31402037

DEP SPECIFICATION

LINE PIPE FOR CRITICAL SERVICE (AMENDMENTS/SUPPLEMENTS TO ISO 3183:2007)

DEP 31.40.20.37-Gen.

February 2011 (DEP Circular 100/11 has been incorporated)

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2011 Shell Group of companies All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior

written permission of the copyright owner or Shell Global Solutions International BV.

DEP 31.40.20.37-Gen. February 2011

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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies. These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards. The objective is to set the recommended standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal. The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by

these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement. 2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part

of a Service Agreement or otherwise). 3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)

which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in Shell GSI.


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TABLE OF CONTENTS

PART I INTRODUCTION ........................................................................................................5 1.1 SCOPE........................................................................................................................5 1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........6 1.3 DEFINITIONS .............................................................................................................6 1.4 CROSS-REFERENCES .............................................................................................6 1.5 SUMMARY OF MAIN CHANGES...............................................................................6 1.6 COMMENTS ON THIS DEP.......................................................................................7 1.7 DUAL UNITS...............................................................................................................7 PART II GENERAL REQUIREMENTS ....................................................................................8 1.1 GENERAL...................................................................................................................8 1.2 APPLICATION ............................................................................................................8 1.3 PRINCIPAL'S ACCESS AND ACTIVITIES.................................................................9 1.4 PIPE FOR INDUCTION BENDS.................................................................................9 PART III AMENDMENTS/SUPPLEMENTS TO ISO 3183:2007 ............................................10 1. SCOPE......................................................................................................................10 2.3 COMPLIANCE TO THIS INTERNATIONAL STANDARD ........................................10 3. NORMATIVE REFERENCES...................................................................................10 4. TERMS AND DEFINITIONS.....................................................................................10 4.18 HFW PIPE.................................................................................................................10 4.29 MANUFACTURER....................................................................................................10 5. SYMBOLS AND ABBREVIATED TERMS................................................................10 5.2 ABBREVIATED TERMS ...........................................................................................10 6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION................................10 6.1 PIPE GRADE AND STEEL GRADE.........................................................................10 6.2 DELIVERY CONDITION...........................................................................................11 7. INFORMATION TO BE SUPPLIED BY THE PURCHASER ....................................11 7.1 GENERAL INFORMATION.......................................................................................11 7.2 ADDITIONAL INFORMATION ..................................................................................11 8. MANUFACTURING ..................................................................................................12 8.1 PROCESS OF MANUFACTURE..............................................................................12 8.3 STARTING MATERIALS ..........................................................................................13 8.4 TACK WELDS...........................................................................................................13 8.5 WELD SEAMS IN COW PIPE ..................................................................................13 8.6 WELD SEAMS IN SAW PIPE...................................................................................13 8.9 COLD SIZING AND COLD EXPANSION .................................................................13 8.10 STRIP/PLATE END WELDS.....................................................................................13 8.11 JOINTERS ................................................................................................................13 8.12 HEAT TREATMENT .................................................................................................13 8.13 TRACEABILITY ........................................................................................................14 9 ACCEPTANCE CRITERIA........................................................................................14 9.1 GENERAL.................................................................................................................14 9.2 CHEMICAL COMPOSITION.....................................................................................14 9.3 TENSILE PROPERTIES...........................................................................................15 9.4 HYDROSTATIC TEST..............................................................................................15 9.6 FLATTENING TEST .................................................................................................15 9.8 CVN IMPACT TEST FOR PSL2 PIPE......................................................................15 9.9 DWT TEST FOR PSL2 WELDED PIPE ...................................................................17 9.10 SURFACE CONDITIONS, IMPERFECTIONS AND DEFECTS...............................17 9.11 DIMENSIONS, MASS AND TOLERANCES.............................................................18 9.12 FINISH OF PIPE ENDS............................................................................................19 9.13 TOLERANCES FOR THE WELD SEAM..................................................................19 9.14 TOLERANCES FOR MASS......................................................................................19 9.15 WELDABILITY OF PSL2 PIPE .................................................................................19 10 INSPECTION ............................................................................................................20 10.2 SPECIFIC INSPECTION ..........................................................................................20 11 MARKING .................................................................................................................27


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11.1 GENERAL.................................................................................................................27 11.2 PIPE MARKINGS......................................................................................................27 11.3 COUPLING MARKINGS...........................................................................................27 12.2 THREAD PROTECTORS .........................................................................................27 14 PIPE LOADING.........................................................................................................27 ANNEX A SPECIFICATION FOR WELDED JOINTERS ..........................................................28 ANNEX B MANUFACTURING PROCEDURE QUALIFICATION FOR PSL2 PIPE..................28 ANNEX C TREATMENT OF SURFACE IMPERFECTIONS AND DEFECTS ..........................31 ANNEX D REPAIR WELDING PROCEDURE...........................................................................31 ANNEX E NON-DESTRUCTIVE INSPECTION FOR OTHER THAN SOUR SERVICE OR

OFFSHORE SERVICE .............................................................................................32 ANNEX F REQUIREMENTS FOR COUPLINGS (PSL 1 ONLY)..............................................43 ANNEX G PSL 2 PIPE WITH RESISTANCE TO DUCTILE FRACTURE PROPAGATION......43 ANNEX H PSL 2 PIPE ORDERED FOR SOUR SERVICE.......................................................43 ANNEX I PIPE ORDERED AS “THROUGH THE FLOWLINE" (TFL) PIPE ............................46 ANNEX J PSL 2 PIPE ORDERED FOR OFFSHORE SERVICE .............................................46 ANNEX K NON-DESTRUCTIVE INSPECTION PIPE ORDERED FOR SOUR AND/OR

OFFSHORE SERVICE .............................................................................................49 PART IV REFERENCES .........................................................................................................54

APPENDICES

APPENDIX 1 LINEPIPE SUBJECTED TO HIGH STRAIN....................................................56 APPENDIX 2 WELDABILITY OF PSL2 PIPE........................................................................58 APPENDIX 3 LINE PIPE FOR DEEPWATER PROJECTS, INCLUDING STEEL

CATENARY RISERS.......................................................................................59 APPENDIX 4 PROCEDURE REQUIREMENTS FOR NDT...................................................61


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PART I INTRODUCTION

1.1 SCOPE

This DEP specifies requirements and gives recommendations for the manufacture and supply of carbon and low-alloy steel line pipe for use in pipelines where the service has been evaluated by the Principal as being “Critical”. Guidance on the evaluation of pipeline service criticality and line pipe selection is given in DEP 31.40.00.10-Gen.

This DEP applies to the following applications; see also (Part II, 1.2).

• all offshore pipelines;

• all pipelines designed for sour service;

• all pipelines subject to high strain (more than 1.5%) in installation or service;

• all line pipe ordered with resistance to ductile fracture propagation.

This DEP does not apply when all of the following conditions are satisfied:

• the design pressure does not exceed 40 barg (580 psi); and,

• the pipeline has been designed with a design factor of 0.5 or lower; and,

• the pipeline is designed for the transportation of category A, B or C fluids (i.e. not for D and E fluids); and,

• the pipeline has a diameter of DN 250 (NPS 10) or less; and,

• the minimum pipeline design temperature is 0°C (32°F) or greater; and,

• The pipeline does not form part of a main transportation infrastructure.

Use of HSAW line pipe may be applied for onshore applications where the diameter and wall thickness requirements are within the manufacturing range for HSAW line pipe. HSAW does not apply when:

• the operating conditions require use of batch inhibition for corrosion control, or

• the seam welds are at risk of corrosion due to water drop out, or

• the use of reliability-based limit state design principles is required to confirm design or operational integrity,or

• in sour service.

This DEP is based on ISO 3183:2007. Part III of this DEP is written in the form of amendments and supplements ISO 3183:2007 (PSL2).

This DEP is applicable only to grades L245 up to L555 (X80) as designated in ISO 3183:2007.

The amendments and supplements in this DEP also apply to API 5L, 44th edition (PSL2), which contains the identical section numbers and content, with the exception of minor deviations listed in Annex N.

This DEP contains mandatory requirements to mitigate process safety risks in accordance with Design Engineering Manual DEM 1 – Application of Technical Standards.

This is a revision of the DEP of the same number dated January 2010; see (1.5) regarding the changes.


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1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorised access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer.

This DEP is intended for use in facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, distribution and supply/marketing. This DEP may also be applied in other similar facilities.

When DEPs are applied, a Management of Change (MOC) process should be implemented; this is of particular importance when existing facilities are to be modified.

If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS

1.3.1 General definitions

The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor.

The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal.

The word shall indicates a requirement.

The capitalised term SHALL [PS] indicates a process safety requirement.

The word should indicates a recommendation.

1.3.2 Specific definitions

Term Definition

Manufacturer Term used in ISO 3183:2007, which shall be taken to mean the Manufacturer/Supplier.

Purchaser Term used in ISO 3183:2007, which shall be taken to mean the Principal.

1.4 CROSS-REFERENCES

Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (Part IV).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the DEP of the same number dated January 2010 which was based on ISO 3183-3.

ISO 3183-1, ISO 3183-2 and ISO 3183-3 were replaced in March 2007 by a consolidated ISO 3183. Due to the fundamental change in overall scope and clause numbering in ISO 3183 it is impractical to summarise the changes here.


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1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at [email protected], using the DEP Feedback Form. The DEP Feedback Form can be found on the main page of “DEPs on the Web”, available through the Global Technical Standards web portal http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

1.7 DUAL UNITS Amended per Circular 100/11 Dual units have been incorporated throughout this DEP.

This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.

mailto:[email protected]

http://sww.shell.com/standards


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PART II GENERAL REQUIREMENTS

1.1 GENERAL

Part III of this DEP is written as amendments and supplements to ISO 3183:2007. Wherever reference is made to ISO 3183:2007, it shall be understood to mean ISO 3183:2007 as amended/supplemented by this DEP.

The amendments and supplements in this DEP shall also apply to API 5L, 44th edition (PSL2), which contains the identical section numbers and content, with the exception of minor deviations listed in Annex N.

For ease of reference, the clause numbering of ISO 3183:2007 has been used throughout Part III of this DEP.

Clauses in ISO 3183:2007 which are not mentioned in this DEP shall remain valid as written.

Tables and figures in this DEP not replacing the corresponding item in ISO 3183:2007 are numbered related to the DEP section they are contained in (e.g. Figure 10.2.5.3).

1.2 APPLICATION

Carbon Steel Line Pipe SHALL [PS] be ordered using this DEP for the following applications:

• all offshore pipelines; • all pipelines designed for sour service; • all pipelines subject to high strain (more than 1.5%) in installation or service; • all line pipe ordered with resistance to ductile fracture propagation.

Line Pipe for onshore applications not addressed above may be designated “Line Pipe for Non-Critical Service” (i.e. pipelines designed for non-sour service and where line pipe is not required to be resistant to ductile fracture propagation or high strain) and may be ordered in accordance with ISO 3183 PSL2 without amendment.

To be classified as Line Pipe for Non-Critical Service all of the following conditions shall be satisfied:

• the design pressure does not exceed 40 barg(580 psig); and, • the pipeline has been designed with a design factor of 0.5 or lower; and, • the pipeline is designed for the transportation of category A, B or C fluids (i.e. not for

D and E fluids); and, • the pipeline has a diameter of DN 250 (NPS 10) or less; and, • the minimum pipeline design temperature is 0°C (32°F) or greater; and, • The pipeline does not form part of a main transportation infrastructure.

Line pipe shall only be ordered in accordance with ISO 3183 PSL1 for non hydrocarbon, non toxic, low pressure (not greater than 20 Barg (2900 psig), and with a minimum design temperature greater than 0°C (32°F) .

Use of HSAW line pipe should be considered for onshore applications where the diameter and wall thickness requirements are within the manufacturing range for HSAW line pipe. HSAW line pipe shall not be used where:

• the operating conditions require use of batch inhibition for corrosion control, or • the seam welds are at risk of corrosion due to water drop out, or • the use of reliability-based limit state design principles is required to confirm design

or operational integrity,or • in sour service.

Prior to order placement, the pipe mill and all sources of coil shall be evaluated technically and approved.


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1.3 PRINCIPAL'S ACCESS AND ACTIVITIES

Principal’s representatives shall be permitted to witness all chemical testing, mechanical testing, and equipment calibration, and to inspect all pipe. Sufficient notice (at least 14 days) shall be given of the time at which the production run is to begin.

The Principal’s representatives shall have free entry at all times to all parts of the Manufacturer’s works that will concern the manufacture, testing, inspection, quality control and shipping of the pipe ordered. This includes the steel mill and the pipe mill. The Manufacturer shall make available to the Principal’s representatives, without charge, all reasonable facilities to inspect, measure, and test the pipe in all stages of production. For example, this includes ultrasonic equipment for wall thickness confirmation.

The Principal’s representative shall have the option to examine all materials rejected for any reason. The Principal’s representative must be informed of any pipe fractures occurring during hydrostatic testing and of any test specimen failures to meet the requirements for any reason. All failed materials shall be retained until examined by the Principal’s representative.

The Manufacturer shall allow the Principal’s representative to inspect each length of pipe after manufacture and testing are completed but prior to loading for shipment.

1.4 PIPE FOR INDUCTION BENDS

The general requirements of ISO 3183:2007 and this DEP apply to pipe intended for induction bending. However, the composition, mechanical properties and dimensions of such pipe shall be dictated by the dimensions and delivery condition of the completed bends, which shall be in accordance with ISO 15590-1 and DEP 31.40.20.33-Gen. The composition, mechanical properties and dimensions of this pipe shall therefore be by agreement between the Manufacturer and the Principal


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PART III AMENDMENTS/SUPPLEMENTS TO ISO 3183:2007

1. SCOPE

Amend first paragraph as follows:

This international standard specifies requirements for the manufacture of product specification level PSL 2 of seamless and welded pipe for use in pipeline transportation systems in the petroleum and natural gas industries.

Add the following:

This DEP is applicable only to grades L245 up to L555 (X80) as designated in ISO 3183:2007. Intermediate grades shall not be used.

2.3 COMPLIANCE TO THIS INTERNATIONAL STANDARD

Delete existing clause and replace with the following:

The Manufacturer/Supplier SHALL [PS] maintain and operate a quality assurance system in accordance with ISO 9001 or an alternative standard approved by the Principal.

3. NORMATIVE REFERENCES

Add the following:

See also (Part IV) of this DEP.

4. TERMS AND DEFINITIONS

4.18 HFW PIPE

Amend this clause as follows:

EW pipe produced with a welding current frequency equal to or greater than 100 kHz.

