dgs-pu-307-rev-0

Abu Dhabi Oil Refining Company

HFW LINE PIPE DGS-PU-307 Rev-0 March 2006

Takreer DGS-PU-307-Rev-0 March-2006 Printed 20-Apr-09 08:46:27 Initials of 23

HFW LINE PIPE

Amendment History

No Date Amendment Description Proposed Approved Incorporated

DGS History

0 March 2006 DGS-PU-307-Rev-0 Previous Project / Lessons Learnt Incorporated

AH/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-PU-307 Rev-0




TABLE OF CONTENTS

1.0 GENERAL.....................................................................................................................3 1.1 INTRODUCTION ..........................................................................................................3 1.2 PURPOSE ....................................................................................................................3 1.3 DEFINITIONS ...............................................................................................................3 2.0 CODES AND STANDARDS ..........................................................................................3 3.0 REFERENCE DOCUMENTS........................................................................................5 4.0 DOCUMENT PRECEDENCE .......................................................................................5 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL...........................................5 6.0 QUALITY ASSURANCE / QUALITY CONTROL...........................................................5 7.0 SITE CONDITIONS ......................................................................................................6 8.0 DOCUMENTATION.......................................................................................................6 9.0 TECHNICAL REQUIREMENTS....................................................................................7 9.1 PROCESS OF MANUFACTURE ..................................................................................7 9.2 CHEMICAL PROPERTIES ...........................................................................................9 9.3 MECHANICAL PROPERTIES ....................................................................................10 10.0 INSPECTION AND TESTING .....................................................................................12 10.1 HYDROSTATIC TESTING ..........................................................................................12 10.2 NON DESTRUCTIVE INSPECTION (NDT) ................................................................12 10.3 DIMENSIONS, WEIGHTS AND LENGTHS ................................................................15 10.4 WORKMANSHIP, VISUAL INSPECTION AND REPAIR OF DEFECTS .....................16 11.0 MARKING AND COATING..........................................................................................17 12.0 RECORDS AND TEST REPORTS .............................................................................18 13.0 SHIPPING AND HANDLING.......................................................................................19 14.0 GUARANTEE..............................................................................................................19 15.0 ATTACHMENTS..........................................................................................................20 APPENDIX A CHARPY V-NOTCH IMPACT REQUIREMENTS .........................................20 APPENDIX B TESTING AND INSPECTION ......................................................................21 ADDENDUM SHEET ...........................................................................................................23

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD ------------------------------

DGS Discipline Committee Member, RRD ------------------------------

DGS Discipline Committee Member Leader, E&PD Abdul Hakim (AH)

Engineering & Technical Services Manager, E&PD Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD Mohamed Al Yabhouni (MAY)




1.0 GENERAL

1.1 INTRODUCTION

This specification supplements the requirements for the manufacture of High Frequency Welded (HFW) line pipe in accordance with American Petroleum Institute (API) Specification 5L, Forty-Third Edition, March, 2004. The electric welded line pipe manufactured to this specification shall conform to the Grade of API Specification 5L as specified in the Purchase Order.

The pipe will be used in liquid hydrocarbon service in non-sour environment up to 20 inch nominal pipe diameter.

Pipe supplied to this specification shall meet or exceed all the requirements of API 5L, Product Specification Level PSL-2 and the additional provisions of this specification.

1.2 PURPOSE

This specification supplements the codes listed in Section 2 of this specification.

1.3 DEFINITIONS

For the purpose of this specification, the following definitions shall apply:

1.3.1 CONCESSION REQUEST - A deviation requested by the CONTRACTOR / SUBCONTRACTOR or VENDOR / SUBVENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorisation to use, repair, recondition, reclaim or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

1.3.2 SHALL - The use of the word “shall” indicates a mandatory requirement.

1.3.3 SHOULD - The use of the word “should” indicates a strong recommendation to comply with the requirements of this document.

2.0 CODES AND STANDARDS

It shall be the CONTRACTOR’s, VENDOR’s, SUBCONTRACTOR’s and/ or SUBVENDOR’s responsibility to be or to become knowledgeable of the requirements of the referenced codes and standards.

The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of contract award shall apply.

