BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
GAIL (India) Limited (A Govt. of India Undertaking) NEW DELHI, INDIA
RE‐ROUTING OF URAN – THAL PIPELINE PROJECT ACROSS DHARMATAR CREEK PROCUREMENT OF (CARBON STEEL BARE / COATING /COATED LINE PIPES)
INTERNATIONAL COMPETITIVE BIDDING DOCUMENT E‐Tender no.8000004049
Volume II of II (Technical)
PREPARED AND ISSUED BY
HYDROCARBON PROJECT ENGINEERS LTD
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
S. No.
HRC
13.
Document Title / Revision Date Document / Drawing No. Description No. Material Requisition For Carbon Steel Bare / HRC/UTPL/LP/CS/2011/01 0 Coating / Coated Line Pipes Standard Technical Specification For LSAW HRC –TS ‐01 ‐001 0 Line Pipe Standard Technical Specification For HSAW HRC –TS ‐01 ‐002 0 LinePipe Specification For 3‐Layer Polyethylene Coating of HRC –TS ‐01 ‐004 0 Line Pipes Specification for Internal HRC‐TS‐01‐005 0 Epoxy Coating Specification for HRC‐TS‐01‐006 0 Concrete Coating Specification for Coal Tar HRC‐TS‐01‐007 0 Enamel Coating Quality Assurance Plan HRC‐TS‐QAP‐001 0 (Guideline) Inspection & Test Plan HRC‐TS‐ITP‐LSAW‐001 0 For LSAW Line Pipes Inspection & Test Plan HRC‐TS‐ITP‐HSAW‐001 0 For HSAW Line Pipes Inspection & Test Plan For 3‐Layer Polyethylene HRC‐TS‐ITP‐3LPE‐001 0 Coating of Line Pipes Inspection & Test Plan For Internal Epoxy HRC‐TS‐ITP‐IEC‐001 0 Coating of Line Pipes Check list ‐ 0
14.
Reference List‐Line pipes
‐
0
15.
Compliance List
‐
1.
2.
3.
4. 5. 6. 7. 8. 9. 10. 11.
12.
16. 17.
Typical Layout Plan For Dump Site Development Details Of Barbed Wire Fencing
Total Pages
Page No.
13
33 32 30 21 12 19 6 5 5 6
6 1
1
0
1
HRC‐M‐SY‐101
0
1
HRC‐M‐SY‐102
0
1
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
MATERIAL REQUISITION
Page 3 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
A. MATERIAL REQUISITION (MR No.: HRC/UTPL/LP/CS/2011/01) PROJECT: URAN – THAL PIPELINE PROJECT (RE‐ROUTING) CLIENT: GAIL (INDIA) LIMITED BID NO.: UTPL/GAIL/HRC/1001
Item No.
Items: Manufacture and supply of bare / Coatedline pipes. 26” x10.3, 9,500 Meters, API 5L Gr. X‐60 PSL‐2 26” x15.9, 3,500 Meters, API 5L Gr. X‐60 PSL‐2 Description Options Qty Carbon steel line pipes 1 2 conforming to API 5L PSL 2 Type
A1 A2
LSAW/ HSAW LSAW/ HSAW
OD WT Grade (Mtr) (inch) (mm)
3
(Bare Pipe)
(Coating works)
(Coated pipe)
Color Band
26
X‐60
10.3 9300
Bare
3LPECoating
Coated
White
26
X‐60
10.3
200
Bare
Bare
Bare
Violet
26
X‐60
15.9 3400
Bare
CTE & Concrete Coating
Coated
Bare
Bare
A3
LSAW
A4
LSAW 26 X‐60 15.9 100 Bare LEGEND:‐ OD = Outside Diameter WT = Wall Thickness LSAW = Longitudinal Seam Submerge Arc Welding HSAW = Helical Seam Submerge Arc Welding 3LPE = Three Layer Poly Ethylene CTE = Coal Tar Enamel
Yellow Red
Page 4 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
The brief scope of different options is as follows: OPTION ‐ 1: Manufacture and supply of Bare line Pipes. OPTION ‐ 2: Taking over and handling of bare line pipes from foreign supplier at India port of entryand from India supplier at supplier’s manufacturing works, transportation and handlingof line pipes upto coating yard / storage yard, application of internal & external coating(as applicable) and transportation & delivery of all bare and coated pipes to Designatedwarehouse / storage yard, including arrangement and maintenance of warehouse /storage yard. OPTION ‐ 3: Manufacture and Supply of Coated / bare Pipes (as applicable), transportation andhandling of all coated / bare pipes to Designated warehouse / storage yard includingarrangement and maintenance of Dumpsite/Storage yard. Note (i) Bidder has to quote for full quantity, else bidder’s offer shall not be considered for evaluation for the corresponding item. (ii) Item no. A1 shall have External 3LPE & Internal Liquid Epoxy coating. (iii) Item no. A3 shall have Internal Liquid Epoxy coating and External CTE & Concrete Coatings. (iv) Item nos. A2 & A4 shall be supplied in bare conditions only, without any External / Internal coating. (v) Item no. A1 & A2 shall be clubbed together and to be awarded in full quantity to single bidder. Therefore, bidder quoting for item no. A1/A2 must quote for full quantity of item no. A1& A2, else the bidder’s offer shall not be evaluated for these items. (vi) Item no. A1 & A2 shall be manufactured by HSAW / LSAW process. (vii) Item no. A3& A4 shall be manufactured by LSAW process only. (viii) A Bidder may either quote for any one of the following four alternatives. a) b) c) d) e)
For Option 1 only For Option 2 only (Refer Note‐2 below) For Option 1 and Option 2 only (Refer Note‐2 below) For Option 3 only (Foreign / Consortium Bidder only) For Option 2 and Option 3 only. (Indian Bidder only) (Refer Note‐1 below)
Note: 1. An Indian Bidder quoting for Option‐3 must quote for all alternatives of Option‐2otherwise their offer for corresponding items will not be considered i.e. and IndianBidder quoting for coated pipes must quote for corresponding coating items also forall alternatives. 2. A bidder quoting for Option‐2 must quote for all alternatives of Option‐2 otherwisetheir offer for corresponding item will not be considered.
Page 5 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
(ix) (x)
HRC
Proposed location of storage yard are:Uran&Mandava, Maharastra Under Option‐II, the Indian Coating Contractor shall receive the delivery of barepipes at the works of Indian Pipe Manufacturer or Designated Indian Sea Portfor transportation to his Coating Plant.
(xi) Deviation to specifications expressed in the offer make the bid liable forrejection. (xii) Color bands of 50 mm width to be placed at both the ends, inside of Bare Pipes at a distance of 50 mm from the pipe ends and outside of 3LPE Coated Pipes at a distance of 450 mm from the pipe ends. (xiii) Inspection by vendor appointed TPI shall be as per EN 10204, 3.2certification. Inspection of Steel Plate/Coil required for manufacturing of Line Pipe shall also be 3.2 certified as per EN 10204. (xiv) Refer commercial Vol. I of II of bid document for detailed scope of work.
Page 6 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
B. REMARKS/COMMENTS 1.0
GENERAL NOTED VENDOR’S COMPLIANCE
Vendor must include the following statement in his bid: We certify that our bid is fully complying with your enquiry dated ………………. Andreferenced ………………………….Compliance with this material requisition in any instance, shall not relieve the Vendorof his responsibility to meet the specified performance. 2.0
COMPLIANCE WITH SPECIFICATION The vendor shall be completely responsible for the receiving/ taking over, design,materials, fabrication, testing, inspection, preparation for shipment, transport, storageat specified Dump Yard/ Warehouse and delivery to designated pipeline layingcontractor of the above items strictly in accordance with the Material Requisition andall attachments thereto.
3.0
4.0
INSPECTION Vendor shall appoint anyone of the following TPIA for inspection purpose. Vendorhas to propose minimum 4 nos. of below listed agencies to be approved by GAIL/ HRC. a) Lloyd Register of Industrial services b) TechnischeUlierwachungsVerein (TUV) c) Det Norske Veritas (DNV) d) AIB – Vincotte e) Bureau Veritas f) SGS g) ABS Industrial Verification India Ltd. h) Velosi Certification Services Apart from inspection by TPIA, inspection shall also be performed by GAIL and or itsauthorized representative / HRC and or its authorized inspection agency (AIA), as setout and specified in the codes and particular documents forming this MR. CERTIFICATION The vendor shall be completely responsible for the design, materials,fabrication, coating, testing, inspection, preparation for shipment, loading ofthe above item strictly in accordance with the Material Requisition and allattachments thereto. All items shall be provided with EN 10204, 3.2Certification. The steel plate/coil required for pipe manufacturing shall also be certified asper EN 10204, 3.2 Certification.
Page 7 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
5.0 5.1
5.2 5.3
HRC
Procurement of Steel Plates/ Coils List of acceptable Steel Plate/Coil Manufacturer The following steel manufacturers are acceptable for the supply of Steel Plates/Coilto be used in the manufacture of quoted line pipes. The Pipe manufacturer shallfurnish specific confirmation for compliance to specifications from any of the twoproposed steel plate/coil manufacturer(s). I. ThyssenKrupp, Germany II. Mannesmann Salzgitter Rohrenwerke, Germany III. Dillinger Hutte, Germany IV. Europipe, Germany V. Ilva (Riva Group), Italy VI. Azovstal, Ukraine VII. Posco, South Korea (Coils upto 17.5 mm WT) (Upto Gr. 80) VIII. Voest Alpine, Austria IX. Nippon Steel, Japan X. AHMSA (Altos Hornos de Mexico), Mexico XI. Essar Steels Ltd, India (Coils upto 14.3 mm WT) XII. Ispat Industries, India (Coils upto 11.1 mm WT) XIII. SAIL, Bokaro, India XIV. JSW Steel Ltd., VIjaynagar (for billets only) XV. Jindal steel & Power Ltd., Raigarh, CG (for billets only) XVI. Kalyani Steel Ltd., Hospet (for billets only) XVII. JSW Steel Ltd., Salem (for billets only) XVIII. Saudi Iron & Steel (Hadeed), Saudi Arabia (Coils upto 14.1 mm WT) XIX. Wuhan Iron & Steel Corporation, China XX. Tianjen Iron & steel Corp. China (Coils upto 17.5 mm WT) XXI. Jindal Iron & steel, China (Upto grade X 80) XXII. JSW India (Coils upto 14.3 mm WT) XXIII. Maanshan Iron & Steel Company Ltd., China (Coils upto 17.5 mm WT)(uptoGr X 80) XXIV. Anyang Iron & steel Group Co. Ltd., China (Coils upto 14.3 mm WT) XXV. Hyundai Steel, Korea (Coils upto 14 mm WT) XXVI. Arcelor Mittal, Germany (Coils upto 21.6 mm WT) (upto Gr. 80) XXVII. Arcelor Mittal, France (Coils upto 21.6 mm WT) (upto Gr. 80) XXVIII. Welspun‐ PCMD, India (Plate upto 14.3 mm WT) XXIX. Shou‐gang Qian‐an Iron & Steel Co. Ltd. (Coils upto 18.4 mm WT) (upto Gr.80) XXX. Benxi Steel, China (Coils upto 17.5 mm WT) (upto Gr. 80) XXXI. ERDEMIR, Turkey (upto Gr. 80) XXXII. US Steel Kosice, Slovak Republic XXXIII. BAU Steel, China In case bidder proposes steel plate/coil manufacturer(s) not covered in the abovelist, then the proposed steel plates/ coils manufacturer must meet the followingcriteria :‐ Steel plate/coil manufacturer(s) must have manufactured and supplied in a singleorder, at least 5000 MT steel plate/coil for the production of line pipes conforming toAPI 5L (PSL‐2) of the same or higher grade as quoted for in the last seven(07) yearsfrom the bid due date.
Page 8 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
5.4 5.5 5.6 5.7
HRC
The steel plate/coil manufacturer have manufactured plate/coils conforming to API 5L(PSL‐2) of same or higher wall thickness as quoted for in the last seven(07) yearsfrom the bid due date. The steel plate/coil manufacturer must have manufactured plate/coils conforming toAPI 5L (PSL‐2) which are equal or higher in terms of plate width as quoted for in caseof LSAW option. A letter of commitment from two proposed steel plate/coil manufacturer for supply ofsteel plates/coils required for the manufacture of line pipes under present bid. Confirmation regarding compliance with applicable requirements for steel plates/coilsspecified in Technical Specifications/ Material Requisition of this Bid Document fromthe proposed steel manufacture shall be furnished.Pipe Manufacturer must submit the track record, along with bid, in duly filed up“Annexure A” with documentary evidence (of steel plate/Coil manufacturer) toestablish the above qualification criteria indicated above at clause No.5.3,5.4,5.5,5.6& 5.7 Such as Purchase order/work order, inspection release4 note/completioncertificate of relevant previous supplies
In the absence of such documentary evidence, Owner/ Consultant reserve the rightto reject the bid without making any reference to the bidder. 5.8 5.9 5.10 5.11 6.0
Bidder to note that steel plate/coil manufacturer shall be qualified at bid stage only. The techno commercially qualified bidder(s) will be informed prior to price bidopening on acceptance of the proposed steel plate / coil manufacturer(s), if any. Bidder’s offer shall be unconditional irrespective of the finally qualified steel plate/coils manufacturer(s). Steel Mill qualified for one bidder during bidding stage shall be considered qualifiedfor other bidder also. The list of all acceptable steel manufacturers shall becommunicated to all qualified bidders. MATERIAL HANDLING & TRANSPORTATION Handling and transportation of coated line pipes to this specification shall meet therequirements of API RP 5L1 or API RP 5LW as applicable. Special attention shall be paid for loading/ unloading and handling works so as to prevent damage of pipe body, polyethylene coating and concrete coating. Bevel protectors shall be removed before the pipe travels through the coating plantand replaced with same or new caps after the pipe is coated. Transportation of line pipe by truck to this specification shall comply with the lawsand regulations of authorities having the jurisdiction over transportation of goods inall jurisdictions between the point of loading and location of destination. Loadingand handling procedure shall comply with the requirements of API RP 5L1. Wooden dun age shall be laid at approximately same interval. Soft material suchas rubber sheet should preferably be applied between pipe and wooden dun age.
Page 9 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
7.0
8.0
HRC
When transporting exterior coated pipe, rubber padding shall be used to separateeach joint from contact with adjacent joints and with the surface of the truck. Reasonable care shall be used in handling to ensure that the pipe reaches itsdestination with the coating intact and undamaged. Pipe shall be handled in a manner to prevent damage to the pipe and its coatedsurfaces. End hooks suitably radiused and lined with plastic or similar approved material or aforklift with suitably padded forks shall be used to pick up pipe. A spreader bar shallbe used between lifting lines. During handling the pipe shall be prevented fromimpacts or jars. Vendor representative shall be advised of any pipe suffering impactor jars. Lifting equipment shall be approved by GAIL / GAIL’s authorized representative.Wire ropes shall not be used in direct contact to lift pipes. APPLICABLE DOCUMENTS General descriptions, requirements and information are listed under point C of thisMaterial Requisition. VENDOR’S DOCUMENTS Vendor shall supply the documentation as listed under point C of this MaterialRequisition.
All documents shall be supplied in English language.
Page 10 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
C. LIST OF ATTACHMENT SL. NO 1 2 3
DOCUMENT TITLE Standard specification for Longitudinal seam submerged arc welded (LSAW) line pipe (onshore) Standard specification for Horizontal seam submerged arc welded (HSAW) line pipe (onshore) Specification for 3 Layer PE coating of Line pipes.
