rp-sp19-999-1300-078-2.pdf

NATIONAL IRANIAN OIL COMPANY SOUTH PARS GAS FIELD DEVELOPMENT

PHASE 19, TOMBAK-IRAN ONSHORE FACILITIES

DOCUMENT TITLE: FABRICATION OF LONGITUDINALLY SUBMERGED ARC WELDED PIPES FOR PIPELINES (SWEET EFFLUENT)

Contract No. : POGC-655-89-35

Class: 1

DOCUMENT NUMBER: RP-SP19-999-1300-078 Rev. No.: 2

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PPI NIOC

PARS OIL & GAS COMPANY

PPL/IOEC/PPI CONSORTIUM

NATIONAL IRANIAN OIL COMPANY

SOUTH PARS GAS FIELD DEVELOPMENT


DOCUMENT TITLE

FABRICATION OF LONGITUDINALLY SUBMERGED ARC WELDED PIPES FOR PIPELINES

(SWEET EFFLUENT)

DOCUMENT NUMBER

RP-SP19-999-1300-078

2 01-Mar-2011 M.Amirfakhri S.Laghaei F. Sorudi A.Nassori XXX Approved for Design

1 11-Jan-2011 M.Amirfakhri S.Laghaei F. Sorudi A.Nassori XXX Approved for Design

0 15-Nov-2010 S.Younessi S.Laghaei F. Sorudi A.Nassori XXX Issued for Approval

REV DATE ISSUE

PREPARED CHECKED AUTH PPI POGC

PURPOSE OF ISSUE APPROVED





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TABULATION OF REVISED PAGES

Page Rev-0 Rev-1 Rev-2 Rev-3 Rev-4 Page Rev-0 Rev-1 Rev-2 Rev-3 Rev-4

1 x 36 x 2 x 37 x 3 x 38 x 4 x x 39 x 5 x x x 40 x 6 x x 41 x 7 x x 42 x 8 x x 43 x 9 x x x 44 x 10 x x 45 x 11 x 46 x 12 x 47 x 13 x 48 x 14 x 49 x 15 x 50 x 16 x 51 x 17 x 52 x 18 x 53 x 19 x 54 x 20 x 55 x 21 x 56 x 22 x 57 x 23 x 58 x 24 x 59 x 25 x 60 x 26 x 61 x 27 x 62 x 28 x 63 x 29 x 64 x 30 x 65 x 31 x 66 x 32 x 67 x 33 x 68 x 34 x 69 35 x 70





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TABLE OF CONTENT 1) GENERAL STATEMENT .. 4 2) ADDENDUM .. 5 3) TEP GENERAL SPECIFICATION N SP STR 532 Rev.4..11





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GENERAL STATEMENT

The attached TOTAL EXPLORATION PRODUCTION (TEP) General Specification n SP - STR - 532 Rev. 4 is confirmed as the Project Specification, except as amended herein, and renumbered/reissued as specification n RP-SP19-999-1300-078 Rev. 2 for SOUTH PARS PHASE 19 Project. This specification is defined as the so-called Project Particular Specification (P.P.S.).

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ADDENDUM The following items refer to the attached TEP General Specification n SP - STR - 532 Rev. 4. The clauses set out below shall modify or replace the existing clauses in the original specification as noted. GENERAL COMMENTS The following terms which are used in this general Job Specification are deleted and replaced by: - Engineering Company by Contractor: shall mean the party which has entered under a Contract agreement with the CONTRACTOR for the design, engineering, procurement and construction of the Onshore Facilities regarding the South Pars Gas Field Development, Phase 19 Onshore Facilities Project. - COMPANY: Shall mean National Iranian Oil Company / Pars Oil & Gas Company, (N.I.O.C.- P.O.G.C.) - CONTRACTOR: Shall mean Consortium of PPL, IOEC and PPI) - ENGINEERING SUB-CONTRACTOR: Refer to Consortium of Sazeh, Nargan & Technimont - TOTAL: shall be read as COMPANY or his nominated representative. - Manufacturer, Supplier or Vendor: Shall mean any person, firm or company which manufacture or supply equipment or services for the performance of any item of the work. - Work: shall mean works and / or services entrusted by CONTRACTOR under the Contract with COMPANY. 1. General (1.1. Scope) Steel grade shall be API 5 L X65 PSL 1 and API 5 L X70 PSL 2 in function of the diameter. The base material of all pipes shall have a good behavior to arrest a long running shear fracture.

All line pipes, mother pipes for bends, shall be longitudinally Submerged Arc Welded and manufactured by the U.O.E. process. Press Bending, or Roll Bending process, may be used, if so agreed at bid stage. 2.2. Line Pipe Data Sheet (Summary) Refer to table in Appendix 1 of this specification. 5.2. Rolling Technique / Heat Treatment All steel plates shall be manufactured by the Thermo-mechanical Controlled Processed

with accelerated water cooling so as to obtain a homogeneous very fine-grained microstructure.

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The detailed thermo-mechanical controlled rolling procedure shall be supplied to OWNER prior fabrication. This procedure shall detail temperature and reduction ratio of the rolling steps.

All calibration certificates of control devices, thermometers, recorders, shall be made available for review by Inspector prior the rolling campaign starts.

The rolling records of each mother plate shall be supplied for review, if an Inspectors request.

5.3. Chemical Composition Minimum and maximum aimed limits for all kind of pipes (U.O.E. / Press Bending pipes and mother pipes) shall be as stated in Appendix 2 of this specification to be filled in and submitted at bid stage by Manufacturer. This shall be the ruling compositions for the order.

5.4. Mechanical Properties and Tests Mechanical tests on plates are required. 5.5.2. Thickness measurement The type and detail of equipment is to be indicated at the bid stage. 5.8. Mill Test Certificates Mill test Certificate shall be 3.1 of EN 10204. to be added as last Para.

6.1. General Requirements All codes and standards shall be considered with their last revision up to 21.Dec.2006 (As per DB-SP19-999-P332-203) The reference standard for all manufacturing test methods shall be acc. to API 5L. Weldability tests are required for the present order. 6.9.1 Diameters Deleted. API 5L (Clause 7.2) shall be followed for Outside Diameter of Pipe Body & inside Diameter of Pipe End Calculations. 6.9.6. Unit Length Shorter pipes (i.e. length between 10.00 m and 11.59 m) may be accepted, provided that total average length per size is 12.20 m minimum. Those shorter pipes shall be differentiated from other pipes by a band of a different color at pipe end.





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6.9.9. Pipe End Preparation Outside weld reinforcement shall be tapered by grinding with a maximum slope 1/6 for line pipes.

6.10.1. Welding Processes The thickness of tack weld made by automatic, if any, shall be indicated on Supplier procedure. Any repair of tack weld by manual welding is only allowed, providing that the weld is ground down to the maximum indicated height.

6.10.2 Welding Consumable c) 3.1.B to be replaced by 3.1. d) No welding consumable without proper batch testing documentation will be accepted. e) 10 ml per 100 gm to be changed to 5 ml per 100 gm. f) The procedure for handling / processing of welding flug shall be submitted at bid stage.

6.10.5. Production Welding The welding voltage variations are acceptable. Voltage: 10%.

7. MILL HYDROSTATIC TESTING

The hydrotest pressure shall be as per required in the general specification in order to get a hoop stress of 95% of the minimum specified yield strength of the pipe material. Refer to table of Appendix 1.

8.1. General Requirements NDT personnel shall be qualified in acc. to ASNT SNT-TC-1A LEVEL II to be added to Para 10.

8.4.2. Radiographic Inspection

- Two (2) penetrameters shall be placed on each radiograph: one on the as-weld reinforcement and one on the ground reinforcement of weld. - NDT Procedure shall meet API 5L.

8.4.3. Magnetic Particle Inspection (M.P.I.) b): Provisions of this paragraph are applicable.

8.5.4. CHARPY V - Notch Tests (Base Metal and Weld) The Inspector may require to have the specimen etched to check the notch location. The testing temperature is stated in Appendix 1.

8.5.6. Drop Weight Tear Tests Test specimen shall be full thickness specimens. The testing temperature is stated in Appendix 1.





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8.7. Mill Certificate Mill Test Certificate shall be 3.1 of EN 10204.

9.1. Repair on Base Material Measured thickness shall always be written (e.g. with chalk) on the pipe ground area. The marking shall be made in such a way to stay readable by the Inspector at the final bench presentation. 10. MARKING OF PIPES

h) Alternatively, a bar code system, placed on the inside of the pipe at both ends, may be implemented to ease the pipe identification.

