, this means agreed in writing

by CLIENT.

“may” Indicates a course of action permissible within the limits

of this document.

“shall” Indicates requirements strictly to be followed in this

document and from which no deviation is permitted.

“should” Indicates that among several possibilities, one is

recommended as particularly suitable, without,

mentioning or excluding others, or that a certain course

of action is preferred but not necessarily required. Other

possibilities may be subject to agreement.

1.3.2. Abbreviations

The following abbreviations shall apply to this specification:

API American Petroleum Institute




ASME American Society of Mechanical Engineers

ASTM ASTM International (formerly American Society for Testing

and Materials)

ASNT American Society for Nondestructive Testing

BOF Basic Oxygen Furnace

CEPcm Carbon Equivalent, based upon the chemical potion of the

Ito- Bessyo carbon equivalent equation

CTOD Crack Tip Opening Displacement

CVN10 Charpy V Notch value for full specimen (10kg indenture)

DWTT Drop Weight Tear Testing

FL Fusion Line

GMAW Gas Metal Arc Welding

HAZ Heat Affected Zone

HV10 Vickers Hardness Number (10kg indentor)

ID Inner Diameter

ISO International Organization for Standardization

J Joule

LSAW Longitudinal Submerged Arc Welding

MPa Mega Pascal

MPI Magnetic Particle Inspection

MPS Manufacturing Procedure Specification

MPQ Manufacturing Procedure Qualification

NACE National Association of Corrosion Engineers

NDT Non Destructive Testing

OD Outer Diameter




PCN Personnel Certification in Non-Destructive Testing

SAW Submerged Arc Welding

SMYS Specified Minimum Yield Strength

UOE U-ing, O-ing and Expansion

UT Ultrasonic Testing

UTS Ultimate Tensile Strength

1.4. Codes and Standards

The manufacture and supply of the LSAW line pipes shall conform to this specification and shall refer to the latest edition (unless otherwise noted) of the codes, standards, references and recommended practices listed below.

American Petroleum Institute, API

API Spec 5L: 2012 Specification for Line Pipe, 45th Edition.

API RP 5L1 Recommended Practice for Railroad

Transportation of Line Pipe

API 5L3 Recommended Practice for Conducting Drop-

Weight Tear Tests on Line Pipe

API RP 5LW Recommended Practice for Transportation of

Line Pipe on Barges and Marine Vessels

API STD 1104 Welding of Pipelines and Related Facilities

API RP 1110 Pressure Testing of Liquid Petroleum Pipelines

American Society of Mechanical Engineers, ASME

ASME B31.8 Gas Transmissions and Distribution Piping

System

ASME Section V Non-Destructive Examination

ASME Section II Boiler and Pressure Vessel Code – Materials

American Standards for Testing Materials, ASTM




ASTM E112 Standard Test Methods for Determining

Average Grain Size

ASTM A370 Standard Test Methods and Definitions for

Mechanical Testing of Steel Products

ASTM E709 Standard Guide for Magnetic Particle Testing

British Standards, BS

BS EN 2910 Methods for Radiographic Examination of

Fusion Welded Circumferential Butt Joints in

Steel Pipes

BS EN 10160 Ultrasonic Testing of Steel Flat Products of

Thickness Equal to or Greater than 6mm

BS EN 10204: 2004 Test Certificated for Steel Products

International Organization for Standardization, ISO

ISO 3183 Petroleum and Natural Gas Industries – Steel

Pipe for Pipeline Transportation Systems

National Association of Corrosion Engineers, NACE

NACE MR0175 Petroleum and Natural Gas Industries –

Materials for use in H2S-containing

Environments in Oil and Gas Production

Other Standards

Recommended Practice No. SNT-TC-1A Personnel Qualification and Certification in Nondestructive testing.

1.5. Order of Precedence

Since this document refers to many codes and standards and also to other specifications, in case of any conflict, CLIENT should be notified by the MANUFACTURER for clarification. Unless otherwise agreed, the following order of precedence is expected to be followed:

1. Vietnam Government Regulations;

2. Vietnam Country Standards;

3. CLIENT supplied technical documents;




4. Project Specifications;

5. International Codes and Standards.

2. QUALITY ASSURANCE SYSTEM

All line pipes shall be covered by inspection certificates signed by CLIENT approved Third Party inspection agency in accordance with EN 10204:2004 Type 3.2.

The MANUFACTURER shall have an established and documented Quality Assurance System in accordance with ISO 9001 as defined elsewhere in the contract. The MANUFACTURER shall maintain this Quality Assurance System throughout the contract period.

The Quality Assurance System shall contain a minimum of a Quality Plan comprising of quality manuals covering all activities of the job. The MANUFACTURER shall also submit an Inspection Plan consisting of detailed procedures of all the inspections to be performed, schedule of inspections and procedures for repair of defective materials.

The MANUFACTURER shall proceed with line pipes and other associated materials, only after CLIENT has approved his Quality Plan and Inspection Plan.

Where the MANUFACTURER’s sub-contracts the whole or main parts of the work, then these requirements shall be applied in full to the sub-contractors and the MANUFACTURER shall be responsible for ensuring that these requirements are satisfied by the sub-contractors.

The MANUFACTURER is responsible for complying with all of the provisions of this specification. CLIENT may make any investigation necessary to satisfy himself and may reject any material that does not comply with any specific requirements. This does not relieve the MANUFACTURER from the obligation to incorporate additional quality procedures, at the discretion of CLIENT (and at the MANUFACTURER's cost), in case serious doubt have arisen about certain quality aspects of the line pipes.

3. GENERAL REQUIREMENTS

The design data that is to be used in this pipeline is contained in Datasheet No.: 304121-PVE-FD-PL-DAS-001 Data Sheet for Line Pipe.

Pipe manufacturing shall be in accordance with this Specification and API 5L: 2012, 45th Edition. The pipeline is designed according to DNV-OS-F101; pipeline welding during installation will be in accordance with Doc. No.:




302141-PVE-FD-PL-SPC-012 Specification for Pipeline Welding, Weld Repair and NDT.

The line pipes will be manufactured by Longitudinal Submerged Arc Welding (LSAW) using a single longitudinal seam. The well seams in the LSAW pipe shall be produced in such a way that at least one submerged-arc welding pass on the inside of the pipe and at least one submerged-arc welding pass on the outside of the pipe shall be made. All pipe materials supplied to this specification shall be manufactured and tested in compliance with the requirements of this specification.

All manufacturing processes viz. steel making, plate rolling, pipe fabrication, heat treatment and etc., will be as stated in the Manufacturing Procedure Specifications (MPS). Minimum required information is listed as per API 5L: 2012, 45th Edition.

The manufacturing procedure specification is required to be qualified. The detailed of the qualification are given in API 5L: 2012, 45th Edition as supplemented in this specification. The MANUFACTURER may provide previous evidence and data to prove that the manufacturing procedure is suitable to produce the required pipe. This shall be subject to CLIENT approval.

Except as amended in this specification, all the requirements of API 5L: 2012, 45th Edition are mandatory.

Pipes shall be provided with reusable type metal bevel protectors and end caps.

The grade of pipe for the pipeline is L450M or X65M, PSL2 as depicted in Table 1 of API 5L: 2012, 45th Edition.

The MANUFACTURER shall furnish all equipment, plant, materials, consumables, spares, stockpile areas, labour and supervision necessary to carry out the line pipe fabrication and testing in accordance with this specification and in a manner satisfactory to CLIENT.

The MANUFACTURER shall ensure that only skilled and experienced personnel approved by CLIENT are used to perform and supervise the scope of work. The MANUFACTURER shall carry out the work with the requirements of this specification.

4. MANUFACTURER OBLIGATIONS

The MANUFACTURER shall furnish all the required materials, supervision, labour, equipment, testing and inspection services, and expenses incidental




to and necessary for the WORKS specified herein in a manner satisfactory to CLIENT.

Linepipe shall be manufactured in accordance with the requirements of Datasheet No.: 304121-PVE-FD-PL-DAS-001 Data Sheet for Line Pipe, this Specification and API 5L: 2012, 45th Edition. Linepipes shall be marked with the API Monogram as per Appendix O of API 5L: 2012, 45th Edition.

Pipes for this project shall be manufactured from the CLIENT approved pipe mills only.

