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8/9/2019 Specification for Seamless Linepipe Lp1-Smls-rv4
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SPECIFICATION FOR
SEAMLESS LINEPIPE
WEST NATUNA PIPELINE PROJECT
INDONESIA TO SINGAPORE
PREPARED FOR
WEST NATUNA GROUP
INTEC PROJECT H-0879.01
JUNE 1998
4 05-JULY-99 INCLUDING MILL CLARIFICATIONSRAB CDK KW
3 11-JUN-99 INCORPORATING MANUFACTURERSCLARIFICATIONS RAB CDK KW
2 13-MAY-99 INCORPORATING BIDCLARIFICATIONS DW CDK RJP
1 15-Jun-98 RE-ISSUED CLIENT COMMENTSINCORPORATED DW CDK RJP
0 14-Apr-98 ISSUED FOR CLIENT APPROVALDW CDK RJP
B1 7-Apr-98 ISSUED FOR CLIENT REVIEWDW CDK RJP
REV. DATE DESCRIPTION BY CHKD APPD CLIENT
SPECIFICATION NO.
8791/09-LP1-SMLS
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TABLE OF CONTENTS
1. GENERAL................................................................................................................................1
2. MANUFACTURING...............................................................................................................2
3. MANUFACTURING MATERIALS......................................................................................2
4. NON-DESTRUCTIVE EXAMINATION..............................................................................3
5. PHYSICAL PROPERTIES AND TESTS .............................................................................5
6. HYDROSTATIC TESTING...................................................................................................6
7. REJECTION OF PIPE JOINTS ................................................................ ............................6
8. CORRECTION OF DEFECTS..............................................................................................7
9. DIMENSIONAL TOLERANCES................................................................ ..........................7
10. MARKINGS AND COATING ...............................................................................................8
11. QUALITY CONTROL............................................................................................................8
12. INSPECTION AND REJECTION.........................................................................................9
13. SHIPMENT ..............................................................................................................................9
14. RECORDS..............................................................................................................................10
15. DOCUMENT SUBMITTALS...............................................................................................10
ATTACHMENTSA Manufacturing Procedure Qualification
B Supplementary Strength Requirements
(This Specification consists of 18 pages)
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1. GENERAL
1.1 This specification defines the minimum technical requirements for the supply of Grade
X65 (448) seamless linepipe.
The following are cited as reference documents to this specification.
Design Basis Memorandum 8791/02-DBM001
General Specification 8791/09-GS1 - Definitions and Specification Directory
General Specification 8791/09-GS2 - Quality Assurance / Quality Control
General Specification 8791/09-GS3 - General Offshore Specification
1.2 Pipe furnished to this specification shall conform to the applicable portions of Section 6
of the latest edition of the DnV Rules for Submarine Pipeline Systems for Quality Level1, the requirements contained in this specification inclusive of Attachment A and the
requirements specified in the Purchase Order. Attachment B shall be required when
specified on the Purchase Order. The latest edition of API Spec 5L shall be used, as areference for requirements not covered by the DnV Rules or this specification. The
linepipe CONTRACTOR shall be licensed to use the API monogram.
1.3 The following supplementary requirements in the DnV Rules are required:
D200 Supplementary Requirement, Fracture Arrest Properties (F)
D400 Supplementary Requirements for Dimensions (D)
1.4 COMPANY has the right to require an audit of the manufacturing facility to determine
the current condition of the facility and to re-certify the facility as being capable ofproducing pipe to this specification.
1.5 COMPANY has the right to require pre-qualification of the manufacturing route
proposed for the linepipe.
1.6 CONTRACTOR shall maintain an effective program for quality assurance and quality
control, planned and developed in conjunction with all functions necessary to meet therequirements of the Purchase Order. The requirement shall be met by the establishment
and implementation of procedures presented to COMPANY. The program shall
demonstrate both recognition of the quality requirements of the contract and an organizedapproach to satisfy these requirements. The program shall ensure that quality
requirements are determined prior to commencement of the work and subsequently
satisfied throughout all phases of production.
1.7 This specification requires the preparation and submittal of a complete and detailedManufacturing Procedure Specification (MPS) at the bidding stage. The MPS will be
qualified by performing Manufacturing Procedure Qualification Tests (MPQT) on joints
selected during the first days production as detailed in this specification and AttachmentA.
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Notes:
1. Maximum value except where range is indicated.
2. If Nb, V, and Ti are employed in any combination, the combined total shall notexceed 0.12% as indicated by ladle analysis.
3. Boron shall not be added intentionally.
4. Minimum Al:N ratio shall be 2:1.5. The total percentage of chromium, nickel, molybdenum and copper shall not
exceed 0.60%
6. The minimum carbon based on product analysis shall be 0.05%.
3.4 The maximum carbon equivalent, calculated by the following formula, shall not exceed
0.42 as indicated by ladle analysis.