DOCUMENT NO.
R
HRC –TS ‐01 ‐001
0
HRC –TS ‐01 ‐002
0
HRC –TS ‐01 ‐004
0
4
Specification for Internal Epoxy Coating
HRC‐TS‐01‐005
0
5
Specification for Concrete coating
HRC‐TS‐01‐006
0
6
Specification for Coal Tar Enamel Coating
HRC‐TS‐01‐007
0
7
Quality assurance plan (Guideline)
HRC‐TS‐QAP‐001
0
8
Inspection & Test Plan (LSAW)
HRC‐TS‐ITP‐LSAW‐001
0
9
Inspection & Test Plan (HSAW)
HRC‐TS‐ITP‐HSAW‐001
0
10
Inspection & Test Plan (3LPE)
HRC‐TS‐ITP‐3LPE‐001
0
11
Check list
Form‐A
‐
12
Reference List‐Line pipes
Form‐B
‐
13
Compliance List Typical Layout Plan For Dump Site Development Details Of Barbed Wire Fencing
Form‐C
‐
HRC‐M‐SY‐101
0
HRC‐M‐SY‐102
0
14 15
Page 11 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
D. DOCUMENT AND VENDOR DATA REQUIREMENT LIST: The table hereunder specifies the quantities and the nature of the documents to besubmitted by the Vendor / manufactures to the Purchaser/ its authorizedrepresentative. VENDOR shall supply the documentation as listed under table ofthis Material Requisition. All documents shall be supplied in English language.
Bidders quoting for line pipe of type equivalent to API 5L PSL‐2 quality line pipe,shall submit technical details justifying their claim against each clause as stipulatedin this MR( Document no. HRC/UTPL/LP/CS/2011/01 Rev.‐0).
The documents required at the inquiry stage and to be included in the bid are listedunder column A. The documents required after award of the AGREEMENT and subject to thewritten approval of the Purchaser/ its authorized representative are listed undercolumn B.
The final and certified documents are listed under column C. Any document, even if preliminary, shall be binding and therefore duly identifiedand signed by the CONTRACTOR. It shall bear the Purchaser’s/ its authorizedrepresentative’s Project reference, the Material Requisition number and theidentification number. The documents are fully part of the supply which shall becomplete only if and when the documents complying fully withthe material requisition requirements are received by thepurchaser/ its authorized representative.
Item
Documents and Data
Number of Copies
Number of Copies
Required Date
Number of Copies
Required Date
1
Drawing / Data submittal list/ Schedule
3
6
2 weeks + Monthly
6
2 weeks after approval
2
Manufacturing Equipment List, Testing Facility, Manufacturing Procedure, test and Delivery Schedule (Item wise)
3
6
2 weeks + Monthly
6
2 weeks
6
3
Progress Report
3
6
2 weeks + Monthly
4
Catalogues / Reference
3
5
Code Compliance Certificates, ISO:9000 or other QAM
3
6
3weeks
6
6
QA/QC Programme
3
6
2 weeks
6
2 weeks after approval 2 weeks after Approval
Page 12 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
Item
HRC
Documents and Data
Number of Copies
Number of Copies
Required Date
Number of Copies
Required Date 2 weeks after Approval + With Final Technical File With Final Technical File 2 weeks before Shipping
7
Inspection andTest ProceduresMaterial & ProductCertifications
3
6
4 weeks
6
8
Material & ProductCertifications
6
1 weeks After test
6
9
Packing / Shipping List / Weight andDimensions.
6
8 weeks
6
10
Final TechnicalFile
8
With Shipping
11
Copy of order/LCcopy forprocurement of steelplate/coil/etc
1
45 days
NOTES: 1) Durations in column B (Required date) are weeks after Purchase Order date 2) Durations in column C (Required date) are weeks after document approval. Due date of each document may be proposed. 3) Latest submittal time for: • Test procedure : 2 weeks before test • Test report : 2 weeks after test 4) Final technical file shall be supplied in hard copy as indicated, and inElectronic format on two (2) CD‐ROMs.
Page 13 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
STANDARD SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDED (LSAW) LINE PIPE Specification No. HRC‐TS‐01‐001
Page 14 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
HRC
Abbreviations: ASTM American Society for Testing and Materials API American Petroleum Institute ID Inside Diameter LSAW Longitudinal Seam Submerged Arc Welded HAZ Heat Affected Zone NDT Non Destructive Testing NPS Nominal Pipe Size OD Outside Diameter, Specified WT Wall Thickness, Specified
Page 15 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
1 2 3 4 5 6 7
HRC
CONTENTS SCOPE REFERENCES PROCESS OF MANUFACTURE AND MATERIAL MATERIAL REQUIREMENTS DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES INSPECTION AND TESTING
MARKING 8 COATING AND PROTECTION 9 DOCUMENTS 10 INSPECTIONS OF FIELD TESTS & WARRANTY (New) APPENDIX‐B REPAIR OF DEFECTS BY WELDING (NORMATIVE) APPENDIX‐C REPAIR WELDING PROCEDURE (NORMATIVE) APPENDIX‐F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR 5 FRACTURE TOUGHNESS TESTING (CHARPY V‐NOTCH) FOR PIPES OFSIZE 4½ OR LARGER SR 6 DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER. SR 19 ADDITIONAL FRACTURE TOUGHNESSREQUIREMENTS (TRANSVERSE CHARPY V‐NOTCH)FOR PSL 2 PIPE APPENDIX‐H PURCHASER INSPECTION (NORMATIVE) APPENDIX‐I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) ANNEXURE‐I MANUFACTURING PROCEDURE SPECIFICATION(New) ANNEXURE‐II FIRST DAY PRODUCTION TESTS(New) ANNEXURE‐III INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING(New) FIGURE 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN FIGURE 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT FIGURE 7.8.3 PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD FIGURE9.8.5.2 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM
Page 16 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001
E‐Tender No. 8000004049
GAIL
AMENDMENT STATUS Sr Clause / Paragraph / Annexure / Exhibit / Drawing Amended
HRC
Page No.
Revision
Date
By (Name)
Verified (Name)
Page 17 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001 GAIL
1.0 1.1
1.2
1.3
1.4
2.0 2.1
E‐Tender No. 8000004049
HRC
SCOPE PURPOSEAND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinalseam submerged arc welded steel line pipe in accordance with the requirements of API(American Petroleum Institute) Specification 5L, Forty‐Third Edition, 2004 and makes restrictiveamendments/ Supplements to API Spec. 5L. Unless modified and or deleted by this specification,the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering as that ofAPI Spec 5L in order to facilitate reference. Additional requirements, which are not specified inAPI Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non‐sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with therequirements of Specification 5L, Forty‐Third Edition, 2004 on line pipe as Product SpecificationLevel PSL 2. PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL 2. GRADES This specification is applicable to PSL 2 line pipes of grade B through X60. DIMENSIONS This specification shall be applied to line pipe of size 16” through 48” (both sizes included) References The latest editions (edition enforces at the time of issue of enquiry) of following additionalreferences are included in this specification: ASTM ASTM E 92 : Test Method for Vickers Hardness of Metallic Materials. Standard Test Methods for Determining Average Grain Size. ASTM E 112 : BS BS 5996 : Specification for the Acceptance Level for Internal Imperfection in SteelPlate, Strip and Wide Flats based on Ultrasonic Testing. ASME IX : Boiler & Pressure Vessel code: Welding & brazing quality. ASME B31.8 : Gas Transmission & Distribution piping system. OISD – 141 : Oil Industries safety distribution piping system API RP 5 L1 : Recommended practice for railroad transmission of line pipe
Page 18 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001 GAIL
E‐Tender No. 8000004049
HRC
3.0
Process of Manufacture and Material 3.1 PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as perthis specification: Welding Process: Submerged Arc Welding as per para 5.1.2.2.1 Type of Pipe: Longitudinal Seam Submerged Arc Welded Pipe as per para 5.1.3.5 Type of Seam Weld: Submerged Arc Weld (Longitudinal Seam) as per para 5.1.4.3 3.2 COLD EXPANSION All pipes shall be mechanically cold expanded for full length. The expansion measured on thecircumference shall range between 0.8 to 1.5% of the value measured before the expansion. Theexpansion shall be measured and recorded for one out of every 50 pipes. 3.3 MATERIAL 3.3.1 Line pipe furnished to this specification shall be made from steel produced in basic oxygen (New)or electric arc furnace. The steel used for manufacture of pines shall be fully killed and finegrained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel shall be made bycontinuous casting only. 3.4 HEAT TREATMENT The pipes shall be produced from plates/skelp which shall be quenched and tempered orcontrolled rolled or combined controlled rolled and accelerated cooled to impart uniformly fineferritic grain structure to the finished steel. Other types of heat treatment shall be agreed uponbetween Purchaser and Manufacturer. 4.0 Material Requirements 4 1 CHEMICAL PROPERTIES 4.1.1 Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance withTable 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table ‐ 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentageof Weight Element Product Analysis (percent by weight ) C 0.16 max. Mn 1.50 max. (For Grade B to X52) 1.60 max. (For Grade X56 to X70) Si 0.15 min. 0.45 max. S 0.015 max. 0.02 max. P
Page 19 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001 GAIL
E‐Tender No. 8000004049
HRC
Al 0.07 max. Nb 0.05 max. V 0.08 max. Ti 0.04 max. (For Grade B toX60) 0.06 max. (For Grade X65 to X70) Cr 0.20 max. Mo 0.10 max. Cu 0.35 max. Ni 0.20 max. N 0.012 max. B 0.0005 max. Note: g (New) i. V+Nb+Ti shall not exceed 0.1 5% ii. Cu‐+‐Ni shall not exceed 0.40% iii. Al/N shall be min. 2 Note: h (New) If alloying elements other than those specified in Table 2B above are added to the steel, thelimits of the additional components shall be agreed with the Purchaser. Note: i(New) Minimum for Si is not applicable for Al killed steel. 4.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specificationshall be analysed and reported, even if those are not purposely added but are present asresiduals only. 4.1.3 Carbon Equivalent (PSL 2 Only) 4.1.3.1 Calculation of Carbon Equivalent Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 4.1.3.2 Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with thefollowing limits: CE (Pcm)≤ 0.20 % CE (IIW) ≤ 0.40 %
Page 20 of 205
BID DOCUMENT FOR PROCUREMENT OF LINEPIPES Bid Document No. UTPL/GAIL/HRC/1001 GAIL
E‐Tender No. 8000004049
HRC
4.2
MECHANICAL PROPERTIES 4.2.1 Tensile Properties The finished pipe (after all heat treatment and expansion or sizing operations) shall conform tothe requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under; API Spec 5L Grade Permissible in excess of SMYS. Psi (MPa) Up to and including X46 19,000 (131) X52 TO X65 22,000(152) X70 and Above 20.000 (138) The ratio of body yield strength and body ultimate tensile strength of each test pipe on whichbody yield strength and body ultimate tensile strength are determined, shall not exceed 0.90,when tested using flattened tensile specimen. The ratio between yield strength and ultimatetensile strength for weld metal of finished expanded pipe shall not exceed 0.90, when testedusing cylindrical all weld specimen. The ultimate tensile strength of the weld shall be equal to or better than the specified minimumultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the formula givenin foot note (a) of Table‐3B and shall comply with the minimum values of API Spec 5L AppendixD. However elongation in no case shall be less than 20%. API Spec 5L, Appendix D standsmodified accordingly. 4.2.2 Fracture Toughness Tests 4.2.2.2 Charpy Impact Tests for PSL 2 For all pipe sizes and specified wall thickness, additional fracture toughness requirements as perSupplementary Requirements Appendix‐F SR 19 of API Spec 5L and as modified in thisSpecification shall be applicable for body, weld and heat affected zone. 4.2.2.3 Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V‐notch Impact Test fordetermination of Shear Area in accordance with Supplementary Requirement SR 5A of API Spec5L and as modified in this specification shall be performed. In addition, whenever line pipes arespecified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) servicein Purchase Order. Drop Weight Tear Test in accordance with Supplementary Requirements SR6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size,grade and wall thickness.
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4.2.3
Metallographic Examination 4.2.3.1 A test specimen for metallographic & hardness examination shall be taken transverse to thelongitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once peroperating shift (12 hrs maximum) whichever is occurring more frequently and whenever changesof grade, diameter or wall thickness are made and whenever significant excursions fromoperating heat treatment conditions are encountered. The specimen extraction shall be as per Fig. 6.2.6.1 of this specification. The specimen shall be suitably ground, polished and etched toreveal the macro‐structure. The specimen shall be visually examined using a minimum 10Xmagnification to provide evidence that proper fusion has been obtained for the full thickness, andthere is proper interpretation of passes, their alignment and texture of weld zone. In caseimperfections or defects are observed, it will become a cause for re‐evaluation of weldingparameters and heat treatment as deemed necessary by Purchaser's Representative. 4.2.3.2 Vickers hardness tests shall be carried out on each specimen taken for metallographicexamination in accordance with ASTM E‐92, at locations indicated in Fig. 6.2.6.2 of thisspecification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected Zoneshall start as close to the fusion line as possible. The resulting Vickers hardness value at anypoint shall not exceed 248 HV10, Modalities of re‐test shall be in accordance with para9.12.2 of API Spec. 5L. 5.0 Dimensions, Weights, Lengths, Defects and End Finishes 5.1 DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviateby more than the values given below from that given in Table E‐6C, Appendix E. API Spec 5LTable 7 stands modified accordingly. Size Tolerances ≥16 and 36 ± 3 mm. Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable onthe inside diameter. The inside diameter, based on circumferential measurement, over a length of 100 mm from theend shall comply with the tolerances specified in API Spec 5L. Inside diameter is defined as ID =(OD‐ 2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specifiedwall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum inside diameter atpipe ends, shall not exceed the following:
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Size Tolerance ≤36”: 0.5%of OD ≥36: ≤ 5mm Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundnesstolerances apply to maximum and minimum diameters as measured with a bar gauge, caliper ordevice measuring actual maximum and minimum diameter. Each pipe shall be measured for conformance to above requirements. All dimensions andtolerances shall be measured and recorded at least 3 times per operating shift (12 hrs.maximum). WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6 o'clockand 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of thisspecification. The tolerances on specified wail thickness shall be (+) 15% and (‐) 0%. API Spec 5L Table 9stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hoursmaximum).
5.3
LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with lengthbetween 10.0 m and 11.5 m can also be accepted for a max. of 5% of the ordered quantity. Theminimum average length of the entire ordered quantity in any case shall be 12.0m. API Spec 5L. Table 11 shall not be applicable. Overall length tolerance shall be (‐) 'Zero and (+) One pipelength to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurementsshall be recorded. 5.4 STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall bechecked for conformance to this requirement. Straightness shall be measured and recorded atleast 3 times per operating shift (12 hours maximum). 5.5 JOINTERS Jointers on pipes are not permitted. 5.6 WORKMANSHIP AND DEFECTS 5.6.1 Dents Allowable dent size shall be as per API Spec 5L.