The linepipes shall be 28" OD LSAW with a single longitudinal seam as specified within this specification and API 5L: 2012, 45th Edition.

Pipe wall thickness and line pipe quantities shall be as identified in the Datasheets, Purchase Order and any other supporting documentation.

The WORKS covered by this specification shall be carried out in accordance with procedures developed by the MANUFACTURER for the WORKS in accordance with the schedule defined in the CONTRACT Documents.

All manufacturing and testing procedures shall be submitted in writing by the MANUFACTURER for review and approval by CLIENT at least four (4) weeks prior to implementation of the WORKS. The WORKS shall be performed in accordance with the approved procedures.

The MANUFACTURER is required to establish an acceptable Quality Plan, comprising quality manual and procedures covering all the activities of the order, to comply with the Quality Systems requirements.

Unless otherwise agreed with CLIENT, the MANUFACTURER's Quality System shall specify the requirements of ISO Quality System.

The MANUFACTURER shall be fully responsible for their Quality Assurance and associated Quality Control processes.

CLIENT acceptance or approval of the MANUFACTURER's methods, procedures, supervision, labour, equipment, testing and inspection services, and any activities related to and necessary for the WORKS shall in no way relieve the MANUFACTURER of his sole responsibility for the safe, efficient and satisfactory performance of the WORKS as specified herein to the satisfaction of CLIENT.

CLIENT shall reserve the right to verify at the MANUFACTURER's premises that the products conform to the specified requirements. Verification by CLIENT shall not absolve the MANUFACTURER of the responsibility to provide an acceptable product, nor shall it preclude subsequent rejection by CLIENT.




Inspection and testing activities by the MANUFACTURER and verification /surveillance activities by CLIENT shall be specified, identified and controlled by the MANUFACTURER's Inspection and Test Plan approved by CLIENT.

The MANUFACTURER shall comply with all the requirements for receiving, hauling, unloading, storage and loading of the line pipes and other associated materials as given in Doc. No.: 304121-PVE-FD-PL-SPC-008 Specification for Transportation, Handling and Storage of Linepipe Material.

The MANUFACTURER shall submit, as a minimum, the required technical documentation as specified in the Invitation to Tender (ITT) and the Material Requisition (MR) at the time of the bidding.

The MANUFACTURER shall submit the list of all exceptions or deviations from this Specification and other referenced specifications or attachments listed in the MR and ITT documents at the time of submission of the bid.

In the event of conflict, inconsistency or ambiguity between the MR/ITT documents, this specification, International Codes or Standards, or any other document referenced, the MANUFACTURER shall refer them to CLIENT for resolution, whose decision shall be final.

5. MANUFACTURING AND FABRICATION REQUIREMENTS

5.1. General Requirements

The pipe material shall conform to the grade API 5L: 2012, 45th Edition L450M or X65M, product specification level 2 (PSL 2) as specified in the Purchase Order.

The MANUFACTURER’s Manufacturing Procedure Specification (MPS) shall be subject to qualification as described in Appendix 1 of this Specification.

Weldability tests shall be conducted in accordance with Appendix 3 and Appendix 4 of this Specification.

Inspection and test requirements are summarized in Appendix 3.

5.2. Manufacturing Procedure

All manufacturing, examination, inspection, testing and repair shall be performed in accordance with the procedures. The procedures shall cover all manufacturing steps from the steel making to finished pipe and the system for quality control in each step. The control of received materials shall also be included in the manufacturing procedures.

The manufacturing procedure shall be submitted to CLIENT for approval. No manufacturing shall commence until CLIENT approval is received.

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Please delete Appendix 4. Girth weld shall be performed by Pipeline installation contractor. Pipe manufacturer have not enough equipment and skill for performing Girth weld (that weld connect 2 pipes together)




The manufacturing procedure shall state the frequency of testing of the manufactured pipe in accordance to API 5L 2012, 45th Edition.

5.2.1. Changes to the Manufacturing Procedure

Any of the following changes to the manufacture of the line pipe will require the Manufacturing Procedure to be re-submitted to CLIENT for qualification and approval.

a. Any change in nominal pipe diameter and/or wall thickness;

b. Any change in steel grade, steelmaking process, rolling condition and heat treatment of the plate/strips;

c. Any change in pipe forming, alignment, clamping and joint design for welding;

d. Any change in welding process, consumables, gases and/or fluxes;

e. Any change in the number of passes and number of welding wires used in each pass;

f. Any change in hot or cold wire or iron powder addition;

g. Any change in pre-heating and post weld heat treatment;

h. Any change in the method of cold expansion and any increase in the cold expansion above that used during qualification.

5.2.2. Steel Making

The steel shall be manufactured by the electric arc furnace process or basic oxygen furnace (BOF) process and shall be fully killed, vacuum degassed and made to fine grain practice (grain size ASTM 8 or finer in accordance with ASTM E112).

Slab for plate rolling should be produced by the continuous casting process. Other casting processes may be offered for approval by CLIENT. All surfaces of the slab shall be inspected visually for defects. Scarfing shall be carried out to produce an acceptable surface for rolling.

5.2.3. Rolling Technique – Heat Treatment

Plates shall be manufactured by thermo-mechanical controlled rolled process.

As the properties of the plate material are dependent upon control of rolling temperature, the mill shall be adequately instrumented to ensure proper control and hence consistency in the physical properties of the product. Control of intermediate and finish rolling temperatures shall form the part of the approved mill procedure.




Banded structure in terms of segregated bands of carbides shall not be acceptable.

Rolling ratio shall be equal to or above 3.5.

5.2.4. Process of Pipe Manufacture

The pipes shall manufacture according to specification API 5L: 2012, 45th Edition with some additional and modified supplementary requirements specified in this specification.

The pipes shall be manufactured from plates by cold forming and mechanical expansion (UOE process) or suitable manufacturing process. 3-roll bending process, with external fibre strain restricted to 1.5 % shall be subject to CLIENT approval.

After execution of the longitudinal seam, the run-on and run-off tabs shall be removed by flame cutting or sawing only (mechanical breaking of tabs shall be for bidden).

The pipes shall be cold expanded or hydrostatically expanded to provide permanent strain in the range at 0.8% to 1.5%. Pipe shall be sized, straightened and hydrostatically tested.

The MANUFACTURER shall conduct all examinations, inspection, dimensional checks and mechanical tests described in this Specification and API 5L: 2012, 45th Edition. The results of all the examinations, dimensional checks and mechanical tests shall conform to the requirements of this Specification and API 5L: 2012, 45th Edition. All results shall be recorded and provided to CLIENT in accordance with the requirements of this Specification and API 5L: 2012, 45h Edition. Weldability tests (as per Appendix 4) shall be carried out for offshore sections using pipes with the highest CEPcm.

5.3. Welding

5.3.1. Welding Processes

The welding process for longitudinal seam shall be confined to the automatic Submerged Arc Welding (SAW) process.

Gas Metal Arc Welding (GMAW) process may be used for tack-welding only provided that the weld is completely smelted by the Submerged Arc Welding process. Tack welding shall be performed for the entire length of the weld to ensure good dimensional control of the linepipe.

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Please delete Appendix 4. Girth weld shall be performed by Pipeline installation contractor. Pipe manufacturer have not enough equipment and skill for performing Girth weld (that weld be connected 2 pipes together)

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or adding more: The weldablity tests of Girth weld (as per Appendix 4) shall be performed by Pipeline installation contractor




Each welding procedure shall be fully detailed in a Welding Procedure Specification (WPS) to be approved by CLIENT, or its authorised representative.

5.3.2. Welding Consumables

Welding consumables shall meet the following requirements:

The weld deposits obtained from the consumables shall satisfy the fracture toughness and hardness requirements of this Specification and shall have tensile properties that are equal to or slightly higher than those of the base metal. Weld metal shall not overmatch the maximum Ultimate Tensile Strength of the base metal by more than 20%.

All welding consumables shall conform to ASME Boiler and Pressure Vessel Code, Section II Part C or approved equivalent.

The MANUFACTURER shall obtain manufacturer’s test certificates (3.1 certificates according to EN 10204) for each batch of consumables used on the job.

The MANUFACTURER'S procedure for storing and handling of welding consumables and flux recycling/reconditioning shall be approved by CLIENT, or its authorised representative, before commencement of production welding. All requirements shall be as per API 5L: 2012, 45th

Edition.