4.29 MANUFACTURER

Add the following:

Where pipe manufacturing and/or heat treatment are subcontracted, the pipe mill and/or the processor shall also be considered to be the Manufacturer/Supplier.

5. SYMBOLS AND ABBREVIATED TERMS

5.2 ABBREVIATED TERMS

Add the following:

AUT Automatic Ultrasonic Testing

FBE Fusion Bonded Epoxy

GMAW Gas Metal Arc Welding

SCR Steel Catenary Riser

ToFD Time of Flight Diffraction

6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION

6.1 PIPE GRADE AND STEEL GRADE

6.1.1 Delete this clause


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6.2 DELIVERY CONDITION


Table 1

Delete reference to PSL1 pipe grades

Delete reference to PSL 2 Grades L390N, L415N, L625M, L690M and L830M

NOTE: Pipes fabricated from thermomechanical rolled material are generally not suitable for hot (induction) bending.

7. INFORMATION TO BE SUPPLIED BY THE PURCHASER

Add the following:

The complete information should be provided at the enquiry stage of the purchase order; however, requirements specifically addressed by this DEP need not be repeated.

7.1 GENERAL INFORMATION

Modify the following:

b) Delete PSL1

Add the following

i) Minimum design temperature (for determination of CVN, DWT and CTOD test temperature)

j) Intended service, i.e. gas or oil for determination of need for, resistance to ductile fracture propagation, sour service high strain, and deep water.

7.2 ADDITIONAL INFORMATION

Add the following:

a)10) Diameter and out-of-roundness for pipes with D/t> 75

Information included in this DEP.

a)3), a)4, a)6), a)9)

b)4), b) 6), b)7)

c)6), c)7), c)8), c)9), c)10), c)11), c)12), c)15), c)16), c)22), c)23), c)25), c)26), c)27), c)40), c)42), c)43), c)44), c)46), c)47), c)49), c)51,

Information not applicable to this DEP.

a)1), a)2), a)9)

b)2), b)3), b)5), b)8), b)11) b)12

c)2), c)5), c)7), c)13), c)13), c)17), c)18), c)24), c)38), c)45), c)48), c)52), c)53)


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8. MANUFACTURING

8.1 PROCESS OF MANUFACTURE

8.1 Delete this clause and replace with the following:

Only PSL 2 pipe shall be supplied in accordance with this DEP. Pipe shall be manufactured by one of the following processes:

Table 2 Delete references to PSL1 grades Delete COWL, COWH, Double-seam SAWL and Double-seam COWL Delete Note d and substitute:

Double-seam SAWL may be permitted only for specific applications and where detailed in the Purchase order

Add NOTE g: HFW pipe is generally limited to a maximum wall thickness of 20 mm (0.8 in). Thickness over 20mm

(0.8 in) may be considered after detailed evaluation; any approval by the Principal shall be on a project by project basis.

Delete Table 3 and replace with the following:

Table 3 Acceptable manufacturing routes for PSL 2 pipe

Type of pipe Starting material Pipe forming Pipe heat treatment Delivery condition

Seamless Ingot, bloom or billet Normalising forming (NOTE 1)

N

Normalising N

Hot forming

Quenching and tempering

Q

Hot forming and cold finishing

Normalising N

Quenching and tempering

Q

HFW Normalising rolled strip Cold forming Normalising weld area

N

Thermomechanically rolled strip

Cold forming Heat treating weld area

M

Heat treating weld area and stress relieving (entire pipe)

M

Hot rolled strip Cold forming Normalising (entire pipe)

N

Quenching and tempering (entire pipe)

Q

SAW Normalised or normalising rolled plate or strip

Cold forming N

Thermomechanically rolled plate or strip

Cold forming M

Quenched and tempered plate

Cold forming Q

As rolled, normalised, or normalising rolled plate or strip

Cold forming Quenching and tempering (entire pipe)

Q

NOTE 1: The finishing temperature shall be greater than 780 °C (1435°F). Pipe finished at a lower temperature than 780°C(1435°F). shall be subjected to a further normalising heat treatment.


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8.3 STARTING MATERIALS

8.3.5 Add new clause:

The abutting edges of strip or plate to be HFW welded shall be milled or machined. Rotary shearing shall not be considered as machining.

8.4 TACK WELDS

8.4.2 Add the following:

Tack welds shall be made using a continuous single pass unless otherwise agreed with the Principal.

8.5 WELD SEAMS IN COW PIPE

Delete this clause.

8.6 WELD SEAMS IN SAW PIPE

Add the following:

The seam welding of HSAW pipe shall be carried out as a separate process from the forming operation (i.e. the welding speed shall be independent of the forming speed)

8.8.1 PSL 1 EW Pipe

Delete this clause

8.8.2 PSL 2 HFW Pipe

Add:

See also Table 3 for acceptable heat treatment routes.

8.9 COLD SIZING AND COLD EXPANSION

8.9.2 Amend this clause as follows:

Cold expansion shall be performed by mechanical means only. The sizing ratio for cold-expanded pipe shall not be less than 0.008 or more than 0.015.

8.10 STRIP/PLATE END WELDS

Replace this clause with the following:

Pipe containing strip end welds shall not be supplied, except for HSAW pipe of above 762 mm OD (30 inch) where strip end welds may be considered subject to the following:

• strip end welds are not within 2 meters from the pipe end;

• welding procedures and NDT procedures to have specific review and approval by the principal;

• These welds to have at least 2 NDT methods applied e.g. UT and RT. NOTE: The Principal shall have the final decision if strip end welds are permitted for any specific

order/project.

8.11 JOINTERS


Jointers shall not be supplied.

8.12 HEAT TREATMENT

Add to this clause:

In addition, the Manufacture shall supply the following information concerning the heat treatment facility for approval by the Purchaser:


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• Type of furnace (e.g. Batch, Walking Beam, etc.); • Method of heating and fuel (if applicable); • Number, position of thermocouples and controlled heating zones; • Arrangement of pipes with furnace; • Identification and control of individual pipes throughout the heat treatment cycle.

8.13 TRACEABILITY

8.13.1 Delete this clause.

9 ACCEPTANCE CRITERIA

9.1 GENERAL

9.1.2 Delete existing clause and replace with the following:

Pipe manufactured to a specific grade shall not be substituted for pipe ordered as a lower grade.

9.2 CHEMICAL COMPOSITION


9.2.2 Delete existing clause and replace with the following:

Table J1 shall apply for all pipe grades and for pipe with t ≤ 35mm (1.38 in) (other than for sour service where Table H1 shall apply) but shall not include Grades L390N, L415N, L625M, L690M and L830M.

The chemical composition limits of pipe with t > 35mm (1.38 in) shall be by agreement or as stated in the purchase order.

The Manufacturer/Supplier’s target product analysis shall be shown in the Manufacturing Procedure Specification. A single value target of CEiiw or CEpcm shall be stated. The range of elements shall be such that the variation in the single value target CEiiw does not exceed ± 0.03 units or CEpcm does not exceed ± 0.02 units with the following additional restrictions:

C 0.03 (HFW and SAW) 0.04 (SMLS)

Mn 0.30 Si 0.25 Ni 0.10 Cu 0.10 V 0.03 Nb 0.02 Al 0.03 Ti 0.015 Mo 0.05 Cr 0.05

NOTE The above figures represent the total range and not a plus or minus tolerance. No changes in the chemical composition (within the tolerances listed above) are permitted from the approved MPS composition. In particular no intentionally added elements shall be increased (beyond the limits above) or removed.

The chemical composition recorded for the pipes used in first-day production testing shall set the datum CE. Where any of the above elements is not intentionally added, the


Page 15

manufacturer may propose maximum values for approval by the Principal. In this case the above ranges shall not apply.

The chemical analysis and reporting in inspection documents shall include all elements covered by the requirements of Table J1.


Table 4

Delete this table.

Table 5

Delete this Table.

9.3 TENSILE PROPERTIES


Table 6

Delete this table.

Table 7

Delete reference to grades L390N, L415N, L625M, L690M and L830M

9.4 HYDROSTATIC TEST


9.6 FLATTENING TEST


No cracks or breaks shall occur in either weld or parent metal during flattening of the test specimen to 50% of the original OD. The specimen shall be further flattened to 1/3 of original OD without cracks or breaks other than in the weld.

9.8 CVN IMPACT TEST FOR PSL2 PIPE

9.8.2.1 Delete the existing clause and replace with the following:

The minimum average (of a set of three test pieces) absorbed energy for each pipe body test shall be as given in Table 8, based upon full-size test pieces. The test temperature shall be lower than or equal to that specified in the table below.

Nominal wall thickness, t (mm)

Test Temperature (°C)

Maximum test temperature(°C)

t ≤ 20 Tmin 0

20 < t ≤ 30 Tmin-10 0

30 < t ≤ 40 Tmin-20 0

40 < t To be advised by the Principal

Nominal wall thickness, t (in)

Test Temperature (°F)

Maximum test temperature(°F)

t ≤ 0.80 Fmin 32

0.80 < t ≤ 1.2 Fmin-50 32


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1.2 < t ≤ 1.6 Fmin-70 32

1.6 < t To be advised by the Principal

Tmin (Fmin) is the minimum design temperature, which shall be specified in the purchase order. If no minimum design temperature is indicated, it shall be taken as 0°C (32°F).

9.8.2.2 Delete this clause

9.8.3 Pipe weld and HAZ tests


The absorbed energy requirements for weld and HAZ tests SHALL [PS] be as stated in Table 8.

If any specimen displays a value less than 60% of the value in table 8 (or a greater value if specified in the specific project requirements), the Manufacturer shall fully investigate the cause and advise the Principal. For any value discplayed of less than the value in table 8 (or a greater value for a specific project), 3 further specimens shall be taken in the same area. All 3 specimens shall comply with the minimum value.

No more than 1 specimen with a value less than permitted in table 8 (or higher figure if specified) shall occur for any 5 specimen tested, or no more than 2 values less than permitted in table 8 (or higher figure if specified) in each 9 specimen tested.

For pipelines in rich gas service or CO2 and pipelines subjected to high strain, the values in table 8 may be increased on a project by project basis, this will be stated in project specifications when applicable.

The test temperature shall be as specified for the pipe body.

Table 8

Delete existing table and replace with the following:


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Table 8 – CVN absorbed energy requirements for PSL2 pipe

Grade

Full-size CVN absorbed energy Minimum average value

(of the set)

J

Full-size CVN absorbed energy Minimum average value

(of the set)

Btu

Pipe body, Weld and HAZ Pipe body, Weld and HAZ

L245 (B) 40 0.0379

L290 (X42) 40 0.0379

L320 (X46) 40 0.0379

L360 (X52 40 0.0379

L390 (X56) 40 0.0379

L415 (X60) 42 0.0398

L450 (X65) 45 0.0427

L485 (X70) 48 0.0455

L555 (X80) 55 0.0521

9.9 DWT TEST FOR PSL2 WELDED PIPE

9.9.1 Delete this clause and replace with the following

For each test (a set of two test pieces), the average shear fracture shall be ≥ 85%. The test shall be performed at the minimum design temperature specified by the Principal in the purchase order. Where it is not possible to test a full thickness specimen, the test temperature shall be adjusted in accordance with API RP3.

9.10 SURFACE CONDITIONS, IMPERFECTIONS AND DEFECTS

9.10.5.2 Delete this clause and replace with the following

For dents, the length in any direction shall not exceed 25% of the pipe diameter.

All sharp gouges (with or without dent) of 1mm (0.04 in) or greater depth shall be considered a defect.

9.10.5.3 Add new clause

Surface condition – seamless pipe

The external surface of all seamless pipes shall be free from scabs, laps, shells, slivers, burrs, metallurgical tears and sharp edged discontinuities that may interfere with the application of thin film (e.g. FBE) coatings and multi-layer coatings where FBE forms the first layer.

Prior to manufacturing procedure qualification, the manufacturer shall submit, for approval by the Principal, acceptance criteria for the surface condition of all seamless pipe, together with historic evidence of the successful FBE coating of such pipe without excessive remedial work.

In the absence of such historic data, the Principal may require the blast cleaning and examination of three pipes during manufacturing procedure qualification and one pipe per 10 test units during production.

The pipes shall be selected at random and heated to a minimum of 70°C (160°F). The outside surface shall be blast cleaned to a surface finish of SA2½ and the pipe then re-


Page 18

heated to 270°C (520°F). Each pipe shall be examined visually over its entire surface for imperfections: that could interfere with the FBE coating process.

If this pipe(s) is rejected then the remaining pipes from the test unit, and one pipe from each subsequent test unit, shall be blast cleaned and examined.

9.11 DIMENSIONS, MASS AND TOLERANCES

9.11.3.1 Add to this clause:

Where stated in the project specification or purchase order the diameter and out of roundness tolerances of Annex J Table J3 as amended by this DEP, shall also apply to pipe ordered for onshore service.

Table 10 Modify as follows:

For all pipe with specified outside diameter greater than 60.3 mm (2.37 in) but with a D/t of less than 75, the pipe end out-of-roundness tolerance shall not exceed 0.0075D or 5 mm (0.2 in), whichever is the less. This tolerance shall apply to the inside diameter. The pipe end out=of roundness tolerances for pipe of D't >75 shall be agreed with the Principal.

Delete footnote "c" of Table 10 and replace with:

For pipe with D ≥ 219.1 mm (8.63 in), the diameter tolerance and out-of-roundness shall be determined using the measured inside diameter.

9.11.3.2 Delete this clause and replace with the following

The tolerances for wall thickness shall be as given in Table J4.

Table 12


Table 12 – Tolerance for random length pipe

Random length

designation

m

Minimum length

m

Minimum average length for each

order item

m

Maximum length

m

12 9 11.5 13.70

15 12 14.25 16.70

18 15 17.0 19.80

Random length

designation

ft

Minimum length

ft

Minimum average length for each

order item

ft

Maximum length

ft

40 30 38 45

50 40 47 55

60 50 56 65

9.11.3.4 Delete this clause and replace with the following:

a) The total deviation from a straight line, over the entire pipe length, shall be ≤ 0.15% of the pipe length, as shown in Figure 1.


Page 19

b) The local deviation from a straight line at each end of 1m (4ft) section shall be ≤ 3.0 mm (0.12 in) as shown in Figure 2.

