Subject : CHT's report on HSAW Vs.

LSAW pipes Full report of the Centre for High Technology on whether GAIL was justified in selecting LSAW pipes only for the Dahej-Uran Pipeline (DUPL) project while excluding HSAW pipes. The following are the findings of the committee: It is evident from the International standards/codes for pipeline design and list of gas pipelines worldwide, that both HSAW and LSAW pipes are used for high-pressure gas transportation. The standards do not differentiate between HSAW and LSAW usage for gas pipelines. The apprehension about the quality of HSAW pipes in respect of seam length, field bending, stress due to pipe forming technique, out of roundness, peaking, weld misalignment etc. are not realistic considering the present level of technology, equipment, quality checks employed by the manufacturers today for production of HSAW pipes. As per published literature, HSAW technology has undergone radical changes since the last 2-3 decades. HSAW manufacturing technology today has best manufacturing technique and quality checks, which includes laser weld tracking equipment for weld alignment control, automatic ultrasonic equipments, controlled bending (to avoid peaking), precision forming equipment to control straightness etc. The stringent quality control tests required for LSAW pipes are also met by HSAW pipes. In Germany, the first standard for high pressure pipelines, DIN 17172 was issued in 1966, which included both LSAW and HSAW pipe common and on a par with each other. In 1967, the specifications API 5LS, for spiral weld pipe (HSAW) were adopted. Estel and Salzgitter pipe mills were first to receive API monogram in 1967. Since then, more and more operators have incorporated both LSAW and HSAW in their specifications. Also, more mills are equipped today to produce HSAW pipes. Recommendations The stipulated use of LSAW and HSAW pipes for high-pressure gas pipelines need not be discriminated without valid evident reasons Based on the above observations and conclusions, it is recommended that spiral welded (HSAW) pipes should also be included along with other type of pipes viz., LSAW, in the tender documents for competitive bidding for high pressure transmission projects. 1.0 Executive Summary GAIL has used Longitudinal Submerged Arc Welded (LSAW) pipes for their 610 Km Dahej to Vijaipur (DVPL) Natural Gas pipeline project. Since, alternative option of using cheaper Helical Submerged Arc Welded (HSAW) pipe was not considered by GAIL( MOP&NG vide their letter No. L-16016 /19/'03 - GP dated 05.08.2004 advised Executive Director, Centre for High Technology (CHT) to examine all the issues involved in selection of pipes (viz., LSAW/HSAW) for high pressure gas transmission, considering following Terms of Reference' and to submit the report to MOP&NG. Terms of Reference 1. What are the specifications followed for high-pressure transmission of natural gas pipelines nationally and internationally and whether HSAW pipes meet the desired specifications? . 2. Nationally and internationally the type of pipes which are used for gas transmission 3. Was GAIL justified in selecting LSAW pipes only, and excluding HSAW 4. Any other related matter including recommendations of appropriate technology for Indian gas sector? Comments on terms of reference 1. As regards specifications followed for high-pressure natural gas pipeline transportation, there is no such national specification. However, there are number of international codes, which are followed for framing up specifications for manufacturer/supplier of line pipes to be used for transportation of high pressure gas through pipelines. Following international codes/standards are mostly referred by national as well as international pipeline operators.

API 5L, ANSI B 31.8 of ASME, AS 2885.2 2002, (USA) . BS 8010 Part 2 (British standard) DIN standard 17172 (German), European standard CEN/TC 234WG3, ISO 3183-3 DNV OS F 101 (Netherlands)

From scrutiny of these International codes, it has been found that these codes/standards specify usage of both HSAW and LSAW pipes. However, the codes specify following requirements for the line pipe irrespective of pipe manufacturing technology (viz., LSAW, HSAW). Process of Manufacturing Metallurgy of the steel (Mechanical and chemical properties) Diameter (outside/inside) of the pipe, Wall thickness, Grade Weight per unit length, Minimum test pressure, SMYS (specified minimum yield strength) Specified ultimate tensile strength, Various methods for inspection & testing the line pipes etc. (Nondestructive & Destructive)