11. PROTECTION OF BEVELS

Bevel Protector is mandatory. 13.2. Upon Completion of Pipe Production (In addition to the General Specification)

Supplier shall provide OWNER with at least one (1) original and three (3) copies plus 1 CD-ROM of the production report.

15. FABRICATION PIPE HISTORY SYSTEM (P.H.S.)

The Supplier shall provide OWNER with a computerised fabrication pipe history. Detailed possibilities are to be supplied by Supplier at bid stage.

APPENDIX A - Referenced documents All above codes and standards shall be considered with their last revision up to 21.Dec.2006 (As per DB-SP19-999-P332-203) to be added.

APPENDIX F - Pipe manufacturing procedure qualification Item F2 (7):

CHARPY V notch test temperature and energy values are provided in Appendix 1 of the present Particular Specification. Additional CHARPY impact tests are required in base material of line pipe only, and following requirements shall be met at test temperature of -29 C with 70 joules minimum average and 52.5 joules minimum single value.

Item F2 (9) As the effluent is a gas, Drop Weight Tear Test shall be conducted for line pipes. The routine test temperatures are stated in Appendix 1 of the present Particular pecification.

Item F2 (12)





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Weldability tests are required: per each pipe mill, weldability tests results on steel similar to that of this order, together with any useful weldability diagrams (e.g., implant tests ) and guidance for use on site welding are also to be supplied by pipe mills.

APPENDIX 1 Line Pipe Data Sheet Summary

Pipeline Section Definition

Onshore PipelineDesign Factor

0.5 Design Factor

0.5 Effluent Gas Liquid

API Steel Grade X 65,PSL 1 X 70,PSL 2 OD Nominal (mm) 42 (1066,8 mm) 42 (1066.8 mm) ID nominal (mm) 1006.4 mm 1022.34 mm

Corrosion Allowance (mm) 1.27 mm 1.27 mm WT Nominal (mm) (CA included)

30.2 mm 22.23 mm

Length according to Refer to requisition Refer to requisition Design temperature (steel) minimum (steady flow)

0 C 0 C

Impact Test - Minimum average - Minimum single

- Test temperature

45 joules 37

-29 C

45 joules 37

-29 C

DWTT - Shear Area Min - Test temperature

85% 0 C

85% 0 C

SSCC / HIC Test No No PWHT Test No No

Mill Hydrostatic Test pressure (bar mini) 207 118

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APPENDIX 2 Aimed Composition (Laddle, % Weight)

Note (1): All elements not stated in above table to be within limits of SP-STR-534. Note (2): NDA = Not deliberately added

ELEMENT Specification Limits Line Pipes

Laddle Check W. Thk. (mm) 30.2

W. Thk. (mm) 22.23

C Mn

% %

Si S P Aj

% % % %

Nb V

% %

Ti Cr Cu Ni

% % % %

Mo % B Ca N

% % %

CEQ PCM

% %

2

TOTAL EXPLORATION PRODUCTION

GENERAL SPECIFICATION

STRUCTURES

SP - STR - 532

FABRICATION OF LONGITUDINALLYSUBMERGED ARC WELDED PIPES

FOR PIPELINES (SWEET EFFLUENT)

Rev. 4 March 97 Up-datingRev. 3 January 94 Minor modificationsRev. 2 December 92 Complete revisionRev. 1 May 82 Minor correctionsRev. 0 January 82 First issue

This document is the property of TOTAL, it must not be reproduced or transmitted to others withoutwritten authorisation from TOTAL.

FABRICATION OF LONGITUDINALLY SP - STR - 532

SUBMERGED ARC WELDED PIPESFOR PIPELINES

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TEP/DDP/DO (SWEET EFFLUENT) Date : March 1997

CONTENTS

Page

1 - GENERAL 5

1.1 - Scope 51.2 - Definitions 51.3 - Quality Assurance/Quality Control 6

2 - PROJECT PARTICULAR SPECIFICATION 6

3 - REFERENCED DOCUMENTS 7

4 - INSPECTION BY THE COMPANY 7

5 - PLATE MANUFACTURE 8

5.1 - General requirements 85.2 - Rolling Technique/Heat Treatment 85.3 - Chemical composition 95.4 - Mechanical Properties and Tests 95.5 - Visual, dimensional and ultrasonic inspections 105.6 - Repairs 115.7 - Marking of plates 115.8 - Mill Certificates 11

6 - PIPE MANUFACTURE 12

6.1 - General requirements 126.2- Process of Manufacture 126.3 - Cold Expansion 126.4 - Base Materials 136.5 - Pipe Manufacturing Procedure Specification (M.P.S.) 136.6 - Qualification of pipe manufacturing procedure 136.7 - Chemical properties 146.8 - Mechanical properties 146.9 - Dimensional and weight requirements 146.10 - Welding 17

7 - MILL HYDROSTATIC TESTING 20

8 - INSPECTION AND TESTING 21

8.1 - General requirements 218.2 - Dimensional inspection 228.3 - Visual examination/Workmanship 22



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8.4 - Non-Destructive Inspection 248.5 - Production Tests 278.6 - Residual Magnetism 308.7 - Mill certificates 31

9 - REPAIR OF DEFECTS 31

9.1 - Repair on Base Material 319.2 - Repair of longitudinal weld seam 32

10 - MARKING OF PIPES 32

11 - PROTECTION OF BEVELS 33

12 - HANDLING, TRANSPORT AND STORAGE OF PIPES 34

12.1 - General 3412.2 - Handling and storage 3412.3 - Transport 34

13 - DOCUMENTATION 35

13.1 - When the bids are submitted 3513.2 - Upon completion of pipe production 3513.3 - Schedule 36

14 - STORAGE OF MECHANICAL TEST SPECIMENS AND RADIOGRAPHS 37

15 - FABRICATION PIPE HISTORY SYSTEM (P.H.S.) 37

APPENDIX A : REFERENCED DOCUMENTS 38

APPENDIX B : TABLE 1 - LADLE CHEMICAL COMPOSITION 40TABLE 2 - PRODUCT CHEMICAL COMPOSITION 41

APPENDIX C : TABLE 3 - TENSILE PROPERTIES OF BASEMETAL AND WELD 42

TABLE 4 - TRANSVERSE IMPACT ENERGY OF BASEMETAL AND WELD 42

APPENDIX D : ULTRASONIC INSPECTION OF STEEL PLATES 43

APPENDIX E : PIPE MANUFACTURING PROCEDURE SPECIFICATION 45

APPENDIX F : PIPE MANUFACTURING PROCEDURE QUALIFICATION 47

APPENDIX G : WELD BEAD ALIGNMENT AND INTERPENETRATION 49



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APPENDIX H : LOCATION OF CHARPY V-NOTCH SPECIMENS 50

APPENDIX I : VICKERS HARDNESS SURVEY IN WELD FOR PROCEDUREQUALIFICATION TESTS 51

APPENDIX J : VICKERS HARDNESS SURVEY IN WELD FORPRODUCTION TESTS 53

APPENDIX K : QUALIFICATION OF WELD REPAIR PROCEDURES 54

APPENDIX L : WELDABILITY TESTS 56



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1 - GENERAL

1.1 - Scope

This specification defines the COMPANY's general requirements for the manufacture andsupply of bare carbon steel pipes to be used in the construction of onshore or underwaterpipelines, for sweet (i.e. non-sour) crude oil or natural gas service.

It applies to longitudinally Submerged Arc Welded pipes (S.A.W.) in Grade B and GradeX42 up to Grade X70 of API Spec 5L Specification.

This Specification shall always be used in conjunction with a Project ParticularSpecification (P.P.S.) detailing the additional tests and requirements or the possiblemodifications to the present specification, based on the particular design conditions of thePipeline Project (see section 2 of this specification).

Requirements are also provided in this specification for pipes to be used in platformtopsides, risers or expansion loops with Wall Thickness in excess of 31.8 mm, or for anyother applications, where the properties of Base Steel are to be ascertained after a Post-Weld Heat Treatment.

No deviation from the requirements stated in the present specification shall be permittedunless prior written approval has been obtained from the COMPANY.

1.2 - Definitions

COMPANY T.E.P. (TOTAL EXPLORATION PRODUCTION)or agents acting on its behalf, shall be referred toherein as the "COMPANY".

SUPPLIER The Companies, or their agents including steel andpipe manufacturers, designated on the Purchase Orderform or Contract as being the selected supplier of thesaid materials and pipes shall be referred to herein asthe "SUPPLIER".