All welding consumables shall be subject to inspection by CLIENT, or its authorised representative. The manufacturer's acceptance test certificates for each batch and lot of consumables shall be available for that purpose. These documents shall certify that the consumables meet the requirements of the relevant standards for classification and grade.

5.3.3. Welding Procedure Qualifications

The welding procedure for the longitudinal weld shall be qualified together with the manufacturing procedure qualification tests (see Appendix 1) based on the submitted WPS.

Repair welding each test weld shall represent a repair of simulated (or actual) defects oriented longitudinally in the longitudinal weld seam. Unless otherwise agreed by CLIENT, or its authorised representative, two repair types shall be qualified by the test.

One deep repair (mid-thickness or 2/3 thickness) simulating a defect located on the fusion line;

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Welding wire: 3.1 Welding flux: 2.2 (According to DNV F101 2012, Section 7, Item B319, Page 108 and conforming to actual welding consummable manufacturer over the world.)




One shallow repair with 2 welds passes minimum simulating a defect located at weld toe. Each welding repair shall be qualified on a pipe section in accordance with API 5L: 2012, 45th Edition and this Specification.

The mid-thickness repair shall be subject to the following tests:

100% visual, radiography, ultrasonic examination and MPI in accordance with Section 11.4 of this Specification.

Charpy tests in accordance with Section 7.3, but with the sets removed from the following locations:

- Repair weld centerline;

- Fusion line between repair weld and original weld;

- Fusion line between repairs welds and parent material.

Macro/hardness test in accordance with Section 7.5 of this Specification;

Two tensile tests transverse to weld as per Section 7.2 of this Specification;

MPI in accordance with Section 11.4 of this Specification;

The shallow repair shall be subject to:

• Macro/hardness test in accordance with Section 7.5 of this Specification.

• 100% MPI in accordance with Section 11.4 of this Specification.

5.3.4. Welder Qualification

Welders or welding operators who have performed a satisfactory welding procedure qualification test are thereby qualified. Other welders shall be qualified by visual and radiographic examination and side bend tests, in accordance with an internationally recognized qualification standard.

6. CHEMICAL PROPERTIES

The chemical composition of the steel shall be as given in Table 6-1. The tolerances and acceptable range applied for each element shall be provided in the MPS. The percentage present of every element in Table 6-1 shall be stated in the product analysis report of the finished pipe even if some elements are not added on purpose but are present as residuals only. No element shall be added to the steel without the written approval of CLIENT.

Ladle and product analyses shall be furnished to CLIENT concurrently with production for each heat of steel. For continuous cast processes, the term "heat" shall define each casting.




The MANUFACTURER shall advise CLIENT or its representative if any deviations outside the limits placed on heat and product analyses in the manufacturing procedure specification (MPS). Each required analysis shall include the determination of each of the elements listed in Table 6-1, together with the analysis for any other elements whose addition has been approved by CLIENT or its representative. Any deviations from the maximum percent specified in Table 6-1 shall be submitted to CLIENT for review and approval.

Table 6-1: Chemical Composition

Element Symbol Product Analysis % (Max.)

Carbon C 0.12

Silicon Si 0.45

Manganese Mn 1.65

Sulphur S 0.01

Phosphorus P 0.02

Copper Cu 0.35

Nickel Ni 0.3

Molybdenum Mo 0.1

Chromium Cr 0.3

Niobium Nb 0.05

Vanadium V 0.05

Titanium Ti 0.05

Aluminium (total) AI 0.05

Nitrogen N 0.008

Boron B 0.0005

Calcium Ca 0.005

Notes:

1. The sum of Nb+V+ Ti shall not exceed 0.15 percent.

2. The soluble Al: N ratio shall not be less than 2:1. Altotal ≤ 0.06%, N ≤ 0.012%.

3. Mo ≤ 0.1%; B ≤ 0.0005%; Cu ≤ 0.35%; Ni ≤ 0.3%; Cr ≤ 0.3%.

4. The carbon equivalent value (CEPcm) based on product analysis shall be calculated by the following formulae, shall not exceed 0.22% for the line pipe material and weld.

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According to API 5L 2012, Annex J, Table J.1 (Plate manufacturer can not produce the steel plate if the chemical composition is more strictly than API 5L standard requirement

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0.5

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0.5

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0.5

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0.5

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0.08

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0.1

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0.06

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0.06

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0.012

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According to API 5L, Table 18 and Table J.6. The chemcial composition and carbon equivalent is on steel only. The weld is not applied for calculating carbon equivalent




V Mo Cr+Mn+Cu Si NiCE =C+ + + + + +5BPcm 10 15 20 30 60

5. Any deliberate addition of Boron (B) or Nitrogen (N) is not allowed.

7. MECHANICAL TESTING

7.1. Test Frequency

The mechanical testing for qualification and production shall be done according to Appendix 3, Testing and Inspection.

The specified destructive tests shall be carried out on one finished pipe selected from each lot of 50 pipes (or part thereof) produced, in both transverse and longitudinal directions for every heat number. CLIENT or its authorised representative, reserves the right to select the pipes for destructive tests.

In addition three of the completely finished pipes of the first day production shall be selected at random for testing to verify that the submitted manufacturing procedure results in fully acceptable pipes. These pipes shall be subjected to the inspection and tests as described in Appendix 1, for Qualification of Pipe Manufacturing Procedure.

7.2. Tensile Test

Acceptance criteria for tensile tests should be per Table J.2, API 5L: 2012, 45th Edition.

Tensile testing will take sample as the mentioned in Appendix 2, Hardness Survey. The tensile, yield and elongation properties of base metal shall be determined.

The actual yield strength of the pipe material shall not exceed the specified minimum yield strength as required by API 5L: 2012, 45th Edition, grade specified by more than 120 MPa (17,404 psi) i.e, Minimum SMYS: 450 MPa, Maximum SMYS: 570 MPA. The actual Ultimate Tensile Strength (UTS) shall be maintained within the range of 535 MPa to 760 MPa. When the round bar specimen is used, the yield strength measured shall be the 0.2% proof stress.

The minimum required elongation shall be determined in accordance with the Table J.2 (note f) in API 5L: 2012, 45th Edition.

Tensile properties shall be determined from specimens removed from the pipe in its final condition (i.e. after mechanical expansion).

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In addition, 1 pipe / 1 heat or 2 pipes / heats of each OD and wall thickness combination. According to DNV OS F101, Section 7, A803 and other project requirement




Tensile strength of weld seam shall be as per Table J2 API 5L: 2012, 45th Edition.

The ratio of yield strength to tensile strength in base material shall not exceed 0.93 in the transverse and longitudinal directions.

7.3. Toughness Test

7.3.1. General

The fracture toughness of the pipe shall be determined in all cases by the use of Charpy V-notch impact tests in accordance with Section 9.8, Annex J of API 5L: 2012, 45th Edition.

Charpy test specimens shall be full-size (10mm x 10mm) transverse specimens whenever possible.

Three sets shall be tested on each test ring taken for tensile testing with three specimens taken from the each of the following positions:

• Pipe body at 90 degrees to the weld

• Weld centerline

• Heat Affected Zone (note 1)

Note 1:

Heat Affected Zone location shall be the zone which gave the lowest energy values in Fusion Line/ Fusion Line + 2mm/ Fusion Line + 5mm tests carried out for Manufacturing Procedure Qualification.

Charpy test specimens shall be located at the mid-thickness of the pipe with the axis of the notch perpendicular to the pipe surface. Specimen locations for weldments are shown in Figure A of Appendix 1.

7.3.2. Test Temperature

The Charpy V-notch impact test temperature shall be as equal as minimum design temperature for thicknesses equal to or below 20mm. For linepipe thicknesses above 20mm, test temperature shall be 10oC below minimum design temperature.

7.3.3. Charpy V-Notch Energy Requirements

In order to have adequate toughness against the ductile fracture, the Charpy V-Notch energy and shear area requirements for line pipe material API 5L: 2012, 45th Edition, X65M shall be observed as per table below, which contains the following nominal values for the minimum average/individual impact values and minimum average/individual shear area.

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Modify: Transverse of pipe body (T180) According to API 5L, Table 20, Table J.7, Annex J and Appendix 2 of this spec.