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Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d).Dents on weld and heat affected zone (HAZ) are not acceptable. 5.6.2 Offset of Plate Edges All pipes shall be checked for offset of plate/ skelp edges. Offset shall be measured and recordedat least 3 times per operating shift (12 hours maximum). 5.6.3 Out‐of‐Line Weld Bead for Pipe with Filler Metal Welds A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment shall bemeasured on radiographic film and calculated using the formula (a+b)/2 where 'a‟ and 'b' are therelative offsets of the outside edges of the seam (refer Figure 7.8.3 of this specification). All pipesshall be checked for out‐of‐line weld bead and shall be measured and recorded at least 3 timesper operating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out on metallographic examinationspecimen as stated at para 4.2.3, 5.6.4 Height of Outside and Inside Weld Beads ‐ Submerged Arc Welds The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.) forall specified wall thickness. All pipes shall be checked for weld bead height using a templatehaving a cut out for weld bead and shall be measured and recorded at least 3 times peroperating shift (12 hours maximum). 5.6.5 Hard Spots Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction andhardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spotshall be removed as a cylinder. 5.6.6 Cracks, Sweats and Leaks Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the requirementof API Spec 5L para 9.9 (c) or (d). 5.6.7 Laminations Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25mm from pipe ends is considered defect and pipe containing such defects shall be cut back untilsuch defects are eliminated. The acceptance limit and disposition of lamination and other type of detects on the plate/skelpshall be as per para 9.8.5.4 of this specification. 5.6.8 Undercuts Undercutting not classified as minor shall be considered a defect. Disposition shall he as follows:
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1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12 ½ % of thespecified wall thickness shall be removed by grinding in accordance with API Spec 5L para 9.9(a) and as modified in this specification. 2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12 ½ % of the specified wallthickness shall be in accordance with API Spec 5L para 9.9 (c) or (d). 5.6.9 Other Defects Any imperfection (measured from the surface) with a depth greater than 5% of the specified wallthickness of the pipe shall be considered a defect and shall be repaired in accordance with para9.9 and as modified in this specification. 5.6.10 Peaking(New) Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6 mm. Each pipeshall be checked for conformance to above requirement. Peaking shall be measured andrecorded at least 3 times per operating shift (12 hrs. maximum). Pipes not complying with theserequirements shall be disposed off as per API Spec. 5L para 9.9 (c) or (d). 5.7 PIPE ENDS 5.7.1 General Pipes shall be furnished with plain ends. 5.7.2 Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L.In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metaland not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wallthickness as indicated in para 7.3 of this specification, shall be a cause for rebevelling. In caseroot face of bevel is less than that specified, the pipe ends shall be rebevelled and rectification byfiling or grinding shall not be done. 5.7.3 Bevel Protectors(New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevelprotectors as per Manufacturer's standard. Bevel protectors shall be of a design such that theycan he re‐used by coating applicator for providing on externally anti‐corrosion coated pipessubsequent to coating of line pipe.
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6.0
INSPECTION AND TESTING 6.1 TESTING OF CHEMICAL COMPOSITION 6.1.1 Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by theManufacturer prior to start of pipe production. 6.1.2 Product Analysis 6.1.2.1 Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes per heat. Pipesselected shall be such that one at the beginning of the heat and one at the end of the heat arealso represented. 6.1.2.2 Sampling Method 6.1.2.2.1Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for productanalysis from plate/skelp may be used provided the traceability of samples is guaranteed. 6.2 TESTING OF MECHANICAL PROPERTIES 6.2.1 Tensile Tests Tensile property shall be determined from specimen removed from pipe which has beensubjected to all mechanical operations. 6.2.1.1 Tensile Testing Frequency One test shall be carried out at the beginning of each shift. Minimum of one testshall be carried out for pipes of each grade, size and specified wall thickness. Inaddition, whenever the production line settings are changed, the first producedpipe shall be tested for residual stress. 6.2.1.2 Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen. 6.2.1.3 Weld Tensile Tests Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from thespecimen either by grinding or machining. Specimen shall be tested for ultimate tensile strengthonly. A cylindrical all weld tensile test shall be carried out at the time of first day production test asspecified in Annexure‐II of this specification to determine the yield strength, ultimate tensilestrength and elongation.
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The cylindrical all weld specimen shall have gauge length, L = 5d, where; L = gauge length (mm) D = diameter of the test specimen (mm) The results of the test shall meet the minimum requirements of the plate/skelp with regard toyield, tensile and elongation parameter. 6.2.2 Fracture Toughness Tests 6.2.2.1 Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens withweld in middle and three transverse specimens with heat affected zone (HAZ) in the middle shallalso be taken. 6.2.2.2 Charpy Testing Frequency The minimum test frequency shall he one test (a set of three specimen each for body, weld andHAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. 6.3 HYDROSTATIC TESTS 6.3.1 Hydrostatic Test Requirements Hydro test shall be carried out after cold expansion. Test pressure shall be held for a minimumperiod of I5 seconds for all sizes and grades of pipes. 6.3.2 Verification of Hydrostatic Teat The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times andmaximum range of 4 times the test pressure. The pressure gauge shall be calibrated by meansof a "Dead Weight" tester only and record shall be maintained. Calibration record shall befurnished to the purchaser’s representative on request. 6.3.3 Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress)generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5Lpara 9.4.3 (Note 2). 6.3.4 Burst Test(New) Burst test shall be done on each type of pipe for each size on lowest thickness. Burst pressure &location of failure shall be recorded. Technical audit shall be carried out by OWNER / OWNERSrepresentative during manufacturing.Minimum Burst Test pressure shall not be less than the actual tensile stress factor computedpressure.
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6.4
DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisions of API Spec5L shall be calibrated with manual instruments at least once per operating shift (12 hoursmaximum). Such calibration records shall be furnished to Purchaser's Representative onrequest. 6.5 VISUAL INSPECTION All pipes shall be visually examined both externally and internally (to the extent feasible) andshall be free of defects in the finished condition. 6.6 NON DESTRUCTIVE INSPECTION The Purchaser reserves the right to depute its Representative(s) to perform inspection andwitness tests in all phases of manufacturing and testing starting from steel making to finished linepipe ready for shipment. Manufacturer shall comply with the provisions regarding inspectionnotice, plant access, compliance and rejection mentioned in Appendix H of API Spec 5L. TheManufacturer shall give the Purchaser reasonable notice of the starting date of normal productionand the work schedule. Any action or omission on part of Purchaser's Representative shall notrelieve the Manufacturer of his responsibility and obligation to supply material in strictaccordance with this specification. 6.6.1 Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordancewith latest edition of ISO 9712 or ASNT No. ASNT‐TC‐1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall haveprior approval of the Purchaser. Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below: i. For UT For UT, at least one level III qualified inspector shall be available to the mill for overallsupervision. A level II inspector is required for shift supervision, manual weld inspection andcalibration of all systems (both manual and automated). ii.For all other NDT methods Evaluation of indications : Level I, II, III inspector Supervision : Level II or Level III inspector (in caseevaluation is by Level I inspector) 6.6.2 Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection ofWeld seam of cold expanded pipe shall be performed after cold expansion and hydro testing. 6.6.2.1 Plate/Skelp Inspection
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The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over a width of atleast 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp shall be ultrasonicallytested for laminations using an oscillating or straight running pattern of probes, so as to provideinspection coverage of at least 20% of the plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re‐examined by manualultrasonic method. If no defects are located during re‐examination, the original findings may beignored. Additional scanning may be requested by Purchaser's Representative to checkquestionable areas. 6.6.2.2 Pipe Ends Inspection The full circumference of both ends of each pipe after beveling shall be 100% ultrasonicallytested for laminations from inside over a circumferential band of at least 25 mm width. Inaddition, full circumference of both ends of each pipe shall be 100 % ultrasonically tested over acircumferential width of at least 50 mm with angular probes to detect cracks. In case of nonavailability of angular probes at the mill, the full circumference of both ends of each pipe shall beinspected with magnetic particle technique over a circumferential width of at least 50 mm todetect surface cracks. 6.6.2.3 Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. 6.6.2.4 Weld Inspection Submerged‐arc welds shall be inspected by ultrasonic methods (Refer Table 24) using automaticultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in thisspecification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be reexaminedby radiography. If during production, repeated ultrasonic indications occur requiring re‐ inspectionby radiography and it appears from radiographs that the nature of defects causing theultrasonic indications cannot be definitely established, the Manufacturer shall prove by otherinspection methods (e.g. by making some cross‐sections in accordance with para 6.2.6 of thisspecification at locations where such indications occur near the end of the pipe) to thesatisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 6.6.2.5Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manualultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged‐arc weld seam shall be radiographically examined for a minimum distance of 8 in.(200 mm) from each pipe end. The results of radiographic inspection shall be recorded. 6.6.3 Radiological Inspection‐Weld Seams 6.6.3.1 Radiological Inspection Equipment The homogeneity of weld seams examined by radiological methods shall be determined bymeans of X‐rays directed through the weld material in order to create a suitable image onradiographic film.
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The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table 2 ofASTM E 94, with minimum density greater than 1.8 measured in connection with radiographicimage of the welding and shall be suitable to allow a sensitivity of at least 1 .8 percent of nominalwall thickness. 6.6.3.2 Radiological Sensitivity Reference Standard The reference standard shall be ISO wire‐type image quality indicator described in 9.8.4.4. 6.6.3.3 Defects Observed During Radiological Inspection Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe material shallbe removed by cutting off the section of pipe containing these defects. The remaining defects freesection of the pipe will be acceptable provided its length is within the specified minimum length, the weld at the new pipe end contains no defects other than those permitted. 6.6.4 Ultrasonic and Electromagnetic Inspection 6.6.4.1 Equipment All automatic ultrasonic equipment shall have an alarm device, which continuously monitors theeffectiveness of the coupling. The equipment for the automatic inspection shall allow thelocalization of both longitudinal and transverse defects corresponding to the signals exceedingthe acceptance limits of the reference standard. The equipment shall be fitted with a paint sprayor automatic marking device and alarm device for areas giving unacceptable ultrasonicindications. All ultrasonic testing equipment shall be provided with recording device. In addition,an automatic weld tracking system shall be provided for correct positioning of the probes withrespect to weld centre. 6.6.4.2 Ultrasonic and Electromagnetic Inspection Reference Standards The reference standard (calibration pipe) shall have the same specified diameter and wallthickness as specified for the production pipe being inspected and shall be of sufficient length topermit calibration of ultrasonic inspection equipment at the speed to be used in normalproduction. The reference standard (calibration pipe) shall also be of the same material, type andhave the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches/holes as per Figure 9.8.5.2of this specification and as given below: ‐ Two longitudinal inside notches of type N 5 at both edges of weld seam. ‐ Two longitudinal outside notches of type N5 at both edges of weld seam. ‐ Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. ‐ Two transverse notches of type N5 across the weld seam, one outside and one inside. A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm The reference standard for plate/skelp UT shall contain continuous machined notch of 8 mmwidth x½ t depth, where „t‟ is the specified wall thickness.
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The reference standard for plate/skelp edge UT and pipe ends shall have ¼ inch dia FBH X1/2tdepth, where’t’ is the specified wall thickness. The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency. If during the above calibration verification, it is found that the equipment has not functionedSatisfactorily in the opinion of the Purchaser's Representative, all the pipes or plate/skelpalreadyinspected after the previous verification shall be inspected again at Manufacturer's cost. 6.6.5Acceptance limits 6.6.5.1 Plate/Skelp Edges(New) Acceptance limit for material edge examination shall be as per criteria laid down for AcceptanceLevel E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population densityassessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissibleimperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 6.6.5.2 Remaining Plate/Skelp(New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptancelevel B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall beconsidered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8mm. (The length is the dimension at right angles to the scan track‐and the width is thedimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissibleimperfection size and larger than the minimum imperfection size per I m x 1 m squareshall not exceed 10.
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6.6.6
6.7
6.8 6.8.1
6.8.2
6.9 6.9.1
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4. Any imperfection exceeding 100 mm length shall not be acceptable and any planarimperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall‐effect gauss meter. All residual magnetism measurements shallbe recorded. DISPOSITION OF PIPE CONTAINING DEFECTS a. The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection toensure complete removal of defects. However for repair of cosmetic type of defects, MPI may notbe conducted if so directed by Purchaser's Representative on case to case basis. The pipeshaving a thickness less than the minimum allowed in accordance with this specification, afterrepair by grinding shall be treated for disposition in accordance with 9.9 (c) or (d). b. Repair welding on parent metal is not permitted. In addition to all NDT requirements random radiography of0.1%the total length shall be done.The area to be radiographed shall be at the sole discretion of the Third Party Inspection Agency. TEST METHODS Guided‐bend Test One face and one root guided bend weld test shall be made on samples cut from pipe. Thefrequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. Thedimension 'A' in guided bend test shall not exceed 4.0 times the thickness of the specimen. Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimumaverage absorbed energy value as per this specification. RETESTS Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested(refer para 6.1.2.1 of this specification). However, during individual testing, each pipe shall befully analyzed to meet the requirements of Table 2B of this specification. Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, themanufacturer may elect to replace the lot (refer para 6.2.2.2 of this specification) of materialinvolved or alternatively to test two more lengths from that lot. If both the new tests meet
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6.10
7.0 7.1
8.0 8.1
9.0 9.1
9.2
9.3
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theacceptance criteria, then the entire pipe in that lot, with the exception of the original selectedlength, shall be considered to meet the requirement. REPROCESSING This para stands cancelled. MARKING General Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be inEnglish language and International System (SI) of units. Marking shall comply with Appendix I ofAPI Spec 5L, and as modified in this specification. COATING AND PROTECTION Coatings Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of anytrace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevelsshall be free of any coating. DOCUMENTS Certification Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material hasbeen manufactured, sampled, tested, and inspected in accordance with this specification andhas been found to meet the requirements. In addition all details as per Appendix FSupplementary Requirement SR 15 shall also be submitted to Purchaser/PurchaserRepresentative during inspection at pipe mill. Retention of Records In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain therecords of all additional tests and calibration records mentioned in this specification including thehard copy records of ultrasonic testing carried out on pipe/plate/skelp as well as pipe ends. Production Report (New) The Manufacturer shall provide six copies of production report in English language indicating atleast the following for each pipe. International System of units (SI) shall be adopted. ‐ Pipe number ‐ Heat number from which pipe is produced ‐ Pipe length and weight ‐ Pipe grade The Manufacturer shall provide six copies of acceptance certificates which shall include theresults of all tests required as per this specification and performed on delivered material givingdetails of, but not limited to, the following:
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10.0
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‐ All test certificates as per SR 15.1. ‐ Records of qualification of welders and procedures for repair welding. ‐ Certified reports of dimensional, workmanship and defects inspection. ‐ Data on test failures, rejected heats/lots, etc. ‐ All other reports and results required as per this specification. The certificates shall be valid only when signed by the Purchaser's Representative. Only thosepipes, which have been certified by the Purchaser's Representative, shall be dispatched from thepipe mill. In the event of small quantities of pipes supplied against this specification, like those for bendsand other similar applications, as specifically called out in the Purchase Order, the productionreport may consist of only test certificates required as per SR 15 of API Spec 5L and other testreports/results required as per this specification. Line Pipe Traceability Data(New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer andshall include, but not limited to, the following: ‐ All marking information ‐ Data of skelp and pipe manufacture ‐ All mechanical properties from test results ‐ All dimensional records ‐ All workmanship and defects inspection records ‐ Final inspection and release date ‐ Description and disposition of repairs ‐ Load‐out /dispatch date ‐ Destination ‐ Consignment details. INSPECTION OF FIELD TEST & WARRANTY (New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that failsunder field hydrostatic test if such failure is caused by a material/manufacturing defect in thepipe. The reimbursement cost shall include pipe, labour and equipment rental for finding,excavating, cutting out and installation of replaced pipe in position. The field hydrostatic testpressure will not exceed that value which will cause a calculated hoop stress equivalent to 95percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that hisRepresentative may witness the hydrostatic test in field, however, the testing and leak (if any)finding and repair operation shall not be postponed because of absence of the Manufacturer'sRepresentative.