INSPECTION AGENCY An independent inspection body (other than anyinspection department of the SUPPLIER or anyinspection agency subcontract by him), or itsmembers, who shall be appointed by COMPANY andthus notified to SUPPLIER.

INSPECTOR The COMPANY's representatives or members fromthe COMPANY's elected INSPECTION AGENCYfor the time being or from time to time duly appointedin writing by the COMPANY to act as itsrepresentatives for the purpose of the contract shall bereferred to herein as the "INSPECTOR".



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MILL The plants, mills, workshops, laboratories or otherlocations where the fabrication, inspection and testingof steel and pipes are to be performed complete or inpart, shall be referred to herein as the "MILL".

CONTRACT DOCUMENTS The material requisitions, material specifications, etc.issued by the COMPANY and attached to thecontract or the purchase order shall be referred toherein as the "CONTRACT DOCUMENTS".

APPROVAL Authorisation in writing given by COMPANY toSUPPLIER to proceed with the performance of aspecific part of the work without releasing in any waySUPPLIER from any of its obligations or liabilitiesunder the contract or at law ; APPROVE,APPROVED and APPROVAL shall be construedaccordingly.

MAY Used to indicate that a provision is optional.

SHALL Used to indicate that a provision is mandatory.

SHOULD Used to indicate that a provision is not mandatory butis recommended as good practice.

1.3 - Quality Assurance/Quality Control

1.3.1 -The SUPPLIER shall operate a Quality Assurance system in accordance with ISO9002, or equivalent, approved by a recognized authority. The Quality Assurance Manualshall be submitted to COMPANY.

1.3.2 -Three weeks prior to commencement of the pipe manufacture, the SUPPLIERshall prepare and submit to COMPANY a written Quality Control Plan which describesthe inspections to be performed during the supply of pipes. The Quality Control Plan shallset forth witness , hold , review and monitor points.

2 - PROJECT PARTICULAR SPECIFICATION

The Project Particular Specification (P.P.S.) shall define the Grade and nominal dimensions (O.D.x W.T.) of pipes to be supplied, the CHARPY-V impact test temperature together with any otherinformation or particular tests to be carried out with related requirements.

The Particular Specification shall include the pipeline Data Sheet, if it is not included elsewherein any other Project Specification.



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3 - REFERENCED DOCUMENTS

The order of precedence of the applicable documents shall be :

the Particular Specification, the present General Specification, the codes and standards in reference.

Applicable Codes and Standards which are to be used in conjunction with this specification arestated in APPENDIX A.

Unless otherwise specifically indicated in writing by the COMPANY, the SUPPLIER shallwork in accordance with the requirements specified herein and the applicable requirements ofthe latest editions at date of CONTRACT award of the referenced Codes and Standards,whenever asked in the present specification.

Where this specification states no overriding requirements, the referenced Codes and Standardsshall apply in full.

Standards equivalent to those referred to herein shall not be substituted without written approvalfrom the COMPANY. Approval of equivalent standards will not, in any way, removeresponsibility from the SUPPLIER to meet the requirements of the Standards referred to andamended herein, in the event of conflict.

The SUPPLIER shall equip himself with copies of all the reference specifications referred to inthis specification and shall make them readily available to all fabrication, testing and inspectionpersonnel involved on the work.

4 - INSPECTION BY THE COMPANY

- All procedures shall have prior approval of the COMPANY. All qualification tests shall takeplace under the supervision of the INSPECTOR.

- The SUPPLIER shall notify the INSPECTOR sufficiently in advance to enable him to bepresent at qualification tests and at all other tests or stages of manufacture subject toacceptance in accordance with this specification.

- The SUPPLIER shall ensure that the INSPECTOR has full and free access to all parts of theMILL during all fabrication stages.

- The INSPECTOR shall ensure that materials and pipes are fabricated in accordance with allthe specified requirements and COMPANY's approved procedures.



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- Inspection by the INSPECTOR shall be carried out during pipe production in order to avoidany special or additional handling. Inspection will be made in such a manner to avoid delay inpipe production insofar as the pipes which are presented to him meet the specifiedrequirements.

- The INSPECTION AGENCY shall finalise its inspection by the application of a specialstamp (or indelible paint marking, when so previously agreed) on the accepted pipes. Diestamping is permitted only on the bevel surface.

- The INSPECTOR shall notify the COMPANY without delay of any difficulty, irregularity,problem or delay liable to occur during pipe production.

- The COMPANY reserves the right to re-check tests carried out by the SUPPLIER. For thispurpose, the COMPANY may request the delivery of samples or specimens for analyse in anindependent laboratory chosen by the COMPANY.

5 - PLATE MANUFACTURE

5.1 - General requirements

- Steel shall be made to the Electric Furnace or Basic Oxygen Converter. Steel shall befully killed and made to fine grain practice (grain size ASTM N 8 or finer).

- All surfaces of the slab shall be inspected for defects and scarfing carried out ifnecessary. Slabs shall be correctly marked and stored to avoid any confusion betweenheats of steel.

- The SUPPLIER shall provide the COMPANY at the bid stage with a plateManufacturing Procedure Specification giving full details of all the characteristics ofthe proposed steel plates (see details in APPENDIX E relating to pipe manufacturingprocedure).

- Except as otherwise previously agreed between the SUPPLIER and the COMPANY,all inspections and tests required for steel plate acceptance shall be carried out at theSUPPLIER's Mill.

5.2 - Rolling Technique/Heat Treatment

Plates shall be manufactured by the Thermomechanical Controlled Process for grade X52and above. Grades lower than X52 may be supplied in the Normalised condition, unlessotherwise stated in the Particular Specification.



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5.3 - Chemical composition

- Chemical composition of steel and its Carbon Equivalent (CE) and Pcm, as determined

on each heat and product, shall be in accordance with TABLES 1 and 2 (APPENDIXB). However, the ruling composition shall be that proposed by the SUPPLIER andapproved by the COMPANY at the bid stage (see para. 5.1 above).

- The SUPPLIER shall carry out ladle and product analyses for all specified elements(plus all other intentionally added elements, when applicable). Location of samplingshall be at midway between plate edges.

- Test frequency shall be as follows : Ladle analysis : one per each heat. Residual elements shall be analysed only on the

first heat produced. Product analysis : at least one per each heat. Analysis of residual elements is not

required on product. Product analysis may be carried out either on plates or onpipes, at the SUPPLIERs option. However, the selected option shall be clarified bythe SUPPLIER at the bid stage.

- Recheck analyses :If any part of the product analysis fails to meet the requirements above, either thewhole heat shall be rejected, or each individual plate shall be fully analysed, and allplates failing to meet the requirements shall be rejected. Samples for recheck analysisshall be taken in the same location as specified for product analysis samples.

5.4 - Mechanical Properties and Tests (when so required in Particular Specification)

- Mechanical properties of the plates shall be measured by means of tensile and impacttests carried out transverse to the principal rolling direction.

Sampling shall be located midway between edge and center of plate.

- Testing procedures and specimens shall be as defined under para. 8.5 for finishedpipes.

- Frequency of mechanical tests : at least one tensile test and one impact test (including aset of 3 Charpy V-notch specimens) shall be made once per each heat.

- Results from mechanical testing carried out on steel plates shall meet the workingranges stated by the SUPPLIER and approved by the COMPANY at the bid stage (seepara. 5.1 above and APPENDIX E).



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5.5 - Visual, dimensional and ultrasonic inspections

Steel plates shall be subject to visual, dimensional and ultrasonic inspections on finishedproduct. Visual and ultrasonic inspection may be carried out at the pipe mill. Wallthickness checking shall be made at both the plate rolling mill and the pipe mill.

5.5.1 - Visual inspection

Steel plates shall be visually examined on both surfaces.

Steel plates shall be free from surface defects such as cracks, notches, laps, tears, fromforeign materials, mill scale and rust, and from abnormal thickness variations.

Cracks, notches and sharp bottom imperfections are unacceptable whatever theirdimensions. Any other imperfection having a depth greater than 3% of the specifiednominal thickness shall be considered as unacceptable defect and shall be repairedprovided that the specified minimum wall thickness is maintained.

5.5.2 - Thickness measurement

Plate thickness measurement shall be made once every ten plates, as a minimum.Measurement shall be carried out on middle and both edges of plates, at both plate ends.This may not apply when an automatic gauge control system including a recording is usedto check/measure the thickness, longitudinally, on both the plate axis and on one plateedge, as a minimum.

Any repair grinding shall initiate thickness checking.

Steel plate thickness measurements shall be such that the specified minimum andmaximum wall thickness of finished pipes are met.