9.12 FINISH OF PIPE ENDS


9.12.2 Threaded ends (PSL1 only)

Delete this clause

9.12.3 Belled ends (PSL1 only)

Delete this clause

9.13 TOLERANCES FOR THE WELD SEAM

9.13.1 Radial offset of strip/plate edges

Delete Table 14 and replace with the following:

Specified wall thickness, T mm

Maximum radial offset mm

T ≤ 10 1.0

10 < T ≤ 20 0.1 T

T > 20 2.0

Specified wall thickness, T in

Maximum radial offset in

T ≤ 0.4 0.04

0.4 < T ≤ 0.8 0.1 T

T > 0.8 0.08

9.13.2.2 Selection Item e)

The outside weld bead shall be removed by grinding for a distance of at least 150mm (6 in) from where stated for all pipe ordered for offshore service or where stated on the Purchase Order. Note: Removal of the outside weld bead is required wherever AUT is intended to be performed on girth

welds during pipeline installation

9.14 TOLERANCES FOR MASS

9.14.1 Delete items a), b) and c), and replace with the following:

For all pipes: +10.0%, -3.5%

9.14.3 Delete items a) and b), and replace with the following:

For all grades: -1.75%

9.15 WELDABILITY OF PSL2 PIPE

Add to this clause:

For all offshore pipelines and for other pipelines where specified in the purchase order, weldability trials shall be carried out. The material shall be as qualified in the manufacturing procedure qualification (Annex B), within the limits specified in Clause B.5. The requirements for weldability testing are given in Appendix 2 of this DEP.


Page 20

10 INSPECTION

10.1.2 Inspection documents for PSL1 pipe

Delete this clause

10.2 SPECIFIC INSPECTION

10.2.1 Inspection frequency


Table 17

Delete this table

Table 18

Delete the existing table and replace with the following:


Page 21

Table 18 – Inspection frequency for PSL 2 pipe

Type of inspection Type of pipe Frequency of inspection

Heat analysis All pipe One analysis per heat of steel

Product analysis SMLS, HFW, SAWL, SAWH

Two analyses per heat of steel (taken from separate pipes)

Tensile testing of the pipe body SMLS, HFW, SAWL, SAWH

Two tests per test unit(c) of pipe with the same cold expansion ratio(a). One test for heats less than 100 tonne

Tensile testing of longitudinal or helical weld

HFW, SAWL, SAWH

Two tests per test unit of pipe with the same cold expansion ratio(a),(b). One test for heats less than 100 tonne

CVN impact testing of pipe body

SMLS, HFW, SAWL, SAWH

Two tests per test unit of pipe with the same cold expansion ratio(a). One test for heats less than 100 tonne. For test temperature of -20°C (-4°F) or below one test for each 100 pipes.

CVN impact testing of longitudinal weld

HFW Two tests per test unit of pipe with the same cold expansion ratio(a). One test for heats less than 100 tonne. For test temperature of -15°C (5°F) or below one test for each 100 pipes.

CVN impact of longitudinal or helical weld

SAWL, SAWH Two tests each for weld, fusion line, FL+2, FL+5 locations per test unit of pipe with the same cold expansion ratio(a),(b). One test for heats less than 100 tonne. For test temperature of -15°C (5°F) or below one test for each 100 pipes.

DWT testing of the pipe body of welded pipe with D ≥ 406.4 mm (16 in) Applicable to gas pipelines only.

HFW, SAWL, SAWH

Once per test unit with the same cold expansion ratio

Guided-bend testing of the longitudinal or helical seam weld of welded pipe

SAWL, SAWH Two tests per test unit of pipe with the same cold expansion ratio. One test for heats less than 100 tonne

Flattening test of welded pipe HFW 4 tests per coil, plus 2 tests in the case of a weld stop

Hardness test on body and seam weld


One test per test unit

Hardness testing of hard spots in cold-formed welded pipe

HFW, SAWL, SAWH

Any hard spot

CTOD testing SAWL, SAWH Once; for manufacturing procedure qualification only

Hydrostatic testing SMLS, HFW, SAWL, SAWH

Each pipe

Macrographic testing of the longitudinal or helical seam weld of welded pipe

SAWL, SAWH Once per shift or when pipe thickness is changed


Page 22


Metallographic testing of the longitudinal seam weld of welded pipe

HFW (a) Manufacturing procedure qualification test: Each pipe

(b) Production: Once per five coils.

Grit blasting and visual examination of outer surface (if required by the Principal)

SMLS (a) Manufacturing procedure qualification test: Three pipes

(b) Production TBA

Visual inspection SMLS, HFW, SAWL, SAWH

Each pipe

Pipe diameter and out of roundness


One pipe out of every 20 pipes but not less than once per 4 hour operating shift or whenever any change in pipe size occurs.

Wall thickness measurement SMLS, HFW, SAWL, SAWH

Each pipe (see 10.2.8.5)

Other dimensional SMLS, HFW, SAWL, SAWH

One pipe out of every 20 pipes


Each pipe or each lot, with the choice being at the discretion of the manufacturer

Weighing of pipe with D ≥ 141.3 mm (5.56 in)


Each pipe

Non-destructive testing SMLS, HFW, SAWL, SAWH

Each pipe

NOTES: a) The cold-expansion ratio is designated by the manufacture (see clause 8.9.3). An increase or decrease in the cold-expansion ratio of more than 0.002 requires the creation of a new test unit

b) In addition, pipe produced by each welding machine shall be tested at least once per week c) “Test unit” is as defined in 4.49

Table 19

Delete this table

Table 20



Page 23

Table 20 Number, orientation and locations of test pieces per sample for mechanical tests

Number, orientation, and location of test pieces per sample(a)

Specified outside diameter D in mm and (in)

Type of pipe Sample location

Type of test

< 219.1 (8.63)

219.1 (8.63) to < 406.4 (16)

≥ 406.4 (16)

Tensile 1L(b) 1T(c) 1T(c) CVN 3T(e) 3T(e) 3T(e)

SMLS, not cold-expanded [see Fig 5 a)]

Pipe body

Hardness 1T 1T 1T

Tensile 1L90(b) 1T180(c) 1T180(c) CVN 3T90 3T90 3T90

Pipe body

DWT — — 2T90 Tensile — 1W 1W CVN 3W 3W 3W

Seam weld

Hardness 1T 1T 1T

HFW [see Figure 5 b)]

Pipe body and weld

Flattening As shown in Figure 6

Tensile 1L90(b) 1T180(c) 1T180(c) CVN 3T90(f) 3T90(f) 3T90(f)

Pipe body

DWT — — 2T90 Tensile — 1W 1W CVN 3W and

9HAZ(g) 3W and 9HAZ(g)

3W and 9HAZ(g)

Guided-bend

2W(d) 2W(d) 2W(d)

SAWL [see Figure 5 b)]

Seam weld

Hardness 1T 1T 1T Tensile 1L(b) 1T(c) 1T(c) CVN 3T 3T 3T

Pipe body

DWT — — 2T Tensile — 1W 1W CVN 3W and

9HAZ 3W and 9HAZ

3W and 9HAZ

Guided-bend

2W(d) 2W(d) 2W(d)

SAWH [see Figure 5 c)]

Seam weld

Hardness 1T 1T 1T NOTES: a) See Figure 5 for an explanation of the symbols used to designate orientation and

location. b) Full-section longitudinal test pieces may be used at the option of the manufacturer. c) If agreed, annular test pieces may be used for the determination of transverse yield

strength by the hydraulic ring expansion test in accordance with ASTM A370 d) For pipe with t > 19.0 mm (0.75 in), the test pieces may be machined to provide a

rectangular cross-section having a thickness of 18.0 mm (0.71 in). e) TBA for wall thicknesses>25.4 mm (1 in) f) Additional 3T specimens for wall thicknesses > 25.4 m (1 in) g) Additional 3W and 9HAZ specimens for wall thicknesses >25.4 mm (1 in)


Page 24

10.2.2 Samples and test pieces for product analysis


Samples shall be taken, and test pieces prepared in accordance with ISO 14284 or ASTM E1806. Such samples shall be taken from the pipe.

10.2.3.1 Test pieces for the tensile test

Delete first sentence of the second paragraph and replace with the following:

If agreed, round test pieces obtained from non-flattened samples may be used.

10.2.3.3 Test pieces for the CVN impact test

Delete the third paragraph and replace with the following:

For test pieces taken in the weld of SAW pipes, the axis of the notch shall be located on, or as close as possible to the weld centreline. The specimen axis shall be aligned with the intersection points of the internal and external weld beads (see Figure 7).

Delete the fourth paragraph and replace with the following:

For test pieces taken in the HAZ of SAW pipes, the axis of the notch shall be positioned at the fusion line, fusion line + 2mm (0.08 in) and fusion line + 5mm (0.2 in). The upper surface of the specimens shall be within 2mm (0.08 in) of the outer surface of the pipe. (See Figure 7). For SAW pipe of wall thickness greater than 25.4mm (1 in)four additional sets of impact specimens, from weld centre line, fusion line, fusion line +2mm (0.08 in) and fusion line +5mm(0.2 in), as shown in Figure 7 but with the lower surface of the specimen within 2mm (0.08 in) of the inner surface of the pipe.

Add paragraphs

For test pieces taken from seamless pipes the specimens axis shall be aligned with the mid-thickness of the pipe.

The impact testing of seamless pipe with wall thickness equal to or greater than 25.4 mm (1 in) shall be as specified in the Purchase Order.

Flattening of coupons prior to removal of specimens is not permitted.

Figure 7

Delete existing figure and replace with the following:

Figure 7 Location of Charpy test specimens for weld and HAZ tests

Fusion Line +5mm (0.2 in)

Fusion Line

Fusion Line +2mm (0.08 in) Weld Metal Centre Line

< 2.0 mm (0.08 in) -

Last deposited Weld Metal


Page 25

Add new clause

10.2.3.8 Test pieces for CTOD test

Test pieces shall be taken from the weld metal, the HAZ and the parent metal and shall be prepared in accordance with ISO 12135. Test specimens shall be Bx2B through thickness notched specimens. For weld metal test, the notch axis shall be located on the weld centre line. For HAZ specimens, the notch axis located so as to sample the fusion line. The central 50 % portion of the specimen shall sample the HAZ and the outer portions shall sample weld metal.

Add new clauses:

10.2.4.8 Hardness test

Add the following

For all pipe ordered for non- sour service hardness surveys (Vickers) shall be carried out as detailed in clause J.8.3.2 with the acceptance criteria specified in J.4.3. The frequency of testing shall be as required for impact testing by Table J.7. The requirements of Annex H shall apply to all pipe ordered for sour service.

10.2.4.9 CTOD test

CTOD testing shall be performed in accordance with ISO 12135. The test temperature shall be the minimum design temperature as stated in the purchase order.

10.2.5 Macrographic and metallographic tests



For HFW pipe, a metallographic examination of the weld seam SHALL [PS] be carried out at a magnification of at least 200 times. The frequency shall be as given below.

(a) Manufacturing Qualification Test:

One specimen shall be taken from each qualification pipe

The manufacturer shall record the following information:

• Width of heat treated zone (unless full body heat treatment carried out);

• Grain size and microstructure of heat treated weld area;

• Deformation angle (i.e. the angle by which the material adjacent to the weld is displaced from the horizontal) or other means of assessment of deformation during welding, as agreed with Principal. (See Figure 10.2.5.3).

The manufacturer shall produce acceptance criteria for approval by the Principal, based on the results of the manufacturing qualification test. These shall be applied in production and shall demonstrate that the entire weld heat affected zone has been heat treated over the full wall thickness and is free of defects. This shall include assessment of the grain size, and general microstructure. Unless agreed otherwise with the Principal, metallographic examination shall also include an assessment of the level of deformation achieved during the welding operation (e.g. deformation angle)

(b) Production

Metallographic examination shall be carried out at a frequency of one per five coils according to the criteria agreed with the Principal. All measurements made against these criteria shall be recorded.


Page 26

Figure 10.2.5.3 Deformation angle – HFW pipe

10.2.6.1 Modify this clause:

Test pressures for welded pipe with D less than or equal to 101.6 mm (4 inch) shall be held for not less than 5 seconds. Test pressures for pipe with D >100.6 mm (4 inch) shall be held for not less than 10 seconds.




The test pressure for all types and sizes of pipe shall be such that the hoop stress, calculated on the basis of the minimum specified wall thickness and including stresses from the end loading, is at least 95% of the specified minimum yield strength.

Table 24

Delete this table

Table 25

Delete this table

Table 26

Delete this table


10.2.7 Visual Inspection

10.2.7.1 Amend this clause as follows:

For HFW and SAW pipes, the inspection shall specifically include the internal weld profile. The entire internal surface of SAW pipes of outside diameter greater than 610 mm (24 in) shall be visually inspected.

10.2.8 Dimensional testing

10.2.8.1 Delete existing clause and replace with the following:

The diameter of the first 10 pipes shall be measured. Thereafter the diameter shall be measured once every 20 pipes but not less than once per 4 hour shift. Unless a specific method is specified in the purchase order, diameter measurements shall be made with a circumferential tape, ring gauge, snap gauge, calliper or optical measuring device.


Page 27

10.2.8..2 Delete existing clause and replace with the following:

The out of roundness of the first 10 pipes shall be measured. Thereafter the diameter shall be measured once every 20 pipes but not less than once per 4 hour shift. The out of roundness shall be determined as the difference between the largest inside diameter and the smallest inside diameter, as measured in the same cross-sectional plane.

10.2.8.3 Delete this clause.

11 MARKING

11.1 GENERAL


11.2 PIPE MARKINGS

11.2.1 i) Add:

Each pipe shall be uniquely indentified.

11.2.3 Add new item:

d) Die stampings shall be coated with a clear lacquer to prevent corrosion at the location of the markings.

11.3 COUPLING MARKINGS

Delete this clause

12.2 THREAD PROTECTORS

Delete this clause

14 PIPE LOADING

Add:

If required by the Purchase Order, each end of each length of pipe shall be provided with a suitable end protector designed to prevent damage to the machined end. End protector shall not be attached to the pipe using tape or other connectors. The design shall be submitted to the Principal and shall be conducive for using crane hooks for lifting. Principal will provide end protector requirements.


Page 28

ANNEX A SPECIFICATION FOR WELDED JOINTERS

Delete this Annex.

ANNEX B MANUFACTURING PROCEDURE QUALIFICATION FOR PSL2 PIPE

B.1 INTRODUCTION

Delete all three sub-clauses and replace with the following:

Manufacturing procedure qualification SHALL [PS] be required for all PSL2 pipe unless otherwise stated by the Principal. Qualification shall be carried out on each combination of diameter and wall thickness supplied unless otherwise agreed with the Principal.

The qualified manufacturing procedure shall form the basis for pipe acceptance. Deviation from the qualified manufacturing procedure shall require full re-qualification in accordance with the requirements of B.5.

