Deep Panuke

Deep Panuke

02U 2008 Jan 09 Issued for Use John H. Gillis Bruce Pulsifer Alvin Alleyne

01U 2008-Dec 17 Issued for Use John H. Gillis Bruce Pulsifer Alvin Alleyne

Rev Date Reason for Issue Prepared Checked Approved Approved Title

Specification for Submerged ARC Welded (SAWL) Line Pipe

DM EN -O22 -SP -PL -92 -0001 02U Project Originator Location Type Disc System No. Sheet Rev

This document is property of EnCana Corporation who will safeguard its rights according to the civil and penal provisions of the law

Specification for Submerged ARC Welded (SAWL) Line Pipe Deep Panuke

DMEN-O22-SP-PL-92-0001.02U of 46

REVISION LIST

REVISION DESCRIPTION OF CHANGES

01U Issued for Use 02U Issued for Use (temperature change from minus 45°C to minus 46°C)

HOLDS AND INPUT STATUS

HOLD No. ACTION REMARKS


DMEN-O22-SP-PL-92-0001.02U of 46

CONTENTS

ABBREVIATIONS............................................................................................................5

1 INTRODUCTION ....................................................................................................6

1.1 GENERAL.......................................................................................................................... 6 1.2 SCOPE OF WORK .............................................................................................................. 6 2 CODES AND STANDARDS ...................................................................................6

2.1 GENERAL.......................................................................................................................... 6 2.2 AMERICAN PETROLEUM INSTITUTE STANDARDS (API) ........................................................ 7 2.3 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ............................................... 7 2.4 AMERICAN SOCIETY FOR NON-DESTRUCTIVE TESTING (ASNT) .......................................... 7 2.5 BRITISH STANDARDS INSTITUTION (BSI) ............................................................................ 7 2.6 DET NORSKE VERITAS (DNV)............................................................................................ 7 2.7 INTERNATIONAL STANDARDS ORGANIZATION (ISO) ............................................................ 8 2.8 AMERICAN SOCIETY FOR MECHANICAL ENGINEER (ASME)................................................. 8 2.9 CANADIAN STANDARD ASSOCIATION (CSA) ....................................................................... 8 2.10 EURONORM ...................................................................................................................... 8 3 GENERAL REQUIREMENTS.................................................................................8

3.1 QUALITY ASSURANCE AND CONTROL ................................................................................. 8 3.2 INSTALLATION AND SERVICE CONDITIONS .......................................................................... 9 4 PROCESS OF MANUFACTURE AND MATERIAL ..............................................10

4.1 GENERAL........................................................................................................................ 10 4.2 STEEL AND PLATE MANUFACTURING PROCEDURE VARIABLES .......................................... 11 4.3 CHEMICAL PROPERTIES AND TESTS................................................................................. 12 4.4 CHEMICAL ANALYSIS REQUIREMENTS .............................................................................. 12 4.5 WELDING CONSUMABLES ................................................................................................ 13 4.6 RESIDUAL MAGNETISM .................................................................................................... 14 5 MECHANICAL PROPERTIES AND TESTS .........................................................15

5.1 TENSILE TESTS ............................................................................................................... 15 5.2 HARDNESS TESTS........................................................................................................... 15 5.3 CHARPY IMPACT TESTS................................................................................................... 16 5.4 DROP WEIGHT TEAR TEST (DWTT)................................................................................. 17 5.5 GUIDED BEND TESTS ...................................................................................................... 17 5.6 CTOD TESTING .............................................................................................................. 17 5.7 RETESTS ........................................................................................................................ 17 6 HYDROSTATIC TESTING....................................................................................20

6.1 MILL PRESSURE TEST ..................................................................................................... 20 6.2 CALIBRATION .................................................................................................................. 20


DMEN-O22-SP-PL-92-0001.02U of 46

7 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND FINISHES....................20

7.1 GENERAL........................................................................................................................ 20 7.2 DIAMETER....................................................................................................................... 20 7.3 WALL THICKNESS............................................................................................................ 20 7.4 WEIGHTS ........................................................................................................................ 21 7.5 LENGTHS ........................................................................................................................ 21 7.6 STRAIGHTNESS ............................................................................................................... 21 7.7 PIPE END PREPARATION AND END SQUARENESS ............................................................. 21 7.8 OUT-OF-ROUNDNESS ...................................................................................................... 21 7.9 LONGITUDINAL SEAM WELDS........................................................................................... 22 7.10 ADDITIONAL QUALITY REQUIREMENTS ............................................................................. 22 8 QUALITY CONTROL REQUIREMENTS ..............................................................23

8.1 GENERAL........................................................................................................................ 23 8.2 VISUAL INSPECTION......................................................................................................... 23 8.3 DIMENSIONAL INSPECTION............................................................................................... 24 8.4 MILL SURVEILLANCE........................................................................................................ 24 9 NON DESTRUCTIVE TESTING (NDT) ................................................................25

9.1 GENERAL........................................................................................................................ 25 9.2 NDT OF PLATES.............................................................................................................. 25 9.3 AUTOMATED ULTRASONIC TESTING OF LONGITUDINAL WELD SEAM.................................. 25 9.4 RADIOGRAPHIC TESTING ................................................................................................. 28 9.5 OTHER ULTRASONIC TESTING ......................................................................................... 29 9.6 MAGNETIC PARTICLE TESTING......................................................................................... 30 9.7 LIQUID PENETRANT TESTING ........................................................................................... 31 9.8 OTHER ACCEPTANCE LIMITS............................................................................................ 31 9.9 PERSONNEL QUALIFICATIONS .......................................................................................... 31 10 WORKMANSHIP AND DEFECT REPAIR ............................................................31

10.1 WORKMANSHIP ............................................................................................................... 31 10.2 REPAIR OF DEFECTS ....................................................................................................... 32 11 LINE PIPE MARKING...........................................................................................33

12 COATING FOR TEMPORARY PROTECTION.....................................................33

APPENDIX A - MANUFACTURING PROCEDURE QUALIFICATION ..........................33

APPENDIX B: MEASUREMENT OF RESIDUAL MAGNETISM....................................41

APPENDIX C - LINE PIPE DATA SHEET .....................................................................43


DMEN-O22-SP-PL-92-0001.02U of 46

ABBREVIATIONS Acronym Definition AUT Automatic Ultrasonic Testing BOF Basic Oxygen Furnace CLR Crack Length Ratio COMPANY Encana CSR Crack Sensitivity Ratio CTOD Crack Tip Opening Displacement CTR Crack Thickness Ratio DWTT Drop Weight Tear Test FL Fusion Line HAZ Heat Affected Zone ID Internal Diameter JCOE Pipe Forming Sequence KIC Plane Strain Fracture Toughness LRF Ladle Refining Furnace May Indicates possible course of action MDT Minimum Design Temperature MIP Manufacturing and Inspection Plan MPQT Manufacturing Procedure Qualification Test MPS Manufacturing Procedure Specification MUT Manual Ultrasonic Testing NDT Non-Destructive Testing OD Outside Diameter OOR Out Of Roundness Pcm Cracking Parameter PQT Procedure Qualification Testing QCP Quality Control Plan SAW Submerged Arc Welding SAWL Longitudinally Submerged Arc Welding Shall Indicates mandatory requirement Should Indicates preferred course of action SMAW Shield Metal Arc Welding SUPPLIER The Party, which manufactures and/or supplies material, equipment,

and services to perform the duties as specified in the scope of supplyTMCP Thermo-Mechanical Control Process UOE Pipe Forming Sequence UT Ultrasonic Testing VO Vacuumed Degassed Will Indicates an intention of action WT Wall Thickness


DMEN-O22-SP-PL-92-0001.02U of 46

1 INTRODUCTION

1.1 General This Specification defines the minimum technical requirements for the manufacture, inspection and testing of double submerged arc, single seam, longitudinally welded SAWL 450 grade carbon steel line pipe suitable for non-sour service for nearshore, onshore and offshore pipeline on the Deep Panuke Development.

This Specification shall be read in conjunction with DNV-OS-F101 2000 supplemented by CAN/CSA Z245.1. DNV-OS-F101 requirements shall apply unless otherwise stated in This Specification.

1.2 Scope of Work

This Specification supplements DNV-OS-F101 2000 and CAN/CSA Z245.1 requirements for line pipe material and is applicable to SAWL 450 I FU grade pipe, dual certified to API 5L X65 PSL 2 according to API 5L Ed. 2004.

The line pipe shall be manufactured in accordance with requirements of DNV-OS-F101 January 2000 and as supplemented by This Specification, including appendices and purchase order. The vendor’s quotation in conformance with This Specification and supplements shall constitute their agreement to meet all of the requirements in the specification.

The quotation shall state if the order will be distributed between more than one SUPPLIER. If a SUPPLIER has more than one mill in a given location, the quote shall specify which one(s) will be used for this order.

2 CODES AND STANDARDS

2.1 General The latest issue of the following codes, standards and regulations shall form part of This Specification. In the event of conflict between This Specification and other specifications, data sheets, applicable codes or references, written clarification shall be sought from COMPANY before proceeding with the work.

SUPPLIER shall be responsible for the quality of materials, workmanship, and compliance with the requirements of legislative authorities, guidance notes and specifications.

The following codes, standards and specifications are referred to or are the basis of some of the requirements in This Specification. However, the requirements in this Specification are generally in accordance with those in DNV-OS-F101 as supplemented by CAN/CSA Z245.1.