5.5.3 - Ultrasonic inspection

Each steel plate shall be ultrasonically inspected in accordance with the provisions statedin APPENDIX D of the present specification.

Inspection records and print out charts of all plates showing locations and dimensions ofimperfections shall be made available to the INSPECTOR for review at the MILL.

The acceptance limits of imperfections are specified in APPENDIX D.



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5.6 - Repairs

Welding repairs are not permitted on plates. The defects can be eliminated only bygrinding provided that the plate thickness is not locally reduced below the specifiedminimum thickness of pipes.

A local Magnetic Particle Inspection according to ASME Code, Section V, may berequested by the INSPECTOR to ensure that the defect has been completely removed.This does not apply to cosmetic grinding areas.

Moreover, plate thickness measurement shall be carried out where a repair grinding(except cosmetic grinding) has been made.

5.7 - Marking of plates

Each plate shall be clearly identified by means of weather resisting markings.

The following minimum indications shall be marked on each plate :

- Purchaser's name- Plate Supplier and Mill name- Heat N- Plate N- Plate wall thickness x width- Plate weight- Steel grade- Order identification.

The SUPPLIER's in-house plate marking may be proposed at bid stage for steel/plate/pipefabrication integrated plants. However, this marking shall include heat number, platenumber and job identification, as a minimum.

5.8 - Mill Certificates

The SUPPLIER shall provide the COMPANY with 3.1.B Mill certificates according toEN 10 204 Std for plates, together with reports of all tests and inspections carried out onplates in accordance with the present specification :

- results of heat and product analyses (see 5.3)- results of mechanical tests (see 5.4)- results of visual inspection (see 5.5.1)- results of thickness measurements (see 5.5.2)- results of ultrasonic inspection (see 5.5.3)



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On Mill certificates, each plate shall be identified in respect of the heat and slab fromwhich it has been produced.

Format of Mill certificates shall be agreed prior to production between the COMPANYand the SUPPLIER.

6 - PIPE MANUFACTURE


- Pipes shall be manufactured in accordance with all the requirements of API Spec. 5L,unless otherwise indicated in the present specification, i.e. API Spec. 5L remainsapplicable for all points not specifically mentioned or modified herein.

Weldability Tests (see APPENDIX L) are to be carried out only when so required inthe Particular Specification.

- The SUPPLIER shall guarantee the overall consistency of the pipe order (includingchemical composition, dimensional, weldability, material traceability), especially ifpipes are manufactured at different mills.

- Except as otherwise previously agreed between the SUPPLIER and the COMPANY,all inspections and tests required for pipe acceptance shall be performed at the pipemanufacturing Mill.

6.2- Process of Manufacture

The pipes shall be manufactured from plates by cold forming using the U.O.E. process(with mechanical expansion), the Press Bending process or the Roll Bending process, andshall have one longitudinal seam made by the automatic Submerged Arc Weldingprocess. The longitudinal weld seam shall include at least one pass made on the inside andat least one pass made on the outside, according to clause 5.1.2.2.1 of API 5L. The jointefficiency factor shall be 1.

After execution of the longitudinal seam, the run-on and run-off tabs shall be removed byflame cutting or sawing only.

6.3 - Cold Expansion

Pipes shall be cold expanded at a permanent straining rate in the range 0.8% to 1.5%. Theexpansion ratio shall be recorded on 3 pipes minimum per shift.

No cold expansion is required on Press Bending pipes and Roll Bending pipes.



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6.4 - Base Materials

The steel plates used in the fabrication of pipes shall meet the requirements defined underSection 5 of this specification.

6.5 - Pipe Manufacturing Procedure Specification (M.P.S.)

The SUPPLIER shall establish a detailed specification for manufacture and inspection ofpipes, describing all proposed operations in their correct sequence together with theirparameters of execution. This document will also mention the characteristics ofequipment and procedures used to carry out these operations.The proposed specification shall include, but not limited to, all pertinent informationsrequired in APPENDIX E.

This detailed specification together with the SUPPLIERs Quality Control Plan shall besubmitted to the COMPANY at the bid stage.

6.6 - Qualification of pipe manufacturing procedure

- One finished pipe among the first pipes produced in each size, grade and steel source(first shift production) shall be subject to all the inspections and tests as described inAPPENDIX F in order to qualify the pipe manufacturing procedure. This pipe shall beselected by the INSPECTOR.

- The SUPPLIER shall submit to the COMPANY the pipe manufacturing procedurequalification test report giving the results of all tests required by the presentspecification.

The report shall be approved and signed by the INSPECTOR who attended the tests.

- The SUPPLIER is allowed to proceed with the pipe manufacture without waiting forthe test results and the INSPECTORs approval, as long as the SUPPLIER isaccepting the risk and responsability of any test failure.

- In case of qualification test results which do not comply with the requirements of thisspecification, the pipe tested as well as all preceding pipes shall be rejected. Thecauses of failure shall be investigated by the SUPPLIER and reported to theINSPECTOR. Manufacture shall resume only after the procedure has been suitablyrevised to the satisfaction of the INSPECTOR and after a new pipe has successfullycompleted the qualification tests laid down in this specification.



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6.7 - Chemical properties

All pipes shall be manufactured from steel which shall have a chemical compositionensuring proper ductility, strength, toughness and weldability under all conventionalwelding processes and techniques used on lay barges and onshore installation works,where applicable.

The SUPPLIER shall carry out product analyses for all specified chemical elements (plusall other intentionally added elements). Those chemical compositions shall be included inMill Certificates.

Heat and Product analyses shall meet the requirements contained in Tables 1 and 2 ofAPPENDIX B. However, the ruling composition shall be that proposed by theSUPPLIER and approved by the COMPANY at the bid stage (see para. 5.3 above).

Number, type, location and frequency of tests shall be as defined under para. 5.3.

6.8 - Mechanical properties

The finished pipes shall meet the requirements stated in Tables 3 and 4 of APPENDIX Cfor tensile properties and Charpy V-notch test requirements respectively.

Number, type, location and frequency of tests shall be as defined under para. 8.5.

Results of mechanical tests carried out on finished pipes shall be included in MillCertificates.

6.9 - Dimensional and weight requirements

The following requirements shall be met on each finished pipe.

Dimensional checks shall be made on each pipe, unless otherwise stated hereafter.Dimensional recordings shall be made as per para. 8.2 of this specification.

Note on definitions :

Checking means that inspection consists to verify that the said dimension is withinthe permitted tolerances (exact dimension is not required) e.g., go - no go gauge check.

Measurement means that a real measurement is carried out and a precise figure is

obtained as a result of it. Recording means that the value of actual measurement as above is recorded and

filed.



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6.9.1 - Diameters

a) Outside Diameter of pipe body : The tolerance shall not exceed + 0.5% of the specifiednominal Outside Diameter, with a max. of + 4 mm.

b) Inside Diameter of pipe ends : The tolerance on the Internal Diameter within 100 mm(4") of the pipe ends shall not exceed +1.6 mm from the nominal Internal Diameterdefined as follows :

nominal I.D. = nominal O.D. - 2 x nominal W.T.

Above diameters shall be checked with a circumferential tape or diameter tape. However,for pipes with O.D. less than 20" a caliper gauge may be used provided that equipmentand procedure have the prior agreement of the COMPANY.

6.9.2 - Out-of-roundness

a) Pipes with O.D. less than 20" : Out-of-roundness at the pipe ends shall be checkedusing an internal ring gauge of diameter 3.2 mm less than the nominal Inside Diameter.This gauge shall pass freely 100 mm into each end of the pipe when held normal to thepipe axis.

b) Pipes with O.D. 20" and larger : Out-of-roundness at pipe ends shall be checked usinga rod gauge or a caliper gauge and measurement of actual major and minor insidediameters of pipe shall be made. The difference between maximum I.D. and minimumI.D. measured within 100 mm at each pipe end shall not exceed 0.75% of the specifiednominal Inside Diameter, with a maximum of 5 mm. Nominal Inside Diameter isdefined in para. 6.9.1b above.

6.9.3 - Peaking

Peaking of the pipe at the weld location shall not deviate by more than 1.6 mm from thetheorical form, when measured transverse to pipe axis using COMPANY approved insideand outside templates (sectors of 20 minimum) or dial gauge.

Checking of peaking shall be carried out 5 times per shift, as a minimum..

6.9.4 - Wall thickness

The tolerance on wall thickness shall be -5% ; +10% of the specified nominal wallthickness.

The thickness shall be checked on a circumferential area (as a minimum, at both sides ofweld and at the area opposite to weld) at both ends of pipe.