The Manufacturer shall inform the Principal within 48 hours of any intentional or unintentional manufacturing deviations from the agreed procedures, dimensional tolerances or composition. Informing the Principal of these changes is essential to pipeline construction planning. The Manufacturer shall communicate these changes even if the finished line pipe meets the requirements of this DEP and ISO 3183:2007.

B.2 ADDITIONAL INFORMATION TO BE SUPPLIED BY THE PURCHASER

Delete list items a) and b)

B.3 CHARACTERISTICS OF THE MANUFACTURING PROCEDURE

Add the following to list item a):

Quality plan detailing all inspection points and tests performed in accordance with ISO 10005 using an agreed format. NOTE: Guidance on quality plans is given in DEP 82.00.10.10-Gen.

Amend list item b) 1) as follows:

Strip/plate manufacturing method including details of rolling conditions, accelerated cooling conditions (if applied) and heat treatment method (N or Q) if applicable.

Add the following to list item b) 5):

For HFW pipe, the seam welding procedure shall also include details of the following:

a) methods to be used for heating strip edges and for the control and monitoring of power input in relation to the temperature of the pipe surface and the speed of the pipe;

b) Frequency (in kHz) of the welding power supply;

c) Welding speed

d) Welding Temperature

e) Welding power

f) Compressive force or displacement used in welding.

g) Temperature of in-line normalising (if applied)

h) details of any protective atmosphere used for welding;

i) methods used to accomplish and control the upset welding of the heated pipe edges;

j) Methods used for trimming of the weld bead.


Page 29

For SAW pipe, the seam welding procedure shall also include details of the following:

a) brand name, classification, size and grade of filler metal and flux;

b) speed of welding;

c) number of electrodes and polarity for each electrode;

d) stickout for each wire;

e) welding current for each wire;

f) welding voltage for each wire.

Add new list item d):

d) For sour service pipe, the hydrogen-induced cracking test procedure shall include full details of the exposure test method required by NACE TM0284 and DEP 30.10.02.16-Gen plus full details of the procedure used for metallographic preparation of the exposed test pieces.

B.4 MANUFACTURING PROCEDURE QUALIFICATION TESTS

B.4.1 Add the following to the existing clause:

The following additional test requirements shall apply:

Tensile tests –General

Parent material and all weld metal tensile tests (at ambient and elevated temperature) shall be conducted so as to record the full stress strain curve up to maximum load. This applies to manufacturing procedure qualification testing only.

Elevated temperature tensile tests

Where required in the purchase order, elevated temperature tensile tests shall be taken in both the longitudinal and (for pipes of outside diameter ≥ 219.1mm (8.63 in) the transverse direction. Testing shall be in accordance with EN 10002-5. The testing temperature and acceptance criteria shall be stated in the purchase order.

All weld tensile tests (SAW only)

All weld tensile tests shall be performed on each of the first-day production test pipes. The tests results shall meet the minimum specified requirements of the plate with regard to yield, tensile strength and achieve a minimum elongation value of 18%. The test method shall be in accordance with EN 876. Where required in the purchase order, all weld tensile tests shall also be performed at elevated temperature Testing shall be in accordance with EN 10002-5; the test temperature and acceptance criteria shall be stated in the purchase order.

Impact tests

For each of the first-day production pipes, a full impact transition curve shall be determined for all location specified in 10.2.3.3., i.e.

Seamless: Pipe body

HFW: Parent material, weld centre line

SAW: Parent material, weld centre line, fusion line, and fusion line +2mm (0.08 in), fusion line +5mm (0.2 in)

At least 12 specimens shall be tested at each position at temperatures range wide enough to obtain upper and lower shelf toughness impact energy values.

CTOD testing (SAW only)



Page 30

Test pieces shall be taken from both the weld and HAZ and shall be SENB type prepared in accordance with ISO 12135. Weld test specimens shall be through thickness notched, the notch being located at the weld centreline. HAZ specimens shall be surface notched from the outside surface so that the fatigue crack tip samples the HAZ within 0.5 mm (0.02 in) of the fusion line. The location of the fatigue crack tip shall be verified by post test sectioning and metallography. Unless otherwise agreed with the Principal, through thickness notched specimens shall be Bx2B and surface notched specimens BxB.

The minimum CTOD value (from a set of three specimens) taken from each of the pipe, weld and HAZ locations, shall be 0.2 mm (0.008 in), when tested at the minimum design temperature given in the purchase order.

Strain aged testing.

Where required by the purchase order, tensile charpy impact, fracture toughness testing and hardness testing shall be carried out in the strain aged condition.

The requirements for testing in the strain aged condition are contained in Appendix 1 of this DEP

Drop Weight Tear tests

In addition to the normal DWTT requirements, a full transition curve shall be established for the parent material on each of the test pipes.

Radiography

The weld seams of all SAW pipes shall be radiographically examined throughout their full length in accordance with (D5.5)

PT or MT

The weld seam shall be subjected to liquid penetrant or magnetic particle testing in order to check for surface defects in the weld and adjacent HAZ.

B.4.2 Delete existing clause and replace with the following:

Unless stated otherwise in the purchase order, the manufacturing procedure shall be qualified by the first-day production tests. This shall be achieved by selecting at random three of the completely finished pipes of the first day’s production. If more than one heat is used in the first-day production pipes, at least two heats shall be represented by the test pipes.

For HFW pipe, the test pipes shall include the pipes made from each end of the first coil of strip.

For orders less than 200 tonne, acceptable data from a previous order for a Shell Group company may be accepted by the Principal provided the pipe grade, size and manufacturing method are similar.

If stated in the purchase order, part or all of the manufacturing procedure qualification shall be carried out prior to first day production.

Add new clauses:

B.5 REQUALIFICATION OF MANUFACTURING PROCEDURE

The following changes to the manufacturing procedure shall require full requalification of the manufacturing procedure:

a) Any change to the steel chemistry which produces a change in the CE of more than +0.03 (see (9.2.2));

b) Any change to the steel de-oxidation practice;

c) A change from ingot casting to continuous casting or vice versa;

d) Any change to the plate or pipe reduction ratio;

e) A change in the finishing temperature during plate or strip rolling outside the


Page 31

approved range;

f) A change in the accelerated cooling start temperature outside the approved range;

g) A change in the finishing temperature outside the approved range, for pipe not subject to further heat treatment;

h) A change in the pipe heat treatment soaking temperature and soaking time;

i) Any change to the welding procedure outside the essential variable limits of ISO 9956-3. In addition for SAW pipe, a change in flux brand name and an increase of more than 20 mm (0.8 in) in the wire stick-out.

B.6 HFW – PARAMETER ENVELOPE

In addition to the essential variables stated in clause B.5, the Manufacturer shall submit for approval by the Principal, the maximum ranges of each of the following parameters for each pipe diameter, thickness and material grade:

• Welding speed;

• Welding Temperature ;

• Welding Power;

• Compressive force or displacement.

The Manufacturer shall also provide details, for approval by the Principal, on how these parameters are to be monitored and recorded.

B7 SURFACE OF SEAMLESS PIPE

The manufacturer shall provide historical evidence that the surface finish of previous production was suitable for the application of FBE coatings. In the absence of such data, three pipes from the first day's production shall be selected at random and heated to a minimum of 70°C (160°F). The outside surface shall be blast cleaned to a surface finish of SA2.5 and the pipe re-heated to 270°C (520°F)

Each pipe shall be examined visually over its entire surface for scabs, slivers, tears and similar surface defects which would, in the opinion of the Principal, interfere with the application of FBE and other coatings.

Should the pipe fail to meet the required standard of surface finish, the Manufacturer shall submit procedures for remedial action and subsequent testing of the production material to guarantee suitability of the production material for FBE coating, for approval by the Principal

ANNEX C TREATMENT OF SURFACE IMPERFECTIONS AND DEFECTS

C2.2 Add the following to existing clause:

All ground areas shall be smoothly contoured at a minimum 3 to 1 slope

C4.5 Delete existing clause and replace with the following:

Weld repairs shall be performed using a welding procedure that is qualified in accordance with Annex D, by a welder qualified in accordance with Annex D.3.

ANNEX D REPAIR WELDING PROCEDURE

D.1.2.b Delete this clause.

D.2.2.a. Welding process

Delete item 1) and replace with the following

A change in the welding process, such as submerged arc welding to shielded metal arc welding.


Page 32

D.2.2.c. Welding materials

Delete items 4) and 5)

D.2.3.4.4.Delete the existing clause and replace with the following;

The minimum average absorbed energy (of a set of three test pieces) for each repair weld and its associated HAZ, shall not be less than that specified in 9.8.3 for the pipe seam weld and HAZ. The test temperature shall be the same as that required for the weld metal and HAZ.

D.2.5 CTOD test

Add new clause

The qualification of repaired weld shall be subject to the same CTOD testing as required by the additions to clause B.4.1 given in this DEP. In this case surface notched specimens shall be used to sample the weld metal and both HAZs (repair/parent material and repair weld/original weld).

ANNEX E NON-DESTRUCTIVE INSPECTION FOR OTHER THAN SOUR SERVICE OR OFFSHORE SERVICE

E.1 QUALIFICATION OF PERSONNEL

Add the following to this clause:

ISO 9712 and EN 473 are considered to be equivalent qualification/ certification systems. ISO 20807 is not considered as equivalent.

E.1.3 Add the following to this clause:

The Manufacturer/ Supplier shall have a NDT UT level 3 available on call during manufacture. All of the Manufacturer/ Supplier NDT specifications and procedures shall clearly state the approval of the NDT Level 3 showing approval date and qualification number and the expiry date of the NDT Level 3 individual.

E.2 STANDARD PRACTICES FOR INSPECTION

Delete existing clause and replace by the following:

Except as specifically modified in this annex, the required non-destructive inspection, other than for surface inspection (see 10.2.7) and wall-thickness verification, SHALL [PS] be performed in accordance with one of the following standards or an equivalent:

a) electromagnetic (flux leakage): ISO 9402, ISO 9598;

b) electromagnetic (eddy-current): ISO 9304;

c) ultrasonic: ISO 9303, ISO 9305, ISO 10124, ISO 11496, ISO12094, ISO 13663;

d) ultrasonic (weld seam): ISO 9764, ISO 9765;

e) magnetic particle: ISO 13664, ISO 13665;

f) radiographic: ISO 12096;

g) liquid penetrant ISO 12095.

A procedure shall be written for every technique describing the inspection process, with as a minimum the essential variables as stated in Appendix-4


Page 33

E.3 METHODS OF INSPECTION

E.3.1.1 Delete existing clause and replace with the following:

The weld seams of welded pipe shall be inspected using the ultrasonic angle beam shear wave method in accordance with ISO 9764 for HFW pipe (longitudinal imperfection detection using a 450 +/- 30probe) and ISO 9765 for SAW pipe (Longitudinal and transverse imperfection detection), full length (100 %) for the entire thickness, as given in Table E.1.

Acceptance levels: ISO 9764 L2 and ISO 9765 L2

Inspection procedures including the use of ToFD shall only be used with the acceptance of the Principal. Advanced ultrasonic techniques (e.g. phased array, EMAT) may only be permitted by the approval of the Principal on the basis of a specific qualification program approved by the Principal.


All SMLS pipe shall be non-destructively inspected full length (100 %), as given in Table E.2. Applicable code: ISO 9303 (longitudinal imperfections) and ISO 9305 (transverse imperfections).

E.3.1.3b Delete existing clause and replace with the following:

Welded pipe shall be inspected following hydrostatic test.

Table E.1

Delete existing table and replace with the following: Table E.1 Pipe-weld seam non-destructive inspection

Non-destructive inspection method (a) Weld seam type Electromagnetic Ultrasonic Radiographic

HFW for t < 6 mm (0.24 in)

one method or a combination of methods is required

not applicable

HFW for t > 6 mm (0.24 in)

not applicable required not applicable

SAW not applicable required if agreed

NOTE (a): The weld seam at the pipe ends may require additional inspection (see E.3.2).

Table E.2


Table E.2 SMLS pipe body non-destructive inspection Non-destructive inspection method

Item Electro-magnetic Ultrasonic Magnetic particle

(circular field)

PSL 2 pipe, any grade Not required unless stated on Purchase Order

required Not required

unless stated on Purchase Order


Page 34

E.3.2 Pipe end inspection — Welded pipe


Pipe end weld seam: If an automated ultrasonic or electromagnetic inspection system is applied to meet the requirements of E.3.1.1, the weld at any pipe ends that are not covered by the automated inspection system shall be inspected for defects by a manual or semi-automatic ultrasonic angle beam method, using the same inspection sensitivity and inspection parameters as specified in E.3.1.1. Alternatively, such non-inspected pipe ends shall be cut off.


For SAW pipe, the weld at each pipe end for a minimum distance of 200 mm (8.0 in) shall be inspected by the radiographic method. The results of such radiographic inspection shall be recorded on either film or another imaging medium (See also E.4). The same area shall be inspected by the ultrasonic method, which shall be taken as the prime inspection method.


Ultrasonic inspection in accordance with the method described in ISO 11496 shall be used to verify that the 25 mm (1 in) wide zone at each pipe end is free of laminar imperfections of ≥ 6.4 mm (0.25 in )in the axial and circumferential directions. The ultrasonic inspection may be undertaken from the outside surface if the pipe end is inspected before weld beveling, if this is undertaken after weld beveling inspection shall be from the pipe internal surface.

Add new clause:

E.3.2.4 SAW Pipe end circumference:

Ultrasonic inspection using 45° angle beam shear wave probes and scanning in two circumferential directions shall be used to verify that the 25 mm (1 in) wide zone at each pipe end is free of axially aligned through thickness cracking. An axially aligned N5 notch is the reference and acceptance level.

E.3.3 PIPE END INSPECTION — SMLS PIPE


E.3.3.1 Pipe end – not tested portion: If an automated ultrasonic or system (combined equipment, operating procedures and personnel) is applied to meet the requirements of E.3.1.2, the end of the pipe that is not covered by the automated inspection system shall be inspected for defects by the semi-automatic ultrasonic angle beam method using the same inspection sensitivity and inspection parameters as specified in E.3.1.2. Otherwise such non-inspected pipe ends shall be cut off.


Ultrasonic inspection in accordance with the method described in ISO 11496 shall be used to verify that the 25 mm (1 in) wide zone at each pipe end is free of laminar imperfections ≥ 6.4 mm (0.25 in) in both axial and circumferential direction. The examination shall be carried out from the inside surface if the pipe is examined after weld bevel cutting. If examination is before bevel cutting, the examination may be undertaken from the outside surface.

