API 5l Spec Ongc

OFFSHORE DIVISION MUMBAI
SPECIFICATION FOR CARBON STEEL SEAMLESS LINEPIPE FOR SUBMARINE PIPELINES (SOUR SERVICE)
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OIL AND NATURAL GAS CORPORATION LTD. INDIA
27 BY APPROVED REMARKS NO. OF PAGES DATE REV.
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CONTENTS
SECTION 1.0 3.0 5.0 6.0 7.0 9.0 10.0 11.0 12.0 14.0 TITLE SCOPE DEFINITIONS PROCESS OF MANUFACTURE & MATERIAL MATERIAL REQUIREMENTS DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS & END FINISHES INSPECTION & TESTING MARKING COATING & PROTECTION DOCUMENTS PRODUCTION REPORTS : : : : : SUPPLEMENTARY REQUIREMENTS NON-DESTRUCTIVE INSPECTION OF SEAMLESS LINE PIPE FRACTURE TOUGHNESS TESTING (CHARPY) 4.5 INCH DIAMETER OR LARGER MANUFACTURING PROCEDURE MILL QUALIFICATION AND FIRST DAY PRODUCTION TESTS INFORMATIONS TO BE FURNISHED AT THE TIME OF BIDDING
APPENDIX - F SR 4 SR 5 ANNEXURE - I ANNEXURE - II
ANNEXURE - III :
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1.0
SCOPE This specification establishes the minimum requirements for the manufacture of seamless steel line pipes to be used for submarine pipelines and risers transporting sour hydrocarbons in accordance with the requirements of API Specification 5L, forty second edition, July 1, 2000 and requirements of NACE standard MR-01-75 and makes restrictive amendments to API Spec. 5L. Unless modified by this specification, the requirements of API Spec. 5L shall be valid. NOTE The sections, paragraphs contained herein have the same numbering as the sections and paragraphs of API 5L, in order to facilitate reference. Additional requirements, which are not specified in API 5L, have also been numbered and marked as (New).
1.1
Purpose and Coverage This specification covers seamless line pipes of pipe diameters up to 406.4 mm OD (16 inches) and grades up to X-65. The Manufacturer shall have the license to use API Monogram for manufacturing of pipes in accordance with the requirements of API Spec 5L, forty second edition, July 1, 2000.
1.2
Product Specification Level (PSL) The line pipes to be supplied under this specification shall be PSL2.
3.0 3.15
DEFINITIONS Special Processes Special process shall be subject to Company approval.
5.0 5.1 5.1.1
PROCESS OF MANUFACTURE AND MATERIAL Process of Manufacture Seamless Process
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Pipes furnished to this specification shall be made from basic-oxygen steel or electric arc furnace steel. The steel shall be fully killed and made with fine grain structure. Steel shall be shall be vacuum degassed and calcium treated for inclusion morphology control. Steel shall be made by continuous casting only. Pipes shall be seamless construction without any welded seam. Manufacturing procedure as mentioned in Annexure-I of this specification shall be prepared and submitted to Company for approval prior to start of production. 5.2 Cold Expansion Seamless pipes shall be non-expanded. 5.4 Heat Treatment The pipes shall be normalized or quenched and tempered. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer. Temperature of furnace shall be controlled and recorded and such records shall be made available to the Company. 6.0 6.1 6.1.1 MATERIAL REQUIREMENTS Chemical Properties and Tests Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance with Table-2B given below. API 5L Table-2B including its notes is cancelled. Table - 2B Chemical Requirements C max. % Mn max. % Si max. % P max. % S max. % 0.14 1.55 0.45 0.015 0.003
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Cr max. % Ni max % Al max. % N max. % Cu min max % Mo max. % B max. % Nb max. % Ti max. % V max. % NOTES : f (New) i) ii) iii) iv)
0.3 0.3 0.06 0.01 0.1 0.35 0.08 0.0005 0.05 0.07 0.09
V + Nb + Ti shall not exceed 0.12% Cu + Ni shall not exceed 0.50 % AI/N ratio shall be minimum 2.0 (Not applicable to Titanium killed steel) Ca/S shall be minimum 2.0 and maximum 3.0 for 0.002 % < S 0.003 % If S 0.002 % and Ca 50 ppm , then Ca/S ratio is not applicable.
