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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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    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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    Specification No. 8791/09-LP1-SMLS

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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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    Specification No. 8791/09-LP1-SMLS

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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.


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