E.4 RADIOGRAPHIC INSPECTION OF WELD SEAMS


The radiographic films used shall be in accordance with ISO 11699-1:1998, class T2 or class T3, and shall be used with lead screens.


The density of the radiograph shall be between 2.0 and 3.5 in the weld metal.


Page 35

E.4.3 IMAGE QUALITY INDICATORS (IQIS)


ISO wire-type IQIs shall be equal to W 1 FE, W 6 FE or W 10 FE, in accordance with ISO 19232-1:2004, and the essential wire diameters shall be as given in Table E.3 for the applicable weld thickness.

E.4.3.3 Delete this clause.

Table E.4

Delete Table E.4

E.4.6 DEFECTS FOUND BY RADIOGRAPHIC INSPECTION

Add to existing clause:

Where retesting of suspect areas indicated by UT is performed with RT, and found to be free of indications, the area shall be subjected to further UT. If the indication is confirmed with the repeat UT and is not caused by geometrical features or acoustic coupling conditions, then the UT indication shall be classed as a crack and the material rejected.

Add new clause:

E.4.8 Use of Filmless Radiography or Digital Radiography

The radiographic inspection of the body weld seam and the weld seam at the pipe ends may be replaced by automatic filmless radiography or Digital Radiography provided that the standard of the automatic filmless radiography is at least equal to the requirements for film radiography specified in this DEP.

The final disposition for suspect areas shall always be made using UT (see clauses E.4.6 and E.5.5.2).

E.5 ULTRASONIC AND ELECTROMAGNETIC INSPECTION

E.5.1.1 Add to existing clause:

Automatic ultrasonic equipment (AUT) SHALL [PS] be used for weld seam and pipe body inspection for detection and sizing of indications. The equipment shall have automatic facilities with the following characteristics:

• registration/ recording of indications on paper and/or on a retrievable medium shall be carried out without any intervention of the ultrasonic operator;

• a device which monitors the effectiveness of the acoustic coupling - a deviation in excess of 10 dB from the good coupling situation indicates a loss of coupling. Loss of coupling shall be recorded and clear automatic acoustic warnings and automatic paint spray shall be activated.

All systems shall be equipped with ruggedised (firm and stable) scanning systems:

For welded pipe, an automated weld tracking system for correct positioning of the probes with respect to the weld centerline shall be used.

The AUT system is considered to be acceptable when the fluctuation of the reference signal between the eight test runs is less than 3-4 dB (+/- 25% of the average value).


Page 36

Acceptance limits for calibration

Manual ultrasonic inspection (MUT) shall only be used to verify the indications rejected by AUT and confirm rejection or acceptance, also to inspect areas not inspected by AUT.

E.5.1.2 Performance test of AUT for mill qualification

The performance test shall be carried out during the qualification of the mill to test the AUT system with the pipes as listed below:

• For the wall thickness category >11.9 mm (0.469 in) to be qualified

One test pipe in the highest wall thickness category to be qualified

• For the wall thickness category < 11.9 mm (0.469 in) to be qualified.

One test pipe with the lowest wall thickness and diameter to be qualified.

The test pipes shall contain the reference reflectors of chapter 7 and two notches or through drilled holes at both pipe ends to mark the border of zones that are not covered by AUT.

The stability tests shall be carried out under the following conditions;

• The reference signals shall be set on 80% screen height (+/- 5%) to be able to see fluctuations in the signal;

• A signal to noise ratio of the reference signals of at least 10dB (to 12 dB, 4x the noise level).

A total of 8 test runs for each test pipe shall be made to confirm the stability of the AUT system. The following listed items shall be reported:

o diameter and wall thickness of the test pipe(s);

o specification of used probes (angles and frequencies);

o drawing of the reference reflectors in the test pipe (above view and cross section);


Page 37

o layout of the probes in combination with the reading channels ;

o printout (paper or digital) of the screen from the individual scans and reference signals marked on the first scan;

o Actual values of the reference signals;

o Actual values of the signal to noise ratio.

The AUT system is considered to be acceptable when the fluctuation of the reference signal between eight test runs is less than 4 dB.

E.5.2 ULTRASONIC AND ELECTROMAGNETIC INSPECTION REFERENCE STANDARDS

Table E.7


Table E.7 — Reference indicators

Reference indicators (a)

Notch location Notch orientation Notch dimensions

Diameter of radially drilled

hole (b)

OD ID Longitudinal Transverse Depth (c) Length (d) Width

Item

% (max) mm (in)

(max) mm (in) mm (in)

HFW seam

Table E.7.1 applies Required Not

Required 5.0 (e) 50 (2) 1.0 (0.04) 1.6 (0.063)(e)

SAW seam

Table E.7.2 applies Required Required 5.0 (e) 50 (2) 1.0

(0.04) 3.2 (0.126)(e)

SMLS pipe

Table E.7.3 applies Required Required 5.0 50 (2) 1.0

(0.04) 3.2 (0.126)

NOTES: 1. Notches are rectangular or U-shaped. 2. For electromagnetic inspection, the reference standard shall contain OD notches, ID notches and a radially

drilled hole. (See E.5.3.4.)

NOTES a) It is not necessary to locate reference indicators in the weld (ferritic, fine grained weld). b) Drilled hole diameters are based upon standard drill-bit sizes.

A hole is not required if a notch is used to establish the reject threshold. c) Depth is expressed as a percentage of the specified wall thickness. It is not necessary for the depth to be less

than 0.3 mm (0.012 in). The depth tolerance is ± 15 % of the specified notch depth or ± 0.05 mm (0.002 in), whichever is greater.

d) Length at full depth. e) Table 7.1 and Table 7.2 apply (see Table 7.Table E.8 for applicable acceptance limits).

E.5.1.2 Weld repair

Add to this clause: Repair of HFW pipe weld seams by grinding and rewelding is not permitted. Surface repair of external and internal HFW weld seam by dressing only by grinding is permitted and if applied, wall thickness is required to be checked after grinding.

Add new table:

Table E.7.1 HFW - Number of Probes for zone of weld for different wall thickness/ reference reflector


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Number of probes for zone of weld/ type of reference reflector

(at both sides of the longitudinal weld)

Wall thickness range

mm (in) inner zone Embedded outer zone

≤ 11.9(0.469 ) one Not required One

12.0 (0.472) to 17.9 0.704) one

One pair in tandem, centered at mid-wall thickness. (1)

One

18.0 (0.709) to 23.9 (0.941) one Two pairs in tandem, centred at

40 % and 60 % of thickness(1) One

mode of operation pulse echo in tandem (2) pulse echo

Reference reflector

N5 notch/ longitudinal

3.0 mm (0.12 in) flat-bottom hole(2)

N5 notch/ longitudinal

NOTES: 1. The use of a direct irradiation method (pulse echo) is allowed provided the main axis of the ultrasonic beam hits the corresponding reference reflector perpendicular within ± 30

2. The flat-bottomed hole shall be located at the mid-thickness of the weld and be perpendicular to the fusion line of the weld.


Page 39

Add new tables

Table E.7.2a SAW - Number of probes for zone of weld for different wall thickness/ reference reflector

Longitudinal imperfection detection Number of probes for zone of weld / type of reference reflector

(at both sides of the longitudinal weld)

Wall thickness range

mm (in) inner zone Embedded outer zone

≤ 11.9 (0.469) One not required One

12.0 (0.472) to 17.9 0.704) One

One, centred at mid-wall position See Fig E1 (a) and (b) for typical

configuration One

18.0 (0.709) to 23.9 (0.941) One Two centred at 40% and 60% of

thickness. See Figures A and B One

24.0 (0.95) to 31.9(1.256) One

Three, centred at 30%, 50% and 70% of thickness. See Figure E1 (a)

and (b) for typical configuration One

32.0(1.26 in) to 41.9 (1.65) One

Four, centred at 25%, 42%, 58% and 75% of thickness. See Figure E1 (a)

and (b) for typical configuration One

mode of operation (pulse echo) See note (1); pulse-echo or tandem pulse echo

reference reflector

Radially Drilled Hole

3.2 mm (0.13 in) equals

0 dB

Acceptance shall be at

–10 dB

3.0 mm (0.12 in) flat-bottom hole (FBH) located at the original weld bevel position at a depth (through

thickness) related to the zone to be inspected. For example of the

location of the reference reflector and transducer set-up, see Figures A

and B

Radially Drilled Hole 3.2 mm

(0.13 in) equals 0 dB

Acceptance shall be at –10 dB

See Note (5)

NOTES: 1. The angle of the probes for embedded zones shall be perpendicular to the original weld bevel ±3°. If the weld bevel is less than 15° (half aperture) the probes shall be used in the tandem arrangement.

2. for longitudinal imperfection detection: transducer angle between 50° and 70° 3. notch type reflectors (N5) at the toes of the weld (ID and OD) may be used to verify start and end of

monitoring gates, not to adjust sensitivity settings. The echo of notch type reflectors shall exceed the recording threshold level. If not the reference sensitivity level shall be adjusted to above 100% FSH. The reject level remains the original 33 % FSH.

4. Alternative numbers and configurations of probes may be used, subject to demonstration of reliable responses from the reference indicators for each zone and the approval of the Principal

5. A 1.6mm (0.063 in) diameter radially drill hole may also be used. In this case the acceptance level shall be 0 dB (100% of reference level)

6. Crack like indications is not permitted in the centre of any weld bead (weld pass -particularly for SAW welding)). The gate setting for the weld bevel inspection shall include the weld pass centre line.


Page 40

Table 7.2b SAW

Transverse imperfection detection / type of reference reflector

With X or K-transmission: probe angles between 50° and 70°

• for thickness up to 12 mm (0.472 in), one set of probes;

• for thickness in excess of 12 mm (0.472 in), two sets of probes one aimed at the inner surface and one at the outer surface.

Reference reflectors - transverse notches N 5 ID and OD

Alternatively “on bead scanning may be applied with a tandem set of transducers. In this case the probe angle shall be 45° ± 3°.

Reference reflectors - transverse notches N 5 ID and OD

Add new figures:

Figure E1(a) Example of transducer set-up and FBH location at 30% and 70% of wall

thickness for one side of the weld

Figure E1(b) Example of tandem transducer set-up and FBH location at 50% of the pipe wall

thickness for one side of the weld (tandem required if the (half) bevel angle is less than 15°)


Page 41

Add new table:

Table E.7.3 SMLS Ultrasonic examination of seamless pipe: probes and reference reflector

Probe angles Probe angle in steel shall be 45° ± 3° (defined in steel at outer surface) See Note 1

Viewing direction Four, opposite directions (Up- and Downstream, Clock- and Counter clockwise)

Coverage Full coverage shall be achieved at the examination sensitivity over the whole volume at all scanning speeds

Longitudinal imperfection detection using N5 notches ID and OD Reference reflectors

Transverse imperfection detection using N5 notches ID and OD

Alternative option

Obliquely oriented imperfections

The longitudinal and transverse imperfection detection systems may be replaced by imperfection detection systems oriented parallel and perpendicular to the helix line along the manufacturing rolling is carried out

The N5 ID and OD notches shall be oriented accordingly NOTE 1. Other probe angles may be approved by the Principal based on the demonstration of repeatable

detection of reference indicators on the calibration pipe

E.5.5 ACCEPTANCE LIMITS

E.5.5.2 Add new item to this clause:

d) Where retesting of suspect areas indicated by UT is performed with RT, and found to be free of indications, the area shall be subjected to further UT. If the indication is confirmed with the repeat UT and is not caused by geometrical features or acoustic coupling conditions, then the UT indication shall be classed as a crack and the material rejected.


Page 42

Table E.8


Table E.8 Acceptance limit Notch type

Side drilled hole size

Flat bottom hole size

Acceptance limit(a)

Item Diameter

mm (in)

Diameter

Mm (in)

(maximum) %

N5 3.0(0.12) 100 SAW,

3.2(0.13)(b) 33 (-10 dB)

HFW N5 3.0(0.12) 100

SMLS pipe N5 100

NOTES: a) Expressed as a percentage of the indication produced by the reference indicator. The reject threshold (see E.5.3) shall not exceed the applicable acceptance limit.

b) A side drilled hole of 1.6 mm (0.063 in) may also be used. In this case the acceptance limit shall be 100 % (0 dB)

E.7 RESIDUAL MAGNETISM

E.7.4 Delete existing clause and replace with the following

Measurements shall be made on each end of a pipe, selected at least three times per 4 h per operating shift.

E.7.6 Delete existing clause and replace with the following

Four readings shall be taken approximately 90° apart around the circumference of each end of the pipe. The average of the four readings shall be ≤ 2.0 mT (20 Gs), with no one reading shall be greater than 2.5 mT (25 Gs).

E.8 LAMINAR IMPERFECTIONS IN THE PIPE BODY OF HFW AND SAW PIPES

E.8.1 Delete existing clause and replace with the following:

For HFW pipe, ultrasonic inspection shall be used to verify that the pipe body is free of laminar imperfections. Inspection shall be performed in accordance with:

a) ISO 12094:1994, if such inspection is done prior to pipe forming; or

b) ISO 10124:1994, if such inspection is done after seam welding.

Acceptance criteria shall be in accordance with Table K.1 of this DEP. The coverage of inspection shall be at least 50% of the total strip/plate or pipe body.

E.8.2 Delete existing clause and replace with the following:

For SAW pipe, ultrasonic inspection shall be used to verify that the strip/plate or the pipe body is free of laminar imperfections. Inspection shall be in accordance with ISO 12094:1994. Coverage of the inspection shall be at least 50% of the total plate/pipe.

Acceptance criteria shall be in accordance with Table K.1 of this DEP.


Page 43

E.9 LAMINAR IMPERFECTIONS ALONG THE STRIP/PLATE EDGES OR PIPE WELD SEAM OF HFW AND SAW PIPES


For HFW and SAW pipes, ultrasonic inspection shall be used to verify that the 25 mm (1 in) wide zone along each of the strip/plate edges or along each side of the pipe weld seam is free of laminar imperfections. Acceptance criteria shall be as follows:

a) ISO 12094:1994, acceptance level E2, if such inspection is done prior to pipe forming; or

b) ISO 13663:1995, acceptance level E2, if such inspection is done after seam welding.

Add new clause:

E.11 LAMINAR IMPERFECTIONS IN THE PIPE BODY OF SMLS PIPES

For SMLS pipe, ultrasonic inspection shall be used to verify that the pipe body is free of laminar imperfections greater than those permitted by ISO 10124, acceptance level B2. The coverage shall be sufficient to detect the minimum defect size as specified in ISO 10124, level B2.

Add new clause:

E.12 THICKNESS MEASUREMENTS FOR SMLS PIPES

For SMLS pipe, ultrasonic thickness measurements shall be carried out. Coverage shall be at least 25% of pipe surface.