DMEN-O22-SP-PL-92-0001.02U of 46

2.2 American Petroleum Institute Standards (API) API 5L Specification for Line Pipe API Q1 Specification for Quality Programs API 1104 Standard for Welding Pipelines and Related Facilities API 5L1 Recommended Practice for Railroad Transportation of Line Pipe API RP 5LW Recommended Practice for Transportation of Line Pipe on Barges

and Marine Vessels API RP 5L3 Recommended Practice for Conducting Drop-Weight Tear Tests on

Line Pipe API BUL 5TI Bulletin on Non-Destructive Testing/Terminology

2.3 American Society for Testing and Materials (ASTM)

ASTM A370 Mechanical Testing of Steel Products ASTM A435 Specification for Straight-Beam Ultrasonic Examination of Steel

Plates ASTM A577 Ultrasonic Angle-Beam Examination of Steel Plates ASTM A578 Straight Beam Ultrasonic Examination of Plain and Clad Steel Plates

for Special Applications ASTM A841 Steel Plates for Pressure Vessels Produced by the Thermo-

Mechanical Control Process (TMCP) ASTM E9 Standard Test Method for Compression Testing of Metallic Materials

at Room Temperature ASTM E92 Test Method for Vickers Hardness of Metallic Materials ASTM E273 Standard Practice for Ultrasonic Examination of the Weld Zone of

Welded Pipe and Tubing ASTM E709 Standard Guide for Magnetic Particle Examination ASTM E747 Standard Practice for Design, Manufacture and Material Grouping

Classification of Wire Image Quality Indicators (IQI) Used for Radiology

ASTM E1032 Standard Method for Radiograph Examination of Weldments

2.4 American Society for Non-Destructive Testing (ASNT)

ASNT SNT- TC-1A 1996

Recommended Practice for Personnel Qualification & Certification in Non-Destructive Testing

2.5 British Standards Institution (BSI)

BS 709 Methods of Destructive Testing Fusion Welded Joints and Weld Metal in Steel

BS 7448-1 Fracture Mechanics Toughness Tests - Part 1: Method for Determination of KIC, Critical CTOD and Critical J Values of Metallic Materials

2.6 Det Norske Veritas (DNV)

DNV-OS-F101 Submarine Pipeline Systems – January 2000


DMEN-O22-SP-PL-92-0001.02U of 46

2.7 International Standards Organization (ISO)

ISO 148 Steel – Charpy Impact Test (V-Notch) ISO 3183, Parts 1 to 3

Petroleum and Natural Gas Industries – Steel Pipe for Pipelines – Technical Delivery Conditions

ISO 6507-1 Metallic Materials – Vickers Hardness Test – Part 1: HV5 to HV10 ISO 6892 Metallic Materials - Tensile Testing at Ambient Temperature ISO 9001/9002 Quality Management Systems ISO 9015 Destructive Tests on Welds in Metallic Materials-Hardness Testing

2.8 American Society for Mechanical Engineer (ASME)

ASME B31.8 Gas Transmission and Distribution Piping Systems.

2.9 Canadian Standard Association (CSA)

CAN/CSA Z245.1 Steel Pipe

2.10 Euronorm

EN 10204 Metallic Products – Types of Inspection Documents

3 GENERAL REQUIREMENTS

3.1 Quality Assurance and Control

After Contract award, SUPPLIER shall submit the following documents to COMPANY for review and approval:

• Quality Manual • Production Schedule • Manufacturing Procedure Specification (MPS) • Manufacturing and Inspection Plan (MIP) • Manufacturing Data Sheets

- Steelmaking and Casting Data Sheet (Mill Sheet) - Plate Rolling Data Sheet - Pipe Manufacturing Data Sheet

• Welding Procedure Specification/Qualification Records • Defect Repair Procedures/Qualification Records • Manufacturing Procedure Qualification • NDT Procedures • Hydrostatic Test Procedure • Sampling and Testing Procedures • Plate and Pipe Traceability Procedures • Pipe Handling, Loading, Transportation, and Packing Procedures


DMEN-O22-SP-PL-92-0001.02U of 46

The following documents shall be submitted at the bid stage:

• Quality Manual • Production Schedule (preliminary) • Manufacturing Procedure Specification (MPS) (preliminary) • Manufacturing and Inspection Plan (MIP) (preliminary) • Manufacturing Data Sheets (steel making, plate rolling) (preliminary) • Welding Procedure Specification (preliminary) • NDT Procedures (preliminary) • Production statistics from previous similar pipe production

SUPPLIER shall have a certified Quality System implemented in accordance with ISO 9001-2000.

SUPPLIER shall be currently licensed to use the API monogram for API 5L products.

The Quality Manual shall show the organization and methods of the quality assurance and quality control systems employed by the SUPPLIER for manufacture and supply of the line pipe.

All testing and inspection activities shall be indicated in the Manufacturing and Inspection Plan, which must be approved by COMPANY prior to the start of production.

A system for traceability of the heat number and the records from all required tests to each individual pipe is to be detailed in a written procedure. Care shall be exercised during storage and handling to preserve the identification of materials.

Three (3) copies of the documentation requirements, stated in DNV-OS-F101, Section 3, Clause F300, shall be submitted to COMPANY, for review and approval. The final report including required documentation, format (hardcopy, pdf, etc.) will be advised by COMPANY at a later date.

Pipe tracking data (tally sheet) shall be in excel format by ascending pipe number and shall include pipe number, size, weight, height, length, heat number and shipping identifier.

Heat tracking data shall be in excel format and shall include heat number, chemical composition, Pcm, calcium to sulfur ratio and derived mechanical properties.

3.2 Installation and Service Conditions

The line pipe to be supplied in accordance with this Specification shall be SAWL 450 I FU as per DNV-OS-F101, dual certified to API 5L X65 PSL 2 according to API 5L Ed. 2004.

The line pipe supplied in accordance with this Specification will be used for the construction of offshore pipeline and for onshore pipeline using traditional cross country construction methods.

The contents of the pipe will be lean hydrocarbon gas.

The line pipe shall comply with NDT Level I as per DNV-OS-F101, Section 6, Clause B100.

The line pipe shall meet the following Supplementary Requirements of DNV-OS-F101, Section 6, Clause B200:

• Fracture arrest properties, suffix F • High utilization, suffix U


DMEN-O22-SP-PL-92-0001.02U of 46

4 PROCESS OF MANUFACTURE AND MATERIAL

4.1 General

All manufacture shall be carried out in accordance with a pre-qualified Manufacturing Procedure Specification (MPS) and Quality Control Plan (QCP) produced by the SUPPLIER as stated in DNV-OS-F101, Section 6, Clause E301, and approved by the COMPANY. Manufacturing Procedure Qualification Test (MPQT) requirements are in Appendix A.

Essential variables for the manufacturing process shall be:

• Steelmaking and casting route • Plate rolling sequence, including temperature ranges • Chemical composition • Mechanical expansion ratio • Welding Procedure Specification • Plate Mill • Pipe Mill

Modification of established and qualified essential variables shall not be allowed during pipe production without appropriate COMPANY approved re-qualification.

The steel shall be made by the Basic Oxygen Process. The steel shall be fully killed and made to fine grain practice and desulfurized. Details of the inclusion shape control treatment shall be given in the MPS.

Slabs shall be produced by the continuous casting process, with precautions to avoid centerline segregation. The methods for mitigating and monitoring segregation shall be included in the MPS. All slab surfaces shall be free of injurious defects and shall be suitable for producing plate for manufactured of coated line pipe.

All plates shall be supplied using the thermo-mechanical control process (TMCP). The TMCP definition refers to the use of properly instrumented controlled rolling practices, followed by air cooling or water cooling. Water-cooling may be interrupted or followed by tempering. No skelp (plate) in the plate mill shall be die stamped.

Pipes shall be fabricated using the JCOE, UOE, or three roll bend process, and shall be single seam longitudinally double submerged arc welded (SAWL). A low hydrogen process may be used for tack welding. Tack welds must be completely remelted by the submerged arc welding process.

Pipes shall be mechanically cold expanded provided that the fiber strain due to expansion shall not exceed 1.5% determined from the average pipe diameters measured before and after expansion in accordance with DNV-OS-F101, Section 6, Clause E606.

SUPPLIER shall submit production statistics from previous pipe production of similar size, type, grade, chemical composition and showing histograms of chemical, mechanical, toughness properties and geometrical parameters distributions through the production. If no such experience or data exists, the SUPPLIER shall explicitly state this in his proposal.


DMEN-O22-SP-PL-92-0001.02U of 46

4.2 Steel and Plate Manufacturing Procedure Variables

The following information shall be included in the MPS supplied with the SUPPLIER bid documentation. Bid proposals that fail to follow the requirements listed below will not be considered.

• Specific steel production facility and plate rolling mill. • Specific steel making method or melting practice (BOF-LRF-VD, etc.), nominal proportions of

scrap (by designated scrap grade) and hot metal charge, nominal weight of heat, and any hot metal treatment (degassing, desulfurization, sulfide shape control, etc.) and details of slag free tapping practices.

• Chemical composition control ranges and specific aimed composition (including limits on residual elements) for heat and product analysis.

• Casting details including usage of argon shrouding methods and implementation of soft reduction further down the strand.

• Segregation control procedures and segregation quality control procedures (macro-etching or phosphorus print of slab cross sections) and normal testing frequency for strand-cast product.

• Note: Sulfur printing is not an acceptable method for monitoring internal quality when sulfphur content, as measured during the heat analysis, is equal or less than 0.005%.

• Slab thickness, width and weight and relationship to final plate thickness. • Hydrogen flake control methods (bake-out, slow cool, stack, etc.), if applied. Indicate hydrogen

content in melt, slab and product. • Slab reheat temperature and time and computer control of process. • Roughing mill start and finish temperature and total reduction. • Finishing mill, controlled rolling start and finish, accelerated cooling start and finish temperatures,

and control range (including reduction sequence with associated rolling temperatures). • Total reduction in the finishing mill or during controlled rolling. • Cross rolling ratio. • Mother plate size (single or double length, single or double width). • Tubular forming methods including estimate of normal ID and OD fiber strain imparted during

forming operations and expansion. • Longitudinal seam-welding technique, seam tracking procedure, welding parameters (amperage,

voltage, travel speed, and heat input), consumables (wire size, wire and flux manufacturer and brand name), flux handling, and all other essential variables as defined in the applicable welding code or standard.

• Methods of non-destructive testing, cold expansion and hydrotest.


DMEN-O22-SP-PL-92-0001.02U of 46

4.3 Chemical Properties and Tests

A ladle analysis shall be made on each heat of steel.

A product analysis of both pipe body and weld metal shall be made on each heat or each batch of fifty (50) pipes, which ever is the most frequent. Sample locations shall be 1/4 WT or 3/4 WT rather than the pipe surface. Analysis shall be performed and reported for all elements covered by This Specification and the MPS. The Pcm value of the weld metal shall not exceed 0.22.

Ladle and product analyses shall meet the requirements of Section 4.4 of this Specification.