Charpy V-Notch Energy

Minimum Average (J)

Minimum Individual (J)

Transverse 45 38

Longitudinal 67.5 57

7.3.4. Fracture Arrest

In addition, the pipe material shall exhibit fracture arrest capabilities. For Grade API 5L X65M linepipe, the minimum average absorbed energy for full size Charpy V specimen located transverse to the pipe axis, in the pipe body, shall be as tabulated below:

OD Wall Thickness

17.5 ≤ WT ≤ 20mm 20 < WT ≤ 25mm

28” 90J (average) 95J (average)

7.4. Drop Weight Tear Test

Full-wall Drop Weight Tear Tests (DWTT) shall be performed, in accordance with API 5L: 2012, 45th Edition and API RP 5L3.

A full DWTT transition curve shall be established as part of the Manufacturing Procedure qualification tests.

Production tests shall be at the rate of one pipe per heat. Three full thickness transverse specimens shall be taken from one length of the pipe from each heat supplied.

DWTT production tests shall be conducted at 0°C.

Each specimen of a set of two production test specimens shall exhibit a minimum of 85 percent shear area on the fracture surface.

Retest criteria shall be as per Section G.3, Annex G, API 5L: 2012, 45th Edition.

7.5. Marco/Hardness Tests

The weld shall be evaluated by removing a pipe cross section containing the weld. The section shall include the weld fusion line, heat affected zone (HAZ) and parent metal on both sides of the weld and shall be polished and etched for examination. The weld shall have complete penetration and fusion. The geometry, including plate edges and inside and outside weld profile shall be

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Please delete. according to Table 20, Table J.7 and Appendix 2 of this spec

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Two According to API 5L, Section 9.9 and Table 20

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Please modify: " the average value of a set of two...." According to API 5L, Section 9.9




within the tolerances specified in the Manufacturing Procedure Specification. There shall be no evidence of defects.

Vickers hardness testing with a 10kg load shall be conducted on the weld cross sections. The hardness traverse shall be in accordance with Appendix 2 of this specification. The hardness shall not exceed 270 HV10 on the base material, weld metal and 300 HV10 in the heat affected zone (HAZ).

If any results exceed this hardness limit, two further sections from the same weld shall be prepared and tested. If either of these specimens give results that exceed the hardness limit the entire heat shall be rejected. CLIENT will define additional tests (if required) for all other heats of steel being supplied.

7.6. Micrography

One specimen of 30mm long in the rolling direction shall be extracted from base material, at 20mm from the weld toe and at 180° to the weld seam. They shall be properly polished and etched. They shall be examined at 5mm from the external and internal surfaces and at mid thickness, every 10mm in the rolling direction, with a magnification of X100. The microstructure shall not show banded structure in terms of segregated bands of carbides or carbide components.

8. DIMENSIONAL REQUIREMENTS

The requirement for mass tolerance will be referred to Section 9.14, API 5L: 2012, 45th Edition. The dimensions, length, weights, and straightness of pipe shall comply with API 5L: 2012, 45th Edition and the following:

8.1. Diameter

8.1.1. Body

Dimensional tolerances on outside diameter (OD) of the pipe body shall not exceed –0.5%; +0.5% of the specified nominal outside diameter (O.D), measured with a diameter tape.

The out-of-roundness of the outside diameter of the pipe at any point along its length shall not exceed the following:

(Max.O.D - Min.O.D)Nominal .O.D ≤ 1.0 percent

Peaking of the pipe body at the weld shall not deviate more than 1.5mm from the design form.

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8.1.2. Ends

The tolerance on the nominal internal diameter within 100mm of the pipe ends shall be within tolerance ±1.6mm.

Nominal ID = Nominal OD - 2 x Nominal Wall Thickness

The out-of-roundness at the pipe ends shall not exceed the following:

(Max.I.D - Min.I.D)Nominal .I.D ≤0.75 percent

ID measurements shall be made at a minimum of six (6) locations using a bar gauge or CLIENT approved alternative, measuring the actual maximum and minimum diameters.

8.2. Wall Thickness

The wall thickness of each pipe shall be checked during production to ensure uniformity.

The pipe wall thickness at any point shall not deviate by more than ±1 mm (10 mm < wall thickness ≤ 20 mm) and +1.5 mm/ -1 mm (wall thickness > 20 mm) from the specified nominal wall thickness.

Note that for any pipe designated to be used for factory induction bends, the pipe wall thickness tolerance shall be + 1.5mm/ −0.0mm from the specified nominal wall thickness).

8.3. Length

The pipe shall be supplied to the following length requirements unless otherwise specified in the Purchase Order:

• The nominal pipe length shall be 12.2m;

• All pipes shall have lengths between 11.9m and 12.4m.

8.4. Straightness

Pipe shall be checked for straightness and the deviation from a straight line shall not exceed 12mm per 12m pipe length or 0.1%. Measurements shall be made using a taut string or wire from end to end along the side of the pipe measuring the greatest deviation.

8.5. Squareness of Pipe Ends

The pipe ends shall be cut square in regard to the longitudinal axis of the pipe within 1.5mm across any diameter.

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Please delete. because the thickness of the bend shall be reduced more than 3 mm (based on actual thickness) at the extrados point after hot induction bending. The bend manufacturer and other project only control the min thickness

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Please modify: 12m.

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Please modify: 11.5m and 12.2m. Because some pipe must be to cut 400 - 450mm for production tests

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Please modify: according to API 5L, 9.12.1.4 "1.6mm"

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Please modify: "a tape" same with other project




8.6. Pipe End Preparation

Pipe ends shall be as per API 5L: 2012, 45th Edition. The pipeline shall be supplied with ends bevelled according to API 5L: 2012, 45th Edition, Clause 9.12.5.2. The MANUFACTURER shall provide 5% spare bevel protectors.

8.7. Jointers

Jointers shall not be permitted.

8.8. Bulges, Dents and Flat Areas

Any sharp deformations shall be unacceptable.

No dents are allowed in the pipe body as well as on weld seams.

8.9. Misalignment of Plate Edges

For pipes with wall thickness greater than 10mm, the maximum radial offset shall not exceed 10% of the specified wall thickness subject to a maximum of 1.5mm. Height of weld bread, misalignment of weld bread will be referred to Section 9.13, API 5L: 2012, 45th Edition.

9. HYDROSTATIC TESTING

Hydrostatic testing of the pipe shall be in accordance with the requirements of Section 9.4 of API 5L: 2012 45th Edition.

The hydrostatic test equipment shall be equipped with a recording gauge that will record test pressure and duration of test applied to each length of pipe. The identity of each pipe under test shall be recorded alongside the pressure trace on the chart. Hydrostatic test records, which include the pipe identity, shall be made available to CLIENT, or its authorized representative.

10. INSPECTION

10.1. General

The MANUFACTURER shall bear full responsibility for the conformity of the supplied items to all requirements of this Specification. The MANUFACTURER shall for this purpose, take all necessary measures, making use of suitable means, devices and qualified personnel to ensure permanent and effective control at each stage of manufacture.

All inspection operations carried out by the MANUFACTURER during pipe manufacture shall be regularly reported and updated. These reports shall be available for inspection by the INSPECTOR at any time.

If during pipe production, unacceptable defects are found at a rate of 5% or more for a specific type of defect, the INSPECTOR shall have the right to

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Geometric deviation (Dent, Bulges, Flat areas, etc.) must be complied to API 5L , Section 9.10.5

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The max radial offset shall comply with Table 14 of API 5L, Section 9.13

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bead




require the MANUFACTURER to increase his Quality control programmed to an appropriate level and to maintain it until the causes of the defect are identified and eliminated.

CLIENT may require the main production to be stopped at any stage of the order if:

a. The total of heats rejected exceeds 10% of the total heats offered;

b. More than 10% of the pipes are rejected (or re-routed for repairs or re-processing) in any day's production.

Production shall not proceed until the cause of the difficulty has been established and corrected as approved by CLIENT.

Only pipes meeting the full requirements of this Specification shall be presented to the INSPECTOR for final acceptance. If pipes are repeatedly rejected for any recurring cause, this shall be sufficient to refuse any more pipes for final examination until the cause has been corrected.