ANNEX F REQUIREMENTS FOR COUPLINGS (PSL 1 ONLY)

Delete this Annex.

ANNEX G PSL 2 PIPE WITH RESISTANCE TO DUCTILE FRACTURE PROPAGATION

Delete this Annex and replace with the following:

G.1 GENERAL

The Charpy test requirements given in clause 9.8 are based on crack initiation principles. For rich gas transmission and two phase pipe lines, higher absorbed energy requirements may be specified to avoid the risk of running fractures. In this case, the Battelle Two Curve method will be used to determine the required absorbed energy. The calculation shall be performed by the Purchaser and the requirements included in the purchase order.

When specified, this additional Charpy impact testing shall be performed on the pipe body only and shall be conducted at the minimum design temperature provided in the purchase order. If the required absorbed energy values are obtained at the test temperature prescribed for fracture initiation, section 9.8.2.1 of this DEP, the additional tests need not be performed.

ANNEX H PSL 2 PIPE ORDERED FOR SOUR SERVICE

H.2 ADDITIONAL INFORMATION TO BE SUPPLIED BY THE PURCHASER

Delete the following items:

Information included in this DEP

b) f) g) h) i) j) k) l)

Information not applicable to this DEP

c), d),


Page 44

H.3 MANUFACTURING

H.3.3.2.4 Amend this clause as follows:

Strip and plate shall be inspected ultrasonically for laminar imperfections or mechanical damage in accordance with Annex K, either before or after cutting the strip or plate, or the completed pipe shall be subjected to full-body inspection, including ultrasonic inspection.

H.3.3.2.5 Delete this clause. Strip/plate end welds are not permitted.

Add new clause:

H.3.3.2.6 Unless otherwise specified by the Principal HSAW pipe shall not be used for sour service.

H.4 ACCEPTANCE CRITERIA

H.4.1.1 Modify this clause as follows:

Table H1 shall apply for all pipe grades and for pipe with t ≤ 35mm (1.38 in).

The Manufacturer/Supplier’s target product analysis shall be shown in the Manufacturing Procedure Specification. A single value target CEiiw or CEpcm, shall be stated. The range of elements shall be such that the variation in the single value target CEiiw does not exceed ± 0.03 units or CEpcm does not exceed ± 0.02 units with the following additional restrictions:

C 0.03 (HFW and SAW)0.04 (SMLS)

Mn 0.30

Si 0.25

Ni 0.10

Cu 0.10

V 0.03

Nb 0.02

Al 0.03

Ti 0.015

Mo 0.05

Cr 0.05 NOTE The above figures represent the total range and not a plus or minus tolerance.

No changes in the chemical composition (within the tolerances listed above) are permitted from the approved WPS composition. In particular no intentionally added elements shall be increased beyond the limits above or removed.

The chemical composition recorded for the pipes used in first-day production testing shall set the datum CE. Where any of the above elements are not intentionally added, the manufacturer may propose maximum values for approval by the Principal. In this case the above ranges shall not apply.

All elements listed in Table H1 shall be reported.

H.4.1.2 Modify this clause as follows.

For pipe with t > 35 mm (1.38 in) the chemical composition shall be agreed with the Principal, with the requirements given in Table H.1 being amended as appropriate.

Table H.2

Delete notes a) and c). Intermediate grades shall not be supplied


Page 45

H.4.4 Hardness test

Modify this clause as follows:

The maximum hardness of the pipe body shall not exceed 240HV10 at the inner surface, centerline and outer surface.

Note for specific orders the hardness limits may be reduced from that specified above.

First paragraph: Delete (22 HRC)

Second paragraph: Delete (26 HRC)

H.7 INSPECTION

Table H.3


Table H.3 Inspection frequency


Hardness testing of pipe SMLS, HFW, SAWL, SAWH

Two tests per test unit of pipe with the same cold expansion ratio(a). One test for heats less than 100 tonne

Hardness testing of longitudinal or helical-seam weld of welded pipe

HFW, SAWL, SAWH

Two tests per test unit of pipe with the same cold expansion ratio(a). One test for heats less than 100 tonne

Hardness testing of hard spots in welded pipe

HFW, SAWL, SAWH

Each hard spot found on the internal or external surface of the pipe

Non-destructive inspection SMLS, HFW, SAWL, SAWH

In accordance with Annex K

HIC test SMLS, HFW, SAWL, SAWH

One test for each of the first three heats applied; thereafter, one test for each test unit of not more than 10 heats of steel

If required, SSC test SMLS, HFW, SAWL,

One test for each pipe provided for manufacturing procedure qualification

NOTE: a) The cold-expansion ratio is designated by the manufacture (see 8.9.3). An increase or decrease in the cold-expansion ratio of more than 0.002 requires the creation of a new test unit

Table H.4

Delete reference to strip/plate end weld

Delete note c.

H.7.3 Test Methods

H.7.3.1.1 Delete this clause and replace with the following:

HIC/SWC tests shall be carried out and reported in accordance with NACE TM0284 and DEP 30.10.02.16-Gen (Amendments/supplements to NACE TM0284) with the exception that the required testing frequency shall be as specified in Table H3


Page 46

H.7.3.1.4 Delete second sentence and replace with the following:

Photographs of any reportable crack shall be provided with the report.

Add:

For tests on HFW pipe, sections containing the weld seam shall be metallographically examined at magnifications of at least 100X for any evidence of cracking at the weld line in the through-thickness direction. All such indications shall be reported. Indications on the weld line with an aggregate length greater than 0.5mm (0.02 in) through thickness are unacceptable.

H.7.3.2.1 Delete this clause and replace with the following:

Sulfide stress cracking tests are required for manufacturing procedure qualification of each pipe thickness. For welded pipe three specimens shall be taken transverse to the weld Testing shall be carried out at 90% of the actual yield of the parent material using the 4 point bend method (internal surface in tension) as described in EFC 16, Appendix 2. Test solution A, EFC 16 Annex A3, shall be used adjusted to a starting pH of 3.5. 1 bara (14.5 psia) H2S shall be used. The distance between the inner supports shall be equal to, or greater than, the width of the weld plus 50 mm (2 in) (25 mm (1 in) each side of the weld). Unless otherwise agreed with the Principal the specimen thickness shall be t or 15 mm (0.6 in), whichever is the less, and the specimen width shall be ≥ 20mm (0.8 in). The applied strain shall be verified by the direct application of strain gauges.

In addition, all SSC test specimens which meet the acceptance criteria of ISO 3183:2007 are to be evaluated for resistance to SOHIC in accordance with ISO 15156-2, Clause B.4.2.3: Two longitudinal metallographic sections shall be taken from each SSC specimen. No ladder-like HIC features or cracks exceeding a length of 0.5 mm (0.02 in) in the through thickness direction are to be permitted.

H.7.3.3.1 Delete first two paragraphs and replace with the following:

Hardness testing shall be performed using the Vickers test in accordance with ISO 6507-1.

Figure H1

Amend note b) as follows:

0.50 mm (0.02 in) from fusion line

ANNEX I PIPE ORDERED AS “THROUGH THE FLOWLINE" (TFL) PIPE

Deleted

ANNEX J PSL 2 PIPE ORDERED FOR OFFSHORE SERVICE

J.2 ADDITIONAL INFORMATION TO BE SUPPLIED BY THE PURCHASER

Delete the following List items:

Information included in this DEP

b), e), g), m), n), p)

Information not applicable to this DEP

c), d)

Add:

q) more stringent tolerances on pipe end out-of-roundness and internal diameter.

r) recording pipe end out of roundness and internal diameter for each pipe end


Page 47

J.3 MANUFACTURING

J.3.3.2.4 Amend this clause as follows:

Strip and plate shall be inspected ultrasonically for laminar imperfections or mechanical damage in accordance with Annex K, either before or after cutting the strip or plate, or the completed pipe shall be subjected to full-body inspection, including ultrasonic inspection.

J.3.3.2.5 Delete this clause. Strip end welds are not permitted.

J.4 ACCEPTANCE CRITERIA

Table J1 (non sour service) shall apply for all pipe grades and for pipe with t ≤ 35 mm

(1.38 in ) but shall not include Grades L625M, L690M and L830M.

The Manufacturer/Supplier’s target product analysis shall be shown in the Manufacturing Procedure Specification. A single value target of CEiiw or CEpcm shall be stated. The range of elements shall be such that the variation in the single value target CEiiw does not exceed ± 0.03 units or CEpcm does not exceed ± 0.02 units with the following additional restrictions:

C 0.03 (HFW and SAW) 0.04 (SMLS)

Mn 0.30

Si 0.25

Ni 0.10

Cu 0.10

V 0.03

Nb 0.02

Al 0.03

Ti 0.015

Mo 0.05

Cr 0.05

NOTE The above figures represent the total range and not a plus or minus tolerance.

No changes in the chemical composition (within the tolerances listed above) are permitted from the approved WPS composition. In particular, no intentionally added elements shall be increased beyond the limits above or removed.

The chemical composition recorded for the pipes used in first-day production testing shall set the datum CE. Where any of the above elements is not intentionally added, the manufacturer may propose maximum values for approval by the Principal. In this case the above ranges shall not apply.

All elements listed in Table H1 shall be reported.

J.4.1.2 Modify this clause as follows.

For pipe with t > 35 mm (1.38 in) the chemical composition shall be agreed with the Principal, with the requirements given in Table H.1 being amended as appropriate


Page 48

J.6 TOLERANCES FOR DIAMETER, WALL THICKNESS, LENGTH AND STRAIGHTNESS

Table J.2

Delete notes a) and e). Intermediate grades shall not be supplied.

Table J.3

Modify as follows:

The pipe end out-of-roundness for pipe > 610 mm (24 in) diameter and with D/t < 75 shall be 0.0075D with a maximum of 5 mm (0.2 in). NOTE: Where required by the purchase order, tighter tolerances on pipe end out-of-roundness and internal

diameter may apply to specific items.

Delete Note c) and substitute:

For pipe with D ≥ 219.1 mm (8.63 in), the diameter tolerance and out of roundness shall be determined using the measured inside diameter.

Add new clause:

J.6.5 Surface condition of pipe ends.

The outer surface of the pipe, for a distance of 200 mm (8 in) from each pipe end, shall be such as to permit the effective use of AUT examination of circumferential joints during pipeline installation. There shall be no pitting in these areas greater than 0.25mm (0.001 in) in depth and the surface finish shall be evaluated during the MPS and this shall be the agreed surface finish for all production pipes.

J.7.1 Radial offset of strip/plate edges


The radial offset of strip/plate edges shall be in accordance with section 9.13.1 of this DEP.

J.8 INSPECTION

J.8.1 Specific inspection

Add.

The test unit for mechanical tests shall be further limited to 100 pipes for diameters less than 508 mm (20 in) and 50 pipes for diameters greater than 508mm (20 in) . NOTE: Where required by the purchase order, the pipe end out of roundness and internal diameter shall be

measured and recorded for each pipe end.

Table J.7

Add note: Where stated in the Purchase Order, higher frequencies of inspection for pipe end internal diameter and out-of roundness may be required.

J.8.2.2 Test pieces for CTOD test

Delete existing clause and replace with the following.

Test pieces shall be taken in accordance with section 10.2.3.8 of this DEP.

Table J.8

Modify this table as follows:

For pipe of D ≥ 219.1 mm (8.63 in) longitudinal and transverse pipe body tensile tests are required at the frequency of testing given for transverse pipe body tests (as modified by J8.1, above)

The acceptance criteria for longitudinal pipe body tensile tests shall be as for the transverse tests, as given in Table J2.


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J.8.3 TEST METHODS

J.8.3.2.1 Delete first two paragraphs and replace with the following:

Hardness testing shall be performed using the Vickers test in accordance with ISO 6507-1.

J.8.3.1 CTOD test



The minimum CTOD value (from a set of three specimens) taken from each of the pipe, weld and HAZ locations, shall be 0.2 mm (0.008 in), when tested at the minimum design temperature given in the purchase order.

Figure J1

Amend note b) as follows:

0.50 mm (0.02 in) from fusion line

ANNEX K NON-DESTRUCTIVE INSPECTION PIPE ORDERED FOR SOUR AND/OR OFFSHORE SERVICE

K.2 GENERAL NON-DESTRUCTIVE INSPECTION REQUIREMENTS AND ACCEPTANCE CRITERIA

K.2.1.2 For pipe with t ≥ W 5.0 mm (0.197 in), ultrasonic inspection in accordance with ISO 11496 shall be used to verify that the 100 mm (4.0 in) wide zone at each pipe end is free of such laminar defects. This can be undertaken from the outside surface if the pipe end is inspected before weld beveling, if inspection is after weld beveling this shall be undertaken from the pipe internal surface.

K.2.1.3 Delete this clause.

K.2.1.4 Amend this clause as follows:

Unless specifically agreed otherwise by the Principal on a project by project basis, the end face/bevel at each pipe end shall be magnetic particle inspected for the detection of laminar imperfections in accordance with ISO 13664.

Laminar imperfections > 6.25 mm (0.246 in) in the circumferential direction shall be classified as defects.

K.2.2.4 Delete existing clause and replace with the following:

Where dressing is carried out, complete removal of defects shall be verified by local visual inspection and by an appropriate NDT method. Imperfections should have been completely removed, and that the remaining wall thickness is within the specified tolerances.

K.3 NON-DESTRUCTIVE INSPECTION OF SMLS PIPE

K.3.1 Ultrasonic inspection for longitudinal imperfections


K.3.1 Ultrasonic inspection for longitudinal and transverse imperfections

All SMLS pipe shall be non-destructively inspected full length (100 %), as given in Table E.2. Applicable code: ISO 9303 (longitudinal imperfections) and ISO 9305 (transverse imperfections), with the acceptance limits being in accordance with Table E.8 of this DEP.


Page 50

K.3.2 Laminar imperfections in the pipe body


For sour service, individual laminations and/or lamination densities exceeding the acceptance limits for sour service given in Table K.1 shall be classified as defects. Compliance with such requirements shall be verified by ultrasonic inspection in accordance with ISO 10124:1994 (except 4.2).

The coverage during automatic inspection shall be 100% of the pipe surface


For offshore service, individual laminations and/or lamination densities exceeding the acceptance limits for offshore service given in Table K.1 shall be classified as defects. If agreed, compliance with such requirements shall be verified by ultrasonic inspection in accordance with ISO 10124:1994 (except 4.2. The coverage during automatic inspection shall be ≥ 50 % of the pipe surface).