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Wall thickness shall be checked using a micro-meter, a limit gage or ultrasonics.

The SUPPLIER shall guarantee the specified wall thickness along full length of finishedpipe. However, random checking at mid-length of pipe shall be made by SUPPLIER at afrequency to be agreed (with a minimum of three times per shift), unless measurementand recording of plate wall thickness was made continuously at plate mill on both the striplongitudinal axis and one strip edge, as a minimum (refer to para. 5.5.2 of thisspecification). Wall thickness print-outs shall the be made available to the INSPECTORin that case, for review at the pipe Mill.

6.9.5 - Weight

Each pipe length shall be weighed individually.

The tolerance on the weight of any single length of pipe shall be -3.5% ; +10% of thenominal weight.

6.9.6 - Unit length

- Pipes shall be supplied in lengths of 12.20 m + 0.60 m. However, when so permitted inParticular Specification, 3% of the pipes may have an individual length between10.00 m and 11.59 m, provided that the average length of each item of the order is12.20 m.No pipes shall be shorter than 10.00 m.

- Jointers made by welding two pipe sections to produce the specified pipe length are notpermitted.

6.9.7 - Straightness

The deviation from a straight line (taut wire) shall not exceed 1.4 mm per metre of length.Straightness shall be checked according 2 planes, as a minimum, displaced by 90. One ofthese planes shall include the longitudinal seam.

Straightness checking shall be carried out 3 times per shift, as a minimum.

6.9.8 - Squareness of pipe ends

The pipe ends shall be cut perpendicular to the pipe longitudinal axis within 1.6 mmacross any diameter. Checking shall be made either at the end facing machine or using anangle, at a minimum frequency of 3 times per shift.



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6.9.9 - Pipe end preparation

- Pipes shall be furnished with both ends bevelled to an angle of 30 +5, -0 with a rootface of 1.6 mm 0.6 mm (1.6 mm + 0.8 mm at weld seam area). Bevelling shall becarried out by straight machining only. There shall be no internal taper. Checking ofbevel dimensions shall be made 3 times per shift, as a minimum.

- Any repair by grinding on the bevel edge further to machine bevelling shall be causefor full rebevelling. However, internal burrs can be removed by filing provided that theroot face is not altered to the satisfaction of the INSPECTOR.

- The inside weld reinforcement shall be ground flush (to - 0.0 mm, + 0.5 mm) with theinside contour of the pipe for a minimum distance of 100 mm from each end.

6.9.10 - Height of Weld Beads

The weld bead height above the prolongation of the original surface of the pipe shall bewithin 0.5 mm and 3.5 mm, independent of wall thickness.

6.9.11 - Offset of Plate Edges

The maximum radial offset shall be 10% of the nominal wall thickness of the pipe with amaximum of 1.5 mm.

6.9.12 - Bulges, dents and flat areas

On the pipe body, deviations from the original contour of the pipe shall not exceed 3 mmdepth, nor shall they extend in any direction greater than 1/4 of the diameter of the pipe.Any sharp bottom deformations are unacceptable.

6.10 - Welding

6.10.1 - Welding processes

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

Gas Metal Arc Welding (GMAW) process may be used for tack-welding only providedthat the weld is completely remetled by the Submerged Arc Welding process.

Weld repair shall be carried out by SAW process or manual Shielded Metal Arc Welding(SMAW) process using low hydrogen electrodes.



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Each welding procedure shall be fully detailed in a Welding Procedure Specification(W.P.S.) form previously approved by the COMPANY.

6.10.2 - Welding Consumables

a) The weld deposits obtained from the consumables shall satisfy the impact toughnessand hardness requirements of this specification and shall have tensile properties thatare equal to or slightly higher than those of the base metal. Weld metal shall notevermatch the specified minimum YS and UTS of base metal by more than 20,000 psi.

b) All welding consumables shall conform to ASME Boilers & Pressure Vessel Code,Section IIC (AWS) or approved equivalent. Manufacturers data sheets shall besupplied to the COMPANY for information.

c) The SUPPLIER shall obtain manufacturers test certificates (3.1.B Certificatesaccording to EN 10 204 Std) for each batch of consumables used on the job.

d) Coated electrodes shall be of the low hydrogen type (i.e. maximum hydrogen contentof 10 ml per 100 grams of Weld Metal).

e) Low hydrogen coated electrodes and welding fluxes shall be stored and used accordingto the recommendations of their manufacturers. If there are no writtenrecommendations available from the manufacturers of consumables the followinginstructions shall be applied :

- Low hydrogen coated electrodes shall be oven dried for at least two hours at 350C.A lower temperature for a longer holding time is not acceptable. Immediately uponwithdrawal from their hermetically sealed container or drying oven, the electrodesshall be kept in a holding oven a approximately 100C before use.

- Electrodes withdrawn from the holding oven shall be used within 2 hours afterwithdrawal. If unused they shall be re-dried for 2 hours at 350C as above.

- Fluxes shall be dry and free of any foreign matter. The fluxes shall be kept in adrying oven at approximately 120C before use.

f) The Supplier's consumables traceability and flux recycling/reconditioning procedureshall be approved by the INSPECTOR before commencement of production welding.

g) All welding consumables shall be submitted to inspection by the INSPECTOR. TheMill acceptance test certificates for each batch and lot of consumables shall beavailable for that purpose. These documents shall certify that the consumables meet therequirements of the relevant standards for classification and grade.



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6.10.3 - Welding procedure qualifications

a) Longitudinal weld seam.

The welding procedure for longitudinal weld shall be qualified together with the pipemanufacturing procedure (see para. 6.6 and APPENDIX F) based on the submittedW.P.S.

b) Repair welding.

Unless otherwise agreed with the COMPANY, two repair types shall be qualified bytests.

- One partial repair (minimum of 2/3 thickness repair) simulating a defect located onFusion Line, and

- One shallow repair with 2 weld passes minimum simulating a defect located at weldtoe.

Where welding from inside of pipe is not intended by the SUPPLIER, nor practicable,nor accepted by the COMPANY, then a through thickness repair simulating a defectcentered in Weld Metal axis shall also be required.

All repairs shall include a minimum preheating of 100C, unless the qualification testhas shown that a higher temperature is necessary.

Each welding repair shall be qualified on a pipe section under realistic conditions to thesatisfaction of the INSPECTOR, in accordance with APPENDIX K.

6.10.4 - Qualification of manual welders

All manual welders shall be qualified as per Appendix C of API 5L and the following.

- Welders who have performed a satisfactory welding procedure qualification test arethereby qualified.

- Other welders shall be qualified by visual and radiographic examinations and side bendtests as follows :

. 100% visual examination

. 100% radiographic examination

. 4 guided side bend tests at locations selected by the INSPECTOR.

No nick-break tests are required.



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6.10.5 - Production welding

The welding conditions used for the longitudinal weld and repair welds shall not departfrom those of the related procedure qualification test.However the following variations are acceptable :

- Amperage : + 10%- Voltage : + 7%- Travel speed : + 10% for automatic welding- Preheating/interpass temperature: -0C, + 50C (provided that max. interpass

temperature of 280C is not exceeded).

7 - MILL HYDROSTATIC TESTING

- The required test pressure shall be computed using the following formula which includes afibber stress of 95% of the minimum specified yield strength of the pipe material :

P =20 x 0.95 x S x t D

P = hydrostatic test pressure in bar,S = minimum specified yield strength in N/mm or MPa,t = specified minimum wall thickness in mm,D = nominal outside diameter in mm.

- In the special case when sealing against the end face of the pipe is made by means of a ramwhich produces a compressive longitudinal stress, the formula stated in SR 14 of API 5Lmay be used (t being the specified minimum wall thickness). However, in no case theresulting pressure shall be less than 92% of SMYS when it is calculated by the standard

Barlows formula, i.e. test pressure shall not be lower than Px xSxT

D=

20 092 ..

- The test pressure shall be held for a duration of not less than 10 seconds for each pipe.

- A Certificate of calibration established less than 12 months before the pipe fabrication, by arecognised authority, shall be provided by the SUPPLIER for the master gauge. However,the pressure gauge and recorder shall be calibrated in-house against the said master gaugebefore start of production, and at least once per week thereafter.

- MILL hydrostatic test pressure prints shall show clearly the pipe number, the date of test, theapplied test pressure and the test duration for each pipe. Prints shall be available to theINSPECTOR for conformance check at the MILL.



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- A MILL hydrostatic test certificate of compliance giving MILL hydrostatic test requirements(test pressure and duration) shall be established by the SUPPLIER and furnished to theCOMPANY and the INSPECTION AGENCY. The SUPPLIER shall certify that everylength of pipes has been tested without any leak or sweat in accordance with the requirementsof this specification.