The MANUFACTURER shall provide office space and inspection facilities as required by the INSPECTOR. Free access shall be allowed to him in the steel mill, the plate or strip mill and the pipe mill at all times during manufacture and testing. A suitable working area shall be reserved for the INSPECTOR at the end of the production line or at any other agreed location so that he can carry out his own inspections of the finished pipes.

All manufacturing procedure qualification tests may be witnessed by CLIENT or its authorised representative. In addition, all pipes may be subject to inspection by CLIENT or its authorised representative. The MANUFACTURER shall give sufficient notice of the time when pipe production is to begin.

CLIENT or its authorised representative will have the option to examine all materials rejected for any reason. The causes for rejection shall be brought to the attention of CLIENT or its authorised representative, and all affected materials shall be retained until examined by CLIENT or its authorised representative.

10.2. Visual Inspection/Workmanship

A visual examination of the inside and outside pipe surfaces, the weld bevels and the weld seam shall be carried out on each pipe. The standards of acceptance shall conform to API 5L: 2012 45th Editions with the following additional requirements.

Pipe bevels containing laminations shall be cut back until clear.




The MANUFACTURER shall take all reasonable precautions to ensure that the pipe surface is free from imperfections that might interfere with the efficient application of an external coating. In addition, the metal surfaces shall be sufficiently clean and smooth to permit Non-Destructive examination. All loose scale shall be removed, and pitting and rough surfaces removed by grinding. Pipe shall have a workmanlike finish, and the MANUFACTURER shall remove those by grinding, mechanical marks and abrasions, such as cable marks, scores, etc., and also imperfections such as scabs, seams, laps, tears, and slivers, even though these imperfections may be shallow enough to be within wall thickness tolerances.

The maximum height of outside and inside weld bead shall be not more than 3.0 mm. All pipes shall be checked for weld bead height and shall be measured and recorded three times per shift.

Defects having a depth greater than 5% of the specified nominal wall thickness shall be considered unacceptable. Minor defects may be removed by grinding or polishing or both, provided that a smooth curved surface is maintained and that the wall thickness is not decreased below the specified minimum.

Any weld undercut with maximum depth of 0.2mm is acceptable in any length. Undercuts, 0.2 mm< depth ≤ 0.5mm are permitted for weld lengths of 50mm maximum. All other undercuts greater than 0.5mm in depth shall be removed by grinding or repaired by welding.

Detects consisting of sharp gouges shall be removed by grinding.

Thickness measurements shall be made on all areas where grinding has been carried out. The final thickness after grinding shall not be less than the specified minimum wall thickness.

Any cracks or leaks shall be clearly marked and the pipe length quarantined and made available for inspection or investigation by the INSPECTOR.

11. NON-DESTRUCTIVE TESTING

The types and extent of NDT required for LSAW line pipe shall be per API 5L: 2012, 45th Edition.

11.1. Procedures

All NDT shall be performed in accordance with written procedures. These procedures shall be approved by CLIENT or its authorized representative, prior to the testing.

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Please delete Acceptance criteria shall be in accordance with API 5L, Annex J, Section 9.10.2




Non-Destructive Testing procedures shall be subject to qualification tests prior to their use in production, unless otherwise agreed by CLIENT or its authorized representative. Qualification records shall be established by the MANUFACTURER and duly signed by the INSPECTOR.

11.2. Personnel

All Non-Destructive Testing personnel shall be properly certified, by a third party, in accordance with ASNT Recommended Practice SNT-TC-1A, PCN or equivalent alternative qualification. All operators shall be certified at Level-II, as a minimum.

11.3. Examination of Plates

All plates shall be inspected visually and tested ultrasonically to ensure freedom from laminations and/or major clusters of inclusions. The coverage, sensitivity and acceptance levels for ultrasonic examination shall be as follows:

11.3.1. Edges

All four edges of the plate, after cutting to final size for pipe forming, shall be examined for laminations and inclusion clusters along a band 75 mm wide and shall meet the minimum requirements of BS EN 10160 Class E2, or equivalent.

11.3.2. Body

The body of the plate or completed pipe shall be ultrasonically scanned and shall meet the minimum requirements of BS EN 10160 Class S1, or equivalent, with respect to laminations and inclusion clusters. Scanning shall be along parallel lines at right angles to the principal rolling direction. The maximum scan line separation shall be 60mm. The maximum number of imperfections allowed in any 1m2 shall be 5.

11.4. Examination of Pipe

In general, all requirements and acceptance criteria for NDT of all types of line pipe shall per to API 5L: 2012, 45th Edition and additional/ supplementary requirements given in this Specification.

11.4.1. Ultrasonic Examination

The weld seam shall be ultrasonically tested after hydrostatic testing and cold expansion. Submerged arc welds shall be inspected over their entire length, for both longitudinal and transverse defects, using ultrasonic examination in accordance with API 5L: 2012, 45th Edition.




The MANUFACTURER shall furnish for approval by CLIENT, or its authorized representative, a complete description of the proposed procedures, including a description of the equipment; the number, size, angle, frequency, mode, and location of the transducers; continuity checking; scanning speed; method of weld tracking; defect marking methods; operator qualification; calibration reference standards, and acceptance limits. During the first day of production, the MANUFACTURER shall demonstrate to the satisfaction of CLIENT or its authorized representative, the dynamic calibration of ultrasonic equipment at normal inspection speed, using an API 5L: 2012, 45th Edition.

The equipment for ultrasonic examination shall be fitted with an automatic paint spray system for marking areas giving ultrasonic indications and areas of loss of ultrasonic coupling with the pipe.

11.4.2. Radiographic Examination

X-ray examination shall be carried out on each end of the weld seam in SAW pipe for a distance of at least 200 mm, any parts of the weld seam not scanned by all probes in the automatic ultrasonic array, on all welding re-starts, repair welds, areas exhibiting ultrasonic indications and welding procedure qualification test welds. All films shall be available for inspection by CLIENT or its authorized representative. Radiographic examination shall be made using X-rays, with fine grain high contrast direct films, lead screens and a single wall, single image technique, generally in accordance with API 5L: 2012, 45th Edition or approved equivalent.

11.4.3. Magnetic Particle Inspection (MPI)

All finished joint bevels of pipe ends and internal and external weld surfaces within 150mm of the pipe ends shall be examined by magnetic particle inspection using the wet technique. MPI shall also be used for the investigation of the surface of specific areas which have been repaired or are considered otherwise suspect.

MPI shall be conducted in accordance with ASTM E709 or approved equivalent. The sensitivity of the method shall be regularly checked using a recognized calibration block or material containing appropriate defects. Direct magnetisation techniques including prods and clamps are not acceptable. AC techniques are preferred.

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Areas exhibiting ultrasonic indications shall be examined AUTO UT and confirmed by Manual UT.Because, The RT can not confirm for all indication of UT

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All repairing area of surface dont need to perform MPI according to API 5L




11.5. Acceptance Limits

11.5.1. Ultrasonic Examination

Acceptance criteria for weld discontinuities shall be in accordance with API 5L: 2012, 45th Edition. Any imperfection which produces a signal of height exceeding the reference to annex E, Section E5.5, API 5L: 2012, 45th Edition shall be considered an unacceptable defect. Any imperfection found by the automatic ultrasonic system shall be further investigated by manual ultrasonic and radiographic examination (see Section 11.4).

11.5.2. Radiography

The acceptance criteria for radiography shall conform to API 5L: 2012, 45th Edition and the following:

Incomplete penetration and lack of fusion of any size are not acceptable;

Elongated slag inclusions shall not exceed 1.5 mm in width and 6.4 mm in length will be referred to table E5, API 5L: 2012, 45th Edition;

Circular slag-inclusions and gas-pockets shall not exceed 2.5 mm in diameter will be referred to table E6, API 5L: 2012, 45th Edition;

The cumulated length of all discontinuities in any 152.4 mm of weld length shall not exceed 12.7 mm;

Maximum area fraction of porosities, on the radiograph, shall not exceed 1% of any 50mm of weld length;

Porosities and inclusions appearing on the radiograph within 50 mm of the pipe end shall be considered as unacceptable defects.

11.5.3. Magnetic Particle Inpsection

Linear indications exceeding 3mm in length shall not be acceptable and shall require re-beveling.