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APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.I. 2 WELD SEAM OF WELDED PIPE B. 1.2.1 Repaired welds shall be inspected both by X‐ray and UT. B.3 Procedure for Repair of Submerged‐Arc and Gas Metal‐Are Welds B.3.1 The defective part of the weld shall be clearly marked on the pipe so that the defect can beeasily located and repaired. B.3.2 Following requirements shall also be complied with for repair welding; a. No repair of weld seam is permissible after cold expansion. b. No repair of weld seam is permissible at pipe ends up to a length of 300 mm. c. Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of thelength of pipe. Maximum two repairs per pipe are allowed. d. Repair welding shall be executed only after specific approval by Purchaser Representative for each repair. e. No repair of a repaired weld is permitted. f. The repair weld shall be performed with a minimum of two passes. B.3.4(New) The Manufacturer shall also maintain a record of repairs carried out. The records shall includerepair number, pipe identification number, welding procedure applicable and NDT details.
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AFPENDIX‐ C REPAIR WELDING PROCEDURE (NORMATIVE) C.2 Repair Welding Procedure Qualification C.2.2 Mechanical Testing C.2.2.3 Transverse Guided‐Bend Test The radius of male member of the jig used for guided bend teats shall be RA=2.25 t, where t isspecified wall thickness of pipe. C.2.2.5 (New) For all pipes where fracture toughness test is specified, Charpy V‐Notch impact test as specifiedshall be included in the Repair Welding Procedure Qualification. C.2.2.6 (New) Hardness test as specified in para 4.2.6.2 of this specification shall be included in the procedurequalification. The location of the hardness measurements is to be indicated taking into accountthe new HAZ of the repaired area.
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APPENDIX‐F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Fracture Toughness Testing (Charpy V‐Notch) for Pipe of Size 4 ½ or Larger SR 5.1 The Manufacturer shall perform Charpy V‐notoh test for determining Shear Area. SR 5.3 The specimen shall be full sized or largest obtainable, sub size in case pipeline diameter andthickness does not permit full size specimen. SR 5.4 Flattened specimen shall not be used. SR 5.5 This para stands deleted. SR 5A Shear Area SR 5A.1 Three transverse specimens representing one test shall be taken from one length of pipe perheat per lot of 100 pipes per combination of pipe size and specified wall thickness, SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32°F (0°C). The average shear value of the fracture appearance of the three specimen shall not be lessthan 75% and the all heat average for each order, per diameter, size and grade shall not beless than 80%. Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR5A.5 stand modified based on above mentioned requirements. Wherever 'heat indicated in APISpec 5L.SR 5A.3, SR 5A.4, SR 5A.5 and SR 5A.6 shall be replaced by Mot'. Lot shall be as perSR5A.1 as above. SR 5B.3 Delete existing section and replace with the following. Theminimumabsorbedenergyrequirementsforfullsize(10x10)specimenstaken transversetothepipeaxisaregiveninthetablebelow. Grade
MinimumAverageValue(J)
B X42 X46 X52 X56 X60 X65 X70 X80
27 27 32 36 39 41 45 48 96
MinimumIndividual Value(J) 22 22 24 27 29 31 34 36 80
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Forotherspecimensizesandorientations,thevaluesaboveshallbemultipliedbythefollowing factors: Size 10x10
Orientation Longitudinal
Factor 1.5
10x7.5
Transverse
0.75
10x7.5
Longitudinal
1.125
10x5
Transverse
0.5
10x5
Longitudinal
0.75
Drop Weight Tear Testing (DWTT) on Welded Pipe SR6.1 When required as per para 4.2.2.2 of this specification, fracture toughness for all pipe size, grades and specified wall thickness shall be determined using Drop Weight Tear Test (DWTT) bythe Manufacturer in accordance with the requirements of SR 6.2 thru SR 6.8 of API Spec 5L andas modified in this specification. SR 6.2 Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes percombination of pipe size and specified wall thickness. Unless specified otherwise, the test shallbe conducted at +32°F (0°C). SR 6.4 At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or mare for thespecified test temperature. Note: Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based onabove mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replacedby Hot'. Lot shall be as per SR6.2 as above. SR19 Additional Fracture Toughness Requirements (Transverse Charpy V‐Notch) for PSL 2 Pipe SR 19.1 Except as allowed by SR 19.2 of API Spec 5L,, fracture toughness testing shall be performed inaccordance with the requirements of para 6.2.2.1 and 6.2.2.2 of API Spec 5L and as modified inthis specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified inthe Purchase Order. The required minimum all heat average full size absorbed energy value(based on a set of three specimens) for transverse body specimen shall be the greater of SR19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as perTable 14 of API Spec. SL, the minimum average absorbed energy value shall be 1.5 times thatapplicable for transverse specimen. The required minimum average full size absorbed energyvalue for weld and HAZ specimen shall also be the greater of SR 19.1 (a) and SR 19.1 (b) of APISpec 5L. In addition, the lowest individual absorbed energy value of the three specimens shallnot be less than 80% of the value specified. SR6
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APPENDIX‐H
H.4
H.5
PURCHASER INSPECTION (NORMATIVE) Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, tins shall beadequate reason to refuse final inspection of subsequent pipes until the cause has beeninvestigated and corrective action taken by the Manufacturer. Purchasershallspecifyif, andtowhatextent, production,qualitycontrolandinspection.
hewillmonitortheManufacturer’s(New)
Sufficientfluorescentlightingbothoverheadandatpipeendsshallbeprovidedat the inspectionarea. Facilitiesshallbeprovidedforrollingeachpipejointforinspection.TheManufacturershallmakeultrasonico rothersuitableequipment availableforusebythePurchasertochecktheremainingwallthicknesswhereany defectshavebeenfoundoutofthepipe.
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APPENDIX‐I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.1 General 1.1.1 Marking shall also include API monogram, Purchase Order number, item number, pipe number,wall thickness (mm), heat number and weight. 1.2 Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencilmarking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. Paint used for stencil marking shall withstand a temperature up to 250°C expected to beexperienced during further external anti‐corrosion coating operations of line pipe by coatingapplicator. 1.3 Sequence of Marking 1.3.4 Specified Dimensions: Actual pipe weight in kg shall also be marked. 1.3.5 Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes ofsame diameter but different wall thickness, as indicated in the Purchase Order. The colour codeband shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends. 1.4 Length Actual length shall be marked in metres. 1.5 Die Stamping Additionally, the pipe number shall be placed by cold rolling or tow stress dot marking on theoutside surface of the pipe at an approximate distance of 50 mm from both ends. In case of nonavailabilityof either cold rolling or low stress dot marking facility in pipe mill, an alternativemarking scheme of a permanent nature may be proposed by the Manufacturer.
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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION
A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspectionprocedures from steel making to finished line pipe shall be prepared and submitted to Purchaser forapproval prior to start of production. Manufacture of pipes shall start only after the approval ofManufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phasesof the production of pipes. The manufacturing procedure shall as a minimum include the following information. ‐ Steel/Plate/skelp maker and plant at which steel is produced. ‐ Steel making process with details of secondary refining process and continuous casting process,nominal weight of each heat. ‐ Target chemistry, range of intentionally added elements, limits on heat and product analysis to beplaced on steel maker. ‐ Plate/skelp rolling procedure indicating number of passes, their temperature and thickness reductionin each pass required by Controlled Rolling Procedure and the finishing temperature. ‐ Heat treatment procedure document established as per para 3.4. ‐ Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details ofequipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard forcalibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling,inspection and recording. ‐ Pipe making procedure including plate edge preparation, forming and any other special processproposed. ‐ Welding procedure specification including the details of welding process, brand name, classification,size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of eachelectrode, welding current and voltage for each wire, edge preparation, tack welding method andspacing of tack weld, details of seam tracking system for both inside and outside welding, method ofchecking the setup of the system, limits of internal and external weld reinforcement etc. In addition to the WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approvedwelders of the EPC Contractor to establish the weld ability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill.Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying outWPS / PWR at site. ‐ Method of weld defect removal. ‐ Detailed methodology of cold expansion.
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‐ Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details ofequipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weldlength at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling,inspection and records. ‐ Full details of radiographic testing equipment including radiographic film. ‐ Dimensional tolerances, frequency of checking, measurement and record in a tabular form includingdetails of instruments and equipments proposed. ‐ Detail of techniques proposed for measurement of end square ness and peaking at the welds. ‐ Hydrostatic testing including details of testing equipment, procedure and the relevant test pressurecalculations. ‐ Marking details. ‐ Handling, storage and shipment procedure. ‐ Production Report Formats. ‐ Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements ofsubmission of manufacturing procedure details can be moderated subject to agreement betweenPurchaser and Manufacturer.
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ANNEXURK ‐II (NEW) FIRST DAY PRODUCTION TESTS
Two lengths each of completely finished pipes of first day's production from two different heats (i.e. atotal of four pipe lengths) shall be selected at random for testing to verify that the manufacturingprocedure results in the quality of pipes which are in complete compliance with this specification. Thepipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevantclauses of this specification. These first day's production tests shall be repeated upon any change in the manufacturing procedure asdeemed necessary by Purchaser Representative. The first day production tests shall be carried out onpipes for each wall thickness, each diameter and each grade of steel. In addition, change of width of coilshall also call for first day production tests. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. Thereport shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends andother similar applications, as specifically called out in the Purchase Order, the first day productiontest shall not be carried out. Pipes in such case shall be accepted based on regular productiontests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptancevalues shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. Allultrasonic indications suggesting imperfections in the weld shall be carefully investigated against thecorresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from theradiograph, a cross section of the weld, at the location of the above‐mentioned ultrasonic indication shallbe made in such a way that the nature of the imperfection can definitely be established. c. Radiographic Examination The weld seam of all pipes shall be examined radiographically for the entire length. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of thisSpecification. Purchaser Representative will select the places in pipe from where the test specimen shallbe removed. The following tests shall be conducted:
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i. Four (4) weld guided bend test specimen transverse to the longitudinal weld shall be removed. Of thefour specimens, two specimens shall be used for the face bend test and two for the root bend test.
ii. Tensile tests shall be conducted on: ‐ Two (2) transverse base material specimens. ‐ Two (2) transverse weld material specimen of the longitudinal weld. ‐ Two (2) cylindrical all‐weld specimen of the longitudinal weld. iii. Six (6) weld cross‐section specimen, three (3) from each end of pipe joint shall be taken forMetallographic examination. Two of these specimens shall be tested for hardness at roomtemperature after etching.
iv. Fracture toughness testing specimen shall be extracted as follows: ‐ Four sets of three transverse specimen each from base metal ‐ One set of 3 transverse specimen with weld in middle ‐ One set of 3 transverse specimen with HAZ in middle The base metal specimen shall be tested at ‐ 40, ‐10, 0, + 20° C for shear area and absorbed energy toproduce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of APISpec. 5L and duly modified in this specification for shear area and absorbed energy respectively shallbe complied with. For other temperatures, the value shall be for information only. The sets of weld andHAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as perSR 19 of API Spec. 5L.
v. At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in atransverse direction. The sets of 3 base metal specimen shall be tested at ‐40, ‐10, 0, +20°C for sheararea to produce full transition curve. The value at the test temperature specified in SR 6 of API Spec 5Lduly modified in this specification shall be complied with. For other temperatures, the value shall be forinformation only.
(Note: This test is to be carried out only when required as per para 4.2.2.2 of this specification) Vi. Hardness test shall be conducted on selected pipes as per requirement of para 4.2.3 of thisspecification.
e. In addition, all the tests and inspections require to be conducted as per this specification shall beconducted on all the pipes selected for testing during first day production test.
f. In case of any test failure, no re‐testing shall be applied and the entire first day production shall berejected.
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ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING
The following information as applicable shall be furnished at Bid stage with respect to line pipe to besupplied.
‐ Name(s) of proposed Manufacturer(s)
‐ Authorization letter(s) from Manufacturer(s) where applicable. ‐ Authorization letter(s) from Manufacturer(s) of steel plates, in case plate manufacturing facility is notan integral part of the Supplier’s pipe mill.
‐ Record of similar supplies made earlier by the Manufacturer for both plates and pipes, giving completedetails of diameter, thickness, length, grade of plate / 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 clause 1.2 of this specification. ‐ A clause wise list of technical deviations, if any, from the requirements of this specification shall befurnished in the Performa enclosed with the Enquiry. Deviations indicated anywhere else in the offer shallnot be considered valid. In case of no deviations, Bidder shall write “NO DEVIATIONS” in the saidPerforma.
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FIGURE: 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN
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FIGURE: 7.8.3 X‐RAY FILM PROCIDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD
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STANDARD SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDED (HSAW) LINE PIPE Specification No. HRC‐TS‐01‐002
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Abbreviations: ASTM American Society for Testing and Materials API
American Petroleum Institute
ID
Inside Diameter
HSAW Helical Seam Submerged Arc Welded HAZ
Heat Affected Zone
NDT
Non Destructive Testing
WPS Nominal Pipe Size OP
Outside Diameter, Specified
WT
Wall Thickness, Specified
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CONTENTS 1 2 3 4 5 6 7 8 9 10
SCOPE REFERENCES PROCESS OF MANUFACTURE AND MATERIAL MATERIAL REQUIREMENTS DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES INSPECTION AND TESTING MARKING COATING AND PROTECTION DOCUMENTS (New) INSPECTION OF FIELD TESTS & WARRANTY APPENDIX ‐ B REPAIR OF DEFECTS BY WELDING (NORMATIVE) APPENDIX ‐ C REPAIR WELDING PROCEDURE (NORMATIVE) APPENDIX ‐ F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR 5 SR 6
FRACTURE TOUGHNESS TESTING (CHARPY V‐NOTCH) FORPIPES OF SIZE 4 ½ OR LARGER DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20OR LARGER, GRADE X52 OR HIGHER.
SR 19 ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS(TRANSVERSE CHARPY V‐NOTCH) FOR PSL 2 PIPE APPENDIX ‐H PURCHASER INSPECTION (NORMAT1VE) APPENDIX ‐ I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATWE) ANNEXURE ‐1 FIRST DAY PRODUCTION TESTS(New) FIGURE 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN FIGURE 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT FIGURE 7.8.3 PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELDBEAD FIGURE 6.6.4.2 REFERENCE STANDARD FOR UT OF HELICAL WELD SEAM
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AMENDMENT STATUS Sr Clause / Paragraph / Annexure / Exhibit / Drawing Amended
HRC
Page No.