The Pcm value as defined below and by product analysis shall meet the values specified in Section 4.4 of this Specification.

BVMoNiCrCuMnSiCPcm 51015602030

++++++

++=

All elements listed in Section 4.4 shall be measured and reported for each product analysis required by This Specification. This requirement applies to both residual and intentionally added elements.

4.4 Chemical Analysis Requirements

The composition of each heat shall comply with the following requirements. SUPPLIER shall propose an aimed chemical composition, which shall be subject to COMPANY’s approval. Once qualified, the aimed chemical composition shall be considered a guaranteed composition for the production.

Table 4-1: Product Chemistry Requirements

Element Product Analysis Max, Weight % / Steel Grade 450

Carbon (range) 0.04 – 0.10 Manganese 1 1.65

Silicon 0.35 Phosphorus 0.020

Sulfur 0.002 Nitrogen 0.010

Aluminum (range) 0.015 – 0.050 Nickel 0.30

Molybdenum 0.10 Chromium 0.30

Copper 0.35 Vanadium 0.05 Niobium 0.04

Titanium 2 0.025


DMEN-O22-SP-PL-92-0001.02U of 46

Table 4-1: Product Chemistry Requirements

Element Product Analysis Max, Weight % / Steel Grade 450

Calcium3 0.006 Boron 0.0005

Carbon Equivalent 0.40 Pcm 4 0.21

V + Nb + Ti 0.12 Al/N 5 ≥ 2.0

Notes: 1. Increases in manganese based on carbon reduction not permitted. 2. Ti is added to control grain growth, Other methods are subject to company approval.3. Inclusion shape control not required for this sulfur level. 4. Pcm shall not exceed the Pcm of MPQT by more than 0.03 and C by more than

0.02%. 5. Not applicable to Ti killed, low Al steels. 6. No intentional additions of boron, antimony, lead, tin, arsenic, bismuth are allowed.

4.5 Welding Consumables

Chemical Analysis - SUPPLIER shall specify the chemical composition of welding wires and electrodes within a range more restrictive than the nominal variation used by the consumable manufacturers to ensure consistent weld mechanical properties. The chemical compositions shall be attached to each applicable Welding Procedure Specification, and shall be provided for COMPANY review and approval.

Mechanical Properties - Welding consumables mechanical properties shall be certified for each batch, with the exception of welding wires and fluxes which might be certified based on their chemical compositions if these are considered strict enough to guarantee weld properties as specified and proven during qualification program. SUPPLIER shall provide Material Test Report(s) in compliance with EN 10204, Inspection Type 3.1.

Handling - SUPPLIER shall adopt welding consumables handling procedures, which shall ensure that moisture pick-up does not occur. The flux handling procedure shall include a moisture check to ensure low hydrogen welds are achieved, i.e., lower than 5 ml/100 g of weld metal. Welding consumables handling procedures shall be provided together with the Welding Procedure Specifications.

Maximum residual moisture content shall not exceed 0.05% for agglomerated type flux. Higher residual moisture contents are acceptable for fused type fluxes. The maximum acceptable residual moisture content shall be established as follows:

1. Perform diffusible hydrogen measurement by the glycerine method, with an acceptance criteria of 4 mg/100 g of weld metal for each of the MPQT and the SAW PQR, as follows:

a. MPQT (re. Appendix A, A.1, A.2, and A.3): to be performed once per MPQT in the order, unless MPS variables listed in A.1 are modified, on at least the first 20 pipes.

• Diffusible hydrogen to be measured by glycerine test on one ID welding line and on one OD welding line.


DMEN-O22-SP-PL-92-0001.02U of 46

o If diffusible hydrogen is not over 4 mg/100 g, the test is passed.

o If diffusible hydrogen is greater than 4 mg/100 g, but not over 5 mg/100 g, manual UT after 48 hours shall be performed on all MPQT pipes (at least 20 pipes, plus all pipes welded in the same shifts).

o If diffusible hydrogen exceeds 5 mg/100 g, the test is failed: flux handling procedure to be reviewed and new MPQT to be performed. In addition, manual UT after 48 hours shall be performed on all pipes welded prior to modifications to flux handling procedure.

• SAW flux moisture shall be checked on all welding lines /all shifts related to MPQT (at least 20 pipes, plus all pipes welded in the same shifts) and shall not exceed 0.05%.

b. SAW PQR (re. Appendix A, A.4): to be performed at least on each WT, unless WPS variables listed in A.5 are modified, on one pipe. On first day, one of MPQT pipes may be used for PQR, without duplication of testing. Same tests on weld as per MPQT, including diffusible hydrogen and SAW moisture check, as follows:

• Diffusible hydrogen to be measured by glycerine test on the same ID welding line and OD welding line of PQR pipe.

o If diffusible hydrogen is not over 4 mg/100 g, the test is passed.

o If diffusible hydrogen is greater than 4 mg/100 g but not over 5 mg/100 g, manual UT after 48 hours shall be performed on all pipes welded in the same shift.

o If diffusible hydrogen exceeds 5 mg/100 g, the test is failed: flux handling procedure to be reviewed and new PQR to be performed. In addition, manual UT after 48 hours shall be performed on all pipes welded prior to modifications to flux handling procedure.

• SAW flux moisture shall be checked on all welding lines used in the same shift as PQR pipe, and shall not exceed 0.05%.

c. Production Control: During production, manual UT after 48 hours from welding shall be performed on one pipe/shift, using a 45° probe located on top of the weld. If chevron cracks are detected, manual UT shall be extended to all pipes welded in the affected shift, plus all pipes in the previous and following shifts, stopping only when a shift completely free from chevron cracking is recorded.

No further hydrogen diffusible measurement, nor SAW moisture check is required, unless a new MPQT or PQR are necessary.

SUPPLIER shall submit flux processing and handling procedures for COMPANY review and approval.

4.6 Residual Magnetism

The maximum residual magnetism value of the finished pipe shall not exceed 20 gauss. Residual magnetism shall be measured using the procedures specified in Appendix B.


DMEN-O22-SP-PL-92-0001.02U of 46

5 MECHANICAL PROPERTIES AND TESTS

All tests specified shall be more stringent or equal to DNV-OS-F101 and supplements for, fracture arrest properties (F) and high utilization (U), unless stated otherwise in this Specification and shall be performed on finished pipe. All the tests shall be carried out on bare material and weld seam.

Sampling procedure shall be proposed by SUPPLIER for approval. COMPANY, in any case, reserves the right to select the pipes to be tested and to witness the tests.

Final samples shall have machined surfaces. Where thermal cutting has been used to remove pipe coupons from which test specimens are prepared, the full extent of the heat affected region shall be removed during final machining.

Test frequency, unless otherwise stated, shall be one pipe out of a lot of fifty (50) produced pipes or one pipe per heat, whichever is smaller. Informative system (computer guarantee) for completeness of sampling plan and ITP shall be maintained. Additional testing under request of inspector may be agreed (however, for example, Material Test Certificates and pipe selection management are still based on computer controlled testing.) SUPPLIER confirms no additional cost for a reasonable number (i.e. 50) of extra tests. Summary of the required tests is in Table 5-1.

5.1 Tensile Tests

Full thickness longitudinal and transverse tensile test specimens shall be in accordance with DNV-OS-F101 and ISO 6892, and taken from finished pipe at 90° from the weld seam. Full thickness ISO proportional strip specimens shall be used for both longitudinal and transverse tests.

Tensile test requirements are given in Table 5-1.

Table 5-1: Yield and Tensile Strength Requirements

Yield Strength MPa (ksi)

Ultimate Tensile Strength MPa (ksi) Steel

Grade Direction Min Max Min Max

YS/UTS*Maximu

m Transverse 450 (65) -- 535 (77.5) -- 0.90

450 Longitudinal 450 (65) 550 (80) 535 (77.5) -- 0.93

The minimum elongation for gauge length shall be not less than 20%.

The requirements of DNV-OS-F101, Section 6, Clause D500, supplementary requirement, high utilization (U) shall be applied. If the results from the mandatory testing meet the requirement SMYS x 1.03, no further testing is required, otherwise the re-test program given in DNV-OS-F101 Section 6, Clause D508 shall apply.

Stress/strain curves in longitudinal and transverse directions shall be recorded during the procedure qualification testing.

5.2 Hardness Tests

One macrosection shall be cut from one end of each pipe selected for testing. It shall be suitably prepared to allow hardness determinations to be made, as shown in Figures 5.1 and 5.2.

The hardness tests shall be made in accordance with ISO 6507-1.


DMEN-O22-SP-PL-92-0001.02U of 46

The hardness level shall be not greater than 240 HV10 for the base metal, weld metal and HAZ. Distance between readings shall be in accordance with ISO 9015.

5.3 Charpy Impact Tests

Charpy V-notch impact testing shall be performed in accordance with the requirements DNV-OS F101 and ISO 148, on specimens taken from the root area 2 mm below the surface ID, with the notch in the following locations:

• Parent Plate, mid-wall • Weld Centre Line • Weld Fusion Line • Weld Fusion Line + 2 mm • Weld Fusion Line + 5 mm

Testing can be reduced during production after MPQT have shown the weakest locations to be selected for production tests. As a minimum, weld metal centerline, FL, FL + 2 mm, FL + 5 mm, and base metal shall be tested during production. Full Charpy V-notch transition curves for base material are not required during production testing.

Only full size Charpy specimens shall be used for qualification and production testing. The notch line shall be cut through the pipe thickness. All specimens shall be transverse to the pipe axis. Specimen sampling in the weld fusion line area shall be as per Figure 5-3.

The Charpy impact energy values shall be 150 J average and 120 J minimum for base material at minus 46°C .

The Charpy impact energy for the weld and heat affected zone shall be determined at minus 46°C. The minimum energy values shall be:

Charpy V-Notch Energy Testing Temperature Steel Grade MPa

(ksi) Average J

(ft-lbs) Minimum J

(ft-l;bs) °C

(°F)

450 (65) 60 (44) 45 (33) minus 46°C


DMEN-O22-SP-PL-92-0001.02U of 46

5.4 Drop Weight Tear Test (DWTT)

For qualification (MPQT), as described in Appendix A, fourteen DWTT specimens (seven sets) shall be tested in accordance with DNV-OS-F101 Section 6, Clause D204, and including two sets shall be tested at the MDT, to produce the full ductile brittle transition curve. These test temperatures may be adjusted by SUPPLIER, if necessary, to produce the full ductile brittle transition curve. The test temperature which corresponds to 85% shear shall be reported to COMPANY. Each set shall be taken from the same joint.