The international codes and standards do not differentiate between LSAW (Longitudinal submerged arc welded) and HSAW (Helical submerged arc welded) pipes. Based on above, HSAW pipes will also meet the desired qualification for high-pressure gas transmission. 2. In India, there are very few pipeline operators who have large network of gas pipeline with large diameter & length. GAIL is the only major company, which operates cross-country gas pipeline since 1986, whereas there are many international companies operating gas pipelines globally for last 40 years or so. Based on published information, it has been found that nationally and internationally both LSAW and HSAW type pipes are used for gas transportation. 3. As per available information, it is observed that GAIL has used both LSAW and HSAW pipes for their HBJ pipelines. They have used 18" OD X60 Grade HSAW pipes in the Bijaipur - Boreri section, whereas LSAW & ERW pipes were used for remaining section of HBJ pipeline. Thereafter, since 1986 they are using LSAW pipes. GAIL has justified selection of LSAW pipes for their subsequent pipelines based on their own technical analysis, feed back from certain pipe manufacturers and pipeline operators. However, as per international codes, usage of both LSAW and HSAW pipes has been specified for high-pressure gas transmission. This is also evident from the list of pipelines worldwide that HSAW pipes were extensively used. 4. It is evident from the International standards/codes for pipeline design and list of gas pipelines worldwide, that both HSAW and HSAW pipes are used for high-pressure gas transportation. The standards do not differentiate between HSAW and LSAW usage for gas pipelines. The apprehension about the quality of HSAW pipes in respect of seam length, field bending, stress due to pipe forming technique, out of roundness, peaking, weld misalignment etc. are not realistic considering the present level of technology, equipment, quality checks employed by the manufacturers today for production of HSAW pipes.

As per published literature, HSAW technology has undergone radical changes since the last 2-3 decades. HSAW manufacturing technology today has best manufacturing technique. and quality checks, which includes laser weld tracking equipment for weld alignment control, automatic ultrasonic equipments, controlled bending (to avoid peaking), precision forming equipment to control straightness etc. The stringent quality control tests required for HSAW pipes are also met by HSAW piipes. In Germany, the first standard for high pressure pipelines, DIN 17172 was issued in 1966, with included both HSAW and HSAW pipe in common and on a par with each other. In 1967, the specifications API 5LS, for spiral weld pipe (HSAW) were adopted. Estel and Salzgitter pipe mills were first to receive API monogram in 1967. Since then, more and more operators have incorporated both LSAW and HSAW in their specifications. Also, more mills are equipped today to produce HSAW pipes. The stipulated use of LSAW and HSAW pipes for high-pressure gas pipelines need not be discriminated without valid evident reasons. In order to eliminate doubts in respect of quality of HSAW pipes, the owner should rightly satisfy itself about the manufacturing technology, procedures and various quality control steps employed by the manufacturer to provide desired quality assurance. If needed, a competent , expert team be entrusted by the owner to ascertain the capability of the manufacturers in ensuring quality of HSAW pipes as a part of detailed technoeconomic evaluation for selection of pipes for high pressure gas pipelines. Based on the above observations and conclusions, it is recommended that spiral welded (HSAW) pipes should also be included along with other type of pipes viz., LSAW, in the tender documents for competitive bidding for high-pressure gas transmission projects. This will enable better quality and price advantage to the gas pipeline operators/clients. 2.0 Background and Terms of Reference 2.1 Background GAIL has used Longitudinal Submerged Arc Welded (LSAW) pipes for their 610 Km Dahej to Vijaipur (DVPL) Natural Gas pipeline project. Since, alternative option of using cheaper Helical Submerged Arc Welded (HSAW) pipe was not considered by GAIL, MOP&NG vide their letter No. L-16016/ 19/ '03 - GP dated 05.08.2004 advised Executive Director, Centre for High Technology (CHT) to examine all the issues involved in selection of pipes (viz., LSAW/HSAW) for high pressure gas transmission, considering following 'Terms of Reference' and to submit the report to MOP&NG. 2.2 Terms of Reference 1. What are the specifications followed for high-pressure transmission of natural gas pipelines nationally and internationally and whether HSAW pipes meet the desired specifications? 2. Nationally and internationally the type of pipes which are used for gas transmission 3. Was GAIL justified in selecting LSAW pipes only, and excluding HSAW pipes? 4. Any other related matter including recommendations of appropriate technology for Indian gas sector? 3.0 Methodology adopted 3.1 Preliminary examination of various related issues were done based on the papers/ documents furnished along with the MOP&NG letter. 3.2 Various international codes and standards were referred to understand the international practices.