Revision
Date
By (Name)
Verified (Name)
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1.0 1.1
1.2 1.3 1.4 2.0
HRC
SCOPE PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture oflongitudinal seam submerged arc welded steel line pipe in accordance with therequirements of API (American Petroleum Institute) Specification 5L, Forty‐ThirdEdition, 2004 and makes restrictive amendments to API Spec. 5L. Unless modifiedand or deleted by this specification, the requirements of API Spec. 5L shall remainapplicable. In addition to this specification, wherever stringent, requirements/ provisions/amendments of the latest 44th edition of API Spec 5L (Effective October – 2008),shall also apply. The sections, paragraphs and appendices contained herein have the samenumbering as that of API Spec 5L in order to facilitate reference. Additionalrequirements, which are not specified in API Spec 5L, have also been numberedand marked as “(New)”. The coverage by this specification is limited to line pipe to be used in onshorepipelines transporting non‐sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordancewith the requirements of API Spec 5L, on line pipe as Product Specification LevelPSL 2”. PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification LevelPSL‐2. GRADE This specification is applicable to PSL 2 line pipes of grade B through X60. DIMENSIONS This specification shall be applied to line pipe of size 18 through 48 (both sizesincluded) REFERENCES The latest edition (edition enforce at the time of issue of enquiry) of followingadditional references are included in this specification: ASTM E 92 : Test Method for Vickers Hardness of Metallic Materials. ASTM R 112 : Standard Test Methods for Determining Average GrainSize. BS 5996 : Specification for the Acceptance Level for InternalImperfection in Steel Plate, Strip and Wide Flats,based on Ultrasonic Testing.
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3.0 3.1
HRC
PROCESS OF MANUFACTURE AND MATERIAL Following paragraphs of API Spec 5L shall be applicable to the line pipemanufactured as per this specification: Welding Process : Submerged Arc Welding as per para 5.1.2.2.1 Type of Pipe : Helical Seam Submerged Arc Welded Pipe as per para5.1.3.11 Type of Seam Weld : Submerged Arc Weld (Helical Seam) as per para 5.1.4.3 SUBMERGED ARC WELDING PROCESS The submerged arc welding equipment shall have an automatic weld trackingsystem capable of ensuring accurate positioning of welding head and the weldingedges of the skelp.
3.2 COLD EXPANSION Pipes furnished to this specification shall be non‐expanded. 3.3 MATERIAL 3.3.1 (New) Line pipe furnished to this specification shall be made from steel produced in basicoxygen or electric arc furnace. The steel used for manufacture of pipe shall be fullykilled and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112.Steel shall be made by continuous casting only. 3.4 HEAT TREATMENT The pipes shall be produced from skelp which shall be quenched and tempered orcontrolled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heattreatment shall be agreed upon between Purchaser and Manufacturer. 3.5 SKELP END WELDS IN HELICAL SEAM PIPE Junctions of skelp end weld and helical seam welds in finished pipe are notpermitted. 4.0 MATERIAL REQUIREMENTS 4.1 CHEMICAL PROPERTIES 4.1.1 Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordancewith Table 5 and notes given below. Table 5 of API Spec 5L stands modified as below: Table ‐ 5: PSL 2 Chemical Requirements for Heat and Product Analyses byPercentage of Weight
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Element Product Analysis (percent by weight) C 0.16 max. (For Grade B to X‐56) 0.12 max.(For Grade 60 to X‐80) Mn 1.40 max. (For Grade B to X56) 1.60 max. (For Grade X60 to X65) 1.70 max. (For Grade X70 to X80) Si 0.15 mm. 0.45 max. S 0.015 max. P 0.02 max. Al 0.07 max. Nb 0.05 max. (For Grade B to X46) Note g(i) (For Grade X52 to X80) V 0.05 max. (For Grade B to X46) Note g(i) (For Grade X52 to X80) Ti 0.04 max. (For Grade B to X46) Note g(i) (For Grade X52 to X80) Cr 0.20 max. Mo 0.10 max. (For Grade B to X65) 0.20 Note g(iv) max. (For Grade X70) 0.25 Note g(v) max. (For Grade X80) Cu 0.35 max. Ni 0.20 max. N 0.012 max. B 0.0005 max. Note: g (New) (i) V+Nb+Ti shall not exceed 0.12% (for Grade X52 to X65) and 0.15%(for Grade X70& X80) (ii) Cu+Ni shall not exceed 0.50%. (iii) Al/N shall be min. 2. (iv) Manufacturer should target to limit Mo within 0.10 % (v) Manufacturer should target to limit Mo within 0.20 % Note: h (New) If alloying elements other than those specified in Table 5 above are added to thesteel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 4.1.2 Elements Analyzed For heat analysis and product analysis, all the elements listed in Table 5 of thisspecification shall be analyzed and reported, even if those are not purposely addedbut are present as residuals only.
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4.1.3 Carbon Equivalent (PSL 2 Only) 4.1.3.1 Calculation of Carbon Equivalent Boron content shall be considered in CE (PCM) formula even if it is less than0.0005%. 4.1.3.2 Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall complywith the following limits: CE (Pcm) ≤ 0.20 % CE (IIW) ≤ 0.40 % The IIW limit shall not apply if C # 0.12%. 4.2 MECHANICAL PROPERTIES 4.2.1 Tensile Properties The finished pipe shall conform to the requirements of Table 3B of API Spec 5Land as modified herein. The actual yield strength shall be as close as possible to the specified minimumyield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5 L Grade Permissible in excess of SMYS.psi (MPa) Up to and including X46 19,000 (131) X52 to X65 22,000(152) X70 and above 20,000(138) “The ratio of body yield strength and body ultimate tensile strength of each testpipe on which body yield strength and body ultimate tensile strength aredetermined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal offinished expanded pipe shall not exceed 0.90, when tested using cylindrical all weldspecimen in accordance with Cl. No. 9.3.1.5 during first day production test”. The ultimate tensile strength of the weld shall be equal to or better than thespecified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with theformula given in foot note (a) of Table‐3B and shall comply with the minimumvalues of API Spec 5L Appendix D. However elongation in no case shall be lessthan 20%. API Spec 5L Appendix D stands modified accordingly.
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4.2.2 Fracture Toughness Tests 4.2.2.1 Charpy Impact Tests for PSL 2(New) For all pipe sizes and specified wall thickness, additional fracture toughnessrequirements as per Supplementary Requirements Appendix‐F SR 19 of API Spec5L and as modified in this specification shall be applicable for body, weld and heataffected zone. 4.2.2.2 Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V‐notch Impact Testfor determination of Shear Area in accordance with Supplementary RequirementSR 5A of API Spec 5L and as modified in this specification shall be performed. Inaddition, whenever line pipes are specified for hydrocarbon service in gaseousphase and Liquefied Petroleum Gas (LPG) service in Purchase Order, Drop WeightTear Test in accordance with Supplementary Requirements SR 6 of API Spec 5Land as modified in this specification shall be also performed for all pipe size, gradeand wall thickness. 4.2.3 Metallographic Examination 4.2.3.1 (New) A test specimen for metallographic & hardness examination shall be takentransverse to the helical weld, from one finished pipe from each lot of 50 pipes perheat or at least once per operating shift (12 hrs maximum) whichever is occurringmore frequently and whenever changes of grade, diameter or wall thickness aremade and whenever significant excursions from operating heat treatmentconditions are encountered. The specimen extraction shall be as per Fig. 4.2.3.1 ofthis specification. The specimen shall be suitably ground, polished and etched toreveal the macro‐ structure. The specimen shall be visually examined using aminimum 10 X magnification to provide evidence that proper fusion has beenobtained for the hill thickness, and there is proper interpretation of passes, theiralignment and texture of weld zone. In case imperfections or defects are observed,it will become a cause for re‐evaluation of welding parameters and heat treatmentas deemed necessary by Purchasers Representative. 4.2.3.2 (New) Vickers hardness tests shall be carried out on each specimen taken formetallographic examination in accordance with ASTM E‐92, at locations indicatedFig. 6.2.6.2 of this specification. Indentation in the Heat Affected Zone shall startas close to the fusion line as possible. The resulting Vickers hardness value at anypoint shall not exceed 248 HV10. Modalities of retest shall be in accordance withpara 9.12.2of API Spec. 5L. 4.2.4 Residual Stress Test (New) Helical pipes shall meet the testing and minimum acceptance criteria set forththis paragraph. The residual stress test shall be carried out on the pipe afterhydrostatic test.
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4.2.4.1 Testing Frequency (New) One test shall be carried out at the beginning of each shift. Minimum of one testshall be carried out for pipes of each grade, size and specified wall thickness.addition, whenever the production line settings are changed, the first producedpipe shall be tested for residual stress. 4.2.4.2 Test Specimen (New) The teat specimen shall be 150mm wide ring cut from one end of the pipe. Thespecimen shall either be cut using flame cutting torch or by sawing. 4.2.4.3 Testing (New) The specimen ring shall be severed by flame cuffing or sawing parallel to thelongitudinal axis of the pipe. The cut shall be 180 degree from the spiral weld. (Specimen ring shall be allowed to cool down to ambient temperature priorcutting) 4.2.4.4 Computation of Residual Stress (New) The increase in circumference, if any, after severing shall be measured usingfiducial marks of known separation on the specimen prior to severing. The residualstress then shall be calculated using following formula. S = {(E*t*C)/(12.556 *R2)}‐{(F*R2)/t} Where: S ‐ Residual Stress, kPa (psi) C ‐ Increase in circumference, mm (in) t ‐ Specified wall thickness, mm (in) E ‐ Young's Modulus of Elasticity, 2 x 108kPa, (29 x 106psi) R ‐ Pipe Radius, mm (0.5 * Specified outside diameter), mm (in) F ‐ 0.1154 in SI units, (0.425 in conventional units) 4.2.4.5 Acceptance Criteria (New) The computed residual stress shall not exceed 10% of the Specified Minimum YieldStress (SMYS) of the pipe. 4.2.4.6 Retests (New) If any specimen fails to meet the requirements of paragraph 4.2.7.5 above, thepipe may be retested once. The retest specimen shall be obtained from the sameend of the pipe from where the failed specimen was obtained. If the resultsobtained from the retest specimen are acceptable, normal test schedule shall beresumed. If the results obtained from retest specimen are not acceptable, the pipeshall be rejected and testing shall resume on the next pipe in the production line.
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5.0 5.1
HRC
If this test also fails all pipes back to the last acceptable test shall be individuallytested and those pipes which pass the test shall be accepted. All pipes that fail topass the test shall be rejected. The manufacturer shall evaluate the reasons for thefailure of the test and rectify the same prior to start of production again. Theregular production shall be resumed only after acceptable test result is achieved. DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS AND END FINISHES DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E‐ 6C, Appendix E. API Spec 5L Table 7 stands modified accordingly. Size 18
Tolerance ± 3mm
> 20 and 36 ± 3mm. Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec SL Table 8 shall beapplicable on the inside diameter. The inside diameter, based on circumferential measurement, over a length of 100 mm from the end shall comply with the tolerances specified in API Spec 5L. Insidediameter is defined as ID = (OD‐ 2WT.) where ID, OD & WT are the insidediameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum insidediameter at pipe ends shall not exceed the following: Size
Tolerance
≤36
:
0.5% of OD
≥36
:
≤5 mm
Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundness tolerances apply to maximum and minimum diameters asmeasured with a bar gauge, caliper or device measuring actual maximum andminimum diameter.
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5.2
5.3
5.4
5.5 5.6 5.6.1
HRC
Each pipe shall be measured for conformance to above requirements. Alldimensions and tolerances shall be measured and recorded at least 3 times peroperating shift (12 hrs. maximum). WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checkedalong the circumference at both ends and at the mid location of pipe body at 12o’clock, 3 o’clock, 6 o’clock and 9 o’clock positions. The wall thickness toleranceshall comply with the requirements of this specification. The tolerances on specified wall thickness shall be (+) 10% and (‐) 0%. API Spec5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift(12 hours maximum). LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipewith length between 10.0mand 11.5 m can also be accepted for a max. of 5% ofthe ordered quantity. The minimum average length of the entire ordered quantityin any case shall be 12.0 m. API Spec 5L Table 11 shall not be applicable. Overalllength tolerance shall be (‐) Zero and (+) One pipe length to complete the orderedquantity. Each pipe shall be measured for conformance to above requirements and allmeasurements shall be recorded. STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Eachpipe shall be checked for conformance to this requirement. Straightness shall bemeasured and recorded at least 3 times per operating shift (12 hours maximum). JOINTERS Jointers on pipes are not permitted. WORKMANSHIP AND DEFECTS Dents Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable.
5.6.2 Offset of Plate Edges Forming and welding operations shall be conducted to minimize coil edge offsetand distortion and peaking at the helical or spiral seams. The manufacturer shallprovide the appropriate tooling with
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HRC
'Vee’ blocks and calibrated dial indicatorsneeded to measure the distortion and misalignment at the seam. All pipes shall bechecked for offset of skelp edges. Offset shall be measured and recorded at least 3times per operating shift (12 hours maximum). Measurements shall be taken attwo locations (at a distance of one to two diameters from each end) on each pipejoint. In case of unacceptable offsets, the manufacturer shall adjust the formingand welding equipment. 5.6.3 Out‐of‐Line Weld Bead for Pipe with Filler Metal Welds A misalignment of weld seam exceeding 3.5 mm shall be rejected. Themisalignment shall be measured on radiographic film and calculated using theformula (a+b)/2 where ‘a’ and ‘b' are the relative offsets of the outside edges ofthe seam (refer Figure 7.8.3 of this specification). All pipes shall be checked forout‐of‐line weld bead and shall be measured and recorded at least 3 times peroperating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out onmetallographic examination specimen as stated at para4.2.3. 5.6.4 Height of Outside and Inside Weld Beads ‐ Submerged Arc Welds The maximum height of outside and inside weld bead shall not be more than 3.2mm (1/8 in.) for all specified wall thickness. All pipes shall be checked for weldbead height using a template having a cut out for weld bead and shall bemeasured and recorded at least 3 times per operating shift (12 hours maximum). 5.6.5 Hard Spots Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in anydirection and hardness greater than 248 HV10 shall be rejected. The section of pipecontaining the hard spot shall be removed as a cylinder. 5.6.6 Cracks, Sweats and Leaks: Sections of the pipe containing cracks, sweats and leaks shall be cut off as per therequirement of API Spec 5L para 9.9 (c) or (d). 5.6.7 Laminations Any lamination or inclusion either extending into the face or bevel of the pipe orpresent within 25 mm from pipe ends is considered defect and pipe containingsuch defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of defects on theskelp shall be as per para 9.8.5.4 of this specification. 5.6.8 Undercuts Undercutting not classified as minor shall be considered a defect. Disposition shallbe as follows: 1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding12½% of the specified wall thickness shall be removed by grinding inaccordance with API Spec 5L para 9.9 (a) and as modified in this specification.
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2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12½% ofthe specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d).
5.6.9 Other Defects Any imperfection (measured from the surface) with a depth greater than 5% of thespecified wall thickness of the pipe shall be considered a defect and shall berepaired in accordance with para 9.9 and as modified in this specification. 5.6.10 Peaking(New) Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6mm. Each pipe shall be checked for conformance to above requirement. Peakingshall be measured and recorded at least 3 times per operating shift (12 hrs.maximum). Pipes not complying with these requirements shall be disposed off asper API Spec. 5L para 9.9 (c) or (d). 5.7 PIPE ENDS 5.7.1 General Pipes shall be furnished with plain ends. 5.7.2 Plain Ends Unless specified otherwise, the pipe ends shall be beveled as per API Spec. 5L.In removing the inside burrs at the pipe ends, care shall be taken not to removeexcess metal and not to form an inside cavity or bevel. Removal of excess metalbeyond the minimum wall thickness as indicated in para 7.3 of this specification,shall be a cause for rebevelling. In case root face of bevel is less than thatspecified, the pipe ends shall be rebevelled and rectification by filing or grindingshall not be done. 5.7.3 Bevel Protectors(New) Both pipe ends of each pipe shall be provided with metallic or high impact plasticbevel protectors as per Manufacturer's standard. Bevel protectors shall be of adesign such that they can be re‐used by coating applicator for providing onexternally anti‐corrosion coated pipes subsequent to coating of line pipe. 6.0 INSPECTIONS AND TESTING 6.1 TESTING OF CHEMICAL COMPOSITION 6.1.1 Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall bereported by the Manufacturer prior to start of pipe production.