American Petroleum Institute (API)




API 5L Specification for Line Pipe, Forty Third edition, March 2004

API 5L1 Recommended Practice for Railroad Transportation of Line Pipe

API 5LW Recommended Practice for Transportation of Line Pipe on Barges and Marine Vessels

American Society of Mechanical Engineers (ASME)

ASME BPV Section V Boiler and Pressure Vessel Code: Non-Destructive Examination

American Society for Testing and Materials (ASTM)

ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM E23 Notched Bar Impact Testing of Metallic Materials

ASTM E92 Test method for Vickers Hardness of Metallic Material

ASTM E112 Test Methods for Determining the Average Grain Size.

ASTM E1268 Standard Practice for Assessing the Degree of Banding of Microstructures

European Committee for Standardization (CEN)

EN 10204 Metallic products - Types of inspection documents

International Organization for Standardization (ISO)

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement System

ISO 9011 Guidelines for Quality and/or Environmental System Auditing

ISO 9712 Non destructive testing qualification and certification of personnel

ISO 1027 Radiographic imaging quality indicators for non destructive testing principles and identification

Deutsches Institut fur Normung (DIN)

DIN SEL 072 Stahl-Eisen-Lieferbedingungen 072 - Ultrasonically Tested Heavy Plate, Technical delivery.

Specification used by “Verlag Stahleisen mbh” Postfach 105 164 4000 Dusseldorf –1.




3.0 REFERENCE DOCUMENTS

The following reference documents, to the extent specified herein, form part of this specification. When an edition date is not indicated for a document, the latest edition in force at the time of contract award shall apply.

Design General Specifications

DB-PU-401 Pipeline Engineering Design Basis

DB-PU-001 Process Design Basis

DGS-PU-308 External Three Layer Polyethylene (3LPE) Coating for Line Pipe

DGS-PU-315 Internal Linings

DGS-PU-317 Insulation of Line Pipes

DGS-PU-319 Pipeline Welding

DGS-PU-322 External Three Layer Polypropylene (3LPP) Coating for Line Pipe

Applicable pipe external coating specification shall be referred.

4.0 DOCUMENT PRECEDENCE

The CONTRACTOR and/ or VENDOR shall notify the COMPANY of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design or manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Specifications and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the CONTRACTOR / VENDOR / SUBVENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require COMPANY’s review/approval prior to the proposed changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE / QUALITY CONTROL

VENDOR’S proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and




systematic control of all quality-related activities performed during design, development, production, installation or servicing (as appropriate to the given system).

Implementation of the system shall be in accordance with the CONTRACTOR’s Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures, be submitted to COMPANY for review, comment and approval as required by purchase/contract documents.

Material certification traceability shall be in accordance with Par. 12.

7.0 SITE CONDITIONS

Site conditions shall be in accordance with Process Design Basis, document number DB-PU-001.

8.0 DOCUMENTATION

MANUFACTURER shall submit the type and quantity of drawings and documentation for CONTRACTOR’s authorization or information as listed in the individual Material Requisitions and Purchase Orders.

All documents, drawing text and dimensions shall be expressed in English language and shall be in the metric system.

Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order.

Comments made by CONTRACTOR on drawing submittal shall not relieve MANUFACTURER or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing.

Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information:

• Official trade name of the MANUFACTURER.

• MANUFACTURER’s drawing number.

• Drawing title giving the description of contents whereby the drawing can be identified.

• A symbol or letter indicating the latest issue or revision.

• PO number and item tag numbers.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the




authority and date of the revision shall be listed. The term "Latest Revision" shall not be used.

9.0 TECHNICAL REQUIREMENTS

9.1 PROCESS OF MANUFACTURE

9.1.1 The Pipe shall conform to the Grades of API 5L line pipe as specified in the Purchase Order, as per Product Specification Level, PSL-2 and as modified by these supplemental requirements.

Specified outside diameter and specified wall thickness shall be as defined in the Purchase Order.

9.1.2 The steel shall be manufactured by the Basic Oxygen Furnace (BOF) or Electric Arc Furnace processes and shall be fully killed and made to fine grain practice. The grain size shall be ASTM No. 7 or finer, as defined in ASTM E 112.

9.1.3 Starting material shall be normalized rolled strip, use of thermo-mechanically rolled strip requires COMPANY approval.