NOTE : g (New) Depending upon the carbon content of the steel produced by the Manufacturer, the following limitations shall apply. For steels with carbon content < 0.12% Ni Si Mn+Cu+Cr Mo V PCM = C + --- + -- + ------------- + ---- + -- + 5B 60 30 20 15 10 The PCM value based on product analysis shall not exceed 0.21 For steel with carbon content > 0.12%
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The Carbon Equivalent (CE) based on product analysis shall be less than or equal to 0.40, when calculated using the formula given below: Mn Cr + Mo + V Ni+Cu CE = C + ---- + -------------- + ---------6 5 15 NOTE : h (New) If alloying elements other than those specified in Table 2B are added to the steel, the limits of the additional components shall be agreed with the Company. 6.1.3 6.2 6.2.1 Deleted MECHANICAL PROPERTIES Tensile Properties The finished pipes (after all heat treatment and sizing operations) shall conform to the requirements of Table-3B of API 5L. However, columns 3 and 5 of Table 3B are not applicable. The actual yield strength shall be as close as possible to the specified minimum yield strength but in no case it shall be more than 133% of the specified minimum yield strength. The ratio between yield strength and ultimate tensile strength of finished pipes shall not be more than 0.90 and elongation shall be at least 20% for thickness 12.5 mm and 22% for thickness > 12.5 mm. 7.0 7.3 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS AND END FINISHES Wall Thickness In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends of pipe body at 12 Oclock, 3 Oclock, 6 Oclock and 9 Oclock positions for conformance to the requirements of this specification when mechanical calipers are used. For the mid location of the pipe, the frequency of measurement of wall thickness shall
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be at least one in every fifty pipes . Alternatively, the full length of pipe can be checked for wall thickness by automatic ultrasonic test. 7.5 Pipe Length Unless otherwise specified in the purchase order, all pipes shall be supplied with length between 11.7 m minimum and 12.7 m Maximum. The minimum average length for the entire order shall be 12.05 m. (Table 11 of API-5L shall not be applicable). 7.6 Straightness The deviation from a straight line for each pipe length shall not exceed 18 mm. All pipes shall be checked for straightness and further straightness shall be measured and recorded at least 3 times per shift. 7.7 Jointers Jointers shall not be permitted. Tolerances on Dimensions and weights. Table-7 - Tolerance for diameter of pipe body. Tolerances on outside diameter of pipe body shall be as per API-5L. Table 8 Tolerance for Diameter at pipe ends. The nominal inside diameter, based on circumferential measurement, over a length of 100 mm from the end shall be as follows: D 10 10 <D 16 + 0.5 mm or + 0.3% D (whichever is greater) 1.6 mm
Nominal Inside diameter is defined as ID = OD-2X 1.05WT where ID, OD & WT are the nominal inside diameter, nominal outside diameter and nominal wall thickness respectively. The internal diameter shall be measured at each end of the pipe using an internal diameter tape. Out of Roundness: The inside diameter, measured with a bar gauge/caliper with micrometer capable of measuring actual minimum and maximum inside diameters. The
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difference between maximum and minimum inside diameters shall comply with the following limits. For diameters 273 mm OD For diameters > 273 mm OD 2 mm 3 mm
Table-9 Tolerance for Wall thickness The following tolerance are allowed on the nominal wall thickness: Nominal diameter 406.4 mm (16 inches) Tolerance + 15%, - 5 %
Note : (New) Each pipe shall be measured for conformance to the requirements stated in Table 7, 8, 9 & 10. All dimensions and tolerances shall be measured and recorded at least three times per shift. These records shall be submitted to Company. 7.8 7.8.1 WORKMANSHIP AND DEFECTS Dents Allowable dents size shall not exceed 2 mm and length shall not exceed half of the pipe diameter provided this dent does not give rise to a hard spot at the internal surface exceeding 248 HV5. Disposition of dents shall be carried out in accordance with para 9.7.6 of API 5L (and as modified hereinafter). 7.8.8 Hard Spots Maximum hardness in suspected hard spots shall be 248 HV5. Sections of pipes where hardness is greater than the allowable value shall be cut off as per requirements of API para 9.7.6 (and as modified hereinafter). 7.8.9 Cracks, Sweats & Leaks No cracks shall be permitted. Section of the pipe containing cracks shall be cut off as per the requirement of API para 9.7.6 (and as modified hereinafter). 7.8.10 Laminations All lamination defects or inclusion/discontinuities related to the bevel of pipe ends are considered unacceptable defects and shall be eliminated only by rebevelling.