12. REPAIRS

12.1. Repairs: Body of Pipe

Repairs by welding on the pipe body are not permitted. The repair of dents is not acceptable.

Surface defects in the pipe outside the welded seam and not encroaching upon the required minimum thickness may be removed by grinding provided a smooth curved surface is maintained and the final thickness after grinding is not less than the required minimum thickness as confirmed by ultrasonic

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Using RT for confirmation of AUT’s imperfections will be not suitable for result Interpretation.

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According to API 5L, Table E.5 and E.6




testing. Apart from minor cosmetic grinding as approved by the INSPECTOR, all repairs shall be carried out before cold expansion and hydrostatic test.

When grinding repairs are made because of imperfections found by Non-Destructive testing, the section of the pipe containing such repairs shall be subjected to re-examination testing using the same Non-Destructive testing techniques and magnetic particle inspect ion after the grinding operation.

12.2. Repairs: Welded Seam of Pipe

All repairs shall be carried out before cold expansion, hydrostatic test and approved by CLIENT or its authorized representative. The repair shall be made by manual metal arc using low hydrogen electrodes to a qualified procedure. Qualification shall be carried out as stated in Section 5.3 of this Specification.

No repair shall be permitted 1mm from each pipe end. Repairs to the welded seam shall be limited to three per pipe. The cumulative length of repair welding shall not exceed 5% of the total weld length on each pipe. The repair of pipe with defects in excess of these limits shall only be permitted with the prior approval of CLIENT or its authorized representative.

Any evidence of cracking in the weld shall be cause for rejection and subsequent investigation.

All weld seam repairs shall be subject to X-radiographic examination, ultrasonic examination and magnetic particle inspection.

13. MARKING AND TRACEABILITY

Pipe shall be furnished bare and free of all mill coating.

Each pipe shall be die-stamped with its unique pipe number on the weld bevel at each end. No other die stamping, hot or cold, shall be permitted.

Paint stenciled markings shall be made at the inside surface of both pipe ends and shall include:

Markings as specified by API 5L: 2012, 45th Edition;

PM3-CM Loop Pipeline;

Purchase order No;

Heat No;

Pipe No;

Hydrotest Pressure;

Weight ;

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According to API 5L, Please modify as below: " All weld seam repairs shall be subject to NDT method that found the defects

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Please modify: "one pipe end..."




Unique Pipe Number;

All units shall be metric. Outside marking shall include diameter, wall thickness, length and material grade at one end only.

The mill unique pipe number is a number which is unique to every individual pipe produced, and which is used for internal mill control. It shall be unique throughout all production for the project regardless of item number or purchase order.

Pipe markings shall include the following information, as applicable:

Name or mark of the manufacturer of the pipe (X);

Number designation of this International Standard (API 5L/ISO 3183) plus, or alternatively, an identical national adoption of this International Standard if agreed;

Specified outside diameter;

Specified wall thickness;

Pipe steel grade (steel name) (see Table 1, API 5L: 2012, 45th Edition);

Product specification level designation;

Type of pipe (see Table 2, API 5L: 2012, 45th Edition);

Mark of the customer's inspection representative (Y), if applicable;

An identification number (Z), which permits the correlation of the product or delivery unit (e.g bundled pipe) with the related inspection document, if applicable.

Except as allowed by 11.2.3 and 11.2.4, API 5L: 2012, 45th Edition, the required markings shall be applied durably, legibly and be as follows:

− On the outside surface of the pipe, in the sequence listed in see 11.2.1, API 5L: 2012, 45th Edition, starting at a point between, 450 mm and 760 mm from one of the pipe ends;

− On the inside surface of the pipe, starting at a point at least 150 mm from one of the pipe ends.

If agreed, low-stress die-stamping or vibro-etching on the pipe surface may be used, subject to the following limitations:

Such marks shall be on the pipe bevel face or within 150 mm of one of the pipe ends;

Such marks shall be at least 25 mm from any weld;




Cold die-stamping [at temperatures < 100 °C (210 °F)] of plate, strip or pipe not subsequently heat treated shall be done only if rounded or blunt dies are used.

For pipe intended for subsequent coating, if agreed, marking may be done at the coater's facility rather than at the pipe mill. In such cases, traceability shall be ensured, e.g. by application of a unique number (by individual pipe or heat of steel).

If a temporary protective coating (see section 12.1.2, API 5L: 2012, 45th Edition) is applied, the markings shall be legible after such coating.

In addition to the markings specified in section 11.2.1, API 5L: 2012, 45th Edition, the pipe length shall be marked as follows, in metres to two decimal places (feet to tenths of a foot) or, if agreed, in a different format and shall be as follows:

The individual pipe length (as measured on the finished pipe) shall be marked:

− At a convenient location on the outside surface of the pipe;

− If agreed, at a convenient location on the inside surface of the pipe.

For pipe furnished with couplings, the length as measured to the outer face of the coupling shall be marked.

If agreed, the manufacturer shall apply a daub of paint, approximately 50 mm in diameter, on the inside surface of each length of pipe. The paint colour shall be as per Table 27, API 5L: 2012, 45th Edition if the pipe grade is applicable; for all other grades, the paint colour shall be as specified in the purchase order.

14. PROTECTION OF PIPE ENDS

End caps (and bevel protectors, where applicable) shall be provided unless otherwise approved by CLIENT. The pipe shall be handled by hook and belt, this belt shall be contacted direct to pipe to prevent breaking. The MANUFACTURER shall provide additional 5% end caps as required by pipe coating manufacturer.

15. HANDLING AND STORAGE OF PIPE

All pipes shall be handled, loaded and shipped in accordance with Project requirements as defined in the Purchase Order.

The MANUFACTURER shall submit loading instructions and diagrams for CLIENT or its authorised representative, approval for all pipes shipped by rail,




truck or vessel. However, approval of these documents shall not relieve the MANUFACTURER of its responsibility for damage during shipment.

All dimensional tolerances and pipe surface conditions specified herein and in API 5L: 2012, 45th Edition shall apply to the pipe as received by CLIENT or its authorised representative, at the shipping destination.

16. RECORDS, TEST REPORTS AND ADDITIONAL INFORMATION

Unless otherwise specified, certificates shall be of Type 3.2 as per BS EN 10204.

The following records and test reports shall be furnished by the MANUFACTURER to CLIENT or its authorised representative:

Certified chemical analysis and mechanical test results; (tensile tests, Charpy V-notch impact tests, hardness test, DWTT, etc.)

Non-Destructive examination reports;

Hydrostatic test certificates;

Weldability test report and MANUFACTURER’s recommendations or guide for welding of pipes;

List of pipes showing pipe numbers, heat numbers, individual length and weight;

Pipe manufacturing procedure qualification test records;

Concession Requests (if applicable);

Date of plate and pipe manufacture;

Dimensional records;

Final inspection and release data;

Description and disposal of repairs;

Load out and despatch data;

Material test certificates (MTRs);

Equipment calibration certificates;

NDT operator certificates and quality plan.

In addition to above, the MANUFACTURER shall provide linepipe tracking data on Electronic Files as approved by CLIENT or its authorised representative. As a minimum, these shall include the following data for each delivered pipe in EXCEL spreadsheet format:

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Please delete. Because weldability test apply to girth weld, Pv Pipe dont perform Girth welding at Pv Pipe factory




Mill unique pipe number;

Heat or Cast Number;

Other identity numbers of importance to the pipe mill traceability; (e.g. parent plate number)

Measured pipe length;

Actual pipe length;

Mill release date;

Other specific data to be recorded shall be agreed with CLIENT or its authorised representative, prior to start of the work.

17. APPENDICES

Appendix 1: Qualification of Pipe Manufacturing Procedure

Appendix 2: Hardness Survey

Appendix 3: Testing and Inspection

Appendix 4: Girth Welding Tests

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Girth welding dont carry out at PV Pipe

CA MAU GAS PROCESSING PLANT PROJECT PACKAGE: ENHANCED CAPACITY FOR PM3-CM GAS PIPELINE

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APPENDIX 1

QUALIFICATION OF PIPE MANUFACTURING PROCEDURE

(06 pages)




QUALIFICATION OF PIPE MANUFACTURING PROCEDURE

Three pipes from the first day production, as defined in Section 7.1 of this Specification

shall be subjected to the inspection and tests as described below in order to qualify the

manufacturing procedure. These pipes may be selected by the INSPECTOR.