For production, (a set) shall be tested at -15°C (5°F) and taken from one length of pipe from every other heat supplied on the order. The test shall be performed in accordance with DNV-OS-F101, Appendix B, Clause A700. The specimen shall meet an average of 85% shear area with a minimum value of 75%.

5.5 Guided Bend Tests

For each pipe wall thickness, guided bend test in accordance with API 5L shall be carried out during qualification and production. Acceptance criteria shall be as specified in API 5L, Paragraph 9.8.3.

5.6 CTOD Testing

For qualification (MPQT) as defined in Appendix A, CTOD tests shall be performed on current pipe, weld metal and HAZ. The minimum CTOD requirement is 0.25 mm (0.009-inch) at minus 15°C (5°F).

5.7 Retests

If any pipe fails to conform to the specified requirements of Section 5, retest of two pipes from the same test lot shall be conducted. Before performing the retest, the SUPPLIER shall provide to COMPANY documented information on the origin and extent of the nonconformance (Nonconformance Report).

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

If test results are influenced by improper sampling, machining, preparation, treatment of testing, the test sample or specimen, as relevant, is to be replaced by a correctly prepared sample or specimen and a retest performed.


DMEN-O22-SP-PL-92-0001.02U of 46

Figure 5-1: Positions for Hardness Measurements – Base Metal

Notes: 1. "•" marks the indentation location. 2. The indents in the HAZ and Parent Material shall be 0.75 mm apart

respectively. The first indent in the HAZ shall be as close to the fusion line as possible.

3. Hardness survey through the thickness of the parent plate. First 5 indents from surface shall be 1 mm apart, then every 2 mm (not shown on the figure).

Figure 5-2: Positions for Hardness Measurements – Weld Metal


DMEN-O22-SP-PL-92-0001.02U of 46

Figure 5-3: Positions for CV Specimens Sampling In Weld

Fusion Line Area

Table 5-2: Welded Line Pipe – Mechanical Testing

Type of Test Location Test Requirements Longitudinal, Pipe Body Q and P Transverse, Pipe body Q and P Tensile Test

Weld Q and P Pipe Body Q and P Charpy V-notch Test

Weld Q and P Drop Weight Tear Test (DWTT) Pipe Body Q and P

Bend Test Weld Q and P Pipe Body Q and P Hardness Test

Weld Q and P Macro Examination Weld Q and P CTOD Test Pipe Body and Weld Q Notes: Q = Tests required for Qualification of the MPS P = Tests required during Production


DMEN-O22-SP-PL-92-0001.02U of 46

6 HYDROSTATIC TESTING

6.1 Mill Pressure Test

Each length of pipe shall be hydrostatically tested considering end effect as per DNV-OS-F101. Section 6, Clause E1100. The holding time at test pressure shall be minimum 10 seconds as per DNV-OS-F101, Section 6, Clause E1106. All test records shall be retained on file. Ram end loading calculations shall be submitted by SUPPLIER for COMPANY review and approval.

6.2 Calibration

All test equipment shall be calibrated to the satisfaction of COMPANY. Hydrostatic test pressure shall be verified using the working gauge calibrated against the check gauge at least once per shift. The check gauge shall be calibrated against the master (dead weight) gauge at least once per week. Each hydrotest shall be recorded on a chart, with date, test pressure, test duration and pipe number.

7 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND FINISHES

7.1 General

Dimensional, weight, length, defect and finish requirements shall be measured and checked in accordance with the COMPANY’s approved procedures and DNV-OS-F101.

7.2 Diameter

Dimensional tolerances on internal diameter over a length of 100 mm from each pipe end shall not exceed +/- 1.2 mm from the nominal internal diameter. Diameter tapes shall be used for measuring pipe diameters 508 mm (20-inch) and greater.

Note: Nominal ID = Nominal OD - 2 x Nominal WT

Check of pipe body diameter shall be performed on 10% of pipes, and if it is found out of tolerance, then each pipe shall be checked over its full length until the problem has been resolved.

7.3 Wall Thickness

Both ends of each pipe shall be checked for thickness with a limit gauge. Specified thickness shall be guaranteed along the length of the finished pipe. Wall thickness on pipe body shall be verified and recorded five pipes per shift along the length by a method to be agreed upon, at a minimum of three positions around the circumference, both sides of the weld, and 180° from the weld. Wall thickness at pipe ends shall be checked at each end (by caliper), at a minimum of three positions around the circumference, both sides of the weld, and 180° from the weld, and recorded five pipe per shift.

Wall thickness at any place, including defect areas shall be within ± 1.0 mm of the specified nominal wall thickness.


DMEN-O22-SP-PL-92-0001.02U of 46

7.4 Weights

Each pipe shall be within -3.5% /+ 10% of the calculated weight for any pipe. The weight of each pipe shall be recorded in the pipe tally by pipe number and included in the stencil markings.

7.5 Lengths

The pipes shall be supplied in lengths of 11.70 m to 12.5 m, with an average length between 12.1 m and 12.3 m. Eighty percent (80%) of the pipes shall have individual lengths between 12.1 m and 12.45 m. A maximum of 5% of the pipe may be in the range of 11.7 m to 11.9 m.

7.6 Straightness

The deviation from a straight line shall not exceed 0.15% of the length.

7.7 Pipe End Preparation and End Squareness

Pipe ends shall be beveled with angle 15° -0° / +5° and root face 2 mm + 1 mm and incorporate end protectors. The out of squareness is to be measured on three pipes per shift and shall meet the requirements of DNV-OS-F101, Section 6, Table 6-14.

7.8 Out-of-Roundness

Out-of-roundness measured at any point along the pipe body shall be ± 1.5%, and measurements shall be performed on a random basis.

Out-of-roundness over a length of 100 mm (4 in) from each end, measured internally, shall not exceed 1% with a maximum of 5 mm.

Out-of-roundness shall be defined as:

100%D

DDOoR

nominal

minmax ×−

=

OoR = Out of roundness in percent Dmax = The greatest measured inside or outside diameter Dmin = The smallest measured inside or outside diameter Dnominal = The specified nominal outside diameter

The out-of-roundness shall be measured using a rod type gauge/external caliper to determine the actual minimum and maximum internal diameter. As a minimum, all pipe ends shall be measured at four locations in the same plane within the 100 mm (4 in) from the pipe ends. The use of a diameter tape is not allowed. Measurements shall be recorded at a frequency of five pipes per shift.


DMEN-O22-SP-PL-92-0001.02U of 46

7.9 Longitudinal Seam Welds

Reinforcement of the inside and outside weld seam shall fall within the range of 0.5 mm to 4.5 mm. Transition to the base material shall be smooth. Weld bead height shall be checked and recorded at a frequency of 10% of pipes per shift.

The reinforcement of the internal weld seam for a distance of at least 150 mm (6-inch) from each pipe end shall be ground to the height of -0.0 to 0.5 mm. The external longitudinal weld seam shall be ground flush with the pipe outside surface to the height of -0.0 to +0.5 mm over 300 mm (12-inch) from the pipe ends to allow for automated ultrasonic examination during installation.

Overlapping of welds shall be no less than 1.0 mm. The radial offset shall be as required by DNV-OS-F101, Section 6, Clause E1211 and Table 6-15. Weld misalignment and offset shall be checked on 10% and recorded on three pipes per shift.

7.10 Additional Quality Requirements

Dents that are deeper than 3 mm or extend in any direction more than 1/4 OD of the pipe outside diameter shall be considered defects. Dents, grooves or gouges with a sharp bottom shall be ground out regardless of size, but shall not reduce the wall thickness below the minimum value allowed in Section 7.3.

Deviation from circularity in the weld area (peaking) shall not exceed 2.0 mm for 200 mm of the arc of the pipe perimeter over a length of 100 mm from each pipe end. Deviation from circularity shall be measured on the internal surface of the pipe using a gauge having a length of 200 mm (8-inch) and a bending radius equal to the nominal pipe inside radius. There shall be no gap between the gauge and the pipe greater than 2.0 mm; otherwise the pipe shall be rejected. At least six pipes per shift shall be measured and values recorded.

Deviation from circularity in the full body of pipe (flatness) shall not exceed 2.0 mm for 200 mm (8-inch) of the arc of the pipe perimeter. Deviation from circularity shall be measured on the external surface of the pipe using a gauge having a length of 200 mm (8-inch) or more and a radius equal to the nominal pipe outside radius. There shall be no gap between the gauge and the pipe greater than 2.0 mm; otherwise the pipe shall be rejected. Measurement shall be taken where indicated by visual inspection.

Weld Linearity - Localized off-seam welds (doglegs) and starved welds are limited to 3.2 mm (1/8-inch) maximum deviation for weld toe linearity. Each pipe shall be inspected visually for weld linearity on the inside and outside surfaces.

When visual inspection indicates a lack of linearity, the deviation from linearity shall be determined by placing a 300 mm (12-inch) long straight edge against the toe of the weld reinforcement so as to straddle the area in question and measuring the perpendicular distance from the side of the straight edge to the weld toe. Any starved weld or dogleg exposing undercut, lack of fill, inadequate penetration, or unmelted bevel is also cause for temporary rejection and shall be gouged/ground out, re-welded, and re-inspected.

Hard Spots - Hard spots shall be defined as areas with hardness greater than 240 HV10. Hard spots of any size shall not be acceptable and repairable only by cut-out.

Arc Burns - Arc burns are defined as localized points of surface melting caused by arcing between electrode or ground and the pipe surface or by arcing from any other source such as electromagnetic inspection equipment. Pipe with any arc burn is not acceptable. If doubt exists as


DMEN-O22-SP-PL-92-0001.02U of 46

to whether a defect is in fact an arc burn, the area may be polished with a wire brush and etched with 5% nital as proof test, or with a COMPANY approved equivalent. Following any such proof testing, the etched area shall be washed.