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7.8.14
Other Defects Any imperfection (measured from the surface) with a depth greater than 5% of the nominal thickness of the pipe is considered unacceptable and shall be repaired in accordance with API para 9.7.6 (and as modified hereinafter).
7.9 7.9.1
PIPE ENDS General Pipes shall be furnished with plain ends.
7.9.3
Plain Ends Pipe ends shall be supplied with standard API bevel. While removing the inside seam burrs at the pipe ends, care shall be taken not to remove excess metal nor to form an inside cavity. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 and Table 9 of this specification, shall be a cause for rebevelling. In case root face of bevel is less than specified, rebevelling shall be done and rectification shall not be made by filling or grinding. Squareness shall be limited to 1.5 mm measured over the diameter at any point. Squareness shall be checked and recorded at least 3 times per shift.
7.9.6 (New)
Bevel Protectors Both pipe ends of all pipes shall be provided with metallic or high impact plastic bevel protectors as per Manufacturers standard.
9.0 9.2 9.2.1
INSPECTION & TESTING Testing of Chemical Composition Heat Analysis For each heat a complete heat analysis certificate must be issued including elements listed in Table-2B and other intentionally added elements. Where the pipe mill is not a part of an integrated steel mill, the heat analysis shall be reported by the Manufacturer prior to start of production.
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9.2.2 9.2.2.1
Product Analysis Sampling Frequency Two pipes per heat of steel shall be analyzed for all elements listed in Table2B. When more than 100 pipes are manufactured from one heat, additional product analysis for one pipe, shall be carried out for every 100 pipes or less of the same heat.
9.2.2.2.1
Seamless Pipe Product analysis shall be carried out only from finished pipes.
9.2.3
Test Reports Test results of all specified chemical analysis shall be furnished to Company.
9.3.1 9.3.1.2
Tensile Tests Tensile Testing Frequency A transverse and longitudinal tensile test shall be carried out for each lot of 100 pipes or less, belonging to the same heat and manufactured by the same process.
9.3.1.3
Longitudinal Tensile Tests A strip test specimen with full thickness shall be taken from finished pipe and tests shall be performed in accordance with API 5L.
9.3.1.4
Transverse tensile Test The transverse tensile tests shall be carried out on flattened rectangular or round bar specimen in accordance with API 5L. For pipe diameters 168.3 mm (6-5/8 inches) and smaller, results of these test shall be reported for information only.
9.3.5
Fracture Toughness Test Tests as described in Appendix F Supplementary Requirement SR-5 (and as specified herein) shall be carried out on all sizes, grades and thickness of line pipes.