C.E. = C + Mn + Cr + Mo + V + Ni + Cu
6 5 15
For carbon less than or equal to 0.12 maximum, the Pcm shall not exceed 0.22.
Pcm = C + V + Mo + Cr + Mn + Cu + Si + Ni + 5B < 0.22
10 15 20 30 60
3.5 Chemical Analysis: Each chemical analysis taken and reported shall include the
percentage of each element specified or restricted by this specification.
4. NON-DESTRUCTIVE EXAMINATION
4.1 All non-destructive examination (NDE) for inspection release of pipe shall be carried out
after completion of heat treatment and cold straightening.
4.2 Each pipe joint shall be subject to the NDE in the following table as a minimum:
TABLE 4-1: TYPE AND EXTENT OF NON-DESTRUCTIVE TESTING1,6
Scope of Testing Method Extent of
Testing
Laminar imperfections at pipe ends covering acircumferential band 50 mm wide
UT 100%
Imperfections in untested ends UT 0%
Residual magnetism -- R
Laminar imperfections in pipe body UT 100%
Thickness testing UT 20%
Longitudinal imperfections, pipe body UT 100%
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5. PHYSICAL PROPERTIES AND TESTS
5.1 Testing shall be carried out after heat treatment and cold straightening. Mechanical
properties required, and the tests to assess them, shall comply with the requirements of
DnV Rules with the additions/changes given in the following sections:
5.2 Testing may be carried out prior to hydrostatic pressure testing provided it can bedemonstrated that there is no significant difference in mechanical properties in regard to
before or after hydrostatic test. This shall be demonstrated on one pipe.
5.3 The following replaces Section E807 and Table E2 in the DnV Rules. The mechanical
testing is to include the testing shown in Table 5-1. The tests required for qualification ofthe MPS are denoted Q and the tests required for production testing are denoted P.
Additional qualification testing is also included in Attachment A.
TABLE 5-1: SEAMLESS LINEPIPE MECHANICAL TESTING
1
Type of Test Testing
Tensile Q&P
Charpy V-notch Q&P
CTOD N/A
Hardness Q&P
Charpy V-notch transition curve Q
Strain aging transition curve Q
Drop weight tear Q&P
Notes:
1. All testing is to be performed in accordance with the requirements of Appendix B
of the DnV Rules as amended by paragraphs 5.3 through 5.7 below.
2. Test needs to be performed only if specified due to ECA requirements.
5.4 Additional Requirements Regarding Tensile Testing: Yield strength shall not exceed the
SMYS value by more than 120 MPa (17,400 psi). Pipe joint with a yield / tensile ratioexceeding 0.90 shall not be acceptable.
Ring expansion methods shall not be used to determine transverse yield strength.
Transverse weld tensile tests shall include determination of tensile strength.
Longitudinal pipe joint body tensile tests shall be taken at 90 degrees from the weld
seam.
5.5 Supplementary Tensile Property Requirements: Refer to Attachment B for
supplementary tensile property requirements applicable only if specified in the Purchase
Order.
5.6 Charpy Impact Tests: Charpy impact tests shall be performed as per DnV Section 6 andDnV Appendix D. Specimens shall be tested at +10C and meet the minimum value
listed in the table below.
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Required Charpy Impact Values for full size specimen (Tested at +10C):
Avg. of 3 Specimen Minimum Individual Value
Pipe Body 150 Joules 135 Joules
Should subsize specimens be required, an appropriate conversion factor shall be selected from
the following table:
Specimen Size
(mm)
Conversion Factor
10 x 10 1
10 x 7.5 .833
10 x 5 .667
5.7 Hardness Testing: Hardness testing shall be in accordance with Section 6, C200 and
Appendix B of the DnV Rules except that the maximum hardness shall be 300 HV10.
5.8 Drop Weight Tear Tests: Drop weight tear tests shall be conducted at a test temperature
of +10C in accordance with the DnV Rules.
6. HYDROSTATIC TESTING
6.1 Pipe joints shall be hydrotested in accordance with the DnV Rules with the following
additions:
Test pressure shall be held for a least 15 seconds.
Hydrostatic testing apparatus shall be equipped to provide test pressure and duration
records for every pipe joint length, and shall be available for COMPANY review.
Each hydrostatic test failure or mechanical expansion failure shall be made known toCOMPANY. All failed pipe joints shall be placed aside and shall be available for
COMPANY inspection.
The hydrostatic test pressure shall be based on the hoop stress as required in SectionE1103 of the DnV Rules unless COMPANY permits the use of combined stresses.
The hoop stress as calculated in Section E1103 shall in no case fall below 90%
SMYS.