Repair may be made only by cut-out or grinding. Such repair by grinding shall be in accordance with API 5L with the addition of compliance with the minimum wall thickness requirements of This Specification.

Other Defects - Laminations, seams, undercut cracks or scabs that intersect a weld at any point shall be considered weld defects. Repair shall be made only by cut-out or grinding. All gouges shall be ground out. Gouges with cracks or tears must be removed. The magnetic particle inspection is to be performed only with an AC magnetic yoke; prods shall not be used.

The surface quality of the inside and outside surfaces shall be suitable for the application of internal flow-coating and external protective coating without any further grinding.

The internal and external pipe surfaces shall be free from surface laminations, seams, scabs, weld spatter, slivers, pits, etc. These may be ground out, provided that the remaining wall thickness complies with the minimum wall thickness requirements.

Any surface porosity in the weld constitutes a defect and is repairable by cut-out, grinding, or weld repair.

8 QUALITY CONTROL REQUIREMENTS

8.1 General

The work shall be inspected in accordance with DNV-OS-F101 and the approved Manufacturing and Inspection Plan. This shall include, but not be limited to, the following clauses. The procedure for these examinations shall be included in the MPS for approval by COMPANY.

8.2 Visual Inspection

The entire length of each pipe shall be visually inspected externally and internally for surface defects.


DMEN-O22-SP-PL-92-0001.02U of 46

8.3 Dimensional Inspection

All specified dimensions (in accordance with Section 7) shall be checked at the frequency specified in Table 8-1.

Table 8-1: Frequency of Dimensional Checks

Dimensional Parameter Section Measurement

Frequency (pipes/shift)

Recording Frequency

(pipes/shift) Inside Diameter 7.2 100% 10% Outside Diameter 7.2 10%/100% (a) 10% Wall Thickness at Pipe Ends 7.3 100% 10% Wall Thickness along Pipe Body 7.3 5 5 Weight 7.4 100% 100% Length 7.5 100% 100% Out-of-Roundness at Pipe Ends 7.8 100% 5 Out-of-Roundness along Pipe Body 7.8 10% 5 Peaking 7.10 100% 5 Straightness 7.6 10% 5 Ends Squareness 7.7 10% 3 Weld Bead Height 7.9 10% 10% Weld Misalignment 7.9 10% 3 Radial Offset 7.9 10% 3 (a) According to Paragraph 7.2.

The measurement frequency may be increased up to 100% upon request of COMPANY, if deviations for the specified values occur. The measurement frequency will be reduced to the frequency stipulated in Table 8-1 after consistent acceptable results are obtained. Recording shall include traceability to pipe number.

8.4 Mill Surveillance

COMPANY, its inspection representative(s), and/or the nominated certifying authority shall have the right to monitor the production and testing of the pipe during any stage of manufacture in which the quality of the finished product may be affected.

MANUFACTURER shall notify COMPANY a minimum of five days prior to the start of production. MANUFACTURER shall provide suitable accommodation (office, Internet hook-up, telephone, and fax) for COMPANY, its inspection representative(s), and/or nominated certifying authority.

Unless otherwise specified, an Inspection/ Project Release Note will be provided by COMPANY inspector(s) and/or certifying authority, which identifies acceptance of the pipe.


DMEN-O22-SP-PL-92-0001.02U of 46

9 NON DESTRUCTIVE TESTING (NDT)

9.1 General

All NDT shall be performed in accordance with DNV-OS-F101, Appendix D, and the requirements of This Specification.

NDT Level I in accordance with DNV-OS-F101, Section 5, Clause B500 shall be applied.

All NDT shall be performed in accordance with written procedures meeting all requirements given in DNV-OS-F101, Appendix D, Clauses A500, B202, B302, B402, B502 and D213. NDT procedures shall be subject to COMPANY approval.

Reported indications shall be classified for the type of imperfections. In case the occurrence per type of imperfection would be higher than the agreed mill standard, an investigation shall be agreed and will be carried out by the SUPPLIER under strict control of COMPANY, and quality corrective action shall be taken.

9.2 NDT of Plates

100% automatic ultrasonic inspection of all plates shall be carried out for detection of laminar imperfection through the entire wall thickness in accordance with ASTM A578. ASTM A578 supplementary requirements S1 (100% scanning of plate), S3 (written UT procedure) and S4 (certification of operators) shall apply. Alternative codes may be used with prior COMPANY approval.

All indications with amplitudes greater or equal to 50% of the initial back reflection and accompanied by a 50% loss of back reflection shall be recorded for investigation with manual ultrasonic testing.

Manual ultrasonic testing of the areas reported during automated ultrasonic testing equipment shall cover a square of minimum 250 mm x 250 mm (10” x 10”) centered on the reported indication. The equipment shall be calibrated against maximum 6 mm diameter flat bottom holes, machined 4 mm below each surface and at mid thickness and the DAC curve established with the maximum response set to 80% of full screen height. For dimensional evaluation, the half-value-drop method shall be used.

Acceptance criteria shall be in accordance with DNV-OS-F101, Appendix D, Table D-2, with the following additions:

In the examination of the longitudinal edges, an allowance in the area width shall be made to cover possible oversized plates and later edge milling and end bevelling.

Acceptance criteria for plate edges shall also be valid for the plate ends (i.e., on the future pipe ends).

9.3 Automated Ultrasonic Testing of Longitudinal Weld Seam

100% of all longitudinal weld seams shall be tested by means of an automated scanning device for detection of defects oriented predominantly parallel to and/or at right angles to the weld seam. In both cases, testing shall be carried out in two opposing directions of beam travel.


DMEN-O22-SP-PL-92-0001.02U of 46

The equipment and the documentation thereof shall meet all requirements given in DNV-OS-F101, Appendix D, Sections D and G700.

A full description of the equipment shall be submitted and shall include, as a minimum, the information required by DNV-OS-F101, Appendix D, Clause D213.

The description of the equipment shall state:

• The number and position of probes dedicated for detection of longitudinal defects and the operational mode (pulse-echo and/or through transmission).

• Probes firing sequence • The number of probes dedicated for detection of transverse defects, their orientation given in

degrees relative to the weld axis and the operational mode (pulse-echo and/or through transmission).

• For each probe, the following information shall be provided: - The probe type and dimensions - The frequency - The probe angle - The chosen number of skips - The distance from the weld centerline to the probe index point - The angle between the ultrasound beam direction and the weld axis

Full weld coverage shall be sketched both for longitudinal and transverse inspection, adopting the beam properties documented by the probe Suppliers’ data sheets.

The equipment shall include devices for weld tracking and provide checks of adequate coupling for each individual probe.

The total automated ultrasonic system shall have a documentation of calibration not older than six months at the start of production.

For all probes, the noise shall be at least 8 dB weaker than the signal from the reference reflector (used for sensitivity setting) at the target distance.

9.3.1 Calibration Block

The calibration block shall contain at least the following artificial reflectors sufficiently separated (with a minimum of 150 mm) from each other so that clearly distinguishable signal indications are obtained:

a. 1.6 mm (1/16-inch) diameter through drilled hole at the weld centerline (target)

b. 1.6 mm (1/16-inch) diameter radial drilled holes up to about mid thickness at the weld centerline, inside and outside (targets)

c. 3.0 mm (0.12-inch) diameter side drilled hole parallel to the weld axis at the weld centre (target)

d. N5 notches parallel to the weld at both sides of the weld toe edge, inside and outside (sensitivity setting)

e. 3.0 mm diameter radial drilled holes in the pipe material 10 mm outside the weld toe edge at both sides (gate setting)


DMEN-O22-SP-PL-92-0001.02U of 46

The length of the N5 notch shall be 1.5 times the probe element size or 20 mm, whichever is shorter. The length does not include any rounded corners. The width of the N5 notches shall not exceed 1 mm. Depth shall be 1.5 mm (± 15%).

Additional artificial reflectors and calibration methods may be suggested by the SUPPLIER, if needed, due to the specific equipment set-up.

9.3.2 Static Calibration

The longitudinal outside and inside probes shall be targeted at the A reflector and the sensitivity for all probes shall be set to 80% of FSH of the echo of the D reflector in the area of interest giving the lowest response. The alarm level shall be set 6 dB below the sensitivity level.

The longitudinal weld centre probes shall be targeted at the C reflector and the sensitivity shall be set as the response from the C reflector to 80% of FSH for all probes. The alarm level shall be set 6 dB below the sensitivity level.

The transverse probes shall be targeted at the B reflectors such that the difference in amplitude when the largest echo is set to 80% of FSH is no more than 3 dB. Sensitivity shall be set as 80% of FSH of the echo of the B reflector in the area of interest giving the lowest response. The alarm level shall be set 3 dB below the sensitivity level.

The variation in sensitivity between the probes in any pair shall be minimized.

The echo height from the target and sensitivity reflectors shall be recorded for each probe without any changes to the amplification, soundpath lengths, or position of the probes. All settings, angles, and offsets from the weld centerline to the probe index point shall be recorded for each probe.

During the static calibration, it shall be verified that each A, B, C and D reflector are detected by both probes in the pair covering the area of interest.

The gates for the longitudinal probes only shall start at the near side E reflector and end at the far side E reflector weld center. Only if geometrical echoes from the weld reinforcement exceed the echo from the far side D reflectors, the gate may end at a maximum of 15 mm from the far side E reflector. Full volumetric coverage through the weldment is required.

The documented tolerance of the weld tracking device and the allowed asymmetrical bead shall be considered when setting the gates. All gate settings shall be recorded.

The maximum allowable scanning velocity (VC) shall be determined according to:

VC ≤ WC • PRF/3

where WC is the narrowest –6 dB beam width at the appropriate operating distance of all probes in the array and PRF is the effective pulse repetition frequency per probe.

9.3.3 Dynamic Calibration

A check of the static calibration shall be performed in the dynamic mode. After each static calibration, the calibration block shall be passed through the ultrasonic testing equipment 3 times at the operational scanning velocity. If a change in gain is required in order to maintain the recorded percentage for the probes when aimed at their respective reference reflectors (used for sensitivity setting except side drilled hole C), these values shall be recorded as an average of the three


DMEN-O22-SP-PL-92-0001.02U of 46

dynamic check results. This average gain, if any, shall be added to the primary gain for each probe during production testing.