9.1.4 The pipe shall be manufactured by the high frequency electric welding (HFW) process with a minimum frequency of 150kHz, which includes high frequency electric-resistance welding and high frequency electric-induction welding.

Pipe shall be manufactured from hot rolled coil and furnished in the “non-expanded” condition. All HFW pipe shall have the abutting edges milled or machined before welding. Rotary shearing shall not be considered to constitute machining.

The weld seam and heat affected zone shall be normalised after welding by re-heating the weld area above the upper critical temperature of 870 °C (1600 °F) minimum and cooling in still air to below 540 °C (1000 °F). The normalising temperature shall be measured by recording and indicating thermometers. Full body normalising, normalising and tempering, or quenching and tempering shall also be acceptable. Heat treatment requirements of pipe manufactured from thermo-mechanically rolled strip shall be advised by the MANUFACTURER with a evidence that mechanical properties will not be degraded due to heat treatment. Details of the proposed heat treatments shall be submitted for COMPANY approval prior to the start of production.

The MANUFACTURER shall conduct all tensile, bend, flattening, weld ductility, fracture toughness and hardness tests described in this specification. Results of all tests shall be recorded and provided to COMPANY. The test results must conform to the requirements of this specification and API 5L for acceptance.

The following documents shall be provided to COMPANY for review prior to the start of production.

• Strip NDT procedures




• Pipe making method including details of methods used for preparing the edge of the strip for welding and for control of misalignment of edges and pipe shape

• Welding operations shall be controlled by a Welding Procedure Specification (WPS) including details of the following:

− Method to be used for heating plate edges and for the control and monitoring of power input in relation to the temperature of the pipe surface and to the speed of the pipe.

− Welding power range

− Welding speed

− Welding temperature

− Frequency (in kHz) of the welding power supply

− Details of any protective atmosphere used for welding

− Methods used for trimming of the weld bead

− Weld seam heat treatment procedure.

• MANUFACTURER’s Quality Control Manual that provides details of the inspection and testing procedures. The details shall include inspection frequency, dimensional tolerances, acceptance criteria, calibration procedures and frequencies, etc. Quality Control Manuals shall be provided by both the steel manufacturer and the pipe MANUFACTURER.

• A description of the plate/strip rolling practices to include rolling ratio, reduction temperature.

• Steel maker and plant at which steel is produced.

• Steel making process and nominal weight of each heat.

• Target chemical composition together with minimum and maximum working limits for heat and product analysis.

• Any cooling rate limitation

• Heat treatment on rolled plates/skelp.

• Ultrasonic plate/skelp testing techniques, coverage and acceptance criteria.

• Method of calibrating ultrasonic equipment and frequency of calibration.




• Method of measuring pipe wall thickness, including sensitivity and calibration technique.

• Techniques for wet magnetic particle inspection.

• Histograms of mechanical test results from previous orders of the same grade pipe in the same or similar sizes.

• Details of method and procedures for hydrostatic testing.

A higher grade of API 5L pipe shall not be substituted for the grade of pipe specified in the Purchase Order without the approval of COMPANY in writing.

First day production tests and production testing frequencies shall be conducted in accordance with Appendix B of this Specification.

9.2 CHEMICAL PROPERTIES

9.2.1 Composition: Product Analysis

Element Maximum Weight Percent C 0.16 Mn 1.6 Si 0.45 S 0.005 P 0.025 Nb 0.05 V 0.08 Ti 0.04 Al 0.06 Cu 0.25 Ni 0.30 Mo 0.25 Cr 0.20 N 0.012 B 0.0005 Ca 0.006

Notes:

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

(2) The sum of Cu + Cr + Ni + Mo shall not exceed 0.6 percent.

(3) The total Al : N ratio shall not be lesser than 2 : 1. Al total ≤ 0.060, N ≤ 0.012.




9.2.2 The carbon equivalent (CE) and Parameter Crack Measurement (Pcm) based on product analysis calculated by the following formulas shall not exceed the following percentages:

CE = C + Mn/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15 ≤ 0.39%

Pcm = C + Si/30 + (Mn + Cu + Cr)/20 + Ni/60 + Mo/15 + V/10 + 5B ≤ 0.21%

9.2.3 The MANUFACTURER shall provide the COMPANY a report giving the heat analysis of each heat of steel used in the manufacture of pipe furnished.

