api 5l spec ongc

7/29/2019 API 5l Spec Ongc

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SPECIFICATION FOR

CARBON STEEL SEAMLESS LINEPIPE

FOR SUBMARINE PIPELINES

(SOUR SERVICE)

VOL-II

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2020B

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SPECIFICATION

FOR


FORSUBMARINE PIPELINES

(SOUR SERVICE)

OIL AND NATURAL GAS CORPORATION LTD.

INDIA

27

BY APPROVED REMARKS NO. OF DATE REV.

PAGES


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CONTENTS

SECTION TITLE

1.0 SCOPE

3.0 DEFINITIONS

5.0 PROCESS OF MANUFACTURE & MATERIAL

6.0 MATERIAL REQUIREMENTS

7.0 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS & END FINISHES

9.0 INSPECTION & TESTING

10.0 MARKING

11.0 COATING & PROTECTION

12.0 DOCUMENTS

14.0 PRODUCTION REPORTS

APPENDIX - F : SUPPLEMENTARY REQUIREMENTS

SR 4 : NON-DESTRUCTIVE INSPECTION OF SEAMLESS LINE

PIPE

SR 5 : FRACTURE TOUGHNESS TESTING (CHARPY)

4.5 INCH DIAMETER OR LARGER

ANNEXURE - I : MANUFACTURING PROCEDURE

ANNEXURE - II : MILL QUALIFICATION AND FIRST DAY PRODUCTION

TESTS

ANNEXURE - III : INFORMATIONS TO BE FURNISHED AT THE TIME OF

BIDDING


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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 DEFINITIONS

3.15 Special Processes

Special process shall be subject to Company approval.

5.0 PROCESS OF MANUFACTURE AND MATERIAL

5.1 Process of Manufacture

5.1.1 Seamless Process


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Pipes furnished to this specification shall be made from basic-oxygen steel orelectric 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 MATERIAL REQUIREMENTS

6.1 Chemical Properties and Tests

6.1.1 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. % 0.14

Mn max. % 1.55

Si max. % 0.45

P max. % 0.015

S max. % 0.003


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Cr max. % 0.3

Ni max % 0.3

Al max. % 0.06

N max. % 0.01

Cu min max % 0.1 0.35

Mo max. % 0.08

B max. % 0.0005

Nb max. % 0.05

Ti max. % 0.07

V max. % 0.09

NOTES : f (New)

i) V + Nb + Ti shall not exceed 0.12%ii) Cu + Ni shall not exceed 0.50 %

iii) AI/N ratio shall be minimum 2.0 (Not applicable to Titanium killed steel)

iv) 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 orequal 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 Deleted

6.2 MECHANICAL PROPERTIES

6.2.1 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 specifiedminimum 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 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS AND END

FINISHES

7.3 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 + 0.5 mm or + 0.3% D (whichever is greater)

10


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difference between maximum and minimum inside diameters shall comply

with the following limits.

For diameters 273 mm OD 2 mm

For diameters > 273 mm OD 3 mm

Table-9 Tolerance for Wall thickness

The following tolerance are allowed on the nominal wall thickness:

Tolerance

Nominal diameter 406.4 mm (16 inches) + 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 WORKMANSHIP AND DEFECTS

7.8.1 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 theinternal 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 becut 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 PIPE ENDS

7.9.1 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 anypoint. Squareness shall be checked and recorded at least 3 times per shift.

7.9.6 Bevel Protectors

(New)

Both pipe ends of all pipes shall be provided with metallic or high impact

plastic bevel protectors as per Manufacturers standard.

9.0 INSPECTION & TESTING

9.2 Testing of Chemical Composition

9.2.1 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 Product Analysis

9.2.2.1 Sampling Frequency

Two pipes per heat of steel shall be analyzed for all elements listed in Table-

2B. 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 Tensile Tests

9.3.1.2 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 ofthree 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 Hardness Test

(New)

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 Hydrogen Induced Cracking Test

(New)

The HIC test shall be carried out in accordance with NACE standard TM-02-

84, 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 TM-

02-84 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 Four Point Bend Test(New)

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 thespecimen 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.

9.3.9 Additional Tests(New)

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 HYDROSTATIC TESTS

9.4.1 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 The test pressure shall be such that hoop stress generated is at least 90% of(New) SMYS, Computed based on the formula mentioned in API 5L para 9.4.3

(Note-2).

9.4.3.2 Test pressure shall be such that the hoop stress generated is atleast 95% of

(New) SMYS and the end load compensation as per the requirements of Appendix-

K shall be taken into account while computing the test pressure.


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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 NON DESTRUCTIVE INSPECTION

9.7.1(a) Inspection Notice

(New)

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 Methods of Inspection

9.7.2.6 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.

9.7.2.7 Ends Inspection

(New)

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.

9.7.2.8 Bevel Inspection

(New)

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 Magnetic Particle Inspection Equipment

(New)

The equipment shall be capable of indicating the presence of lamination type of

defects in the bevel.

9.7.6 Disposition of Defects

9.7.6 a 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.

9.7.6 b 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.

9.10 Retests

9.10.1 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.

9.10.2 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 berejected 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 MARKING

10.1 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 COATING AND PROTECTION

11.1 Coating

Unless otherwise stated in the Purchase Order, the pipe shall be delivereduncoated, 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 DOCUMENTS

12.1 Certification

12.1.2 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 PRODUCTION REPORTS

(New)

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 anddynamic 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) At the beginning of each normal inspection shift

ii) At least once during each inspection shift.

iii) 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 thereference 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) a reduction of the original back wall echo obtained on an

ultrasonically clean area of the steel.

2. 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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discontinuity on the scan line exceeds that given in clause SR

4.3.3.d(1) hereinafter.SR 4.3.3.(b) Pipe Surface

(New)

Acceptance criteria of the pipe surface shall be as below:

SR 4.3.3(c) Laminations:

(New)

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) Inclusion Clusters:

(New)

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.

SR 5.3 Flattening of pipe wall is not permitted.

SR 5.4 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.

SR 5 B.1 The test temperature shall be 100C.

SR.5 B.2 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.

SR 5 B.4 At the test temperature, the acceptance criteria for impact values for three full

sized specimens shall be as given below :

Grade Min. Average Min. Individual

Gr-B 27 J 21 J

X-42 29 J 22 J

X-46 32 J 24 J

X-52 36 J 27 J

X-56 39 J 29 J

X-60 41 J 31 J

X-65 43 J 33 J

Note : 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-0177-

90. 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-02-

84, 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) Tensile tests shall be conducted on two transverse and two longitudinalbase material specimens.

ii) 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) Hardness tests shall be carried out on selected pipes as per requirement of

para 9.3.6 of this specification.

c) 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.


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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.


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