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In addition, CTOD tests shall be carried out once for the entire order on the pipe with maximum CE as per the requirements of BS 7448, 1991. One set of three specimens shall be taken in the transverse direction. The tests shall be carried out at 10C. Minimum acceptable CTOD value shall be 0.35 mm. These tests shall be performed in addition to the first day production tests. 9.3.6 (New) Hardness Test Vickers hardness tests as per ASTM E-92 shall be carried out on samples of pipes at locations indicated in Figure 9.3.6 to establish that the hardness of the pipe material is less than 248 HV5. Testing frequency shall be same as for tensile tests as specified in para 9.3.1 of this specification. Modalities of retest shall be in accordance with para 9.10 9.3.7 (New) Hydrogen Induced Cracking Test The HIC test shall be carried out in accordance with NACE standard TM-0284, Test Method for Pipeline Steels for Resistance to Stepwise Cracking. Three specimens shall be taken from each test pipe (120 degree apart in circumferential direction) and shall be tested in the test solution of NACE TM02-84 for 96 hours. The acceptance criteria for crack sensitivity ratio (CSR) shall be 0.00%. The HIC test shall be carried out one pipe from each of the first three heats and then on one pipe from every ten subsequent heats. The selection of the specific sample heat shall be as per the decision of the Company Representative. If one specimen fails to meet the acceptance criteria, three more specimens shall be taken from the same pipe for retests. If one of these fails, two additional pipes of the same heat shall be selected and from each of these two pipes three specimens shall be taken for retests. If one of these six specimens fail, the heat shall be rejected. If retest results are acceptable, only the pipes from which the earlier (failed) specimens were taken shall be rejected and all other pipes of the heat shall be accepted. Should a specimen fail to pass the retest, then Company Representative shall have the right to decide on the further testing to distinguish heats which can be accepted. 9.3.8 (New) Four Point Bend Test Four point bend test specimen preparation and size shall be as per ASTM G 39 except that thickness shall be minimum 5 mm. One set of three specimens shall be machined from the middle of the pipe wall thickness. The specimen shall be machined transverse to the pipe axis. The specimens shall be bent using Four point Loading jigs to reach a stress level of 72% SMYS and then immersed in NACE solution as per NACE standard TM-01-77-90 for a period
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of 96 hours with the inner surface in tension. Testing sequence shall be in accordance with NACE TM 0177-90. The acceptance criteria shall be that the specimen shall not have any SSC cracks when examined visually as well as with wet magnetic particle technique. Four point bend test shall be carried out on one pipe from each of the first three heats and then on one pipe from every ten subsequent heats. The selection of the specific sample heat out of every ten heats shall be as per the decision of Company Representative. If one specimen fails to meet the criteria, the retest and acceptance procedure shall be as mentioned in Clause 9.3.7 above. Additional Tests Additional test described in Annexure-II of this specification shall be performed on first days production to verify that the manufacturing procedure results in the quality of pipes which are in compliance with this specification. 9.4 9.4.1 HYDROSTATIC TESTS Hydrostatic Test Requirements The test pressure shall be held for a minimum period of 10 seconds for all sizes and grades of pipes. 9.4.2 Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall be calibrated with a Dead Weight tester and the record shall be maintained. Calibration records shall be furnished to Company Representative on request. The calibration shall be conducted at start of a run and after a hydrostatic burst/leak failure. 9.4.3 Test Pressure The test pressure for all sizes and grades of pipes shall not be less than the maximum pressure calculated based on either of the following criteria mentioned at para 9.4.3.1 and 9.4.3.2: 9.4.3.1 (New) 9.4.3.2 (New) The test pressure shall be such that hoop stress generated is at least 90% of SMYS, Computed based on the formula mentioned in API 5L para 9.4.3 (Note-2). Test pressure shall be such that the hoop stress generated is atleast 95% of SMYS and the end load compensation as per the requirements of AppendixK shall be taken into account while computing the test pressure.
9.3.9 (New)
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9.6
Visual Inspection The visual inspection of entire length of each pipe shall be carried out both internally and externally for surface defects.
9.7 9.7.1(a) (New)
NON DESTRUCTIVE INSPECTION Inspection Notice The manufacturer shall inform the Company, by reasonable notice of time of starting date of normal production and the work schedule. Company reserves the right to depute its Representatives to the Mill, who will witness tests and inspection of the pipes during production and check that the requirements of this specification are complied. If during the controls carried out in the mill, unacceptable defects are found to occur at a rate over or equal to 5% for a specific type of defect or defects are found after inspection/clearance by manufacturer, the Companys Representatives shall have the right to request that the quality control program be increased to an appropriate level and maintained until the defect causes are identified and eliminated. All the tests and inspections shall be carried out in the Mill at the Manufacturers care and account.