Variation of gate setting should not be above the tolerance of the weld tracking device.

Dynamic checks shall be undertaken by passing the calibration block through the ultrasonic testing equipment at the operational scanning velocity. The dynamic check shall be repeated at least once every 4 hours during production or once per every 10 pipes tested, whichever is the longer time period but also whenever there is an equipment operator changeover and at the start and end of a testing run.

The equipment shall be deemed to be out of calibration if:

• The response from target and sensitivity setting reflectors, except side drilled hole C, during the dynamic check falls 3 dB below the recorded value from the reference dynamic check (see Section 9.3.3).

• The gate setting during the dynamic check is changed by more than ± 1.5 mm from the recorded value from the static calibration.

• If any of the parameters which were used during the initial static calibration are changed. If the equipment is deemed out of calibration, it shall be re-calibrated in accordance with Section 9.3.2 and 9.3.3 of This Specification and all pipes tested since the last successful dynamic check shall be re-tested.

Insufficient coupling shall be deemed to occur if the transmission signal deteriorates more than 10 dB.

For production testing, the gain for each probe shall be increased by 3 dB: the total gain will thus be the gain required to set the echo at 80% of FSH + added gain from dynamic check (if any) + the added 3 dB for production testing. This 3 dB increased gain may be removed during production, subject to approval, if excessive number of false indications would appear during actual inspection. In addition, this gain increase shall be removed during dynamic check.

The alarm level for each probe shall be set not higher than the sensitivity setting of the reflector in the area of interest giving the lowest response during static calibration/first dynamic check. Alarm level for transverse probes shall be set for B reflectors.

Anti-noise suppression shall be set to the lower practical level to be established before production.

Indications triggered by the alarm shall be investigated by radiographic testing according to Section 9.4, or by MUT according to Section 9.5 of this Specification. If the presence of a defect is not confirmed by radiography or visual examination (VE), or sized shorter than the manual ultrasonic testing (MUT) according to Section 9.5.2 of this Specification, shall be used for final judgment.

9.4 Radiographic Testing

Radiographic testing shall be performed at each pipe end over a length of 300 mm (12-inch) and shall include the area not covered by the automatic ultrasonic testing.

Radiographic examination shall be performed according to DNV-OS-F101, Appendix D, Clause B200.

Acceptance criteria for radiographic examinations are:

• DNV-OS-F101, Appendix D, Clause G732 and Table D-4 (Note 3 not applicable)


DMEN-O22-SP-PL-92-0001.02U of 46

9.5 Other Ultrasonic Testing

Ultrasonic testing shall be performed over a 50 mm (2-inch) wide band at each pipe end, over the length of the longitudinal weld at each pipe end not covered by the automatic ultrasonic examination, whenever required according to Section 9.3 above, on weld seams for detection of delayed hydrogen cracks and on all weld repairs.

Probes with beam angles of 0°, 45°, 60°, 65°, 70°, and 75° and frequencies between 2 and 5 MHz shall be available for manual ultrasonic testing. The use of the highest frequency probes shall be preferred. Calibration blocks shall be a section of project pipe.

9.5.1 Pipe Ends Circumferential UT

Ultrasonic testing over a 50 mm (2-inch) wide band at each pipe end shall consist of scanning for the detection of laminations and through thickness planar defects. The 50 mm (2-inch) and shall be from the future weld preparation and an allowance shall be made for later end beveling.

Manual ultrasonic testing, semi-automated, or automated equipment may be used.

For detection of laminations, calibration shall be performed according to ASTM A578. For dimensional evaluation, the half-value-drop method shall be used.

No laminations wider than 6 mm or with a maximum area of 100 mm2 are acceptable.

For detection of through thickness planar defects, calibration shall be performed on a rectangular notch with a depth 3% of the pipe thickness. A DAC curve consisting of three points shall be established for all probes. Scanning shall be performed on both circumferential directions. ASTM A577 shall apply.

Indications exceeding 20% of DAC curve, while scanning for through thickness planar defects, shall be further investigated and the amplitude maximized using probes with different angles.

Acceptance criteria for through thickness planar flaws are:

• No maximized indications exceeding the DAC curve are acceptable. • No flaws intersecting the inside or outside surface of the pipe are acceptable. • No cracks are allowed. • Defects may be repaired by grinding, within the wall thickness tolerance, or by cutting pipe.

9.5.2 Manual UT (MUT) of Weld Seam

Manual ultrasonic testing (MUT) of welds shall be performed in accordance with DNV-OS-F101, Appendix D, Clause B300, and the following requirements.

Calibration shall be against a reference block with a 1.6 mm diameter through drilled hole. A DAC curve consisting of three points shall be established for all probes. Indications exceeding 20% of DAC curve shall be further investigated and the amplitude maximized using probes with smaller and larger angles.

All maximized indications exceeding 25% of DAC curve shall be reported.

The scanning speed shall not exceed 100 mm (4-inch)/second. Scanning of areas indicated by AUT and weld repaired portions shall be performed transverse to the longitudinal axis of the weld with 100% overlap on scan lines. The scanning shall include a check along the weld with a 0° probe


DMEN-O22-SP-PL-92-0001.02U of 46

for laminar defects that may interfere with the testing. Scanning for transverse defects shall be included as detailed in Section 9.5.3.

Acceptance criteria are:

• No cracks. • Indications exceeding 33% of DAC curve shall be investigated by radiographic testing according to

Section 9.4. If the presence of a defect is not confirmed by radiography or visual examination (VE), the acceptance criteria is that no indications exceeding 100% of DAC curve are acceptable. If the presence of a defect is confirmed by RT or VE, the acceptance criteria shall be according to Section 9.4 of This Specification, provided that the defect size on the radiograph is confirmed by MUT.

9.5.3 UT for Delayed Hydrogen Cracking

Out of line testing for delayed hydrogen cracking shall be carried out minimum 48 hours after welding by AUT or MUT on a minimum of one pipe per shift (rotating the test pipes between the various welding machines). This requirement may be reduced to one pipe per day if the test results of the first 1,000 produced pipes are acceptable and the moisture contents of the flux do not increase above the values obtained in the first week of testing. The test results shall be reported in writing to COMPANY within 2 weeks after completion of all the examinations for the first 1,000 produced pipes.

The reference block shall contain a 1.6 mm (1/16-inch) diameter through drilled holes at the weld centerline.

For “on bead” scanning, a DAC curve shall be established against the 1.6 mm (1/16-inch) diameter weld centerline hole using 3 points (e.g., 1/2, 1 and 1-1/2 skip).

“On bead” scanning shall be performed manually in both directions and a number of 100% overlapping scans shall be performed. A 45º probe shall be used for the initial scanning “on bead”. Indications exceeding 20% of DAC curve shall be further investigated and the amplitude maximized. All maximized indications exceeding 33% of DAC curve shall be reported.

Indication exceeding 50% of the DAC curve are unacceptable, unless the imperfection was already identified and found acceptable by normal NDT operations.

9.6 Magnetic Particle Testing

Magnetic particle testing shall be performed in the following locations:

• On all ends of finished pipes (root face and bevel) • On the external seam for a minimum of 200 mm (8-inch) from each end • On all weld repairs to confirm removal of the defects Magnetic particle inspection shall also be carried out on the full length of longitudinal weld as required by DNV-OS-F101, Section 6, Table 6-13.

Magnetic particle testing shall be performed with the wet method in accordance with DNV-OS-F101, Appendix D, Clause B400.

Fluorescent particles shall be preferred. The ambient visible light shall not exceed 20 lux at the place of examination when fluorescent particles are used.


DMEN-O22-SP-PL-92-0001.02U of 46

Manual magnetic particle testing shall be performed by AC yoke.

Acceptance criteria for pipe ends are:

• Any indication exceeding 5 mm in length is unacceptable and shall be removed by machining and re-examined.

Acceptance criteria for the longitudinal weld, including weld ends, are:

• DNV-OS-F101, Appendix D, Clause G730. • No laminations, laps, or cracks are allowed.

9.7 Liquid Penetrant Testing

Liquid penetrant testing of ferro-magnetic materials shall not be accepted as a substitute for magnetic particle testing, but may be used as a supplement.

Liquid penetrant testing shall be in accordance with DNV-OS-F101, Appendix D, Clause B500.

9.8 Other Acceptance Limits

In addition to the requirements of DNV-OS-F101, the following shall be applicable:

• Any imperfection that reduces the wall thickness below the specified minimum shall be considered a defect and the pipe shall be discarded.

• Surface laps, shells, slivers, laminations and all sharp edged imperfections, e.g., gouges, are unacceptable defects. Surface finish and surface defects shall also comply with the requirements specified in Section 7.10 of this Specification.

9.9 Personnel Qualifications

All personnel performing NDT and interpretation of results shall be qualified to Level II in accordance with ASNT Document No. SNT-TC-1A or equivalent.

COMPANY shall reserve the right to reject any NDT operator who is not performing the work in compliance with the approved procedures.

All MUT operators shall demonstrate to be familiar with and be able to document experience with the applicable NDT technique. COMPANY reserves the right to qualify each operator for the specific applicable technique.

10 WORKMANSHIP AND DEFECT REPAIR

10.1 Workmanship

All pipe defects shall be assessed and accepted or rejected in accordance with DNV-OS-F101 and Sections 7.10 and 9.2 through 9.8 of this Specification.

The pipe surfaces shall be free from loose and tightly adhering scale or any other defects that may interfere with the application of the selected coating system. Scale is defined as something that cannot be normally removed by a blasting operation.


DMEN-O22-SP-PL-92-0001.02U of 46

10.2 Repair of Defects

10.2.1 Pipe Body Repairs

No repairs by welding shall be made to the pipe body.

10.2.2 Weld Defect Repairs

All repairs to welds shall be reported to COMPANY.

Weld defects (other than cracks) may be treated only by grinding, weld repair, or cut-out. Any crack within 150 mm (6-inch) of the original pipe end shall be repaired by cut off. Any crack in the weld area (weld and heat affected zone) located more than 150 mm (6-inch) from the original pipe end, whether found by visual, ultrasonic, radiological or electromagnetic methods of inspection is cause for removal of the joint. If cracking occurs near the pipe ends, the defective pipe section may be cut if the remaining length is within the specified pipe length range.