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6.1.2 Product Analysis 6.1.2.1Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes perheat. Pipes selected shall be such that one at the beginning of the heat and one atthe end of the heat are also represented. 6.1.2.2Sampling Method 6.1.2.3 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples forproduct analysis from skelp may be used provided the traceability of samples isguaranteed. 6.2 TESTING OF MECHANICAL PROPERTIES 6.2.1 Tensile Tests Tensile properties shall be determined from specimen removed from pipe whichhas been subjected to all mechanical and heat treatment operations. 6.2.1.1Tensile Testing Frequency Tensile tests shall be made at the frequency of one test per inspection lot asshown in Table 13, except as modified below: Table 13: Maximum Inspection Lot Size for Tensile Testing For Size >12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table13 shall also be applicable. 6.2.1.2Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen. 6.2.1.3Weld Tensile Tests Inside and outside weld reinforcement in excess of pipe wall thickness shall beremoved from the specimen either by grinding or machining. Specimen shall betested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first dayproduction test as specified in Annexure‐II of this specification to determine theyield strength, ultimate tensile strength and elongation. “As an alternate all weld metal tensile test can be carried out at the time of firstday production on the test sample as per ASME Sec. II C. This test shall berepeated in case any change in batch of wire‐ flux combination.”
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GAIL
HRC
The cylindrical all weld specimen shall have gauge length, L = 5d, where; L = gauge length (mm) D = diameter of the test specimen (mm) The results of the teat shall meet the minimum requirements of the skelpwithregard to yield, tensile and elongation. “As an alternate all weld metal tensile test can be carried out at the time of firstday production on the test sample as per ASME Sec.II C. This test shall berepeated in case any change in batch of wire‐ flux combination.”
6.2.2 Fracture Toughness Tests 6.2.2.1Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transversespecimens with weld in middle and three transverse specimens with heat affectedzone (HAZ) in the middle shall also be taken. 6.2.2.2Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimens each forbody, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size andspecified wall thickness. 6.3 HYDROSTATIC TESTS 6.3.1 Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for each pipe of allsizes and grades. 6.3.2 Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5times and maximum range of 4 times the test pressure. The pressure gauge shallbe calibrated by means of a "Dead Weight" tester only and records shall bemaintained. 6.3.3Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress(fibre stress) generated is at least 95% of SMYS, computed based on the formulamentioned in API Spec 5L para 9.4.3 (Note 2). 6.4 DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisionsof API Spec 5L shall be calibrated with manual instruments at least once peroperating shift (12 hours maximum). Such calibration records shall be furnished toPurchaser's Representative on request.
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6.5 6.6
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VISUAL INSPECTION All pipes shall be visually examined both externally and internally (to the extentfeasible) and shall he free of defects in the finished condition. NON DESTRUCTIVE INSPECTION The Purchaser reserves the right to depute its Representative(s) to performinspection and witness tests in all phases of manufacturing and testing startingfrom steel making to finished line pipe ready for shipment. Manufacturer shallcomply with the provisions regarding inspection notice: plant access, complianceand rejection mentioned in Appendix H of API Spec 5L. The Manufacturer shall givethe Purchaser reasonable notice of the starting date of normal production and thework schedule. Any action or omission on part of Purchaser's Representative shallnot relieve the Manufacturer of his responsibility and obligation to supply materialin‐strict accordance with this specification.
6.6.1 Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied,in accordance with latest edition of ISO 9712 or ASNT No. ASNT‐TC‐1A orequivalent. All NDT shall be performed in accordance with written procedures. Theseprocedures shall have prior approval of the Purchaser. Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below: (i) For UT ‐ For UT, at least one level III qualified inspector shall be available to themill for overall supervision. A level II inspector is required for shift supervision,manual weld inspection and calibration of all systems (both manual andautomated). (ii) For all other NDT methods Evaluation of indications : Level I, II, III inspector Supervision : Level II or Level III inspector(in case evaluation is by Level I inspector) 6.6.2 Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that finalinspection of weld seam shall be performed after hydro testing. 6.6.2.1 Skelp Inspection The longitudinal edges of the skelp shall be 100% ultrasonically inspected overwidth of at least 25 mm from the trimmed skelp edge. Remaining skelp shall beultrasonically tested for laminations
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using an oscillating or straight running patternof probes, so as to provide inspection coverage of at least 20% of the skelpsurface uniformly spread over the area.
Alternatively, skelp UT inspection can be performed after pipe forming provided allapplicable requirements as specified above are complied with. Locations showing indications above the acceptance limits may be re‐examined bymanual ultrasonic method. If no defects are located during re‐examination the original findings may be ignored. Additional scanning may be requested byPurchaser's Representative to check questionable areas.
6.6.2.2 Ends Inspection The full circumference of both ends of each pipe after beveling shall be 100%ultrasonically tested for laminations from inside over a circumferential band of atleast 25 mm width. In addition, full circumference of both ends of each pipe shallbe 100 % ultrasonically tested over a circumferential width of at least 50 mm withangular probes to detect cracks, in case of non‐availability of angular probes at themill, the full circumference of both ends of each pipe shall be inspected withmagnetic particle technique over a circumferential width of at least 50 mm todetect surface cracks. 6.6.2.3 Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detectdefects. 6.6.2.4 Weld Inspection Submerged‐arc welds shall be inspected by ultrasonic methods (Refer Table‐24)using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5and as modified in this specification. Pipe end welds shall be inspected inaccordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonicinspection shall be re‐ examined by radiography, if during production, repeatedultrasonic indications occur requiring re‐ inspection by radiography and it appearsfrom radiographs that the nature of defects causing the ultrasonic indicationscannot be definitely established, the Manufacturer shall prove by other inspectionmethods (e.g. by making some cross‐sections in accordance with para 6.2.6 of thisspecification at locations where such indications occur near the end of the pipe) tothe satisfaction of Purchaser that these are not injurious defects as stipulated inthis specification. 6.6.2.5 Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected bymanual ultrasonic equipment with same sensitivity and capability as automaticequipment. Submerged‐arc weld seam shall be radio graphically examined for a minimumdistance of 8 in. (200 mm) from each pipe end. The results of radiographicinspection shall be recorded. 6.6.3 Radiological Inspection‐Weld Seams 6.6.3.1 Radiological Inspection Equipment The homogeneity of weld seams examined by radiological methods shall bedetermined by means of X‐rays directed through the weld material in order tocreate a suitable image on radiographic film.
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The film used for radiographic inspection of weld seam shall be class 1 or 2 as perTable‐2 of ASTM E 94; with minimum density greater than 1.8 measured inconnection with radiographic image of the welding and shall be suitable to allow asensitivity of at least 1.8 percent of nominal wall thickness.
6.6.3.2 Radiological Sensitivity Reference Standard The reference standard shall be ISO wire‐type image quality indicator described in 9.8.4.4. 6.6.3.3 Defects Observed During Radiological Inspection Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipematerial shall be removed by cutting off the section of pipe containing thesedefects. The remaining defects‐free section of the pipe will be acceptable providedits length is within the specified minimum length, the weld at the new pipe endcontains no defects other than those permitted. 6.6.4 Ultrasonic and Electromagnetic inspection 6.6.4.1 Equipment All automatic ultrasonic equipment shall have an alarm device, which continuouslymonitors the effectiveness of the coupling. The equipment for the automaticinspection shall allow the localization of both longitudinal and transverse defectscorresponding to the signals exceeding the acceptance limits of the referencestandard. The equipment shall be fitted with a paint spray or automatic markingdevice and alarm device for areas giving unacceptable ultrasonic indications. Allultrasonic testing equipment shall be provided with recording device. In addition,an automatic weld tracking system shall be provided for correct positioning of theprobes with respect to weld centre. 6.6.4.2 Ultrasonic and Electromagnetic Inspection Reference Standards The reference standard (calibration pipe) shall have the same specified diameterand wall thickness as specified for the production pipe being inspected and shall beof sufficient length to permit calibration of ultrasonic inspection equipment at thespeed to be used in normal production. The reference standard (calibration pipe)shall also be of the same material, type and have the same surface finish and heattreatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches/holes as per asper Figure 9.8.5.2 of this specification and as given below; ‐ Two longitudinal inside notches of type N5 at both edges of weld seam. ‐ Two longitudinal outside notches of type N5 at both edges of weld seam. ‐ Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. ‐ Two transverse notches of type N5 across the weld seam, one outside and oneinside. ‐ A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm. The reference standard for skelp UT shall contain continuous machined notch of 8mm width x ½ t depth, where “t” is the specified wall thickness. The reference standard for skelp edge UT and pipe ends shall have ¼” inch diaFBH x ½ t depth, where “t” is the specified wall thickness.
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HRC
The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency.
If during the above calibration verification, it is found that the equipment has notfunctioned satisfactorily in the opinion of the Purchaser's Representative, all thepipes or skelp already inspected after the previous verification shall be inspectedagain at Manufacturer's cost. 6.6.4.3Acceptance limits 6.6.4.3.1Skelp Edges(New) Acceptance limit for material edge examination shall be as per criteria laid down forAcceptance Level E2 of BS 5996:1993, which is reproduced hereunder for readyreference. 1. No individual imperfection of length less than 20 mm shall be considered forpopulation density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than themaximum permissible imperfection size and longer than 20 mm per 1m length)shall not exceed 4. Disposition of any defect shall be as per API Spec L, para 9.9 (c) or (d). 6.6.4.3.2Remaining Skelp(New) Acceptance limit for material body examination shall be as per criteria laid down forAcceptance level B4 of BS 5996: 1993 which is reproduced hereunder for readyreference: 1. No individual imperfection that does not exceed all of the following dimensionsshall be considered for population density assessment: Area: 300 mm2, Length:35 mm, Width: 8 mm. (The length is the dimension at right angles to the scantrack and the width is the dimension parallel to the scan track) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximumpermissible imperfection size and larger than the minimum imperfection sizeper 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and anyplanar imperfection not parallel to the skelp surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 6.6.5 Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one readingshall exceed 25 gauss when measured with Hall‐effect gauss meter. All residualmagnetism measurements shall be recorded.
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6.7
HRC
DISPOSITION OF PIPE CONTAINING DEFECTS Suitable tools to eliminate defects by grinding shall be used. The repaired areashall be 100% rechecked by magnetic particle or ultrasonic inspection to ensurecomplete removal of defects. However for repair of cosmetic type of defects,MPI may not be conducted if so directed by Purchaser's Representative on caseto case basis. The pipes having a thickness less than the minimum allowed inaccordance with this specification, after repair by grinding shall be treated fordisposition in accordance with API Spec 5L para 9.9 (c) or (d). TEST METHODS
6.8 6.8.1 Guided‐bend Test One face and one root guided bend weld test shall be made on samples cut frompipe. The frequency of testing shall be same as for tensile test as per para9.3.1.2 of this specification. The dimension ‘A’ in guided bend test shall not exceed4.0 times the thickness of the specimen. 6.8.2 Charpy Test Individual test value for any specimen shall not be less than 80% of the requiredminimum average absorbed energy value as per this specification. 6.9 RETESTS 6.9.1 Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individualtesting, each pipe shall be fully analyzed to meet the requirements of Table 5 ofthis specification. 6.9.2 Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptancecriteria, the manufacturer may elect to replace the lot (refer para6.2.2.2 of thisspecification) of material involved or alternatively to test two more lengths fromthat lot. If both the new tests meet the acceptance criteria, then all pipes in thatlot, with the exception of the original selected length, shall be considered to meetthe requirement. 6.10 REPROCESSING This para stands cancelled. 7.0 Marking 7.1 GENERAL Marking specified in API Paragraphs and otherwise specified in the Purchase Ordershall be in English language and international system (SI) of units. Marking shallcomply with Appendix‐I of API Spec 5L and as modified in this specification.
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8.0 8.1
9.0 9.1
9.2
9.3
HRC
COATING AND PROTECTION COATINGS Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare,free of any trace of oil, stain, grease and paint. Varnish coating shall be applied onthe marking area. Bevels shall be free of any coating. DOCUMENTS CERTIFICATION Manufacturer shall furnish to Purchaser a certificate of compliance stating that thematerial has been manufactured, sampled, tested, and inspected in accordancewith this specification and has been found to meet the requirements. In addition alldetails as per Appendix F Supplementary Requirement SR 15 shall also besubmitted to Purchaser/Purchaser Representative during inspection at pipe mill.
RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shallretain the records of all additional tests and calibration records mentioned in thisspecification including the hard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends. PRODUCTION REPORT(New) The Manufacturer shall provide six copies of production report in English languageindicating at least the following for each pipe. International system of units (SI)shall be adopted. ‐ Pipe number ‐ Heat number from which pipe is produced ‐ Pipe length and weight. ‐ Pipe grade The Manufacturer shall provide six copies of acceptance certificates which shallinclude the results of all tests required as per this specification and performed ondelivered material giving details of, but not limited to, the following:
‐ All test certificates as per SR 15.1. ‐ Records of qualification of welders and procedures for repair welding. ‐ Certified reports of dimensional, workmanship and defects inspection. ‐ Data on test failures, rejected heats/lots, etc. ‐ Alt other reports and results required as per this specification.
The certificates shall be valid only when signed by the Purchaser's Representative.Only those pipes, which have been certified by the Purchaser's Representative,shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, likethose for bends and other similar applications, as specifically called out in thePurchase Order the production report may
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HRC
consist of only test certificates requiredas per SR 15 of API Spec 5L and other test reports/results required as per thisspecification. 9.4
LINE PIPE TRACEABILITY DATA(New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compactDisc (CD). The specific data to be recorded shall be agreed between Purchaser andthe Manufacturer and shall include, but not limited to, the following:
10.0
11.0
‐ All marking information ‐ Data of skelp and pipe manufacture ‐ All mechanical properties from test results ‐ All dimensional records ‐ All workmanship and defects inspection records ‐ Final inspection and release date ‐ Description and disposition of repairs ‐ Load‐out /dispatch date ‐ Destination ‐ Consignment details. INSPECTION OF FIELD TESTS & WARRANTY(New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this orderthat fails under field hydrostatic test if such failure is caused by amaterial/manufacturing defect in the pipe. The reimbursement cost shall includepipe, labour and equipment rental for finding, excavating, cutting out andinstallation of replaced pipe in position. The field hydrostatic test pressure will notexceed that value which will cause a calculated hoop stress equivalent to 95percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advanceso that his Representative may witness the hydrostatic test in field, however, thetesting and leak (if any) finding and repair operation shall not be postponedbecause of absence of the Manufacturer's Representative. WEDABILITY TEST (APPLICABLE FOR GRADE X‐80 ONLY)(New) Manufacturer shall carry out a weld ability test to establish that quality girth weldingmeeting various requirements mentioned in this specification can be achieved. Thistest shall be carried out using pipes from any of the first three heats with highestcarbon equivalent for each size and each wall thickness specified in the purchaseorder. In case more than one mill is proposed to manufacture pipes, the weld abilitytest shall be carried out for each mill. Welding procedure shall comply therequirements of API 1104. Procedure for field weld ability test shall be submitted bythe manufacturer and approved by Purchaser prior to commencement of test. Weld ability test results complying various test requirements mentioned in thisspecification shall be submitted for Company information. Weld ability test shall beconducted for all tests as per this specification including mechanical, impact,DWTT, hardness, NDT etc. The acceptance criteria shall be as per therequirements of this specification. In case of failure of any test results to complythe specification requirements, manufacturer shall revise the welding procedureadopted and carry out
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the tests again to comply the specification requirements.Manufacturer shall submit the test results to Purchaser to comply specificationrequirements prior to shipment/ dispatch of pipes.