9.7.2 9.7.2.6
Methods of Inspection Finished pipes of all grades and all sizes shall be inspected by ultrasonic method in accordance with API 5L Supplementary Requirement SR-4. Ultrasonic inspection can be carried out before or after the mill hydrostatic test. Ends Inspection The full circumference of both ends of each pipe after beveling shall be 100% ultrasonically tested for lamination and inclusion type defects over circumferential bands of at least 25 mm width.
9.7.2.7 (New)
9.7.2.8 (New)
Bevel Inspection Bevels of all pipes shall be inspected with magnetic particle technique for checking the presence of laminations or inclusions. Residual magnetism after MPI shall not exceed 20 gauss measured by Hall Effect Gauss Meter.
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9.7.2.9 (New)
Magnetic Particle Inspection Equipment The equipment shall be capable of indicating the presence of lamination type of defects in the bevel.
9.7.6 9.7.6 a
Disposition of Defects Suitable tools to eliminate the defects by grinding shall be used. The repaired areas shall be 100% rechecked by magnetic particle method to ensure complete removal of defect. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be rejected. Repair Welding on the pipe Body is not allowed. Defects in the pipe material such as laminations may be removed by cutting off the section of pipe containing these defects. The remaining defect-free section of the pipe will be acceptable provided its length is within the specified minimum length and the pipe ends are tested for laminations as per requirements of this specification. Retests Recheck Analysis If any part of the full product analysis on any one of the fully analyzed pipes fail to meet the requirements of para 6.1.1 above, either the whole heat shall stand rejected or each individual pipe shall be fully analyzed and all pipes failing to meet the requirements of para 6.1.1 above shall rejected.
9.7.6 b
9.10 9.10.1
9.10.2
In case one of the test specimens fails to conform to the specified requirements, a retest on four additional pipes from the same lot shall be made. If all re-tests give positive result, then the pipe, which gave the negative result, shall be rejected and the balance lot shall be accepted. In case of negative result of one of the re-test specimens, the lot may be rejected or each of the remaining lengths shall be tested individually. The pipes, which give results as per requirement of this specification, shall only be accepted.
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10.0 10.1
MARKING Marking General Marking specified in API Paragraphs and specified herein shall be in English using Metric Units. Marking shall also include API Monogram, purchase order number, item number, heat number, wall thickness (MM), pipe number weight and grade. Weight marked shall be the actual weight of the pipe. All pipes shall be marked with API monogram.
10.2
Location of Markings Marking shall be paint stenciled on each length of the pipe at right angles/parallel to the pipe axis approximately 300 MM from one end with letters 30 MM or larger in height. Stencil marking shall be placed on the outside/inside surface of each length for pipe diameters 406.4 mm (16) and below. Stencil marked portions shall suitably be varnish coated for transit protection.
10.3.5
Grade and class A color code band shall be marked on inside or outside surface of finished pipe for identification as indicated in SR-3 (Appendix F ) of API 5L.
10.7
Die Stamping The pipe number shall be placed by cold rolling on the outside surface of the pipe at an approximate distance of 20 mm from both ends. Alternatively, the pipe number shall be cold die stamped on the bevel surface of one end of the pipe. Cold die stamping is not permitted on the pipe body.
11.0 11.1
COATING AND PROTECTION Coating Unless otherwise stated in the Purchase Order, the pipe shall be delivered uncoated, free of heavy rust, oil stains and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coatings.
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12.0 12.1 12.1.2
DOCUMENTS Certification PSL2 Certification requirements Manufacturer shall furnish to Company a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix-F Supplementary requirement SR-5 and SR-15 shall also be submitted to Company/Company Representative during inspection at pipe mill.
12.2
Retention of Records In addition to the records indicated in API Table 22, the Manufacturer shall retain the records of all additional tests mentioned in this specification including the ultrasonic testing carried out on pipe as well as pipe ends.
14.0 (New)
PRODUCTION REPORTS The Manufacturer shall provide the Company a report in six copies, indicating for each pipe length at least the following: Pipe identification number. Heat number from which the pipe is produced Pipe length Pipe Weight Pipe grade.