If any of the first day production tests fail, production shall be halted and all pipes

produced shall be identified and rejected. The reason for the failure shall be identified

to the satisfaction of CLIENT or its authorised representative. The manufacturing

procedure shall be amended. A new set of tests shall be conducted on the first day’s

production to the new procedure. MPQT shall be performed for each OD and wall

thickness combination.

A1 Visual and Dimensional Inspection

The selected pipe shall be inspected for compliance with dimensional tolerances, wall

thickness and surface condition in accordance with the requirements of this

Specification.

A2 Non-Destructive Tests

The entire pipe shall be subject to ultrasonic examination and either electro-magnetic or

magnetic particle examination for longitudinal and transverse defects and laminations.

This shall include MPI examination of pipe ends.

The weld seam shall be subject to x-radiography along its full length.

A3 Chemical Analysis

A chemical analysis shall be carried out on the pipe body and on an all-weld-metal

coupon.

A full chemical analysis shall be made on inside weld bead and outside weld bead. As a

minimum, all the elements as per the composition requirement of the applicable

consumable specification shall be analysed.

A4 Mechanical Tests

Tensile Tests

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Two tensile specimens (one longitudinal and one transverse directions to pipe axis) in

accordance with API 5L: 2012, 45th Edition shall be removed from each pipe end.

Strip specimens shall be used unless otherwise agreed by CLIENT or its authorised

representative.

The yield strength, tensile strength, elongation and yield to tensile strength ratio shall

conform to the requirements of this Specification.

An all-weld-tensile test specimen shall be prepared. The yield strength shall lie in the

range specified for the yield strength of the pipe.

Charpy V Tests

Charpy V specimens shall be removed from two (2) locations (1 location at each end of

the pipe).

The specimens shall be cut transverse to the pipe axis. Sets of 3 Charpy specimens

shall be notched at each location, in the weld metal, FL, FL + 2mm and FL + 5mm

locations as shown in Figure A of Appendix 1. Among the three positions FL, FL + 2mm

and FL + 5mm, the one giving the lowest average value shall be selected for routine

production test and shall be referred to as "Heat Affected Zone” Charpy test. The shear

area shall also be reported and shall meet requirements as specified in Section 7.3.

Charpy V tests shall also be conducted in the base metal, weld metal and HAZ to

determine full Charpy energy and shear transition curves to ASTM A370. The tests shall

be carried out in the transverse direction for a minimum of 6 temperatures ranging

from -70° to 0°C. Results and curves shall be supplied for information only.

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Please modify: "two transverse directions to pipe axis" according to Table 20, API 5L

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Please delete. Weld metal is area to be mixed between Base metal and welding wire, welding flux. Yield strength can not lie in the range specified for the yield strength of the pipe.

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Figure A: Charpy Impact Specimen Locations

Notes:

1. Charpy V-notch centrelines are as marked above

2. Specimen locations are:

Weld metal centreline (WM)

Fusion line (FL)

Fusion line plus 2mm (FL+ 2)

Fusion line plus 5mm (FL+ 5)

3. For fusion line specimens the specimen centreline intersects the fusion line at specimen mid-thickness

4. FL+ 2 and FL+ 5 specimen locations are shown exaggerated for clarity

Specimens for procedures and trial production shall be etched to aid notch location

Crack Tip Opening Displacement Test (CTOD)

3 sets of CTOD tests shall be carried out in accordance with BS 7448, on full pipe

thickness, transverse test pieces. The notch positions shall be in the weld centreline and

HAZ locations at a test temperature of 0°C. The measured fracture toughness of base

metal and the weld metal shall, as a minimum, have a CTOD value of 0.15 mm.

Guided Bend Test




2 bend test weld specimens shall be cut and tested according to API 5L: 2012, 45th

Edition; 2 sides bend tests.

Drop Weight Tear Test

Drop Weight Tear Tests shall be carried out in accordance with API 5L: 2012, 45th

Edition and API RP 5L3. Tests shall be performed on the pipe at 0°C. The minimum

individual shear area shall be 85%.

In addition a full transition curve shall be established on one pipe from each grade. The

temperature range shall be as for the Charpy transition curve.

A5 Macro-Hardness and Microstructure Examinations

The two (2) macro sections shall be cut, one from each end of the pipe. They shall be

examined to determine the acceptability of the weld in accordance with the

Manufacturing Procedure Specification. At each of these locations a Vickers Hardness

survey shall be carried out in accordance with Appendix 2. Hardness shall not exceed

250 HV10 for the weld cap and the parent material, weld root and weld mid thickness.

Base metal metallurgical microstructure and grain size evaluation shall be carried out at

mid-thickness. Photographs of microstructure shall be supplied. Acceptance criteria shall

be as outlined in Section 7.6.

A6 Girth Welding Tests

A full girth weld shall be produced using the test pipe and tests conducted in

accordance with Appendix 4.

A7 Records

The MANUFACTURER shall submit to CLIENT or its authorised representative, the pipe

manufacturing procedure qualification test reports giving the results of all tests required

by this Specification for review and approval.

A8 Rejection

In case of results that are not satisfactory with respect to this Specification, the pipe

tested as well as the preceding pipes shall be rejected. The causes of failure shall be

investigated and reported to the INSPECTOR. The burden of proof that the rejected

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pipes meet the requirements lies solely with the MANUFACTURER. Production shall

resume only after the procedure has been suitably revised to the satisfaction of CLIENT

or its authorised representative. A new qualification test pipe shall be produced

according to this Specification.

A9 Hydrostatic test

Test pressures shall be held for not less than 10s.

In order to ensure that every length of pipe is tested to the required test pressure, each

tester, except those on which only continuous welded pipe is tested, shall be equipped

with a recording gauge that can record the test pressure and the test duration for each

length of pipe, or shall be equipped with some positive and automatic or interlocking

device to prevent pipe from being classified as tested until the test requirements

(pressure and duration) have been met. Such records or charts shall be available for

examination at the manufacturer's facility by the purchaser's inspector, if applicable.

The test-pressure measuring device shall be calibrated by means of a dead-weight

tester, or equivalent, no more than four months prior to each use. At the option of the

manufacturer, test pressures that are higher than required may be used.

Note: In all cases, the specified test pressure represents the gauge pressure value

below which the pressure is not permitted to fall during the specified test duration.

All the tests relevant also refer to table “Test and Inspection” in Appendix 3.




APPENDIX 2

HARDNESS SURVEY

(03 pages)




FIGURE B1 - HARDNESS SURVEY

Sample for hardness test shall be taken the end of related pipes and for welded pipe,

each sample shall be contain of section for the longitudinal seam at it centre.

a) Longitudinal Weld (Refer Figure 5b: API 5L-2012)

Figure b1: Sample and Test Piece Orientations and Locations SAWL Pipes

Notes:

1. W — transverse sample, centred on the weld

2. T180 — transverse sample, centred ≈ 180° from the longitudinal weld

3. T90 — transverse sample, centred ≈ 90° from the longitudinal weld

4. L90 — longitudinal sample, centred ≈ 90° from the longitudinal weld

Table b.1 - Number, Orientation and Location of Test Pieces per Sample for

Mechanical Tests

Type of

pipe

Sample

location Type of test

Number, orientation and

location of test pieces per

samplea

Specified outside diameter D

mm (in)

SAWL Pipe body Tensile 1T180c,d

CVN 3T90




Seam weld

Tensile 1We

CVN 3We and 3HAZe

Guided-bend 2We

Hardness 1We

Notes:

a) For double-seam pipe, both longitudinal weld seams in the pipe selected to represent the test

b) If agreed, annular test pieces may be used for the determination of transverse yield strength by the hydraulic ring expansion test in accordance with ASTM A 370.

c) For deep-water pipelay, additional longitudinal tests might be specified, with the requirements and test frequency being as agreed.

d) For double-seam pipe, both longitudinal weld seams in the pipe selected to represent the test unit shall be tested.

b) Girth Weld (Refer to Figure H.1b-API-5L-2007)

Figure b2: Location of Hardness Tests for SAW Pipe

Notes:

a. Weld centreline.

b. 0, 75 mm (0.03 in) from fusion line.

c. 1 t from fusion line.

d. 1,0 mm (0.04 in) spacing in visible HAZ

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APPENDIX 3

TESTING AND INSPECTION

(05 pages)




TESTING AND INSPECTION

Test/Inspection Qualification Tests During production

Frequency Remarks Frequency Remarks

VISUAL/DIMENSIONAL

INSPECTION

Dimensions All pipes All pipes

Pipe end squareness All pipes 3 pipes per shift,

min.