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HRC
APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.1.2 Weld Seam of Welded Pipe B.1.2.1 Repaired welds shall be inspected both by X‐ray and UT. B.3 Procedure for Repair of Submerged‐Arc and Gas Metal‐Arc Welds B 3.1 The defective part of the weld shall be clearly marked on the pipe so that thedefect can be easily located and repaired. B.3.2 Following requirements shall also be complied with for repair welding: a. No repair of weld seam is permissible alter hydrostatic testing. b. No repair of weld seam is permissible at pipe ends up to a length of 300mm. c. Cumulative length of weld seam repairs on one pipe length shall notexceed 10% of the length of pipe. Maximum two repairs per pipe areallowed. d. Repair welding shall be executed only after specific approval byPurchaser Representative for each repair. e. No repair of a repaired weld is permitted. f. The repair weld shall be performed with a minimum of two passes. B.3.4 (New) The Manufacturer shall also maintain a record of repairs carried out. The recordsshall include repair number, pipe identification number, welding procedureapplicable and NDT details.
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APPENDIX‐C REPAIR WELDING PROCEDURE (NORMATIVE) C.2 Repair Welding Procedure Qualification C.2.2 Mechanical Testing C.2.2.3Transverse Guided‐Bend Test The radius of male member of the jig used for guided bend tests shall be RA=2.25 t, where “t” is specified wall thickness of pipe. C.2.2.5 (New) For all pipes where fracture toughness test is specified, Charpy V‐Notch impact test as specified shall be included in the Repair Welding Procedure Qualification. C.2.2.6 (New) Hardness test as specified in para 6.2.6.2 of this specification shall be includedin the procedure qualification. The location of the hardness measurements is tobe indicated taking into account die new HAZ of the repaired area
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APPENDIX‐F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Fracture Toughness Testing (Charpy V‐Notch) for Pipe of Size 4 1/2 orLarger SR 5.1 The Manufacturer shall perform Charpy V‐notch test for determining Shear Area. SR 5.3 The specimen shall be full sized or largest obtainable sub size in case pipelinediameter and thickness does not permit full size specimen SR 5.4 Flattened specimen shall not be used. SR 5.5 This para stands deleted. SR 5A Shear Area SR 5 A.1 Three transverse specimens representing one test shall be taken from onelength of pipe per heat per lot of 100 pipes per combination of pipe size andspecified wall thickness. SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be testedat ‐20.2°F (‐29°C), The average shear value of the fracture appearance of thethree specimen shall not be less than 75% and the all heat average for eachorder, per diameter, size and grade shall not be less than 80%. Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements.Wherever 'heat' indicated in API Spec 5L SR5A.3, SR 5A.4, SR 5A.5 and SR5A.6shall be replaced by 'lot'. Lot shall be as per SR5A.1 as above. SR 6 Drop Weight Tear Testing (DWTT) on Welded Pipe SR6.1 When required as per para4.2.2.2 of this specification, fracture toughness forall pipe size, grades and specified wall thickness shall be determined using DropWeight Tear Test (DWTT) by the Manufacturer in accordance with therequirements of SR 6.2 thru SR 6.8 of API Spec 5L and as modified in thisspecification. SR 6.2 Two transverse specimen shall be taken from one length of pipe per heat perlot of 100 pipes per combination of pipe size and specified wall thickness.Unless specified otherwise, the test shall be conducted at +32°F (0°C). SR 6.4 At least 80% of the heats shall exhibit a fracture appearance shear area of 75%or more for the specified test temperature. Note: Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated inAPI Spec SR6.5 shall be replaced by 'lot'. Lot shall be as per SR6.2 as above.
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SR19 Additional Fracture Toughness Requirements (Transverse Charpy‐V‐Notch) for PSL 2 Pipe SR 19.1 Except as allowed by SR 19.2 of API Spec 5L, fracture toughness testing shallbe performed in accordance with the requirements of para 9.3.5.1 and 6.2.2.2of API Spec 5L and as modified in this specification, with a test temperature of‐20.2°F (‐29°C), or at a lower temperature as specified inthe Purchase Order.The required minimum all‐heat average full size absorbed energy value (basedon a set of three specimens) for transverse body specimen shall be the greaterof SR 19 (a) of API Spec 5L and SR 19.1(b). In case longitudinal specimen isapplicable as per Table 14 of API Spec. 5L, the minimum average absorbedenergy value shall be 13 times that applicable for transverse specimen. Therequired minimum average full size absorbed energy value for weld and HAZspecimen shall also be the greater of SR 19.1(a) and SR 19.1 (b) of API Spec5L, In addition, the lowest individual absorbed energy value of the threespecimens shall not be less than 80% of the value specified.
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APPENDIX‐ H PURCHASER INSPECTION (NORMATIVE) H.4
H.5
Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause,this shall be adequate reason to refuse final inspection of subsequent pipesuntil the cause has been investigated and corrective action taken by theManufacturer. Purchasershallspecifyif, andtowhatextent,hewillmonitortheManufacturer’s(New) production,qualitycontrolandinspection.
Sufficientfluorescentlightingbothoverheadandatpipeendsshallbeprovidedat the inspectionarea. Facilities shallbeprovidedforrollingeachpipejointfor inspection.TheManufacturershallmakeultrasonicorothersuitableequipment availableforusebythePurchasertochecktheremainingwallthicknesswhereany defectshavebeenfoundoutofthepipe.
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APPENDIX‐I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) General 1.1 Marking shall also include Purchase Order number/item number, pipe number,heat number and weight. 1.2 Location of Markings Paint used for stencil marking shall withstand a temperature up to 250°Cexpected to be experienced during further external anti‐corrosion coatingoperations of line pipe by coating applicator. 1.3 Sequence of Marking 1.3.1 Specified Dimensions: Actual pipe weight in kg shall also be marked. 1.3.2 Grades and Class: A colour code band shall be marked on inside surface of finished pipe foridentification of pipes of same diameter but different wall thickness, asindicated in the Purchase Order. The colour code band shall be 50 mm wideand shall be marked at a distance of ISO mm from the pipe ends. 1.4 Length Actual length shall be marked in meters. 1.5 Die Stamping Additionally, the pipe number shall be placed by cold rolling or low stress dotmarking on the outside surface of the pipe at an approximate distance of 50mm from both ends. In case of non‐availability of either cold rolling or lowstress dot marking facility in pipe mill, an alternative marking scheme of apermanent nature may be proposed by the Manufacturer. 1.0
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ANNEXURE ‐I (NEW)
FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from twodifferent heats (i.e. a total of four pipe lengths) shall be selected at random fortesting to verify that the manufacturing procedure results in the quality of pipeswhich are in complete compliance with this specification. The pipes thus testedshall be considered to be the test pipes required per heat or per lot as perrelevant clauses of this specification. These first day’s production tests shall be repeated upon any change in themanufacturing procedure as deemed necessary by Purchaser Representative.The first day production tests shall be carried out on pipes for each wallthickness, each diameter and each grade of steel. In addition, change of widthof coil shall also call for first day production test. The Manufacturer shall submit to Purchaser a report giving the results of alltests mentioned below. The report shall be agreed and signed by PurchaserRepresentative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, likethose for bends and other similar applications, as specifically called out in thePurchase Order, the first day production test shall not be carried out. Pipes‐ insuch case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The testmethod and acceptance values shall be as per this specification unless specifieddifferently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparentsurface defects. b.Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automaticultrasonic equipment. All ultrasonic indications suggesting imperfections in theweld shall be carefully investigated against the corresponding points on theradiographs. If the ultrasonic indication cannot be fully explained from theradiograph, a cross section of the weld, at the location of the above‐mentionedultrasonic indication shall be made in such a way that the nature of theimperfection can definitely be established. c.Radiographic Examination The weld seam of all pipes shall be examined radio graphically for the entirelength. d.Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet therequirements of this specification. Purchaser Representative will select theplaces in pipe from where the test specimen shall be removed.
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The following tests shall be conducted: i. Four (4) weld guided bend test specimen transverse to the helical weld shall beremoved. Of the four specimen, two specimen shall be used for the tact‐ bendtest and two for the root bend test. ii. Tensile tests shall be conducted on: ‐ Two (2) transverse base material specimen. ‐ Two (2) transverse weld material specimen of the helical weld. ‐ Two (2) cylindrical all‐weld specimen of the helical weld. iii. Six (6) weld cross‐section specimen, three (3) from each end of pipe joint shallbe taken for metallographic examination. Two of these shall be tested forhardness at room temperature after etching. iv. Fracture toughness testing specimen shall be extracted as follows: ‐ Four sets of three transverse specimen each from base metal ‐ One set of 3 transverse specimen with weld in middle ‐ One set of 3 transverse specimen with HAZ in middle The base metal specimen shall be tested at ‐ 40, ‐10, 0, + 20° C for shear areaand absorbed energy to produce full transition curve. The value at the testtemperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified inthis specification for shear area and absorbed energy respectively shall becomplied with. For other temperatures, the value shall be for information only.The sets of weld and HAZ specimen shall be tested for absorbed energy only atthe same test temperature applicable as per SR 19 of API Spec. 5L. v. At points selected by Purchaser, twelve (12) DWTT specimens shall be removedfrom base metal in a transverse direction. The sets of 3 base metal specimenshall be tested at ‐40, ‐10, 0, +20°C for shear area to produce full transitioncurve. The value at the test temperature specified in SR 6 of API Spec 5L dulymodified in this specification shall be complied with. For other temperatures,the value shall be for information only. (Note: This test is to be carried out onlywhen required as per para4.2.2.2 of this specification) vi. Hardness test shall be conducted on selected pipes as per requirement of para6.2.6 of this specification. vii. One specimen from one pipe end shall be taken for residual stress test. In addition, all the tests and inspections require to be conducted as per thisspecification shall be conducted on all the pipes selected for testing during firstday production test.
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FIGURE: 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN
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3‐LAYER POLYETHYLENE COATING OF LINEPIPES Specification No. HRC‐TS‐01‐004
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CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0
SCOPE REFERENCE DOCUMENTS PLANT SCALE AND INSTALLATION MATERIALS FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING MEASUREMENT AND LOGGING COATING PROCEDURE AND QUALIFICATION PIPE SURFACE PREPARATION COATING APPLICATION INSPECTION AND TESTING HANDLING, TRANSPORTATION AND STORAGE REPAIR OF COATING MARKING QUALITY ASSURANCE ANNEXURE‐I COMBINATIONS OF COATING MATERIALS
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AMENDMENT STATUS Sr Clause / Paragraph / Annexure / Exhibit / Drawing Amended
HRC
Page No.
Revision
Date
By (Name)
Verified (Name)
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2.0
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SCOPE This specification covers the minimum requirements for supply/arrangement ofall materials, plant, equipment, plant sites, consumables, utilities and applicationincluding all labour, supervision, inspection and tests etc. for application ofexternal anti‐corrosion coating of pipes by using 3 Layer Side ExtrudedPolyethylene coating conforming to DIN‐30670, 1991, 'Polyethylene Coating forSteel Pipes and Fittings' and the requirements of this specification. REFERENCE DOCUMENTS Reference has also been made to the latest edition of the following standards,codes and specifications. The edition enforce at the time of floating the enquiryshall be termed as latest edition. a. ASTM D‐149 : Standard Test Methods of Dielectric BreakdownVoltage and Dielectric Strength of Solid ElectricalInsulating Materials at Commercial Frequencies. b. ASTM D‐257 : Standard Test Methods for D‐C Resistance orConductance of Insulating Materials. c. ASTM D‐543 : Standard Method of Test for Resistance of Plastics to Chemical Reagents. : Standard Method of Test for Water Absorption ofPlastics. d. ASTM D‐570 e. ASTM D‐638 : Standard Method of Test for Tensile Properties ofPlastics. f. ASTM D‐792 : Standard Test Method for Density and SpecificGravity(Relative Density) of Plastics byDisplacement. g. ASTM D‐1238 : Test Method for Flow Rates of Thermoplastics byExtrusion h. ASTM D‐1525 : Test Method for Vicat Softening Temperature ofPlastics i. ASTM D‐1603 : Test Method for Carbon Black in Olefin Plastics j. ASTM D‐1693 : Test Method for Environmental Stress Cracking ofEthylene Plastics k. ASTM D‐2240 : Test Method for Rubber PropertyDurometer Hardness l. ASTM D‐3895 : Test Method for Oxidative‐induction Time ofPolyolefins by Differential Scanning Calorimetry m. ASTM G‐42 : Tentative Methods for Cathodic DisbondingofPipeline coatings Subjected to Elevated or CyclicTemperatures. n. API RP 5L1 : Recommended Practice for RailroadTransportation of Line pipe. Transportation of Line Pipe on Barges and MarineVessels o. API RP 5LW : p. DIN EN 10204 : Metallic Products Types of Inspection Documents
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q. DIN 53735 r. ISO 8502‐3
3.0 3.1
3.2
3.3
3.4
HRC
:
Testing of Plastics: Determination of Melt Index ofThermoplastics.
:
Preparation of Steel Stubstrates before Applicationof Paints andRelated Products ‐Part 3 ‐ Assessment of Dust on Steel SurfacesPrepared for Painting (Pressure Sensitive TapeMethod)
s. ISO 9002 : Quality Systems: Specification of Production andInstallation : Preparation of Steel Substrates before Applicationof Paints and t. ISO 11124 Related Products u. SIS 055900 : Preparation of Steel Substrates before Applicationof Paints and Related Products –VisualAssessment of Surface Cleanliness v. API 5L : Specification for Line Pipe w. ASME B31.8 : Gas Transmission and Distribution PipingSystems. x. ASME B31.4 : Liquid Transportation Systems for Hydrocarbons,Liquid Petroleum Gas, Anhydrous Ammonia, andAlcohols y. CSA Z245.20‐98: External Fusion Bond Epoxy Coating for SteelPipe. The CONTRACTOR shall be familiar with the requirements of these documentsand shall make them readily available at the coating plant to all personsconcerned with carrying out the works specified in this specification. PLANT SCALE AND INSTALLATION CONTRACTOR shall size coating plant(s) after evaluating the scale of work andthe time schedule required for the works. Coating plant(s), both new and existing,shall be installed into a yard whose geometry and dimensions are such as toallow the execution of a continuous work schedule. For this purpose theCONTRACTOR shall ensure non‐stop work execution owing to prohibitiveadverse weather conditions and install requisite equipment and plant in roofedand adequately weather protected areas. Plant equipment, machinery and other facilities shall be in first class operatingcondition to at least meet the job requirements of quality and production. Wornout and improvised plants are not acceptable. The CONTRACTOR shall, at his own responsibility and cost, provide andprepare all necessary area for the storage of bare and coated pipe and all othermaterials, for coating yard, stock‐piling and other temporary installation. Foreach area, CONTRACTOR shall provide necessary agreements as requiredwith the land owner(s) / relevant Authorities, and, on work completion, to cleanand pay settlement and claims for damages, as applicable. The CONTRACTOR shall at its own responsibility and cost, provide for water andpower supply and other utilities and consumables and obtain authorizationregarding access roads and other permits required for the execution of worksconforming to all the requirements of the governing Authorities.