7. REJECTION OF PIPE JOINTS
7.1 The following requirements shall supersede those in DnV Rules:
If more than ten (10) percent of any days production fails to meet the requirementsherein, COMPANY acceptance inspection shall cease and all continuing production
shall be marked and set aside until CONTRACTOR ascertains and corrects the failure
cause.
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Characteristic to be Tested Extent of
Testing Tolerance
Wall thickness, t < 15 mm 100% 12.5% and tmmin9 t
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12. INSPECTION AND REJECTION
12.1 CONTRACTOR shall maintain continuous supervision of its inspection procedures.
CONTRACTOR shall allow adequate time on its schedule for final COMPANY approvalof manufacturing and inspection procedures.
12.2 All first-day production tests will be witnessed by COMPANY. COMPANY shall be
permitted to witness all chemical testing, mechanical testing, equipment calibration, and
steelmaking and to inspect all pipe joints. Sufficient notice (at least 14 days) shall begiven of the time at which the steel production and also pipe production will start.
12.3 COMPANY shall have free entry at all times to all parts of the CONTRACTORs works
that will be concerned with the manufacture, testing, inspection, quality control and
shipping of the pipe ordered. This includes the steel mill and the pipe mill. TheCONTRACTOR shall make available to COMPANY, all reasonable facilities to inspect,
measure and test the pipe in all stages of production. For example, this includesultrasonic equipment for wall thickness confirmation.
12.4 COMPANY shall have the option to examine all materials rejected for any reason.COMPANY must be informed of any pipe fractures occurring during cold expansion or
hydrostatic testing and of any test specimen failures. All failed materials shall be
retained until examined by COMPANY.
12.5 The CONTRACTOR shall allow COMPANY to inspect (at a frequency of 10% perquantity) each length of pipe after manufacture and testing is completed but prior to
loading for shipment. COMPANY shall be provided with, by CONTRACTOR, a means
for rotating the pipe and ample lighting to facilitate thorough visual inspection of both
internal and external surfaces. COMPANY and the CONTRACTORs inspectors shallnot inspect the pipe concurrently.
12.6 All pipe joints having repetitive imperfections must be segregated and COMPANY
informed of the extent and cause of the imperfections. The CONTRACTOR shall informCOMPANY of actions taken to prevent the imperfections.
12.7 COMPANY shall be given the opportunity to witness the calibration of each piece of
NDT equipment each time that it is calibrated or re-calibrated.
12.8 After production has commenced on the Order, CONTRACTOR shall notify COMPANY
at least twenty-four (24) hours in advance of any changes in production schedules.
12.9 COMPANY shall operate independently of CONTRACTOR inspectors.
13. SHIPMENT
13.1 CONTRACTOR shall submit to COMPANY for approval, procedures for handling,
stacking during storage, and stacking and securing pipe for shipment.
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13.2 All handling, loading and unloading shall be performed in such a manner as to avoid
mechanical damage and corrosion, using slings or pipe-shaped padded hooks with a
spreader bar attached.
13.3 Rail cars, trucks, lighters, ships or other conveyances shall be cleaned of debris or anysubstance that might damage the pipe prior to loading.
13.4 Suitable timber and other dunnage shall be used to protect the pipe against damage in
transit.
13.5 Loading onto or into rail cars, trucks, lighters, ships or other conveyances shall beperformed in accordance with Project Specification 8791/09-LP6 and API 5L1 or API
5LW as appropriate.
13.6 No on-deck overseas shipment is allowed without prior written approval by COMPANY.
13.7 Finished pipe shall be stored at the mill or marshalling yard in a manner to prevent
damage and excessive corrosion of the pipe.13.8 Pipe shall not rest on projections which could result in point stresses or be allowed to rub
on an adjacent object.
13.9 Bevel protectors shall be provided for all pipe ends.
14. RECORDS
All records indicated herein shall be fully identified with the specific materials they
represent. Records shall be available for COMPANY examination at the time and placeof inspection, whether at the point of manufacture or other CONTRACTOR locations.
CONTRACTOR shall keep these records for three years after pipe joints have beenshipped:
Certificates of Compliance of required nondestructive testing.
Radiographic films for review by COMPANY or third-party inspectors.
Pyrometer charts or other detailed records for all heat treatment performed, such aspostweld, normalizing, and heating for forming.
Charts or other records of required hydrostatic, pneumatic and other tests. Test logsshall include test data, testing fluid, test duration, test fluid temperature, test pressure,a description of the item tested, a traceable identifying number such as a shop order
number, and the signature of CONTRACTOR shop inspector witnessing the test.
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15. DOCUMENT SUBMITTALS
All documentation shall be compiled into a data book. CONTRACTOR shall submit to
COMPANY for approval, all documentation produced during the WORK as required by
the DnV Rules, including but not limited to the following:
a.) Q.C. Proceduresb.) Ladle Analysis (each heat)
c.) Product Check Analysis (each heat)
d.) Results of Manufacturing Procedure Qualificatione.) Certified Examination Reports
f.) Certified Mechanical Test Reports
g.) Mill Certificatesh.) Special Tests Results required by this Specification
i.) Storage Procedures
j.) Release Certificates
All certificates shall be in the English language, use metric units of measure and shall be
visibly signed by both CONTRACTOR and COMPANY.