K.3.4 SUPPLEMENTARY NON-DESTRUCTIVE INSPECTION OF SMLS PIPE

K.3.4.1 Amend this clause as follows:

SMLS pipe shall be ultrasonically inspected for the detection of transverse imperfections in accordance with ISO 9305:1989, acceptance level L2/C.

Table K.1

Replace this table with the following:

Table K.1 Acceptance criteria for laminar imperfections

Maximum individualimperfection

Minimum imperfection size considered

Maximum population density(a)

Area Length Area Length Width Service Condition

mm2 mm mm2 mm mm Pipe body (or strip/plate body)

Non-sour 1 000 300 35 8 10

[per 1,0 m x 1,0 m square](b)

Sour 100

Not specified

30 5 5 5

[per 500 mm x 500 mmsquare](c)

Strip/plate edges or areas adjacent to the weld seam d

Sour or offshore 100 20 ( — 10 — 3

[per 1,0 m length]

NOTES 1. For an imperfection to be larger than the minimum imperfection size, the minimum area, minimum length and minimum width given for the pipe body (or strip/plate body) all have to be exceeded.

2. For the purpose of determining the extent of suspect area, adjacent suspect areas separated by less than the smaller of two minor axes of the imperfections shall be considered as one imperfection.

NOTES: a) Number of imperfections smaller than the maximum and greater than the minimum imperfection size.

b) For pipe with D < 323,9 mm or strip/plate widths less than 1 000 mm, the maximum population density is referred to 1,0 m2 .

c) For pipe with D < 168,3 mm or strip/plate widths less than 500 mm, the maximum population density is referred to 0,25 m2 .

d) The maximum imperfection area of edges is the product of the maximum imperfection length, where length is the dimension parallel to the material edge and the transverse dimension. An imperfection is considered to be larger than the maximum imperfection size if either the length or the transverse dimension is exceeded.


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Service Maximum individual Minimum imperfection size

Condition imperfection considered

Maximum population density(a)

Area Length Area Length Width

in2 in in2 in in

Pipe body (or strip/plate body)

10 [per 3.3 ft

x 3.3 ft

Non-sour 1.6 0.47 1.38 0.3 square](b)

5 [per 1.6 ftx 1.6 ft

Sour 0.16 Not

specified 0.047 0.2 0.2 square](c)

Strip/plate edges or areas adjacent to the weld seam d

3

Sour or offshore 0.16 0.8 — 0.4 —

[per 3.3 ft length]

NOTES 1. For an imperfection to be larger than the minimum imperfection size, the minimum area, minimum length and minimum width given for the pipe body (or strip/plate body) all have to be exceeded.

2. For the purpose of determining the extent of suspect area, adjacent suspect areas separated by less than the smaller of two minor axes of the imperfections shall be considered as one imperfection.

NOTES: a) Number of imperfections smaller than the maximum and greater than the minimum imperfection size.

b) For pipe with D < 12.8 in or strip/plate widths less than 40 in, the maximum population density is referred to 10.8 ft2 .

c) For pipe with D < 6.6 in or strip/plate widths less than 20 in, the maximum population density is referred to 2.7 ft2 .

d) The maximum imperfection area of edges is the product of the maximum imperfection length, where length is the dimension parallel to the material edge and the transverse dimension. An imperfection is considered to be larger than the maximum imperfection size if either the length or the transverse dimension is exceeded.

K.4 NON-DESTRUCTIVE INSPECTION OF HFW PIPE

K.4.1 Non-destructive inspection of the weld seam


The full length of the weld seam shall be ultrasonically inspected for the detection of longitudinal imperfections, with the acceptance limits being in accordance with Table E.8 of this DEP. The probe per weld distribution shall be in accordance with Table E.7.1 of this DEP.

K.4.2 Laminar imperfections in the pipe body


The pipe or strip/plate body shall be ultrasonically inspected for the detection of laminar imperfections in accordance with ISO 10124:1994 (except 4.2) or ISO 12094, respectively, to acceptance limits for the relevant application as given in Table K.1.

For sour surface applications:


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For strip/plate and pipe examination the coverage during automatic inspection shall be 100% of the pipe surface.

For offshore, non sour, applications:

The required levels of coverage are ≥ 50% of the pipe or plate/strip surface.

K.4.3 Laminar imperfections on the strip/plate edges or areas adjacent to the weld seam


The strip/plate edges or the areas adjacent to the weld seam shall be ultrasonically inspected over a width of 25 mm (1 in) for the detection of laminar imperfections, in accordance with ISO 12094 or ISO 13663. The acceptance limits shall be as given in Table K.1.

K.4.3 Supplementary non-destructive inspection

Delete this clause.

K.5 NON-DESTRUCTIVE INSPECTION OF SAW PIPE


The full length of the weld seams of SAW pipe shall be ultrasonically inspected for the detection of longitudinal and transverse imperfections in accordance with ISO 9765:1990, acceptance level L2, with the following modifications:

a) The notch depth shall be ≤ 2.0 mm (0.080 in). b) The use of internal and external longitudinal notches located on the centre of the

weld seam for equipment standardization purposes is not permitted. The sensitivity of the longitudinal imperfection detection probes shall be adjusted on the radially drilled hole, Table E.7.2.

c) As an alternative to the use of the reference hole for equipment calibration for the detection of transverse imperfections, it is permissible to use acceptance level L2 internal and external notches, lying at right angles to, and centered over, the weld seam. In this case, the Manufacturer may elect to grind both the internal and external weld reinforcements to match the pipe contour in the immediate area and on both sides of the reference notches. The notches shall be sufficiently separated from each other in the longitudinal direction and (if ground flush) from any remaining reinforcement, to give clearly identifiable separate ultrasonic signal responses. The full signal amplitude from each of such notches shall be used to set the trigger/alarm level of the equipment.

d) The manufacturer may apply the provisions of K.5.3 to retest the suspect areas. The probe per weld zone distribution shall be in line with Table E.7.2 of this DEP.

K.5.1.2 Delete this clause. Strip end welds are not permitted.

K.5.1.3 Delete this clause. Jointers are not permitted.

K.5.2 LAMINAR IMPERFECTIONS IN THE PIPE BODY AND ON THE STRIP/PLATE EDGES

K.5.2.1 Delete this clause and replace with the following:

The pipe or strip/plate body shall be ultrasonically inspected for the detection of laminar imperfections in accordance with ISO 12094 to acceptance limits for the relevant service conditions as given in Table K.1 with the following coverage requirements:

For sour surface applications:

For strip/plate and pipe examination the coverage during automatic inspection shall be 100 % of the pipe surface.

For offshore, non-sour applications:


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The required levels of coverage for plate/strip and pipe shall be ≥ 50% of the pipe surface.


The strip/plate edges or the areas adjacent to the weld seam shall be ultrasonically inspected over a width of 25 mm (1 in) for the detection of laminar imperfections, in accordance with ISO 12094 or ISO 13663. The acceptance limits shall be as given in Table K.1.

K.5.3 NON-DESTRUCTIVE INSPECTION OF THE WELD SEAM AT THE PIPE ENDS/REPAIRED AREAS


The length of weld seam at pipe ends that cannot be inspected by the automatic ultrasonic equipment and repaired areas of the weld seam (see Clause C.4), shall be subjected to the following:

a) For the detection of longitudinal imperfections semi-automatic or manual ultrasonic inspection using the same inspection sensitivity and inspection parameters as is specified in K.5.1.1 and radiographic inspection in accordance with Clause E.4. Note: Manual ultrasonic inspection may be approved by the Principal as an interim measure, but the manufacturer shall plan to install an automatic or semi automatic system within an agreed time frame.

b) For the detection of transverse imperfections, automatic or semi-automatic ultrasonic inspection using the same inspection sensitivity and parameters as is specified in K.5.1.1 and radiographic inspection in accordance with Clause E.4. Note: Manual ultrasonic inspection may be approved by the Principal as an interim measure, but the manufacturer shall plan to install an automatic or semi automatic system within an agreed time frame.

For manual ultrasonic inspection, the maximum scanning speed shall be 150 mm/s (6 in/s).

Where testing of areas performed with both UT and RT, and found to be free of RT indications, the area shall be subjected to further UT. If the indication is confirmed with the repeat UT and is not caused by geometrical features or acoustic coupling conditions, then the UT indication shall be classed as a crack and the material rejected

K.5.4 SUPPLEMENTARY NON-DESTRUCTIVE INSPECTION OPERATION


Each pipe shall be tested over the final 25 mm (1 in) at each end with UT using a 45° shear wave probe to disclose axially aligned, through-thickness cracks. The manufacturer may perform this examination on the ends of the plate ends prior to forming/welding. Cracks are not permitted and if found, cracked areas shall be cut-off and the pipe end re-tested.


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PART IV REFERENCES

In this DEP, reference is made to the following publications: NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,

together with any amendments/supplements/revisions thereto.

2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS

Pipeline engineering (amendments/supplements to ISO 13623)

DEP 31.40.00.10-Gen.

Welding of pipelines and related facilities (amendments/supplements to ANSI/API STD 1104)

DEP 61.40.20.30-Gen

Line pipe induction bends (amendments/supplements to ISO 15590-1)

DEP 31.40.20.33-Gen

Welding of Deepwater Pipelines, Flowlines, and Steel Catenary Risers (based on API 1104)

DEP 37.81.40.31-Gen

Hydrogen induced cracking sensitivity test (amendments/supplements to NACE TM0284) Project Quality Assurance

DEP 30.10.02.16-Gen DEP 82.00.10.10-Gen

AMERICAN STANDARDS

Standard practice for measuring thickness by manual ultrasonic pulse-echo contact method

ASTM E 797

Issued by: American Society for Testing and Materials 1916 Race Street, Philadelphia Pa 19103 USA

EUROPEAN STANDARDS Non-destructive testing – Qualification and certification of personnel

EN 473

Destructive tests on welds in metallic materials – longitudinal tensile test on weld metal in fusion welded joints

EN 876

metallic materials – Tensile testing – Part 5: Method of testing at elevated temperature

EN 10002-5

Issued by: CEN Rue de Stassart 36 B-1050 Brussels Belgium

Copies can also be obtained from national standards organizations

INTERNATIONAL STANDARDS

Quality systems - Model for quality assurance in design, development, production, installation and servicing

ISO 9001

Non-destructive testing – Qualification and certification of personnel.

ISO 9712

Quality assurance requirements for measuring equipment – Part 1: Metrological confirmation system for measuring equipment

ISO 10012-1

Seamless and welded steel tubes for pressure vessels – Ultrasonic testing for detection of laminar imperfections

ISO 10124

Steel tubes for pressure purposes – Qualification and certification of non-destructive testing (NDT) personnel

ISO 11484


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Submerged arc-welded steel tubes for pressure purposes - Radiographic testing of the weld seam for the detection of imperfections

ISO 12096

Induction bends, fittings and flanges for pipeline transportation systems – Part 1, Induction bends

ISO 15590-1

Non-destructive testing – Qualification of personnel for limited application of non-destructive testing

ISO 20807

Issued by: ISO Central Secretariat 1, ch. de la Voie-Creuse Case postale 56 CH-1211 Genève 20, Switzerland

Copies can also be obtained from national standards organizations.

NORWEGIAN STANDARDS

Offshore standard, Submarine pipeline systems DNV OS-F101 Issued by: Det Norske Veritas Industri Norge AS Veritasveien 1 1322 Høvik Norway

EUROPEAN FEDERATION OF CORROSION Guidelines on materials requirements for carbon and low alloy steels for H2S-containing environments in oil and gas production

EFC 16

Issued by: Maney Publishing on behalf of the Institute of Materials 1 Carlton House Terrace London SW1Y 5DB


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APPENDIX 1 LINEPIPE SUBJECTED TO HIGH STRAIN

A1.1 GENERAL

The following requirements are additional to those specified for PSL 2 pipe ordered for offshore service by ISO 3183:2007 (Annex J) and this DEP. Applicable to pipe for pipelines subject to a single event nominal strain (elastic + plastic), in any direction > 1.0 % or accumulated strain > 2 %, during installation or operation. These conditions apply to all pipelines subjected to high strain, whether onshore or offshore, at pipe grades up to and including L450.

For pipe proposed for installation by reeling, reelability data shall be provided for the pipe proposed (previous data for pipe in terms of the same pipe grade, dimensions, manufacturing process, chemical composition, and heat treatment etc). The data shall be provided for both before and after reeling trials/simulations including but not limited to: stress/strain curves, fatigue, toughness, yield/tensile including ratios, etc.

A1.2 MECHANICAL PROPERTIES

The results of all longitudinal tensile tests shall conform to the requirements of Table J2 to the following modifications:

• Tensile specimens shall be of the proportional type, in accordance with ISO 6892. The gauge length shall be equal to 5.65S0, where S0 is the original cross-sectional area of the specimen;

• The yield strength shall not exceed the specified minimum value by more than 120 MPa (17405 psi). or vary more than 100 MPa (14505 psi) from the agreed MPS value;

• The ratio of yield to tensile strength shall not exceed 90%;

• The elongation shall not be less than 20%.

One set of longitudinal Charpy impact specimens shall be taken at a frequency of one set per test unit from the pipe body. The specimens shall be through-thickness notched and located at mid-thickness. The minimum Charpy impact energy for these tests shall be 100 J (0.945 Btu) (average) 80 J (0.075 Btu) (individual). The testing temperature shall be as given in Table 8.

For the manufacturing procedure qualification test, the longitudinal tensile and Charpy impact tests shall be carried out in both the as-received condition and after a heat treatment simulating thin-film coating. This shall consist of holding at 250°C (480°F)for a minimum of 10 minutes, or as specified in the purchase order. The Principal may require all production longitudinal tensile and Charpy impact test to receive the same heat treatment prior to testing, subject to the results of the manufacturing qualification test.

A1.3 SPECIFIC REQUIREMENTS, HFW PIPE

HFW pipe shall be subject to the following heat treatment:

(a) Full body quench and temper;

Or

(b) Weld seam online quench followed by full body temper.

A1.4 STRAIN AGED PROPERTIES

The following shall form part of the manufacturing procedure qualification test for each combination of diameter and wall thickness. .

Samples of pipe body shall be subject to a longitudinal, uni-axial strain of 3.0% (or greater if stated in the purchase order). A sufficient number of strain gauges shall be used to verify even straining. (Refer DNV F101 – Appendix B: A1200)


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Samples of the longitudinal seam weld (SAW and HFW pipe) shall be similarly subject to uni-axial straining to 3.0% strain (or lesser value if stated in the purchase order) transverse to the seam.