If any welding cracks are detected, SUPPLIER shall present a documentation regarding the origin of the defect, with the appropriate corrective actions to the COMPANY in a shortest possible time period.

Repairs by grinding necessitate non-destructive re-inspection, except for visually detected undercut. A local magnetic particle examination shall be carried out according to ASTM E709 to ensure that the defect is completely removed and the repair is acceptable. Ultrasonic wall thickness checks are not required for cosmetic grinding.

10.2.3 Weld Repair Limitations

Repairs to welded seams shall be made using shielded metal arc welding (SMAW), or other COMPANY approved welding processes.

No repairs by welding are permitted after expansion. Neither back-to-back repairs nor repairs of weld repairs shall be acceptable. Each weld repair shall consist of minimum two passes. The minimum length of repair is 150 mm (6-inch). The minimum distance between two repairs shall be 200 mm (8-inch). Repair welds shall be no closer than 150 mm (6-inch) to the pipe ends.

Manual repair welds shall be ground smoothly to the original weld contour.

If the total (cumulative) length of the weld repair on a pipe exceeds 1 m (3.28 ft), or the number of the places to be welded exceeds three, the pipe shall not be repaired without specific authorization of COMPANY.

10.2.4 Arc Stop/Restart

Arc stop/restart is always considered as a repair and subject to weld repair qualification.

Weld Defect Removal

If carbon arc gouging is used for defect removal, at least 3.2 mm (1/8-inch) additional metal shall be removed by chipping or grinding to completely remove the carburized area.


DMEN-O22-SP-PL-92-0001.02U of 46

11 LINE PIPE MARKING

The following data shall be paint stenciled clearly on the internal surface of both ends of each pipe:

• Manufacturer’s Name • Project and COMPANY Name • Purchase Order Number and Item Number • DNV-OS-F101 • Grade and Type of Steel • Size (Diameter, Wall Thickness, Length) • Weight • Heat Number and Unique Pipe Number • Supplementary Requirements FU The pipe number shall be cold die stamped on the bevel at both pipe ends at about 10 mm from the weld. Cold or hot die stamping of the pipe body is prohibited.

The mill assigned Pipe Number shall not be repeated in any one purchase order item.

Unless otherwise specified, the pipe surface shall be suitable for application of the specified coatings by being free from oil and grease as well as surface defects.

Permanently rejected pipe shall be white banded.

SUPPLIER shall include a sketch of marking in the MPS.

12 COATING FOR TEMPORARY PROTECTION

Unless otherwise specified in the Purchase Order, the pipes shall be delivered in bare condition. Requirements for special protective coatings and/or linings shall be agreed at the time of order.

The pipe external and internal surfaces shall be free from oil and dirt.


DMEN-O22-SP-PL-92-0001.02U of 46

APPENDIX A

MANUFACTURING PROCEDURE QUALIFICATION


DMEN-O22-SP-PL-92-0001.02U of 46

APPENDIX A - MANUFACTURING PROCEDURE QUALIFICATION

A.1 General

Manufacturing Procedure Qualification Testing (MPQT) shall be carried out prior to the start of production. Alternatively, MPQT may be carried out after the start of production, with pipe produced up to the point at which the results of the MPQT are known at the SUPPLIER’s risk. MPQT shall be witnessed by COMPANY and MPQT results will be submitted to COMPANY for review and approval prior to the start of production. A manufacturing procedure shall be established for each combination of steel slab source, steelmaking and casting method, target chemistry, plate manufacturing route, pipe forming procedure, seam welding procedure, hydrostatic test procedure, mechanical testing and NDT procedures. Care shall be taken to ensure that the pipe forming method used to produce the qualification pipe(s) produces metallurgical results, strains, and stresses that are identical to the production pipe.

SUPPLIER shall guarantee that during production the following are in compliance with those used in the MPQ. Any variation shall be qualified.

• The manufacturing process and/or the control procedures

• Used plants and equipment

• The testing and measuring equipment

During the MPQT, SUPPLIER may be subject to a process audit by COMPANY in order to evaluate:

• Application of the Quality System

• Application and compliance with the MIP

• SUPPLIER ability to keep under control the characteristic process parameters

• The operating characteristics of the non-destructive test equipment in conformity with the requirements of Section 9, of this Specification

• Traceability

A minimum of 20 pipes shall be manufactured from at least two different heats. All the pipes shall be subject to the visual, dimensional and NDT inspection, as required by this Specification.

A total of four pipes from at least two heats shall be selected for MPQT and subjected to all of the tests and inspections required during production and those required below to qualify each manufacturing procedure. Table A.1 of this Specification provides a summary of the tests required for manufacturing procedure qualification.

Destructive tests shall be carried out after final NDT, visual and dimensional controls.

The results of all the tests will be evaluated by COMPANY who will authorize the mill to produce line pipes, if they fully comply with the requirements of this Specification.


DMEN-O22-SP-PL-92-0001.02U of 46

A.2 Tests on Base Material

Tensile tests shall be done, both in longitudinal and transverse direction, using ISO proportional specimens, with strain measured up to maximum load.

High temperature tensile tests according to ISO 6892 shall be performed on both ends of the pipes subjected to testing (16 specimens in total). Tests shall be done at 50°C (122°F) and 60°C (140°F) in the longitudinal direction. Yield and ultimate tensile strength, elongation at fracture and yield ratio shall be reported for information. Stress-strain curve up to maximum load shall also be reported.

Charpy V transition curves shall be plotted for each selected pipe for the base metal in accordance with the requirements of DNV-OS-F101, Section 6, Clause D202. Test temperatures selected shall produce the full ductile brittle transition curve. The test temperatures may be adjusted by SUPPLIER, if necessary, to produce the full ductile brittle transition curve.

Charpy V transition curves (at the same test temperatures specified above) shall be obtained for the base material in the strain aged condition as per DNV-OS-F101, Section 6, Clause D203. The samples shall be aged at 250°C (482°F) for one hour and the minimum absorbed energy at minus 46 °C (5°F) shall not be less than 50% of the energy absorption in the undeformed/un-aged condition and not less than 150/120 J (111/-89 ft-lbs).

Base metal DWTT transition curves using full or reduced wall thickness specimens shall be developed for each selected pipe by duplicate tests to define the transition from ductile to brittle behavior. Duplicate specimens shall be tested at a sufficient number of temperatures to define the transition from ductile to brittle behavior.

A.2.1 Crack Tip Opening Displacement Test (CTOD)

Fracture toughness testing of the base material shall be carried out at minus 15°C (5°F), as per BS 7448, on Bx2B through-thickness notched specimens. The measured fracture toughness shall, as a minimum, have a CTOD value of 0.25 mm.

A.3 Tests on Weld Seam

At the start of production, diffusible hydrogen contents of SAW longitudinal weld shall be checked and shall be lower than 5 ml/100 g of weld metal. SAW flux moisture shall also be checked once per shift per welding machine. Maximum moisture content shall be 0.05% in the case of agglomerated type flux (see Section 4.5 of this Specification for specific requirements for determination of moisture content in flux for both the MPQT and during production welding).

The following tests are required for each of the pipes to be tested:

• Two transverse weld tensile (see Section 5.1 of this Specification) and two all-weld metal tensile tests (inside and outside weld) as per DNV-OS-F101, Appendix B, Clauses A 404 and A 405

• Four side bend tests (see Section 5.5 of this Specification)

• One transverse macro specimen

• One hardness survey

• Weld Charpy specimens from the same locations as in Section 5.3 of this Specification


DMEN-O22-SP-PL-92-0001.02U of 46

The mechanical properties of the weld metal are to meet the minimum requirements of the base material along the transverse direction stipulated in Table 5-1 of this Specification.

The transverse macro specimen shall be polished, etched, and examined. The weld, as examined on the macro specimen, shall be sound and free from cracks, undercuts and other defects. The section shall show full penetration and fusion at the root.

Vickers Hardness surveys shall be carried out in accordance with ISO 6507-1, using a 10 kg load. The hardness testing shall be performed in accordance with Figure 5-2 of This Specification. The hardness shall not exceed 240 HV10 in the weld metal, heat affected zone and base material.

Charpy tests shall consist of three specimens removed from each of the locations detailed in Figure 5-3 of this Specification. All specimens for procedure qualification shall be individually etched prior to notching and the locations agreed with COMPANY.

A.3.1 Crack Tip Opening Displacement Test (CTOD)

Fracture toughness testing of the weld material and the HAZ of the longitudinal weld shall be carried out at minus 46 °C (5°F), as per BS 7448, on Bx2B through-thickness notched specimens. The measured fracture toughness shall, as a minimum, have a CTOD value of 0.25 mm.

A.4 Welding Procedure Qualification

Welding procedures for the longitudinal seam and for repair welds shall be qualified in accordance with DNV-OS-F101, Appendix C. SUPPLIER may perform the welding procedure qualification as part of the first day’s production at SUPPLIER’s risk.

Welding Procedure Specification for the longitudinal seams and repair welds shall include the following information:

a. Pipe material, standard grade, and any modifications.

b. Diameter and wall thickness (nominal).

c. Sketch of joint showing plate edge preparation, joint fit-up, and tolerances.

d. Line-up tolerances.

e. Welding process.

f. Welding consumable(s), including fluxes and gases, chemical analysis, trade name(s) and the American Welding Society (AWS) classifications. Storage and handling shall be recorded.

g. Welding parameters, number of consumables, current, voltage, type of current and polarity, travel speed, heat input, gas mixture, flow rate, welding consumable diameter and ranges to be applied.

h. Welding position.

i. Welding direction.

j. Sketch showing welding bead sequence.


DMEN-O22-SP-PL-92-0001.02U of 46

k. Minimum pre-heating and maximum interpass temperatures. Preheat to be measured 75 mm (3-inch) from the weld bevel and interpass temperature to be measured immediately adjacent to the weld bevel.

l. Root treatment.

m. Defect removal technique (i.e., grouting, air arc gouging, filing, etc.)

The material used for the test shall be the same steel grade, target chemistry, manufacturing method and size as that used in production. The test shall be carried out using the same or equivalent equipment as that used in production. All production stages, which may affect material properties, shall be incorporated including compressive reduction in the O-ring press and cold expansion.