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ATTACHMENT A
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ATTACHMENT A
MANUFACTURING PROCEDURE QUALIFICATION
A.1 GENERAL
Pipe joint production procedures shall be qualified by actual testing. CONTRACTOR
shall submit written procedure, for COMPANY review and approval, with bid.
A.2 WRITTEN PROCEDURE SPECIFICATION
CONTRACTOR written procedures shall contain the following minimum information:
A.2.1 Steel maker and steel making processes, including selection and percent of scrap and
details of hot metal treatment secondary refining techniques, ladle treatments, degassing,
casting techniques and equipment used for continuous casting, if applicable.
Amount of slab or round removed from front and end of pour, method of taking ladleanalysis, procedures for sulfur prints or macros of slab, scarfing practice.
A.2.2 Chemical Composition and Target Chemistry
A.2.3 Details of pipe making and sizing.
A.2.4 Details of heat treatment including:
Austenizing temperature with tolerances
Maximum and minimum time at austenizing temperature
Details of quenching including water flow and water temperature control
Tempering temperature with tolerances
Maximum and minimum time at tempering temperature
Methods used to minimize distortion
A.2.5 Details of cold straightening and cold sizing including maximum cold strain.
A.2.6 CONTRACTOR shall supply data on pipe joints with a similar chemistry and
manufacturing process, that shows adequate field weldability to COMPANY. Withoutsuch data, or as directed by COMPANY, CONTRACTOR shall conduct field weldability
trials with COMPANY approved manual (stick) and semi-automatic / automatic
(GMAW) welding procedures.
A.2.7 Pipe joint hydrotest and NDE procedures.
A.2.8 Essential variables for each manufacturing step are to be established. The following
changes in the manufacturing processes for linepipe will require re-qualification of the
MPS.
Any change in raw material scrap content, when relevant, above that qualified.
Any changes in steelmaking process, alloying practice, rolling or working conditionand heat treatment.
Increase in ladle analysis of 0.02%C or 0.03 in Pcm values above that qualified.
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Any change in pipe forming process.
Any change in final heat treatment condition.
Any change in method for cold expansion/reduction and any increase in cold
expansion/sizing/finishing from that used during qualification.
A.3 MANUFACTURING PROCEDURE QUALIFICATION TEST
On the first day of production, three (3) pipe joints shall be randomly selected by
COMPANY for examination and testing in accordance with the requirements of the DnVRules and the following:
A.3.1 Each test pipe joint shall be examined visually on both surfaces for compliance with the
quality requirements of this specification.
A.3.2 All of the inspection, measurement, testing and NDE requirements for production pipe
contained in the main body of the specifications shall be performed on each test pipe
joint.
A.3.3 CTOD TESTING
CTOD testing shall be conducted in accordance with BS 7448 and Appendix B of the
DnV Rules. All values shall be greater than 0.15 mm. Values obtained shall besubmitted to COMPANY.
A3.4 STRAIN AGING TEST
Strain aging testing shall be performed in accordance with DnV Appendix B and DnV
Section 6, D200. The coupons shall be tested at temperatures between 70 degrees C and
+ 20 degrees C and Charpy Energy and Shear transition curves shall be established. The
Charpy Energy value at +10 degrees C shall be greater than 113 joules average with nosingle value less than 101 joules.
A3.5 CHARPY V-NOTCH TRANSITION CURVE
Charpy V-notch energy and shear area curves are to be established by testing at least 5
sets of coupons from one of the test joints. Testing shall be conducted between 70degrees C and +20 degrees C. The minimum average Charpy energy value at +10 degrees
C shall be 150 joules minimum average with no single value less than 135 joules.
A3.6 WELDABILITY TEST
Four, full-length pipe joints shall be selected from the first days production for
weldability testing to be conducted by the installation contractor. These joints shall
receive all of the inspections and testing and acceptance required of production pipejoints. The joints shall be shipped as directed in the Purchase Order.
A.3.7 For procedure approval, the results of all the above tests shall comply with the minimum
requirements of this specification.
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ATTACHMENT B
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ATTACHMENT B
SUPPLEMENTARY STRENGTH REQUIREMENTS
The following additional requirements will be required when compliance withAttachment B is required by the Purchase Order.
Additional Requirements
The mean transverse yield strength shall be greater than or equal to SMYS plus two
standard deviations of the transverse yield strength distribution.
The mean transverse tensile strength shall be greater than or equal to SMTS plus threestandard deviations of the transverse tensile strength distribution.