After straining, the samples shall be aged at 250 °C (480°F) for one hour. The following mechanical tests shall be performed:

Pipe body:

• Two longitudinal tensile tests;

• One set of three longitudinal Charpy impact tests ;

• One through thickness hardness survey (HV10), per Fig J.1.a).

Weld seam:

• One all-weld tensile test (SAW only);

• Four sets of charpy impact tests at weld, fusion line, fusion line+2 mm (0.08 in)and fusion line +5 mm (0.2 in) in accordance with 10.2.3.3;

• One hardness survey (HV10) per Fig J1 b) or c).

The impact test temperature shall be as specified for the unstrained tests.

The acceptance criteria for all mechanical tests shall be as specified for the unstrained tests.

Where required by the Purchase order for SSC testing, as specified in clause H.7.3.2.1, shall be performed on samples of the longitudinal seam weld strain -aged as specified above.

A1.5 SSC TESTS AT HIGH STRAIN

Where required be the purchase order, high strain SSC tests shall be conducted on the parent material as part of the manufacturing procedure qualification. Three specimens shall be taken from the parent material in the longitudinal direction. Testing shall be carried out using the 4 point bend method (internal surface in tension) as described in EFC 16, Appendix 2. The distance between the inner supports shall be equal to, or greater than, the width of the weld plus 50 mm (2 in) (25 mm (1 in) each side of the weld). Unless otherwise agreed with the Principal the specimen thickness shall be t or 15 mm (0.6 in), whichever is the less, and the specimen width shall be ≥ 20 mm (0.8 in). The applied strain, solution starting pH and H2S partial pressure shall be as stated in the purchase order and shall be verified by the direct application of strain gauges.

In addition, all SSC test specimens which meet the acceptance criteria of ISO 3183:2007 are to be evaluated for resistance to SOHIC in accordance with ISO 15156-2, Clause B.4.2.3: Two longitudinal metallographic sections shall be taken from each SSC specimen. No ladder-like HIC features or cracks exceeding a length of 0.5 mm (0.02 in) in the through thickness direction are to be permitted.

Testing shall be applied to each combination of diameter and wall thickness and within the essential variables stated in B.5. These tests shall be in addition to the trans-weld SSC tests, carried out at 90 % of actual yield that may be required under clause H 7.3.2.1. NOTE It is unlikely that high in-service strains will be permitted under severe sour service and the test

conditions required by the purchase order should represent the anticipated process conditions.


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APPENDIX 2 WELDABILITY OF PSL2 PIPE

A2.1 GENERAL

For all offshore pipelines and for other pipelines where specified in the purchase order, weldability trials SHALL [PS] be carried out. The material shall be as qualified in the manufacturing procedure qualification (Annex B), within the limits specified in Clause B.5, as modified by this DEP.

One trial each shall be carried out for the maximum and minimum wall thicknesses to be produced, or as agreed with the Principal.

Data from previous weldability trials may be accepted, in whole or part, in lieu of testing by the Principal. The material used in the previous trials shall be identical in grade, and manufacturing procedure to the pipe to be supplied and shall be of similar diameter, wall thickness and similar in chemical composition (within the limits of Annex H table H1).

A2.2 WELDING

Girth welds shall be carried out in accordance with welding procedure specifications representative of those used by installation contractors and approved by the Principal. The production of these welds and subsequent testing shall be in accordance with DEP 61.40.20.30-Gen (Modifying ISO 13847)

Typically, welds shall be produced by the mechanised/automatic GMAW process with arc energies for each weld pass in the range 0.6-1.0 KJ/mm (14.5-24 Btu/in). Alternative welding processes and parameters shall be as stated in the purchase order.

At least one full butt weld shall be produced for each trial and sufficient weld length shall be produced to extract all the required test specimens.

Additional welds may be required to be supplied for testing conducted by the Principal. The number and dimensions of these weld test pieces shall be stated in the purchase order.

A2.3 MECHANICAL AND CORROSION TESTING

Mechanical testing of the welds shall be carried out in accordance with section 5.4.3. of DEP 61.40.20.30-Gen. (critical service) with the following modifications

Fracture toughness testing shall be carried out for the fusion line/HAZ only as follows:

For elastic design:

SENB CTOD specimens shall be used. A minimum CTOD value of 0.25 mm (0.01 in) shall be achieved in all tests.

For SCR pipe: Minimum allowable CTOD shall be 0.51 mm(0.02 in) For high strain (Appendix 1 applies)

At least 6 CTOD specimens (SENB or SENT, as stated in the Purchase order) shall be tested in accordance with the requirements of DEP 61.40.20.30-Gen to develop a R-curve for the HAZ. The required R-curve shall be defined in the Purchase Order.

The design temperature relevant to CTOD and impact testing shall be stated in the purchase order.

The acceptance criteria for tensile, hardness and impact testing shall be as stated in section 5.4.3 of DEP 61.40.20.30-Gen.

Where required by the purchase order, corrosion (SSC) testing shall be carried out in accordance with section 5.4.3.9 of DEP 61.40.20.30-Gen. The specimen thickness shall be t or 15mm (0.6 in), whichever is the less. Specimens not exhibiting surface cracking after testing are to be evaluated for resistance to SOHIC in accordance with ISO 15156-2, Clause B.4.2.3: Two longitudinal metallographic sections shall be taken from each SSC specimen. No ladder-like HIC features or cracks exceeding a length of 0.5 mm (0.02 in) in the through thickness direction are to be permitted


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APPENDIX 3 LINE PIPE FOR DEEPWATER PROJECTS, INCLUDING STEEL CATENARY RISERS

A3.1 SCOPE

This appendix, when stated on the purchase order or project documentation, specifies the requirements for line pipe used on deepwater projects. These requirements are in addition to those stated in this DEP, ISO 3183:2007 and API Spec 5L 44th Edition. NOTE: The requirements of Annex J and Appendices 1 and 2 shall apply to all pipes for deepwater projects

unless specifically stated otherwise on purchase orders for specifc projects.

When specified in the purchase order or project documentation for sour service the requirements of Annex H, as modified by this DEP, shall also apply.

A3.2 GENERAL

For seamless pipe all billets and slabs shall be scarfed or peeled prior to rolling or forming. Continuous cast rounds shall be conditioned to the Manufacturer’s specifications.

Pipe straightness and length shall be measured and recorded for each pipe. Unless otherwise stated by Principal, 85% of pipe shall be in the range 11.9 m to 12.5 m (39 ft to 41 ft) with the remaining 15% in the range of 11.6 m to 12.8 m (38 ft to 42 ft).

The wall thickness negative tolerance shall be -5 %. The wall thickness positive tolerance for seamless pipe shall be +15 %.

A3.3 ADDITIONAL TESTING FOR SAW PIPE

During first day production manufacturer shall perform circumferential compressive stress tests. A compressive stress-strain curve shall be developed. The units used on each axis of each compressive stress-strain curve shall be clearly identified. The compressive stress-strain curves shall cover a range of at least –2.0 % strain.

During first day production manufacturer shall perform ring splitting residual stress tests. If residual stresses are large, greater than 25 % of SMYS, the Principal shall be informed immediately in order to have the pipe collapse tested.

A3.4 WELDABILITY TEST

Weldability testing shall be in accordance with (Appendix 2) of this DEP, however unless otherwise stated in the purchase order DEP 37.81.40.31-EPP shall be used instead of DEP 61.40.20.30-Gen for the production, testing and inspection of the welds.

CTOD requirements shall be as follows: For SCR pipe: Minimum allowable CTOD shall be 0.51 mm(0.02 in) For flowlines and high strain testing: minimum allowable CTOD shall be 0.25 mm (0.01 in) The charpy impact test temperature shall be a minimum of -18°C (-5°F) and CTOD at a minimum of 0°C (32°F).

A3.5 PIPE ENDS

Pipe ends shall be either bevelled or square cut, as required by the purchase order. When a bevel angle is specified the plus or minus tolerance shall be 2 1/2°, unless otherwise specified. Root face shall be as described by Clause 9.12.5.2 of ISO 3183:2007/API Spec 5L 44th edition, except there shall be no internal bevel resulting from removal of the internal burr.

The inside diameter of each end of each pipe for a distance of 102 mm (4 in) from the end, shall be as specified in Table J.3, but shall not be more than 1.6 mm (0.063 in) larger, nor more than 1.6 mm (0.063 in) smaller than specified, as measured with inside calipers, inside micrometers, a rod gauge, or similar device. For SCR applications the inside diameter of each end of each pipe for a distance of 102 mm (4 in)from the end, shall not be


Page 60

more than 1.6 mm (0.063 in) larger, nor more than 1.6 mm (0.063 in) smaller than specified.

The inside diameter at the ends may be machined, on the condition that the termination of the machining is parallel over 200 mm (8 in) of the pipe, and that all wall thickness tolerances are maintained.

If end machining is required to meet these tolerances and the Manufacturer has end machining capabilities that meet the requirements of the Deepwater Projects Addendum, then the Deepwater Projects Addendum shall apply. Manufacturer may submit a proposal to Principal to meet the requirements of the Deepwater Projects Addendum.

If the inside diameter at the ends is machined, a minimum distance for machining of 200 mm (8 in) from the pipe end shall be required, unless specifically approved by the Principal. Any end-machining required to meet these tolerances shall be approved by the Principal.

A3.6 NON-DESTRUCTIVE INSPECTION

After all manufacturing and heat treatment procedures have been completed on seamless pipe, the entire steel volume of each length of pipe (100%) shall be inspected by both ultrasonic and electromagnetic methods in accordance with this DEP and Annexes E & K of ISO 3183:2007/API Spec 5L 44th edition, and the additional requirements herein.

Prior to edge preparation and forming, all plate (100%) for SAW pipe shall be subjected to an ultrasonic examination in accordance with this DEP and Annexes E and K of ISO 3183:2007/API Spec 5L 44th edition to detect discontinuities parallel to the rolled surfaces. At the option of the manufacturer, this inspection may be performed after the pipe fabrication is complete.

All weld seams for SAW pipe shall be inspected full length (100%) by ultrasonic examination in accordance with this DEP and Annexes E and K of ISO 3183:2007/API Spec 5L 44th edition.

For Steel Catenary Riser pipe the ultrasonic testing equipment requires qualification and approval in accordance with Shell Quality Services’ TC 11.1 Rev. 1 (16 August 2001) “Quality Services’ Process for Performing UT/EMI System Capability Study”.

Each length of pipe shall be measured along the full length for wall thickness. Each bidder shall submit with their quotation all details of their proposed inspection and the amount of coverage.

There shall be no laminations within 150 mm (6 in) of the pipe ends.

A3.7 WORKMANSHIP

The pipe shall contain no dents that affect both the outside surface and the inside surface, and the pipe shall contain no dent on the outside surface with a depth exceeding 1.6 mm (0.063 in) for seamless pipe and 0.8 mm (0.03 in) for SAW pipe. Pounding out or jacking out dents is prohibited.

For the whole order no more than 0.5% of the pipe welds may be repaired. No individual repair can be attempted more than once.

A3.8 MARKING AND COATING

Any additional marking requirements, if applicable, will be included in the purchase order (including the requirement for marking in US units and conformance to US anti-dumping regulations).


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APPENDIX 4 PROCEDURE REQUIREMENTS FOR NDT A procedure shall be present for every technique describing the inspection process, with as a minimum the essential variables as mentioned below in the different tables

Ultrasonics

chapter Essential variables

scope Diameter- and thickness range

Personnel • qualification and performance if requirements

Inspection Technique(s) • straight beam, angle beam, contact, and/or immersion Scanning (manual or automatic)

equipment • Type and supplier ultrasonic instrument(s). specifications (warning signals, marker etc)

• probe type(s), frequency(ies), and element size(s) shape(s) angle(s) suppliers

• computerized program identification and revision, when used

calibration a) calibration pipe identification b) Dimensions of the calibration pipe (diameter and thickness) and

reference reflectors c) drawing of the reference reflectors in the test pipe (above view

and cross section) d) layout of the probes in combination with the reading channels e) parameters of the inspection (guiding principle, gate settings,

inspection speed etc)

Acceptance criteria • Acceptance criteria for the inspection and decision tree

Reporting

Reporting shall include at least the following items: a) procedure identification and revision; b) instrument reference level gain and, if used, damping; c) identification of the pipe; d) wall thickness and diameter of the pipe; e) position, depth and size of the defect(s) at reporting level (50%

of the reference level); f) date and time of inspection; g) responsible operator.


Page 62

Liquid penetrant


scope Material to be inspected


Inspection Technique(s) • Method of applying penetrant • Method of removing excess surface penetrant • Method of applying developer

equipment • materials including developers, emulsifiers, etc

General a) Surface preparation (finishing and cleaning) b) Minimum and maximum time periods between steps and drying

aids c) Decrease in penetrant dwell time d) Increase in developer dwell time (Interpretation Time) Minimum

light intensity e) Surface temperature outside: 5°C to 52°C ( 40°F to 126°F)

Acceptance criteria • Acceptance criteria for the inspection

Magnetic particle


scope Material to be inspected


Inspection Technique(s) a) Magnetizing technique b) Magnetizing current type or amperage c) Magnetic particles (fluorescent/visible, color, particle size,

wet/dry d) Method of particle application e) Method of excess particle removal f) Methods of identifying flaw indications and discriminating

between flaw indications and false or non-relevant indications

equipment • Supplier of the equipment

General • Surface preparation

• Minimum light intensity surface temperature

• Instructions for identification and confirmation of suspected flaw indications



Page 63

Eddy Current


scope thickness range


Inspection Technique(s) • Mode of inspection: differential or absolute • Scanning mode: manual, mechanized probe driver, remote

controlled fixture

equipment • Manufacturer and model of eddy current equipment • Probe type and size • Probe manufacturer, part number, and description • Length of probe cable and probe extension cables

calibration • Identity of calibration reference standard(s)

• Examination frequencies, drive voltage, and gain settings

• Minimum digitization rate

• Maximum scanning speed during data recording

Acceptance criteria • Acceptance criteria for the inspection and decision tree

Reporting

Reporting shall include at least the following items • procedure identification and revision • Scanning direction during data recording, i.e., push or pull • date and time of inspection • responsible operator


Page 64

Radiography


scope thickness range


Inspection Technique(s) • conventional or digital • single wall / double wall

equipment a) isotope or maximum X-ray voltage used b) manufacturer and model no. of digitizing system if used c) film brand and designation d) image quality indicators (IQI) e) Intensifying Screens if used

general a) radioscopic parameters b) image processing parameters c) image display parameters d) image archiving e) manipulation system


Reporting The radioscopic examination system shall, as a minimum, include the following:

• film number and result of the inspection: accept or reject

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