Elements not mentioned in this table shall not be intentionally added without COMPANY's approval.

9.2.4 The MANUFACTURER shall provide the COMPANY a certified product analysis of the finished pipe. The product analysis shall include all elements listed in paragraph 9.2.1 above and any other intentionally added elements and shall be performed on two pipes per heat.

9.2.5 If the product analysis fails to meet the criteria specified in clause 9.2.1 then recheck analysis shall be carried out. Recheck analysis requirements and acceptance criteria shall conform to API 5L, except that in the event a recheck analysis fails to meet the criteria and the MANUFACTURER elects to test the remaining pipe lengths individually, the analysis shall be made for all elements listed in paragraph 9.2.1.

9.2.6 The MANUFACTURER shall furnish reports on all heat analysis, product analysis and recheck analysis. These analyses shall include all elements listed in paragraph 9.2.1.

9.3 MECHANICAL PROPERTIES

9.3.1 The tensile tests and properties shall conform to API 5L for the grade of pipe specified in the Purchase Order. Tensile testing frequency shall be two pipes per heat.

Transverse tensile properties shall be determined on flattened rectangular specimens.

9.3.2 The actual yield strength of the line pipe shall not exceed the specified minimum yield strength by more than 140 MPa.

9.3.3 The ratio of yield strength to tensile strength shall not exceed 0.90.

9.3.4 The following tests shall be required.

• Flattening tests shall be conducted in accordance with API 5L and the following requirements. No cracks or breaks shall occur in either weld or parent metal during flattening of the test specimen to 50 percent of its original OD. The specimen shall be further flattened to 1/3 of original OD without cracks or breaks other than in the weld. One test shall be made on sample cut from one pipe per heat per lot of 50 pipes for all grades, pipe sizes and wall thickness covered by this specification.




• Weld ductility tests shall be conducted on full section specimens in accordance with API 5L.

9.3.5 The fracture toughness of the pipe shall be determined by the use of Charpy V-notch impact tests in accordance with API 5L Supplementary Requirement SR5. The test temperature shall be 0 °C (32 °F) or the minimum design temperature which ever is minimum.

Charpy test specimens shall be full-size (10 mm x 10 mm) transverse specimens whenever possible. If pipe size (geometry) does not permit extraction of a full size specimen, the largest obtainable sub-size specimen shall be used. Sub-size specimens shall be in accordance with API 5L SR5. When one-half size transverse specimens are not obtainable due to pipe size, longitudinal specimens may be substituted with the approval of COMPANY. Charpy test specimens shall be transverse with the axis of the notch perpendicular to the pipe surface. The notches shall be located on the centreline of the weld and the heat affected zone (HAZ) and the pipe body at 90degrees to weld, i.e. three sets of specimens are required.

The Charpy V-notch energy requirements shall be in accordance with Appendix A of this Specification.

The percent shear area shall be reported for all Charpy test specimens. The percent shear for each specimen shall not be less than 50 percent.

9.3.6 During the first day of production, the following additional tests shall be performed. For each test described below, one complete set of specimens shall be taken from each of three pipes selected by the CONTRACTOR’s representative. Specimens shall be taken from the head of the coil, the middle of the coil and the tail of the coil.

The pipe MANUFACTURER shall conduct tensile, bend, flattening, weld ductility, fracture toughness and hardness tests. Results for all tests shall conform to the requirements of this Specification and API 5L.

9.3.7 The weld of one pipe per one hundred (100) pipes or less from each pipe lot per heat shall be evaluated by removing a pipe cross section containing the weld. A minimum of three specimens shall be examined from one pipe. The section shall include the weld, the complete heat-treated zone and the parent metal on both sides of the weld and shall be polished and etched for examination at 50x magnification. The weld shall have complete penetration and fusion. The geometry, including plate or coil edges and inside and outside weld profile shall be within the tolerances specified in the Manufacturing Procedure Specification. There shall be no evidence of defects. The etched section shall demonstrate that the normalised zone is completely through the pipe wall thickness and of sufficient width to encompass the entire weld and heat-affected zone. The grain size shall be ASTM No. 7 or finer. A photomicrograph at 100x magnification shall be furnished for each specimen and the grain size shall be reported on the mill test report.