3.3 Review of various reports/data published in international literature, technical papers discussed at various technical forums and collected from various other sources, as well as information downloaded from internet. 4.0 Codes and Standards for gas pipelines 4.1 As regards specifications followed for high-pressure natural gas pipeline transportation, there is no such national specification. However, there are number of international codes, which are followed for framing up specifications for manufacturer/supplier of line pipes to be used for transportation of high pressure gas through pipelines. Following international codes/standards are mostly referred by national as well as international pipeline operators. API 5L, ANSI B 31.8 of ASME, AS 2885.2.2002, (USA) BS 8010 Part 2 (British standard) DIN standard 17172 (German) European standard CEN/TC 234WG3, ISO 3183-3 DNV OS F 101 (Netherlands)

4.2 The standard API 5L is considered to be most comprehensive for framing up Gas & Oil pipeline specifications. It may be noted that this standard also refers to various other codes, which are given on page 2 of this standard. This standard also specifies (clause 4.1 & 4.2) the information to be supplied by the purchaser as well as the various conditions subject to agreement between the purchaser and the manufacturer are given under clause no. 4.3 (Annexure - 1). 4.3 From scrutiny of these International codes, it has been found that these codes/standards specify usage of both HSAW and LSAW pipes. However, the codes specify following requirements for the line pipe irrespective of pipe manufacturing technology (viz., LSAW, HSAW). Process of Manufacturing Metallurgy of the steel (Mechanical and chemical properties), Diameter (outside/inside) of the pipe, Wall thickness, Grade Weight per unit length, Minimum test pressure, SMYS (specified minimum yield strength) Specified ultimate tensile strength, Various methods for inspection & testing the line pipes etc. (Non destructive & Destructive)

4.4 The international codes and standards do not differentiate between LSAW (Longitudinal submerged are welded) and HSAW (Helical submerged arc welded) pipes. Based on above, HSAW pipes will also meet the required qualification for high-pressure gas transmission. 5.0 Pipe manufacturing process 5.1 Pipes for the oil and gas industry is manufactured by either of the following four methods Seamless process Longitudinally welded by electrical resistance welding (ERW pipe) Longitudinally welded U-O-E formed pipe using submerged arc welding (LSAW) Helical or spiral welded pipe using submerged arc welding (HSAW)

5.1.1 Seamless Process

The seamless process is a process of hot working steel to form a tubular product without a welded seam. If necessary, the hot worked tubular product may be subsequently cold finished to produce the desired shape, dimensions and properties. (Annexure -2, Page 6) 5.1.2 Longitudinally welded by electrical resistance welding (ERW pipe) In this process, pipe is manufactured by electrical welding of the edges to form a longitudinal seam. The edges to be welded are mechanically pressed together and the heal of welding is generated by the resistance to flow of the electric current. (Annexure -2, Page 37) 5.1.3 Longitudinally submerged are welded (LSAW) Pipes In LSAW technology, steel plates are used which is processed into cylindrical shape. The plates employed for longitudinally welded pipe are formed on presses featuring open dies for the U-ing and closed dies for the O-ing operation. The process is also sometimes referred to as the UOE process (U-ing, O-ing, Expanding) and is applied in the manufacture of longitudinally welded large-diameter pipe in individual lengths up to 18m. The edges of the plate thus formed are brought close to each other and then tack welded buy automatic tack welding machine along the seam from outside. The seam is subsequently welded by submerged arc welding process that produces coalescence of metals by heating them with an arc or arcs between a bare metal consumable electrode or electrodes and the pipe. A blanket of granular, fusible material on the work shields the arc and molten metal. Pressure is not used, and part or all of the filler metal is obtained from the electrodes. At least one pass shall be on the inside and at least one pass shall be on the outside. The welded pipes are then taken to mechanical or hydraulic expanders for proper sizing and roundness by cold expansion. Modern plants employing this process are variously designed for a pipe diameter range from approximately 100 to 1620 mm. Depending on the material and diameter, the wall thickness range from 6 to 40 mm. (For detailed manufacturing process refer Annexure -2, Page 50)