Manufacturer shall provide six copies of acceptance test certificates which shall include the results of all testing required as per this specification and performed on delivered pipes giving details of, but not limited to, the following All test certificates mentioned in para SR 15.1 (a) thru (i). Certified reports of dimensional measurements/tolerance Information on test failure, rejected heats etc. Information on production and shipping All other reports and results required as per this specification.
Such documents shall indicate pipe identification number, the origin of each individual test specimen, etc. and shall be written in English only. International system of units (SI) shall be adopted.
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The certificates shall be valid only when signed by Company representative. Only those pipes which have been certified by Company representative shall be dispatched from the Pipe Mill.
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APPENDIX - F SUPPLEMENTARY REQUIREMENTS SR 4 NON DESTRUCTIVE INSPECTION OF SEAMLESS LINE PIPE SR 4.1 Supplementary Non-Destructive Inspection All pipes shall be inspected full length by the ultrasonic method for detection of transverse and longitudinal defects and laminations, particularly at the ends. SR 4.3.1 Ultrasonic Inspection Equipment All ultrasonic equipment shall have an automatic alarm device for the continuous checking of ultrasonic coupling. The equipment for the automatic inspection shall allow the localisation of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking system for areas giving ultrasonic indications. All ultrasonic equipment shall be provided with recorders. SR 4.3.2 Reference Standards The reference standard shall be according to the cases, taken from the production to be controlled, and of such dimensions as to allow the static and dynamic calibration of the control system. The calibration of ultrasonic equipment with the standard shall be carried out under the same inspection conditions of pipes of normal production. Ultrasonic equipment used for inspection of pipes shall be calibrated in accordance with BS 5996 latest edition). The calibration shall be performed at following intervals: i) ii) iii) At the beginning of each normal inspection shift At least once during each inspection shift. Every time the running of the systems gives raise to doubt on its efficiency.
If during the calibration verification, it is found that notches or holes of the reference standard are not revealed, or if the signals caused by notches or holes of the calibration samples do not switch on the automatic alarm or marking and selection device, all pipes or plates already checked from the previous verification shall be re-inspected at Manufacturers cost.
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SR 4.3.3
Acceptance Limits
SR 4.3.3.(a) Definitions (New) 1. Discontinuity: Any internal features of the steel that results in either. a) the appearance of an echo on oscilloscope screen between the surface position and the back wall echo position, OR b) 2. a reduction of the original back wall echo obtained on an ultrasonically clean area of the steel.
Laminations: A discontinuity is termed a Lamination when the flaw echo is at least 50% of the reduced back wall echo or causes complete loss of the back wall echo and has an intercept on the scan line as specified in clause SR 4.3.3 c(1) herein after.
3.
Inclusion Cluster: A discontinuity is termed an inclusion cluster, if a) individual discontinuities give rise to flaw echoes that are at least 50% of the reduced back wall echo or cause at least a 50% reduction in the back wall echo obtained in an ultrasonically clean area of the steel. Further, the distance between individual discontinuities is less than 12 mm. Although the intercept of each individual discontinuity on the scan lines is less than that for laminations, the total intercept of the cluster exceeds that given in clause SR 4.3.3.d(1) hereinafter. OR b) the back wall echo is reduced by at least 50% of the echo obtained on an ultrasonically clean area of the steel without simultaneous appearance of a flaw echo whose height is at least 50% of the reduced back wall echo, and the intercept of the
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SR 4.3.3.(b) (New) SR 4.3.3(c) (New)
discontinuity on the scan line exceeds that given in clause SR 4.3.3.d(1) hereinafter. Pipe Surface Acceptance criteria of the pipe surface shall be as below: Laminations: 1. All discontinuities that have an intercept on scan line of 13 mm shall be included in the summation of total defect area irrespective of their individual area. 2. Maximum area of any individual discontinuity shall not exceed 1000 mm. 3. Maximum total area of discontinuity in any areas measuring 1 m x 1 m shall not exceed 3000 mm. 4. Any lamination exceeding 100 mm in length shall not be acceptable and also any lamination not parallel to the surface is not acceptable.