A series of Vickers hardness testing with a 10 kg load shall be conducted on the etched specimens selected by COMPANY/CONTRACTOR. These series of reading




shall extend from unaffected base metal on one side across the weld to unaffected base metal on the other side. Three hardness traverses shall be made across the weld area, two (2) millimetres from each pipe surface and one in the middle of the pipe wall thickness. Hardness tests shall be made in the parent metal (each side), heat-affected zone (each side) and weld fusion face. The spacing between hardness impressions shall be 0.75 mm. The hardness impressions nearest the fusion line shall be within 0.5 mm of the fusion line. The hardness shall not exceed 300 HV10.

9.3.8 After removal of the external and internal flash of HFW pipe, the thickness of the weld area shall not exceed the thickness of the parent metal by more than 0.75 mm (0.030 inch), nor shall it be less than the thickness of the parent metal unless otherwise agreed upon by COMPANY. Fracture toughness of the weld zone shall be tested using the criteria for paragraph 9.3.5. Charpy test specimens shall be transverse with the axis of the notch perpendicular to the pipe surface. The notches shall be located on the centreline of the weld and the heat affected zone (HAZ), i.e. two sets of specimens are required.

10.0 INSPECTION AND TESTING

10.1 HYDROSTATIC TESTING

10.1.1 Hydrostatic testing of the pipe shall be in accordance with API 5L and the following.

10.1.2 Each length of pipe shall withstand, without leakage, a hydrostatic test to a test pressure such that the hoop stress, calculated on the basis of minimum specified wall thickness and including stresses from end loading, is at least 95 percent of the specified minimum yield strength. If applied, the end load compensation factor as determined by the formula given in API 5L, Appendix K shall be used. The test pressure shall be held for not less than 10 seconds, during which time the full length of the weld seam shall be inspected for leaks.

10.1.3 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. Hydrostatic test records shall be made available to the COMPANY’s Representative.

10.2 NON DESTRUCTIVE INSPECTION (NDT)

10.2.1 All NDT examinations shall be performed by personnel qualified by a third party in accordance with ASNT Recommended Practice SNT-TC-1A, Level II. Personnel interpreting results of any non-destructive testing shall be qualified by a third party to SNT-TC-1A Levels II or III. For Ultrasonic Testing (UT) at least one level III qualified inspector shall be available to the mill (on call) for overall supervision.

All NDT shall be performed in accordance with written procedures. These procedures shall have the prior approval of COMPANY.

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 additional




non destructive testing using the same non destructive testing techniques and magnetic particle testing after the grinding operation.

All non-destructive inspection equipment shall be checked at least twice per eight (8) hour working shift to demonstrate effectiveness of calibration and operational procedure. Such inspection equipment shall also be checked immediately following any equipment failure or equipment adjustment. These equipment checks shall either be regularly scheduled or with enough notice so that the COMPANY’s Representative may witness equipment checks each time.

10.2.2 Each plate or strip shall be ultrasonically tested for laminations using an oscillating scanning pattern. The scanning coverage using this technique shall be a minimum of 12.5 %. Alternatively, the scanning shall be executed along straight, evenly distributed parallel lines with a scanning coverage of at least 25 %. Coil for pipe may be tested after welding of the longitudinal seam by rotary ultrasonic testing of the pipe body. The coverage in this case shall be 100 %.

In addition, the longitudinal edges of a plate or coiled strip shall be 100 % ultrasonically tested over a width of at least 25 mm from the trimmed plate/coil edge. This may be performed either before or after pipe forming. For pipe subjected to 100 % rotary ultrasonic testing, longitudinal edge UT is not required.

For lamination detection in plate/coil, the acceptance limit shall be based on lamination size and accuracy and in accordance with the classification of SEL-072 as described below.

Location Acceptance Levels

Plate/Coil body Table 1, Class 1

Plate /Coil edges Table 2, Class 1

10.2.3 The entire length of weld seams shall be ultrasonically tested after hydrostatic testing. Weld seams of pipe shall be inspected for longitudinal defects. Acceptance criteria for weld discontinuities shall be in accordance with API 5L.

10.2.4 Calibration of ultrasonic equipment may be based upon either notches or holes; however, reference standards shall contain both notches and holes. The MANUFACTURER shall furnish, for COMPANY approval, a complete description of his 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 the COMPANY’s Representative, the effectiveness of his equipment and procedures,




using an API 5L reference standard, approved by COMPANY. The details of this standard shall be in accordance with API 5L.