8 - INSPECTION AND TESTING


- The SUPPLIER shall bear full responsibility for the conformity of its supply to allrequirements of this specification. He shall, for this purpose, take all necessarymeasures, making use of suitable means, devices and qualified personnel, enablinghim to ensure permanent and effective control at each stage of manufacture.

- The SUPPLIER shall develop a Quality Control Plan (refer to para. 1.3 of thisspecification) for approval by the COMPANY and shall carry out all inspections andtests required by this specification.

- All inspections carried out by the SUPPLIER during pipe manufacture shall form thesubject of constantly updated reports. These reports shall be available for consultationby the INSPECTOR at any time.

- If during the main production, more than 7% of the pipes are rejected in any day'sproduction or re-routed for repairs or re-processing, then the INSPECTOR shall havethe right to ask the SUPPLIER to increase his Quality Control Programme to anappropriate level and to maintain it until the causes of defective quality are identifiedand eliminated. Where above rate attains 10%, the INSPECTOR may require the mainproduction to be stopped.

- Only pipes fully meeting the requirements of this specification shall be presented to theINSPECTOR for final acceptance.

- The SUPPLIER shall provide office space and inspection facilities, as required by theINSPECTOR, in the MILL. Free access shall be allowed to him at all times duringmanufacture and testing. A suitable working area shall be reserved for him at the endof the production line or at any other agreed location so that he can carry out his owninspections on the finished pipes.

- See also the provisions of Section 4 of this specification, for information.

- All finished pipes shall be submitted to production tests and inspections as defined inthe following paragraphs.



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- All Non-Destructive procedures shall have prior approval of the COMPANY and shallbe subject to qualification tests prior to their use in production. Further to acceptableresults, qualification records shall be established by the SUPPLIER, where necessary,and duly signed by the INSPECTOR.

- All Non-Destructive inspection personnels shall be properly certified according to BS,EN or COFREND scheme and shall have also been approved by the INSPECTORbefore any involvement on the order. NDT operators shall be certified level 2, as aminimum. The SUPPLIER shall supply the INSPECTOR with a list of inspectionpersonnels working on the job, showing their scope of qualification.

8.2 - Dimensional inspection

All specified dimensions (as per para. 6.9) shall be checked on each pipe, unlessotherwise indicated herein. Recording (refer to definition in para. 6.9) of dimensionalmeasurements shall be carried out, as a minimum, 3 times per shift, unless a higherfrequency is deemed necessary by the SUPPLIER or, otherwise, agreed at the bid stage.

Additional wall thickness measurements shall be carried out in ground areas (see Section9 of this specification), except for cosmetic grinding.

8.3 - Visual examination/Workmanship

8.3.1 - Visual examination

A visual examination of the total inside and outside pipe surfaces and of the weld seamshall be carried out on each pipe. For pipe of 24" O.D. and larger, the inside inspectionwill be made by "crawling" through the pipe.

The bevels shall be smooth and free from tool marks.

The standards of acceptance shall conform to API 5L, clause 7.8, with modifications asfollows.

8.3.2 - Defects

8.3.2 - Workmanship and Defects

The standards of acceptance shall conform to API 5L, Clause 7.8, with modifications asfollows :

a) Bulges, dents and flat areas : Refer to para. 6.9.12 of this specification.



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b) Offset of Plate Edges : Refer to para. 6.9.11 of this specification.

c) Out-Of-Line Weld Bead : the offset between the centre lines of the internal andexternal weld beads shall not exceed 3 mm. The narrowest point of the weld beadcross-section shall not be less than one-fourth (1/4) of the nominal wall thickness of thepipe with a minimum of 4 mm (see Figures in APPENDIX G). Checking for beadmisalignment shall be performed on specimens prepared for hardness test (see para.8.5.5 of this spec).

d) Height of Weld Beads : Refer to para. 6.9.10 of this specification.

e) Hard spots : the hardness is limited to 300 HV5 (or equivalent) to all parts of the pipe.

f) Cracks and leaks : All cracks, sweats and leaks are not acceptable. They shall beclearly marked and the pipe set aside for investigation by the SUPPLIER and theINSPECTOR.

The SUPPLIER shall determine the cause of cracks with reporting to theINSPECTOR. Based on the findings, the SUPPLIER shall then define and maintain allappropriate measures to avoid occurrence of cracks, to the satisfaction of theINSPECTOR.According to the origin of cracks the INSPECTOR may require an increase ofinspection from the SUPPLIER.

g) Laminations : Pipe bevels showing linear indications exceeding 3 mm shall be cutback.

h) Arc Burns : Repair by welding is not permitted.

i) Undercuts : Undercuts with a max. depth of 0.4 mm are acceptable in any length.Undercuts with a max. depth of 0.8 mm and not exceeding 5% of the wall thicknessare acceptable provided that :- their length is less than one-half of the wall thickness,- there is no more than two such undercuts in any 300 mm of weld length.

Undercuts which are coincident at inside and outside weld are not permitted.

Undercuts exceeding the above limits shall be removed by grinding or repaired bywelding.

j) Surface condition of pipe : Pipes shall be free from defects and shall have aworkmanlike finish. Pipe surface shall be substantially free from mill scales, scabs,pits, scores and laps, as well as unrepaired tears, raised slivers, bristles of steel, sharpnotches, scratches or mechanical marks (e.g. excessive roll marks).All those defects shall be removed by grinding. Thickness measurements shall be madeon all areas where grinding has been carried out. The final thickness after grinding shallnot be less than the specified minimum wall thickness.



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k) Other Defects :

- All sharp-bottom imperfections shall be considered as unacceptable defects,regardless of depth.

- Any imperfection showing a depth exceeding 5% of the specified nominal wallthickness shall be considered as unacceptable.

8.4 - Non-Destructive Inspection (Clause 9.7 of API 5L)

8.4.1 - Ultrasonic Testing (UT)

Apart from the ultrasonic examination to be performed on the plates (refer to para. 5.5.3of this specification.), all non-destructive inspections shall be carried out after completionof pipe manufacture, expansion (if any) and hydrostatic test.

a) Inspection of longitudinal weld seam.

The longitudinal weld seam shall be examined full length by multiprobe automaticultrasonic method. A detailed procedure shall be submitted by the SUPPLIER.

a.1-Ultrasonic Inspection Equipment

The equipment shall examine the weld and adjacent area for both longitudinal andtransverse defects. The equipment shall be fitted with an automatic paint spraysystem for marking the areas giving ultrasonic indications and areas where a loss ofultrasonic coupling with the pipe has occurred.

a.2-Reference Standards

The reference standard shall be made from a pipe manufactured for the order.However, with prior approval of the COMPANY, pipe production may start with areference standard made from a pipe of same diameter and wall thickness having alongitudinal weld of same profile and width.

The reference standard shall be of sufficient length so as to permit the detection ofthe standard reflectors while the equipment is travelling at its normal inspectionspeed. The standard reflectors shall consist, as a minimum, of the following :

one 1.6 mm (1/16") radially drilled hole (through thickness) in the weldcentreline,

four longitudinal N5 notches, 2 internal and 2 external of pipe, machined in theHAZ on both sides of weld,

two weld centreline N5 notches machined longitudinally, one internal and oneexternal of pipe,

two N5 notches machined transverse to weld, one internal and one external ofpipe,

two 3 mm flat bottom holes drilled in weld centreline, half thickness depth,inside and outside.



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The width of notches shall not exceed 1.0 mm.

The reference level shall be the lowest of the signals produced from any of theabove specified reflectors and the trigger/alarm level shall be set on 100% of thisreference level.

The reference pipe shall also contain two 1.6 mm or 3 mm dia (at Mills option)drilled holes located 4 mm away from weld toes (one on each side of weld seam)for checking the ultrasonic gate width.

The reference pipe shall be re-run, for calibration purposes, as a minimum :

once at the beginning of each normal inspection shift ; at least once during each inspection shift ; whenever any doubt arises on the ultrasonic efficiency by agreement between the

INSPECTOR and the SUPPLIER.

If during the calibration check, the standard reflectors do not produce signals of therequired magnitude, the calibration shall be re-adjusted, and all pipes accepted sincethe previous successful calibration shall be re-examined.

a.3-Acceptance Limits

Any imperfection which produces a signal of height exceeding the reference leveldefined above shall be considered an unacceptable defect unless it can bedemonstrated that the imperfection does not exceed the provisions of para. 8.3 and8.4.2 of this specification. Any imperfection found by the automatic ultrasonicsystem shall be further investigated by radiography.

b) Inspection of pipe ends :

The full circumference of each pipe end after bevelling shall be ultrasonically checkedfor laminar imperfections over a band 50 mm wide with manual or automaticultrasonic tester. This width is extended to 60 mm when the inspection is made beforebevelling.