Repair welding procedures shall be qualified by a simulated repair welded joint. A suitably long excavation shall be gouged out to full depth, sufficient to perform the required mechanical testing and re-welded using SMAW. Only one repair attempt per location shall be allowed.

Simulated repair shall include:

• Shallow repair

• Deep repair (75% of the weld thickness)

• Arc stop/restart

The weld procedure qualification tests shall include 100% radiography, magnetic particle inspection, and ultrasonic testing (including on-bead examination) at least 48 hours after weld completion in accordance with this Specification.

The following tests are required:

• Two transverse weld tensile and two all-weld metal tensile test (inside and outside weld) as per DNV-OS-F101, Appendix B, Clauses A404 and A405

• Four side bend tests

• One transverse macro specimen

• One hardness survey

• Weld Charpy specimens from the same locations as per Section 5.3 of this Specification

The mechanical properties of the weld metal are to meet the minimum requirements of the base material along the transverse direction stipulated in Table 5-1.

The transverse macro specimen shall be polished, etched, and examined in accordance with BS 709. The weld as examined on the macro specimen shall be sound and free from cracks, undercut and other defects. The section shall show full penetration and fusion at the root. Dimensional requirements, as per Section 7.9 of this Specification, shall be checked.

Vickers Hardness surveys shall be carried out in accordance with ISO 6507-1 using a 10 kg load. The hardness testing shall be performed in accordance with Figure 5-2 of this


DMEN-O22-SP-PL-92-0001.02U of 46

Specification. The hardness shall not exceed 240 HV10 in the base material, weld metal, and heat affected zone.

Charpy tests shall consist of three specimens removed from each of the locations detailed in Section A.2 of This Specification. All specimens for procedure qualification shall be individually etched prior to notching and the locations agreed with COMPANY.

The PQR (Procedure Qualification Record) shall include the following documentation:

• A record of all welding parameters used in the test

• Test results (including photomacrographs)

• NDT reports

• Third party approved mill certificates for materials used in the test

• Heat treatment records (if applicable)

• Consumable batch test certificates

• Shop welding instruction sheets

A.5 Essential Variables

The limitations of essential variables shall be as per DNV-OS-F101, Appendix C, Clause D600, with additional requirements as stated below. Changes in any of the essential variables shall require a new Welding Procedure Specification and qualification.

• Any change in base materials target chemical analysis or heat treatment condition.

• Any change in material thickness.

• Any change in consumable trade name, grade, classification, or source of origin.

• Any change in wire/flux combination.

• Any increase in electrode size.

• Any increase in the number of electrodes used.

• Any change in heat input, current, voltage, or welding speed of more than ± 10%.

• Any increase in preheat of more than 25°C from the specified maximum interpass temperature.

• Any decrease in preheat or an increase of more than 20°C on the specified maximum interpass temperature.

• The time taken for the procedure weld shall be no more than 1.25 times the time taken for a weld of similar length and thickness in production.

• Any change in root treatment.

A.6 Weldability Requirements

SUPPLIER shall provide weldability data on the response of the material to thermal cycles in the heat affected zone of welds in terms of hardenability, toughness, or softening.


DMEN-O22-SP-PL-92-0001.02U of 46

Existing weldability data shall be presented at the bid stage, provided it was generated on steels with similar steel composition and processing. Acceptance of all or part of such data will be at COMPANY’s discretion.

If SUPPLIER does not have weldability data acceptable to COMPANY, SUPPLIER shall perform the weldability trials to the start of production. The weldability trials shall be witnessed by COMPANY.

It is the intent of this section of the specification to identify potential welding problems prior to field installation. To this end, SUPPLIER shall be requested to perform welding trials demonstrating highest heat input tolerance (defined here as 2.5 to 3.0 kJ/mm for all passes except the root) for softening and low heat input tolerance for hardness (defined here as 0.5-1.0 kJ/mm for all passes).

The test method, essential variables, and acceptance criteria shall be as required by This Specification for procedure qualification and the requirements stipulated in API RP 2Z. CTOD testing in the coarse grained and fine grained regions of the heat affected zone (HAZ) shall be undertaken. The CTOD test temperature shall be minus 15°C (5°F) and the acceptance criteria shall be 0.25 mm minimum.

A.7 Residual Stress Measurement

SUPPLIER shall provide residual stress measurement for similar grade, diameter and wall thickness data for COMPANY review and approval. If data is not available, ring splitting tests shall be performed in accordance with COMPANY approved procedures.

A.8 Presentation of Results

At the completion of all the MPQ tests, a final report shall be prepared by SUPPLIER. The report shall contain complete documentation regarding the test conditions and results.


DMEN-O22-SP-PL-92-0001.02U of 46

Table A.1 - Summary of Manufacturing Procedure Qualification Testing Requirements

Type of Tests Testing Requirements

Chemical Analysis 1 analysis on Ladle and 1 on each selected pipe, as per Section 4.4.

Hydrostatic Section 6 Dimensional Section 7 Wall Thickness Measurement At 1 m internal along 3 longitudinal planes displayed

by 90°, as per Section 7.3 Visual Section 8.2 Ultrasonic Sections 9.3 and 9.5 Radiography Section 9.4 Magnetic Particle Both pipe ends and longitudinal weld seam, as per

Section 9.6 Tensile 1 longitudinal/transverse as per Section 5.1 Hardness Section 5.2 and Figures 5-1 and 5-2 Charpy V-Notch Section 5.3 and Figure 5-3 DWTT Section 5.4 Guided Bend Test Section 5.5 Charpy V-Transition Curves Section A.2 Charpy V-Notch on Strain Aged Samples

Section A.2

DWTT- Transition Curves Section A.2 CTOD Tests Sections A.2.1, A.3.1, and A.6


DMEN-O22-SP-PL-92-0001.02U of 46

APPENDIX B

MEASUREMENT OF RESIDUAL MAGNETISM


DMEN-O22-SP-PL-92-0001.02U of 46

APPENDIX B: MEASUREMENT OF RESIDUAL MAGNETISM

Measurements shall be made using a Hall-effect gaussmeter or other type of calibrated instrument approved by COMPANY. The gaussmeter shall be operated in accordance with written instructions demonstrated to give accurate results. The accuracy shall be verified at least once each day that the gaussmeter is used.

Measurements shall be made on each end of at least three pipes per working shift. One pipe shall be taken from the beginning of the shift, one from near the middle and one from the end of the shift. The results shall be recorded.

Pipe shall be measured subsequent to inspection and handling with electromagnetic equipment, and prior to shipment from SUPPLIER’ s facility.

As a minimum, four readings 90° apart shall be taken around the circumference of each end of the pipe. The maximum residual magnetism of the four readings shall not exceed 20 gauss when measured with a Hall-effect gaussmeter, or equivalent values with other types of instruments.

Any pipe that does not meet the above requirements shall be considered defective. In addition, all pipes produced between the defective pipe and the last acceptable pipe shall be measured. Alternatively, if the pipe production sequence is documented, pipe may be measured in reverse sequence beginning with the pipe prior to the defective pipe until at least three consecutive pipes meet the requirements. Pipe produced prior to the three acceptable pipes need not be measured. Pipe produced after the defective pipe shall be measured until at least three consecutive pipes meet the requirements.

All defective pipes shall be degaussed full length and re-measured, or rejected.


DMEN-O22-SP-PL-92-0001.02U of 46

APPENDIX C

LINE PIPE DATA SHEET


DMEN-O22-SP-PL-92-0001.02U of 46

Line Pipe Data Sheet General Information

Company Name: EnCana Corporation Project Name: Deep Panuke

Development EnCana Document No.:

DMEN-O22-SP-PL-92-0001.02U Jurisdiction: DNV-OS-F101 Supplemental Jurisdiction: CAN/CSA Z245.1

Pipe Description Inside Diameter mm 530.4 Wall Thickness mm 21.2 Material Grade SAWL 450 I FU Manufacturing Process Submerged Arc Welded Application Export Pipeline Quantity 200 metres * Refer to Contract for actual quantity Joint Length: Min.: 11.7 m Max.: 12.5 m Average: 12.1 to 12.3 m End Finish: Yes Beveled -15°, +5°, -0°; Root -2 mm +/- 1 mm X Protective Coating (Type and Millage): Fusion Bonded Epoxy (FBE) **Bevel End Protection: Yes Metal Band Plastic Composite Other Shipping: X API 5L1 X API 5LW X Other (Bidder to detail) ** Bidder to specify type

Standard Requirements Yes No Non-Sour Service (Max. Hardness HV10240) X Charpy V-Notch Impacts (3 Specimens per Set) X

Base Material: (Average/Minimum)

150/120 (111/89)

Joules (ft-lbs) minus 46°C

Test Temperature

X

Weld Material: (Average/Minimum)

60/45 (44/33) Joules (ft-lbs) minus 46°C

Test Temperature

X

HAZ: (Average/Minimum)

60/45 (44/33) Joules (ft-lbs) minus 46°C

Test Temperature

X

Average/Minimum Shear Area: 85/75 % Per Set X

Tensile Requirements: See Table 5-1 X Drop Weight Test: See Paragraph 5.4 X Crack Tip Opening Displacement Tests: See Paragraph 5.6 X

Hydrotest: Per DNV-OS-F101, Section 6, Clause E1100

10 Seconds X


DMEN-O22-SP-PL-92-0001.02U of 46

Line Pipe Data Sheet Supplementary Requirements

Yes No General Requirements: G1 Manufacturing Procedure Specification X G2 Girth Welding Procedure Qualification/Data X G3 Longitudinal and Transverse Tensile Tests X G4 Compressive Mechanical Test X G5 Ring Splitting Residual Stress Test X G6 Measurement of Residual Magnetism X G7 Charpy V-Notch Testing X G8 Enhanced Dimensional Requirements X SAW Pipe Requirements: SA1 Pipe End Lamination Inspection X SA2 Weld End Magnetic Particle Inspection X SA3 Hydrogen Induced Cracking Tests X SA4 Sulfide Stress Corrosion Tests X SA5 Ultrasonic Inspection of Skelp/Plate X SA6 Manufacturing Procedure Qualification X

Deep Panuke

Documents

Transcript of Deep Panuke