10.2.5 The complete circumference of each pipe end shall be examined ultrasonically from inside for laminations. The examination shall cover a width that includes the entire bevel. Alternatively the pipe may be tested from the outside surface prior to bevelling and in such case a band of at least 25 mm wide to include the eventual bevelled area shall be examined. Laminations are not acceptable in this area.

10.2.6 All non destructive inspection equipment shall be checked at least twice per eight (8) hour working shift to demonstrate effectiveness of calibration and operational procedure. Such inspection equipment shall also be checked immediately following any equipment failure or equipment adjustment. These equipment checks shall either be regularly scheduled or with enough notice so that the COMPANY’s Representative may witness equipment checks each time.

10.2.7 When grinding repairs are made because of imperfections found by non destructive testing, the section of pipe containing such repairs shall be subjected to additional Non Destructive testing using the same Non Destructive Testing techniques and magnetic particle testing after the grinding operation.

10.2.8 Residual Magnetism

Any detrimental magnetic fields resulting from magnetic particle (wet or dry) inspection, electro-magnetic inspection or any other magnetic equipment shall be checked and removed if it exceeds the following requirements. The pipe shall be checked subsequent to any inspection that uses a magnetic field, handling with any electromagnetic equipment and prior to shipment from the mill.

The pipe ends shall be checked for residual magnetism as follows:

• Measurements shall be made on the root face using a Hall-effect gaussmeter or other type of instrument approved by COMPANY. However, in the case of dispute, measurements with the Hall-effect gaussmeter shall govern. The gaussmeter shall be operated in accordance with written instructions demonstrated to produce accurate results. The accuracy shall be verified at least once each day that the gaussmeter is used.

• Measurements shall be made on each end of at least three (3) pipes per working shift. One pipe shall be taken from the beginning of the shift, one from near the middle and one from the end of the shift.

• Readings shall be taken around the circumference of each end of the pipe. No reading shall exceed 30 gauss when measured with a Hall-effect gaussmeter or equivalent values with other types of instruments.

• Any pipe that does not meet the above requirements shall be considered defective.




• In addition, all pipe produced between the defective pipe and the last acceptable pipe shall be measured. Alternately, if the pipe production sequence is documented, pipe may be measured in reverse sequence beginning with the pipe produced prior to the defective pipe until at least three (3) consecutive pipes meet the requirements. Pipe produced prior to the three consecutive acceptable pipes need not be measured. Pipe produced after the defective pipe shall also be measured until at least three (3) consecutive pipes meet the acceptance requirements.

• All defective pipe shall be degaussed full length and re-measured or permanently rejected.

10.3 DIMENSIONS, WEIGHTS AND LENGTHS

10.3.1 General

Dimensions, length, weights and straightness of pipe shall comply with API 5L and the following. Measuring equipment shall have a resolution and accuracy at least five (5) times finer than the tolerance of the parameter being measured.

10.3.2 Length

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

• A minimum of 95% of the pipes shall be between 11.0 and 12.5 m in length.

• No pipe shall be less than 9.0 m in length.

10.3.3 Wall Thickness

Pipe wall thickness at any point shall not deviate from the specified wall thickness by more than plus 10 percent or minus 5 percent.

10.3.4 Diameter

Pipe Body:

The outside diameter of the pipe shall not be more than 0.75 percent larger than specified outside diameter, nor more than 0.25 percent smaller than specified outside diameter as measured with a diameter tape.

Pipe Ends:

For a length of 100m from each pipe end, the internal diameter shall not deviate from nominal, internal diameter by more than ± 1.5mm. The nominal internal diameter is defined as the specified outside diameter D (given in metric table) minus twice the specified wall thickness. Internal diameter shall be measured using internal gauge or




measuring tape inside the pipe. The method and equipment used shall be approved by COMPANY.

10.3.5 Out-Of-Roundness

The out-of-roundness of the outside diameter of the pipe shall not exceed the following:

(Maximum OD - Minimum OD) / Specified OD = 1.0 percent

10.3.6 Straightness

Pipe shall be checked for straightness and deviation from a straight line and shall not exceed 0.20 percent of the pipe length. Measurements shall be made using a taut string or wire from end to end along the side of the pipe measuring the greatest deviation. No less than five pipes per shift (at random) shall be checked as well as any pipe that does not appear to meet this requirement.