Inspection procedure shall be according to ASTM A578 Std.

Any internal laminar imperfection exceeding an area of 60 mm shall not be acceptable.

8.4.2 - Radiographic inspection

Radiographic inspection in accordance with ISO/DIS 12096 Std shall be carried out on thelongitudinal weld at each pipe end over a minimum distance of 250 mm and also on thoseparts of the weld not scanned by all probes in the automatic ultrasonic inspection, on allwelding re-starts, repair welds, ultrasonic indications and welding procedure qualificationtest welds.



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Radiographic inspection shall be made by X-rays using fine grained high contrast directfilms (AGFA-GEVAERT type D5, EASTMAN-KODAK type T, or equivalent), leadscreens and a single wall, single image technique.

Procedure for marking of radiographs shall have prior approval of the INSPECTOR.

The following shall also apply :

- ISO wire penetrameter (to be used on every radiograph) as per ISO 1027.- Maximum sensitivity across the weld, using a source side penetrameter, shall be as

follows with regard to weld thickness T :T 10 mm: 2.0 %

10 mm



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b) When so required in the Particular Specification, the total weld length shall be MPIchecked at a frequency of one pipe per shift. For 24" O.D. pipes and above this shallinclude the internal weld seam. Acceptance shall be to para. 8.3.2 of this specificationand API 5L, clause 9.7.5.3, except that repair by welding is not permitted.

8.5 - Production Tests

The following production tests shall be carried out on base material and weld seam inaccordance of API 5L requirements and the following. The INSPECTOR reserves theright to select the pipes to be tested and to witness the tests.

8.5.1 - Product Chemical Analyses

A product analysis shall be carried out on both the pipe selected for tensile test and onanother pipe from same heat.

Sampling shall be located at 180 to the weld seam.

8.5.2 - Tensile Tests (base metal and weld)

- Tensile tests in base material shall be transverse to pipe axis and located at 90 to theweld seam.However, longitudinal tensile tests in addition to the transverse tensile tests arerequired for submarine pipelines. Specimens shall be cut at same location as above.

Strip specimens shall be used for longitudinal and transverse tests. Round barspecimens may be used where practicable for transverse tests, only when so previouslyagreed with the COMPANY.

- Transverse weld tensile tests shall apply regardless of diameter and shall record thetransverse ultimate tensile strength and location of rupture.

- Requirements of Table 3 of APPENDIX C shall be met for all above tensile tests.

- Tensile tests in base metal and weld shall be carried out on one finished pipe from eachlot of produced pipes as defined hereafter :

. O.D. less than 20" : 100 pipes

. O.D. equal to or above 20" : 50 pipes



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A lot includes only pipes of a same size and grade coming from a same heat. Anyfraction of a lot shall be subjected to full testing as above.

- According to the minimum levels of tensile properties obtained on plates, theINSPECTOR reserves the right to select the pipes for production testing in order tocheck that the mechanical properties required for the pipes have been actually obtainedwith plates whose properties are at the minimum of the tensile range.

8.5.3 - Guided Bend Tests

- Guided bend tests shall be conducted transverse to weld seam in accordance with therequirements of clause 9.8.2 of API Spec. 5L, except that the specimens shall be bentin a test jig of the following dimensions :

Radius of male member RA : 4t

Radius of female member RB : 5t + 1.5 mm

Width of male member A : 8tWidth of groove in female memberB : 10t + 3 mm

- One face-bend and one root-bend test, with weld reinforcement removed from bothfaces, shall be carried out for wall thickness of 12.7 mm and less. For wall thicknessabove 12.7 mm, these tests shall be replaced by 2 side bend tests. Specimens to be fullpipe wall thickness with a specimen width of 12.5 mm.

- Testing frequency shall be 2 bend tests per each lot of 50 pipes or less per heat.

8.5.4 - CHARPY V-Notch Tests (Base material and Weld)

Three Charpy V-notch impact tests (one for base material testing and two for weld testingas indicated hereafter) shall be taken from the same pipe as that selected for tensile testing(see para. 8.5.2 above). Each test shall consist of 3 specimens notched through the pipewall thickness.

- one set shall be cut in base material transverse to pipe axis and located at 90 to theweld seam,

- one set shall be cut with the notch centered in weld metal axis,

- one set shall be cut with the notch centered in Heat Affected Zone (HAZ) at theposition selected for the routine production test according to para. F.2 (7) ofAPPENDIX F.

The figure for double-Vee weld in APPENDIX H shows the notch locations in weld.

All sets shall be tested at the test temperature stated in the Particular Specification (or so-called routine test temperature). The test temperature shall not be higher than 0C.



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For acceptance, the results of energy absorption for the above notch locations shall not beless than the values stated in Table 4 of APPENDIX C for full size specimens (10 x10 mm).

As far as possible, full size specimens shall be used. If sub-size specimens are foundnecessary due to pipe curvature and wall thickness, the required absorbed energy figuresshall be those for full size specimens (see Table 3) multiplied by the corresponding factorsgiven in the Table below.

Specimen(mm)

MultiplyingFactor

10 x 1010 x 7.510 x 6.710 x 5

15/67/92/3

Impact tests are not required for wall thickness below 6.35 mm.

8.5.5 - Macrography/Hardness Test

One specimen shall be extracted from the selected pipe for tensile tests (see para. 8.5.2above).

The specimen shall be polished and etched for macrographic examination. The weldcross-section shall be examined to ensure that weld profile is satisfactory as per para.8.3.2 above and APPENDIX G.

A VICKERS hardness survey shall then be carried out using a 5 kg load in accordancewith APPENDIX J. No individual hardness value shall exceed 300 HV 5. If any resultexceeds this limit, all pipes from that lot/heat shall be rejected. However, this hardness testis not required for pipe in Grade X 46 or lower grade together with wall thickness notexceeding 12 mm or for in Grade X 52 with wall thickness not exceeding 10 mm,provided that the maximum hardness obtained at Pipe Manufacturing ProcedureQualification does not exceed 270 HV5, to the satisfaction of the INSPECTOR.

8.5.6 - Drop Weight Tear Tests

In case of gas pipeline with 20" O.D. or larger, grade X52 or higher, wall thicknessexceeding 8 mm, a pipe from each heat shall be tested by Drop Weight Tear Testing inaccordance with SR-6 of API 5L Std. The testing temperature shall be that stated in theParticular Specification. This temperature shall not be higher than 0C.



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The minimum individual shear area value shall be 85% for all tests.

Relevant marking of pipes is not required.

8.5.7 - Defective Test Specimens

If both the SUPPLIER and the INSPECTOR are of the opinion that a specimen fails dueto improper machining or preparation, then the said specimen will be discarded andanother specimen substituted.

If any test specimen fails due to some defect in the material, it may be substituted byanother test specimen with prior approval of the INSPECTOR. The nature of the defectshall be made clear by the SUPPLIER and the INSPECTOR will specify additional non-destructive testing to ensure that the defect constitutes really an isolated anomaly.

8.5.8 - Retests

Where one specimen fails to conform to the specified requirements, a retest may beaccepted by the INSPECTOR pending further investigation of the failure is made by theSUPPLIER. Where it is thought that the failure can be an isolated case, then a retest onfour (4) additional pipes from the same heat/lot of pipes shall be carried out.

Should all retests give acceptable results, then only the pipe which gave the unacceptableresult shall be rejected.

Should one (or more) of the retests give unacceptable results, then the complete heat/lot ofpipes may be rejected unless each of the remaining pipes of the said heat/lot is testedindividually. The pipes which will give acceptable results according to this specificationwill not be rejected, always providing that such individual tests shall not produce arejection equal or superior to 50% of the pipes so tested. Should that be the case then allpipes of the said heat/lot shall be rejected.

8.6 - Residual Magnetism

Residual magnetism at pipe ends shall not exceed 25 Gauss. Checking shall be made atrandom within the SUPPLIERs Mill, with a minimum of 5 pipes checked per shift, usinga calibrated Hall effect gauss-meter or other equipment approved by the INSPECTOR.



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8.7 - Mill certificates

- The Particular Specification shall state which type of inspection test Certificate,according to EN 10 204 Std, is required to support the delivered pipes. Certificate3.1.B is required, as a minimum. When 3.1.C certificate is required in the P.P.S., theMill certificate shall be established by the pipe manufacturer.