SR 4.3.3.(d) (New)
Inclusion Clusters: 1. All inclusion cluster areas with intercept of 25 mm or more shall be included in the count. 2. Maximum average discontinuity area per square meter of surface shall not exceed 1500 mm. 3. Maximum total discontinuity area in any area measuring 1 m x 1 m shall not exceed 5000 mm.
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APPENDIX - F SUPPLEMENTARY REQUIREMENT SR-5 FRACTURE TOUGHNESS TESTING (CHARPY) 4.500 inch DIAMETER OR LARGER SR 5.1 The Manufacturer shall perform the Charpy V-notch tests in accordance with the latest edition of ASTM A 370 using absorbed energy criteria and the requirements mentioned herein. Flattening of pipe wall is not permitted. Specimens shall be taken in a transverse direction, when it is not feasible to secure even half-size specimens in transverse direction because of pipe size or wall thickness, test specimens shall be taken in a longitudinal direction to pipe axis. The test temperature shall be 100C. The testing frequency shall be as specified in API 5L. Three specimens representing one test, shall be machined from a sample taken in a manner mentioned in para SR.5.4 above. At the test temperature, the acceptance criteria for impact values for three full sized specimens shall be as given below : Grade Gr-B X-42 X-46 X-52 X-56 X-60 X-65 Note Min. Average 27 J 29 J 32 J 36 J 39 J 41 J 43 J Min. Individual 21 J 22 J 24 J 27 J 29 J 31 J 33 J
SR 5.3 SR 5.4
SR 5 B.1 SR.5 B.2
SR 5 B.4
: The average impact values are determined by finding the mean of the values of each group of three specimens from each sample taken separately. The minimum impact value is determined by considering the values of the individual specimens from the sample.
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ANNEXURE - I (NEW) MANUFACTURING PROCEDURE A Manufacturing Procedure outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The manufacturing procedure shall as a minimum include the following information. Pipe Materials Steel making process with details of secondary refining process and continuous casting process. Pipe making procedure, including special Processes (Ref. Para 3.15 of this specification), if any proposed. Heat treatment procedure document established as per para 5.4 of this specification. Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipment proposed. Testing for mechanical properties including hardness and CTOD. Ultrasonic testing of pipes using automatic and manual equipment including details of equipment, scanning pattern, reference standard plates for calibration and dynamic calibration procedure, inspection and recording. Non-destructive testing for pipes including details of all equipment, the techniques and the procedure for checking, calibration and recording. Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. Testing procedure for HIC, Four point bend test and SSC test including sampling and preparation of specimens, test apparatus, test solution, testing sequence including loading and evaluation/ failure detection. Marking details. Handling, storage and shipment procedure. Production Report Formats.