10.3.7 Bevels

Pipe ends shall be bevelled in accordance with API 5L unless otherwise specified in the Purchase Order.

10.3.8 Jointers

Jointers shall not be supplied.

10.4 WORKMANSHIP, VISUAL INSPECTION AND REPAIR OF DEFECTS

10.4.1 All first-day production tests will be witnessed by the CONTRACTOR and COMPANY’s Representative. In addition, all pipes will be subject to inspection by the COMPANY’s / CONTRACTOR’s Representative. MANUFACTURER shall give sufficient notice (17 days) and ahead of the time pipe production is to begin.

10.4.2 The COMPANY’s Representative shall have free entry at all times to all parts of the works which concern the manufacture, testing, inspection, quality control and shipping of the pipe ordered, including the steel mill, the plate or strip mill and the pipe mill.

10.4.3 The pipe mill and steel mill shall make available to the COMPANY’s Representative without charge all reasonable facilities to inspect, measure and test the pipe in all stages of production including, for example, ultrasonic equipment for wall thickness measurements after grinding repairs.

10.4.4 The COMPANY’s Representative shall have the option to examine all materials rejected for any reason. The causes for rejection shall be brought to the attention of the COMPANY’s Representative and all affected materials shall be retained until examined by the COMPANY’s Representative.




10.4.5 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. 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 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.

10.4.6 The pipe shall contain no dents which affect the curvature of the pipe at the longitudinal weld or at the pipe ends. Pounding out or jacking out dents is prohibited. All cold formed dents with a sharp bottom gouge and all sharp gouges, without dents deeper than one mm shall be considered defects which require repair or rejection. Repair shall only be permitted with the approval of the COMPANY’s Representative.

10.4.7 The radial offset of the edges for pipe with a specified wall thickness of 10 mm or less shall not exceed 0.5 mm. For pipe with wall thickness greater than 10 mm, the maximum radial offset shall not exceed 5 percent of the specified wall thickness. Offset shall be measured and recorded on the macros for the hardness specimen one pipe per heat.

10.4.8 Weld Repairs

No welding repairs are permitted to the weld or parent metal.

11.0 MARKING AND COATING

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

11.2 No die stamping, hot or cold, shall be permitted.

11.3 The pipe shall be paint stencilled at both ends, in accordance with API 5L on the surface of the pipe within 200 mm of the ends. Pipe markings shall show: steel grade, service ("NS", for "non-sour"), pipe diameter (OD), length, weight and wall thickness. Sizes, weights, lengths and pressures shall be given in metric units. Colour of marking as specified in the Material Requisition for Line Pipe.

11.4 Pipe marking shall also include the unique pipe number, lot number, heat number and whatever other designation is required so that complete traceability is maintained and each length of pipe can be specifically linked to all applicable chemical, mechanical and other required tests and to each step of the manufacturing, testing and inspection operations.

11.5 The location of the longitudinal weld shall be marked on the inside of each pipe end with a 2-inch (50 mm) daub of heat-resistant white paint.




11.6 COMPANY approved bevel protectors or end caps shall be furnished for all pipe. Bevel protectors shall be re-usable type. The type of bevel protectors/end caps to be used shall be furnished to COMPANY for approval prior to start of the production.

11.7 Pipes of the same diameter but of different wall thicknesses or material shall, in addition to any other requirements be colour coded to provide visual identification. The proposals for the colour coding shall be provided to COMPANY for approval.

12.0 RECORDS AND TEST REPORTS

Unless otherwise specified, certificates shall be of type 3.1C as per European Standard EN 10204.

The following records and test reports shall be furnished by the CONTRACTOR to COMPANY at no cost to COMPANY.

• Certified chemical analysis and all mechanical test results from qualification and production (tensile test: Charpy V-notch impact tests, hardness test).

• Non destructive examination reports

• Hydrostatic test certificates

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

• Approved concession requests

MANUFACTURER shall also provide line pipe tracking data in electronic file. The specific data and file format shall be agreed with COMPANY prior to the start of work and shall include but not limited to the following:

• Marking information

• Date of plate/skelp and pipe manufacture

• Heat Number

• All mechanical properties and test results.