- Mill Certificates shall make reference to API Spec. 5L together with the presentGeneral Specification and applicable Particular Specification.

- Mill Certificates shall also imperatively show the following :

. rolling technique/heat treatment of base material,

. ladle analysis including Carbon Equivalent and Pcm,

. pipe n with reference to heat n (and slab n, where possible),

. mechanical test results and product chemical analysis (including CE and Pcm) withreference to pipe n,

. dimensional inspections with results,

. non-destructive tests performed with results,

. any supplementary tests and inspections carried out.

- Format of Mill certificates shall be agreed with the COMPANY prior to pipeproduction.

9 - REPAIR OF DEFECTS

Apart from cosmetic grinding, all repairs shall be carried out before cold expansion (if any) andhydrostatic test.

9.1 - Repair on Base Material

- Repair by welding on pipe base metal is not permitted. This requirement applies also towelding repairs of any cavity resulting from removing of arc burns (see para. 8.3.2).

- Repair of dents and flat areas is not permitted.

- Defects in the body of the pipe shall be removed by grinding. A smooth curved surfaceshall be obtained. Thickness measurements shall be made on all areas where grindinghas been carried out. The final thickness after grinding shall be not less than thespecified minimum wall thickness.

- Repair of bevels shall be made by full re-bevelling only.



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9.2 - Repair of longitudinal weld seam

- Unacceptable defects in the longitudinal weld seam, except as specified below, may beremoved by grinding and repaired by welding carried out by qualified welders (seepara. 6.10.4) and using a previously qualified welding procedure (see para. 6.10.3).

- No welding repair is permitted over a length of 200 mm from each pipe end.

- Longitudinal weld seam containing cracks shall not be weld repaired. The section ofpipe containing cracks shall be cut off. Then, acceptability of the remaining pipe shallbe based on length requirements as per para. 6.9.6.

- For each pipe, the total length of welding repairs shall not exceed 5% of the pipe lengthand the number of repaired areas is limited to three maximum. Repairs shall beseparated by at least one pipe O.D. of unrepaired weld.

- Repair of a weld area previously repaired is not permitted.

- Back to back repair is not permitted.

- Each welding repair shall have a minimum length of 100 mm, even if the defect is ofless extent.

- The defect shall be completely removed by grinding and the resulting cavity shall bethoroughly cleaned and inspected, before welding, by magnetic particle or dyepenetrant method to insure complete removal of the defect.

- The external surface of the repair weld shall be subject to suitable grinding in order toobtain an uniform appearance and to merge smoothly into the base material.

- Each repaired area shall be 100% radiographically and MPI tested according to para.8.4.2 et 8.4.3 of this specification.

10 - MARKING OF PIPES

a) Each pipe shall be clearly identified by means of markings made with indelible white oryellow paint, and a circumferential coloured painted band 50 mm wide on the externalsurface of one pipe end at 200 mm approx. of pipe end. The colour shall be defined in theParticular Specification or otherwise agreed with the SUPPLIER in due time.

b) The quality of paint employed and its application shall be designed to provide inscriptionsthat shall be perfectly readable for a least three months on pipes exposed to outdoor weatherconditions. Marking and stamping will be protected by varnish.



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c) Marking (paint stencilling) shall begin at least 200 mm from the bevel and shall be madecircumferentially using letters and figures of 25 mm minimum in height. Metric units shall beused to state pipe length.

Free-hand marking is limited to variables only and shall be properly carried out to thesatisfaction of the INSPECTOR.

d) Unique pipe number shall be allocated sequentially and marked on the pipes.

e) Stencilling shall be made at inside surface of both pipe ends as follows.

Marking may be made in a sequence convenient to the pipe manufacturer but shall includethe following minimum information.

- At one pipe end (full stencilling) :. TOTAL/Purchaser's name. Purchase Order n. Steel Grade. O.D. x W.T.. Heat Number. Pipe number. Pipe length. Brand mark/logo of Mill

- At the second pipe end (reduced stencilling) :. Pipe number. Pipe length

f) The following shall be die stamped on the bevel surface at a point opposite to longitudinalseam, at the pipe end where full stencilling as above has been made :

- the mark of the INSPECTION AGENCY,- the pipe number, when so required in the Particular Specification.

g) Marking shall be approved by the INSPECTOR prior to pipe production.

11 - PROTECTION OF BEVELS

Where pipes are required by the Particular Specification to be delivered with pipe bevelprotectors, these shall be submitted with full details by the SUPPLIER at the bid stage.



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12 - HANDLING, TRANSPORT AND STORAGE OF PIPES

12.1 - General

The SUPPLIER shall submit to the COMPANY for review and approval a handling,transport and storage procedure detailing the proposed methods of handling, stackingduring storage, and stacking and securing pipes for transportation and shipment.

All handling, loading and unloading shall be performed in such a way as to avoidmechanical damages and to prevent stresses which might result in dent or out-of-roundness. The SUPPLIER shall be responsible for any permanent deformationssubsequent to Mill acceptance and resulting from loading, storing, stacking, transportationor shipping, where applicable according to the scope of CONTRACT.

12.2 - Handling and storage

All handling shall be performed with slings, or pipe-shaped padded hooks approved by theINSPECTOR.

Stored pipes shall be adequately supported at all times to prevent permanent deformationof pipes and to give protection to bevelled ends.

The SUPPLIER shall take all necessary precautions during storage to prevent pipes fromcorrosion, as well as from dirt and surface defects which could be injurious for thesubsequent coating.

12.3 - Transport

Loading onto or into rail cars, trucks, ships or other conveyances shall be performed inaccordance with API RP 5L1 or API RP 5LW, as appropriate. In all cases loading shall bein accordance with a procedure approved by the COMPANY.

Rail cars, trucks, ships or other conveyances shall be cleaned of debris or any substancethat might damage the pipes.

Suitable timber and other dunnage shall be used to protect the pipes against damageduring transit.



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13 - DOCUMENTATION

The following minimum documentation shall be delivered by the SUPPLIER.

13.1 - When the bids are submitted

- the Pipe Manufacturing Procedure Specification (refer to 5.1, and APPENDIX E),

- alternative percentage of shorter pipes offered if less than that stated in 6.9.6. or inP.P.S. (when applicable),

- weldability test specification (when applicable),

- description of the proposed bevel protectors (if any),

- handling, transport and storage procedure for pipes,

- Quality Assurance Manual,

- Quality Control Plan (typical),

- pipe supply track record as well as histograms of chemical and mechanical test resultsfrom previous orders of the same pipe grade and similar dimensions, as proofs ofcapability to produce pipes according to this specification,

- Welding tests carried out by the SUPPLIER on similar pipe material and dimensionsgiving evidence of acceptable weldability as regard to applications defined in para. 6.7of this specification (when so required in the P.P.S.).

- details of offered fabrication Pipe History System (P.H.S.), when required in the P.P.S.

- at SUPPLIER's option, any other pertinent technical information relating to theproposed pipe supply.

- The SUPPLIERs deviations/qualifications to present specification. Where nodeviations are stated in the bid, then the potential SUPPLIER shall be considered asfully accepting the requirements of present specification.

13.2 - Upon completion of pipe production

- A production report shall be furnished by the SUPPLIER. It shall include, but not belimited to, the information and documents stated hereafter :

. steel making process and plate manufacturing procedure specification,

. non-destructive reports of stell plates,



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. Mill test certificates of plates,

. Pipe Manufacturing Procedure Specification,

. reports of pipe manufacturing procedure qualification tests,

. reports of non-destructive procedure qualification tests,

. Mill hydrostatic test certificate of compliance,

. Mill test certificates for production tests made on pipes,

. all inspection reports for pipes,

. Quality Control Plan,

. report of weldability tests (if any) and SUPPLIERs recommendations or guidancefor site welding of supplied pipes,

. list of heat numbers showing pipe numbers, individual length and weight, totallength and weight produced per heat,

. histogram of the results of production tests (chemical and mechanical) anddimensions of pipes (length, as a minimum), when so required in ParticularSpecification.

. compilation of concessions/deviations, if any, granted by the COMPANY duringpipe production.

- The Particular Specification shall state the number of originals and copies of theproduction report which are to be supplied to the COMPANY.

- The INSPECTION AGENCY shall stamp (rubber-stamp) and sign these documentsfor the acceptance of pipes meeting all the requirements of this specification.

13.3 - Schedule

- The pipes can be dis

rp-sp19-999-1300-078-2.pdf

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