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ANNEXURE - II (NEW) MILL QUALIFICATION AND FIRST DAY PRODUCTION TEST Mill Qualification Tests Prior to start of regular production, the following tests shall be carried out, in order to qualify the Mill for regular production of pipes. Sulphide Stress Cracking Test. Manufacturer shall carry out NACE standard tensile test (Method A) for Sulphide Stress Cracking Test in accordance with NACE standard TM-017790. The test shall be carried out at 60, 72,80,90 and 100% SMYS stress levels to produce a curve. Minimum stress for failure after 720 hours shall be atleast 72% of SMYS. Hydrogen Induced Cracking Test. The HIC test shall be carried out in accordance with NACE standard TM-0284, Test Method of Pipeline Steel for Resistance to Stepwise Cracking and as specified in clause 9.3.7 of this specification. The acceptance criteria for crack sensitivity ratio (CSR) shall be 0.00%. Four Point Bend Test Manufacturer shall carry out Four Point Bend Test using NACE solution as specified in clause 9.3.8 of this specification. The acceptance criteria shall be that the specimen shall not have any SSC cracks when examined visually as well as with wet magnetic particle method. Mills shall be considered qualified only subsequent to successful completion of all the tests as mentioned above. Requirement of these tests maybe waived by mutual agreement between Company and the Manufacturer in case Manufacturer possess records of successful performance of this test on a previous supply of line pipes produced by the same method of manufacture, similar chemical composition and grade of steel and subjected to similar heat treatment provided such tests had been performed not earlier than two years prior to this enquiry. Such test certificates duly witnessed and approved by an internationally reputed independent Inspection Agency along with a
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description of the tests performed shall be furnished by the Manufacturer in case Manufacturer desires a waiver of this test. FIRST DAY PRODUCTION TESTS Two lengths of completely finished pipes ( in case of only one heat on first day ) or two lengths from the first two heats i.e. one pipe from each heat ( in case of more than one heat on first day ) of first days production shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The first day production tests shall be carried out on pipes of maximum diameter and minimum wall thickness. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as required in the relevant paragraphs of this specification. These first days production tests shall be repeated upon any change in the manufacturing procedure or any change in the source of raw materials as deemed necessary by Companys Representative. The Manufacturer shall submit to Company a report giving the results of all tests mentioned below. The report shall be agreed and signed by Companys Representative, prior to start of regular production. The various tests to be conducted on each pipe shall be as follows. a) Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects in accordance with Section 7,9 & 10 respectively of this specification. b) Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of the relevant sections of this specification. The following tests shall be conducted : i) ii) Tensile tests shall be conducted on two transverse and two longitudinal base material specimens. At points selected by Companys Representative, three impact test specimens shall be removed from the base material. Specimens shall be tested at 100C
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iii) c)
Hardness tests shall be carried out on selected pipes as per requirement of para 9.3.6 of this specification.
CTOD testing shall be carried out in accordance with the requirements of BS 7448, 1991. One set of three specimens shall be taken in transverse direction. The test shall be carried out at 10C. Minimum acceptable critical CTOD value shall be 0.35 MM. Average CTOD value shall be reported. In addition all the data on fatigue pre-cracking front are required. (Crack length at the following positions i.e. both surfaces, 25%, 50% and 75% of the specimen thickness, the minimum and the maximum angle between the crack and the plane of the notch).
d)
Corrosion Tests i) HIC test shall be carried out as per clause 9.3.7 of this specification. ii) Four point bend test shall be carried out as per clause 9.3.8 of this specification.
e)
In addition, all the tests and inspection required to be conducted on each pipe as per this specification shall be conducted on all the pipes selected for testing during first day production test.
VOL-II Spec No.
2020B
ANNEXURE - III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING The following information as applicable shall be furnished by the manufacturer at at Bid stage with respect to line pipe to be supplied. Name(s) of proposed Manufacturer(s) Authorization letter(s) from Manufacturer(s) Record of similar supplies made earlier giving complete details of diameter, thickness, length, grade of pipe, service, year, name of project, name of client and contact person. In particular, details of similar supplies made over the last five years shall be furnished. Descriptive technical catalog(s) of the proposed Manufacturer(s) Copy of valid certificate of Authority to use API monogram as per para 1.1 of this specification.. A clause wise list of technical deviations, if any, from the requirements of this specification. Deviations indicated anywhere else in the offer shall not be considered valid.
VOL-II Spec No.
2020B

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OIL AND NATURAL GAS CORPORATION LTD. INDIA

27 BY APPROVED REMARKS NO. OF PAGES DATE REV.

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APPENDIX - F SR 4 SR 5 ANNEXURE - I ANNEXURE - II

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DEFINITIONS Special Processes Special process shall be subject to Company approval.

5.0 5.1 5.1.1

PROCESS OF MANUFACTURE AND MATERIAL Process of Manufacture Seamless Process

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PIPE ENDS General Pipes shall be furnished with plain ends.

9.0 9.2 9.2.1

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9.7 9.7.1(a) (New)

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12.0 12.1 12.1.2

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SR 4.3.3.(b) (New) SR 4.3.3(c) (New)

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SR 5 B.1 SR.5 B.2

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