• All dimensional records.

• Final inspection and release date.

• Descriptions and disposal of repairs.

• Load out data/despatch date




13.0 SHIPPING AND HANDLING

13.1 All pipes shall be handled, loaded and shipped in accordance with API RP 5L1, Recommended Practice for Railroad Transportation of Line Pipe and API RP 5LW, Recommended Practice for Transportation of Line Pipe on Barges and Marine Vessels.

13.2 MANUFACTURER shall submit loading instructions and diagrams for COMPANY approval for all pipe shipped by rail, truck or marine vessel. However, approval of these documents shall not relieve the MANUFACTURER of its responsibility for damage during shipment.

13.3 All dimensional tolerances and pipe surface conditions specified herein and in API 5L shall apply to the pipe as received by the COMPANY at the shipping destination. Pipes shall not be shipped in the upper deck.

14.0 GUARANTEE

MANUFACTURER shall bear all costs to seek, find and repair all leaks and/or ruptures which occur during field hydrostatic testing and which result from defects traceable to the manufacture of the pipe. The field test will not exceed a pressure that will cause a circumferential fibre stress greater than 100 percent of the specified minimum yield strength of the pipe based on the minimum specified wall thickness. COMPANY may elect to raise and lower the field test pressure one or more times either as part of a planned testing routine or as a consequence of a failure in the pipeline or in the testing equipment; however, these pressure cycles shall in no way relieve the MANUFACTURER of its obligations.




15.0 ATTACHMENTS

APPENDIX A

CHARPY V-NOTCH IMPACT REQUIREMENTS

Pipe Grade

Minimum Average Value

(Joules)

Minimum Individual Value

(Joules) Gr. B 27 22 X 42 27 22 X 52 55 45 X 60 57 50 X 65 60 53

NOTES:

(1) Minimum absorbed energy requirements for full size (10mm x 10mm) transverse specimens.

(2) For other specimen sizes and orientations, the above values shall be multiplied by the following factors:

Size (mm) Orientation Factor

10 x 10 Longitudinal 1.5

10 x 7.5 Transverse 0.75

10 x 7.5 Longitudinal 1.125

10 x 5.0 Transverse 0.5

10 x 5.0 Longitudinal 0.75




APPENDIX B TESTING AND INSPECTION

First-day Production Tests During Production

Test/Inspection Frequency Remarks Frequency emarks

VISUAL

INSPECTION

- dimensions

- pipe end squareness

- straightness

- surface defects

all pipes

all pipes

all pipes

all pipes

external

all pipes

2 pipes per shift

at least one pipe in 5

all pipes

external

ULTRASONIC

EXAMINATION

- pipe ends

- plate/skelp

- weld seam

all pipes

all plates/skelp

all pipes

25 mm of pipe ends

25 mm of trimmed plate material

all pipes

all plates/skelp

all pipes

25 mm of pipe ends

25 mm of trimmed plate material

MT

- seam weld

- bevel faces

all selected pipes

all pipes

only if ultrasonic

testing is impossible

all pipes

only if ultrasonic testing is impossible




First-day Production Tests During Production

Test/Inspection Frequency Remarks Frequency Remarks

PHYSICAL TESTS

- tensile test

- weld tensile test

- flattening test

- weld ductility test

- macro, micro,

hardness

all selected pipes

all selected pipes

all selected pipes

all selected pipes

three pipes

(3 specimens per pipe)

Offset to be recorded

two pipes per heat

as above

test per API 5L

(paragraph 9.3.2)

test per API 5L

(paragraph 6.2.5)

one pipe per 100

(3 specimens per pipe)

Offset to be recorded

Charpy V-Notch test

transition curve one pipe One pipe/10 heats

at minimum testing temperature

two selected pipes

one pipe per 100 pipe/heat

HYDROTEST all pipes all pipes

CHEMICAL

COMPOSITION

- Heat analysis

- Product analysis

one per heat

two per heat

one per heat

two per heat

Residual Magnetism

All Pipes 10% of the pipes




ADDENDUM SHEET

All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in this addendum sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

dgs-pu-307-rev-0

Documents

approved dgspu

takreer dgspu

date amendment description

initials page

visual inspection

date description source

destructive inspection

chemical properties