Straightness All pipes 3 pipes per shift,

min.

Surface defects All pipes External &

internal All pipes

External &

internal

Out-of-roundness All pipes All pipes

Height of weld beads All pipes All pipes

Recorded 3

pipes per shift,

min.

ULTRASONIC

EXAMINATION

Plates All plates All plates

Longitudinal weld All pipes All pipes

Weld repairs All weld repairs Manual

examination

MPI

Longitudinal weld All pipes

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all weld repair that defects found by UT






Pipe ends All pipes

Bevel + 150 mm

internal and

external weld

surfaces

All pipes

Bevel + 150

mm internal

and external

weld surfaces

Repairs by grinding only All ground areas

Weld repairs

All weld repair

procedure

tests

All weld repairs

RADIOGRAPHY

longitudinal weld All pipes 100 % weld All pipes 200mm each

ends

weld repairs

All weld repair

procedure

tests

All weld repairs

RESIDUAL MAGNETISM All pipes 3 pipes per shift

min.

MECHANICAL TESTS

Tensile tests 3 pipes 1 pipe per 50 Minimum 2 per

heat

Weld tensile test (*) 3 pipes 1 pipe per 50 Minimum 2 per

heat

Charpy V-Notch 3 pipes 1 pipe per 50 Minimum 2 per

heat

CharpyV Notch transition

curve

1 per pipe

size N/A

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2 pipes

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2 pipes

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2 pipes

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All weld repair that defects found MPI

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all ground areas that suspect have defects

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Drop Weight Tear Test:

Transition curve(1) 1 pipe N/A

At minimum design

temperature(1) 1 pipe 1 pipe per heat

Macro, plus hardness(1) 1 pipe 1 pipe per shift Minimum 2 per

heat

Metallographic

Examination(1) 1 pipe 1 pipe per shift

Minimum 2 per

heat

Bend Test 1 pipe 2 side bend 1 pipe per 50 Minimum 2 per

heat

CTOD Test 1 per pipe

size N/A

Fracture Arrest 3 pipes 1 pipe per 50 Minimum 2 per

heat

HYDROTEST All pipes All pipes

CHEMICAL

COMPOSITION

Heat analysis 1 per heat 1 per heat

Product analysis 2 per heat Pipe body and

weld metal 1 pipe per 50

Minimum 2 per

heat on pipe

body

WELDABILITY

QUALIFICATION TEST

1 girth seam

test

Section 9.15, API

5L 2012. N/A

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WELDING

CONSUMABLES

Manufacturer’s Test

Certificates

Each batch Each batch

REPAIR WELD

PROCEDURE

QUALIFICATION TEST

1 per pipe

size

Deep repair and

shallow repair

Note:

1. These items will be selected within the 3 available pipes for these tests.

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APPENDIX 4

GIRTH WELDING TESTS

(04 pages)

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GIRTH WELDING TESTS

D1 SUPPORTING DATA

Supporting data demonstrating the suitability of the linepipe for field welding or similar

past report shall be supplied at the qualification stage. The data shall demonstrate

that the pipe can be welded by either shielded metal arc welding (SMAW) or

mechanised/semi-automatic welding, typically by the gas metal arc welding (GMAW)

process, without preheat, post-heat, post-weld heat treatment. The data shall

demonstrate that the pipe meets the requirements of this Appendix after welding.

Where such data does not exist, or is deemed unsatisfactory by CLIENT, the tests

specified in this Appendix shall be carried out. The necessity for such tests will be

determined at the qualification stage.

D2 GENERAL

To prove the weldability of the pipes produced, the MANUFACTURER is required to

carry out weldability tests using a procedure similar to one used in the field without

significant or excessive precautions, without mismatch due to out-of roundness, and

without preheat, post-heat or post weld heat treatment (PWHT). The intent is that

during pipe laying, the following hardness and toughness requirements can be met in

the weld and heat affected zone (HAZ) of welds made without preheat, post-heat or

PWHT:

Maximum hardness 250 HV10 on the weld root and the weld cap.

Charpy V notch impact energy in accordance with this Specification

Separate tests are required for each material grade/ heat number.

The requirements for testing are stated below. The MANUFACTURER may submit

alternative proposals for review and approval by CLIENT.

D3 MATERIAL

The base material shall be chosen to reflect the maximum carbon equivalent of the

pipes in question. However, the steel used may have the product maximum carbon

equivalent (CE in Section 6 of this Specification) minus 0.02% or Pcm minus 0.001%.




CLIENT or its authorised representation, shall approve the heat analysis of the steel or

pipe to be used for the weldability tests.

D4 WELDING PROCEDURE SPECIFICATION

The MANUFACTURER shall submit a detailed welding procedure Specification (WPS)

outlining his proposals. The proposed groove profile shall be such that the welding will

result in a straight HAZ on one side of the bevel. The WPS proposal shall be subject to

approval by CLIENT or its authorised representative, prior to start of welding.

D5 TEST WELDS

A test weld shall be prepared and shall consist of butt welding together two (2) pipe

sections as noted below, unless otherwise agreed by CLIENT or its authorised

representative. The weld shall comprise of two sections of 5m minimum length,

making a total minimum welded pipe length of 10m, which shall be subject to the

tests detailed below.

The weld shall be made with the shielded metal arc welding process, using low

hydrogen electrodes capable of meeting the Charpy acceptance criteria of this

Specification.

Welding position 5G, vertical down for 28” linepipe

Heat input 1kJ/mm ± 0.1 kJ/mm

Preheat and post-heat shall not be carried out.

PWHT shall not be carried out.

D6 TESTING AND INSPECTION

General

All the tests shall be carried out in accordance with this specification.

Dimensional tolerance

Dimensional checks shall be carried out at the fit-up stage to provide a record of pipe

dimensions prior to welding and to confirm pipe is within the required tolerances.

Radiographic Examination




Before cutting the specimens, the test weld shall be 100% radio graphed in

accordance with this Specification.

Hardness Survey

Vickers hardness survey shall be conducted on the above macro sections, according to

Figure B1, Appendix 2.

Charpy V Test

Charpy tests shall be taken in weld and HAZ (FL, FL+2mm and FL+5mm), in

accordance with this Specification, with specimens taken from the 3 or 9 o’clock

position at mid-thickness. Acceptance criteria for impact values and test temperature

shall be as per this Specification only.

Macrography and Micrography

3 specimens shall be taken, one at 12 o’clock and one at 6 o’clock position from weld

seam and subject to macrography and micrography examination.

Additional Tests

The test weld shall be subject to the following additional tests:

Ultrasonic examination

Magnetic Particle Inspection

Transverse weld tensile tests

Face and root bend tests

All-weld tensile tests

D7 ACCEPTANCE CRITERIA

All test welds as described above shall meet the following requirements.

Maximum hardness shall be 250HV10 at the weld root and the weld cap.

Tensile properties and Charpy V notch energy in accordance with the requirements of

this Specification.

The MANUFACTURER should note that the girth weld tests shall be acceptance tests

for the pipes, and they form part of the Manufacturing Procedure Qualification Test.




D8 REPORTING

Following completion of the test programmed, the results and final report from the

MANUFACTURER shall be submitted directly to CLIENT or its nominated specialist. The

final report shall include, as a minimum, the following:

Weld Procedure Specification;

Weld Procedure Qualification record giving details of the actual welding parameters for

each pass, consumables used, bevel geometry;

Mill Certificates for materials used;

Dimensional records;

NDT and mechanical test results; (including any failures)

Any other testing agreed with CLIENT or its authorised representative;

Any necessary photographs, macrographs and micrographs (if any)

The interpretation of results and conclusions of the MANUFACTURER, including his

recommendations for production welding of pipe installation.

304121 pve fd pl spc 001 draft (comment by pvpipe) (1)

Documents

manufacturing procedure

project overview

general requirements

welding processes

welding consumables

loop pipeline specifications

linepipe a1

fabrication requirements