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3.5
3.6 3.7 4.0 4.1
4.2
4.3
HRC
The CONTRACTOR shall at its own expense provide a fully equipped laboratoryand test facilities with adequate inventory to carry out tests required for theprocedure qualification and regular production. Outside testing for qualificationand regular production is not acceptable to COMPANY. The CONTRACTOR shall be fully responsible for adherence to all statutoryregulations applicable for handling and disposal of the hazardous chemicalsduring the coating works. The CONTRACTOR shall be responsible for obtaining all statutory approvals /clearances from relevant Authorities including Pollution Control Board, asapplicable for the coating plant(s). MATERIALS The three layer coating system shall comprise of a powder epoxy primer,polymeric adhesive and a polyethylene top coat. Coating materials shall besuitable for the service conditions and the pipe sizes involved. The coatingmaterials i.e. epoxy powder, adhesive and polyethylene compound shall haveproven compatibility. The coating system and materials shall be pre‐qualifiedand approved by COMPANY in accordance with provisions Annexure I of thisspecification. CONTRACTOR shall obtain prior approval from COMPANY for thecoating system and coating materials, The coating materials Manufacturer shall carry out tests for all propertiesspecified in para 5.3.1 and 5.3.2 for each batch of epoxy, adhesive andpolyethylene compound. In addition, the Manufacturer shall also furnish InfraredScan for each batch of epoxy powder. The coating materials Manufacturer shallissue test certificates as per DIN EN 10204, 3.1B for each batch of materialssupplied to CONTRACTOR and the same shall be submitted to COMPANY forapproval prior to their use. In addition to Manufacturer's certificate, the CONTRACTOR shall draw samplesfrom each batch of epoxy, adhesive and polyethylene in the presence ofCOMPANY Representative and test for the following properties at the coatingyard at least one week prior to its use, to establish compliance with theManufacturer's test certificates. a. Epoxy Powder: i. Gel Time ii. Cure time iii. Moisture content iv. Thermal Characteristics (Tg1, Tg2, ΔH) b. Adhesive: i. Specific Gravity ii. Melt Flow Rate iii. Vicat Softening Point c. Polyethylene: i. Melt Flow Rate ii. Specific Gravity iii. Vicat Softening Point iv. Moisture Content v. Oxidative Induction Time
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4.4
4.5
4.6 5.0 5.1
5.2
5.3
HRC
In case of failure of any of the above tests in a batch, that batch of material shallbe tested for all other tests required as per para 5.3.1 and 5.3.2 including thetests which failed. If all tests pass, the batch shall be accepted for coating. If anyof the tests fail, entire batch of material shall be rejected and shall not be usedfor the coating. All materials to be used shall be supplied in sealed, damage free containers andshall be suitably marked with the following minimum information: a. Name of the Manufacturer b. Type of Material c. Batch Number d. Place and Date of Manufacture e. Shelf Life/Expiry Date (if applicable) f. Quantity All materials noted to be without above identification shall be deemed suspectand shall be rejected by COMPANY. Such materials shall not be used forcoating and shall be removed from site and replaced by CONTRACTOR at hisexpense. CONTRACTOR shall ensure that all coating materials are properly stored inaccordance with the Manufacturer's recommendation at all times, to preventdamage and deterioration in quality prior to use. CONTRACTOR shall be required to use all materials on a date received rotationbasis, i.e. first in‐ first used basis. FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING The coating shall be able to withstand a maximum in service operatingtemperature of (+)650C and shall conform to 'S’ Type of coating as per DIN30670. In addition, in open storage the coating must be able to withstand atemperature of at least (+)80°C, without impaling its serviceability andproperties specified. The top coat polyethylene used shall be a black readymade compound, fullystabilized against Influence of ultraviolet reaction (i.e. sunlight), oxygen in airand heat (due to environmental temperature as specified above). Noappreciable changes shall occur during exposure to such environments up to atleast a period of 6000 hours. The CONTRACTOR shall submit certificate fromManufacturer in this regard. Properties Properties of coating system and coating material shall comply the requirementsindicated in subsequent paragraphs. In case the coating / material properties aretested as per test methods / standards other than specified herein below, thesame may be accepted provided the test procedures and test conditions aresame or more stringent than the specified.
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5.3.1 Properties of Epoxy Powder and Adhesive CONTRACTOR shall choose such a brand of epoxy powder and adhesive thatwill achieve the functional requirements and properties of coating system asspecified in para 5.1 and 5.3.3 of this specification respectively. Epoxy powderproperties shall be as per CSA Z245.20.98. The colour of epoxy powder shall beeither green or dark red or any other colour approved by COMPANY except greycolour. Copolymer grafted adhesive shall have the following properties: SI. No. Properties Unit Requirement Test Method a. Melt Flow Rate(190°C/2.16kg) g/10 minutes 1 .0 min ASTM D1238 b. Vicat Softening Point °C 100 min. ASTM D1525 c. Specific Gravity ‐ 0.926 min. ASTM D 792 5.3.2 Properties of Polyethylene Compound SI. No. Properties Unit Requirement Test Method a. Tensile Strength@ + 25° C N/mm2 17 min. ASTM D 638 ASTM D 1238 or b. Melt Flow Rate(190DC/2.16kg) 9/10minutes 0.25 min. DIN 53735 0.926 min. (MDPE) c. Specific Gravity @+ 25°C ‐ ASTM D 792 0.941 min. (HDPE) d. Hardness @ + 25 °C Shore D 50 min. ASTM D 2240 Water Absorption, 2 hours, @ + e. % 0.05 max. ASTM D 57 25 °C f. Volume Resistivity @ + 25°C Ohm‐cm 1016min. ASTM D 257 Dielectric withstand, g. Volts/ mm 30,000 min. ASTM D 149 1000 Volt/sec rise @ + 25°C h. Vicat Softening Point °C 110 min. ASTM D 1525 i. Elongation % 600 min. ASTM D 638 Oxidative Induction Time in j. Oxygen at 220°C, Aluminum pan, Minutes 10 ASTM D389 no screen Environmental Stress Crack Resistance (ESCR) (for F k. 50) :Medium Density‐ Hours 300 ASTM D1693 Condition "C” High Density‐ Condition "B" l. Carbon Black Content % 2 min ASTM D 1603
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5.3.3 Properties of Coating System SI. No. Properties Unit Bond Strength (using Type 2 Test Assemblyi.e. a. Kg/cm Dynamometer). @20+/‐5°C @65+/‐5°C Impact Strength Joules per (Min. of 30 impacts on body mm of b. along the length. No coating breakdown allowed thickness when tested at 25 Kv) Indentation Hardness@23+/‐ mm c. 2°C@70+/‐2°C d. Elongation at Failure % e. Coating Resistivity (*) Ohm ‐ m2 f.
Heat Ageing (*)
‐
g.
Light Ageing (*)
‐
h i. 6.0
Cathodic Disbondment@ + 65° C after 30Days @ + 65°C after 48 hrs Degree of Cure ofEpoxy. PercentageCure, ΔH. ΔTg
mm radius of disbondment (**) % 0
Requirement
Test Method
8.0 min 5.0 min
DIN 30670
7 min
DIN 30670
0.2 max 0.3 max 300 min. 10 8 min. Melt Flow Rate shall not deviate by more than 35% of original value Melt Flow Rate shall not deviate by more than 35% of regional value
DIN 30670 DIN 30670 DIN 30670 DIN 30670
DIN 30670
15 max
ASTM G42
95 +3/ ‐2
CSA Z 245.20‐98(***)
(*) Test carried out in an independent laboratory of national / internationalrecognition on PE top coat is also acceptable. (**) Disbondment shall be equivalent circle radius of total unsealed area as perASTM G42. (***) Temperature to which the test specimens are to be heated during cyclicheating shall however be as per the recommendations of epoxy powdermanufacturer. MEASUREMENT AND LOGGING CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipecoating including pipe number, heat number, diameter, length, wall thickness,defects, coating number, batches of materials, sampling, testing, damages,repairs, rejects and any other information that COMPANY considers to berelevant and required for all incoming bare pipes and COMPANY approvedoutgoing coated pipes as applicable. CONTRACTOR'S documentation shall bedesigned to ensure full traceability of pipe and coating materials through allstages of coating and testing. CONTRACTOR shall submit this information inthe form of a report at the agreed intervals. The above data shall also beprovided in MS ACCESS format in Compact Disc (CD). CONTRACTOR shallprovide one Computer Terminal to COMPANY
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Representative formonitoring/tracking of the above. The CONTRACTOR shall also submit thematerial balance details to COMPANY for information at the end of each shift. 7.0 7.1
COATING PROCEDURE AND QUALIFICATION Upon award of the CONTRACT, the CONTRACTOR shall submit within two (2)weeks, for COMPANY approval, a detailed report in the form of bound manualoutlining, but not limited to, the following: a. Details of plant(s), location(s), layout, capacity and production rate(s). b. Details of the equipment available to carry out the coating works includingsurface preparation, epoxy powder application and its recycling system,adhesive & polyethylene extrusion, moisture control facilities available forcoating materials.
7.2
c. Details of process control and inspection equipment required for the coatingprocesssuch as temperature control, thickness control, holiday testers, etc d. Details of chemical pre‐treatment facilities including process control andinspection equipment for phosphoric acid wash, de‐ionized water wash andchromate wash. e. Facilities in the yard for unloading, handling, transport, production, storage,stockpiling, loading of bare and coated pipes and warehouses for storage ofother coating materials. f. Plant Organization Chart and availability of manpower including coatingspecialist g. Details of utilities/facilities such as water, power, fuel, access roads andcommunication etc. After approval has been given by COMPANY, no change in plant set‐up shall bemade. However, unavoidable changes shall be executed only after obtainingwritten approval from COMPANY. At least four (4) weeks prior to the commencement of production coating, adetailed procedure of the CONTRACTOR'S methods, material proposed, etc. shall be formulated by the CONTRACTOR and submitted for COMPANYapproval in the form of a bound manual. The procedure shall include, but notlimited to, the following information and proposals: a. Pipe inspection at the time of bare pipe receipt. b. Steel surface preparation, including preheating, removal of steel defects,method of pipe cleaning, dust removal, abrasive blast cleaning and surfaceprofile; methods of measurements and consumables. c. Complete details of chemical pre‐treatment viz phosphoric acid wash, deionizedwater wash, and chromate wash including product data sheets,health and safety sheets and manufacturer's recommended applicationprocedure. d. Pipe heating, temperatures and control prior to epoxy application. e. Complete details of raw materials including current data sheets showingvalues for all the properties specified together with quality control andapplication procedure recommendations from manufacturer(s).
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7.3
HRC
f. Application of FBE powder, adhesive and polyethylene, includingcharacteristics, temperature, line speed, application window, curing time, etc. g. Quenching and cooling, including time and temperature. h. Quality Assurance System, Quality Plan, Inspection and Test Plan andreporting formats, including instrument and equipment types, makes anduses, etc i. Detailed method of repair of coating defects duly classified depending uponnature and magnitude of defects and repair thereof including coatingstripping technique j. Details of instrument and equipment calibration methods including relevantstandardsand examples of calibration certificates. k. Complete details and inventory of laboratory and equipment for procedurequalification and regular production l. Pipe handling and stock piling procedure. m. Sample of recording and reporting formats, including laboratory reports,certificates and requirement as per clause 6.0 of this specification. n. Complete details of test certificate for raw material including test methodsand standard used. o. Test certificates from PE compound manufacturer for tests for thermal aging,coating resistively and aging under exposure to light. These test certificatesshall not be older than three years. p. Health, Safety and Environment Plans. q. Storage details of coating materials and chemicals. r. Continuous temperature monitoring at various stages of coating Procedure Qualification Tests (PQT) shall be carried out only after obtainingwritten approval of the above procedure from COMPANY. No change in theprocedure shall be made after approval has been given by the COMPANY.However, unavoidable changes shall be executed only after obtaining writtenapproval from COMPANY. Prior to start of production, the CONTRACTOR shall, at his expense, carry out acoating PQT for each pipe diameter on max. wall thickness, for each type ofpipe, for each coating material combination, and for each plant; to prove that hisplant, materials, and coating procedures result in a quality of end productconforming to the properties stated in clause 5.3, relevant standards,specifications and material manufacturer's recommendations. CONTRACTORshall give seven (7) working days notice to witness all procedures and tests. A batch representing a normal production run, typically 15 pipes, shall be coatedin accordance with the approved coating procedure and the coating operationswitnessed by COMPANY Representative. Out of these pipes, at least one pipeshall be coated partly with epoxy and partly with both epoxy and adhesivelayers.
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HRC
At least 5 (five) test pipes shall be selected by COMPANY Representative forcoating procedure approval tests and shall be subjected to procedurequalification testing as described hereinafter. All tests shall be witnessed by theCOMPANY Representative. Out of 5 (five) test pipes, 1 (one) pipe partly coatedwith epoxy and partly coated with both epoxy and adhesive layers shall beincluded. Remaining 4 (four) test pipes shall have all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a partof coating operations as detailed subsequently Qualification of Procedures
7.4 7.4.1 Epoxy Powder Application & Recycling During pre‐qualification, air pressure in the epoxy spray guns, satisfactoryfunctioning of monitoring system, line speed vs coating thickness, etc. shall beestablished. Dew point of air used to supply the fluidized bed, epoxy spraysystem and epoxy recycling system shall be recorded during the PQT. Also, the CONTRACTOR shall remove samples of reclaimed powder from thereclamation system. These samples of reclaimed powder shall be subject to adetailed visual examination, thermal analysis and moisture content tests. Theproperties of the reclaimed powder shall be within the range specified by theManufacturer of epoxy powder. In case the properties of the reclaimed powderare out of the range specified by the Manufacturer, CONTRACTOR shall not usethe reclaimed powder during the regular production. 7.4.2 Pipe Pre‐heating The CONTRACTOR shall establish the temperature variation due to in‐comingpipe temperature, line speed variation, wall thickness variation, emissivity,interruptions, etc. and document the same during the PQT stage. During PQT,proper functioning of pipe temperature monitoring and recording systemincluding alarm/hooter shall be demonstrated to the COMPANY Representative. 7.4.3 Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance withthe requirements of this specification. The ratio of shots to grits shall beestablished during procedure qualification testing, such that the resultant surfaceprofile is not dished and rounded. The qualification shall be performed through avisual inspection, measurement of roughness and check of the presence of dustin the abrasive blast cleaned pipe surface. 7.4.4 Chemical Pre‐treatment 7.4.4.1 Phosphoric Acid Wash followed by De‐ionized Water Wash The procedure to apply the chemical pre‐treatment viz. phosphoric acid washfollowed by de‐ionized water wash shall be In accordance with therecommendations of the manufacturer and shall result in intended cleaningrequirements of this specification. Working solution preparation, maintainingconcentration, application procedure including method of spreading, spreadingrate, drying times, etc. depending upon the cleanliness/temperature of theincoming pipe and the line speed shall be established. Temperature of thechemical, pipe pre‐heat temperature vs. line speed vs. dwell time, rinsingprocedure, testing & control, rectificatory measures, drying procedure etc.
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shallbe clearly established during PQT. Also the quality of the deionized water shallbe established during PQT. 7.4.4.2 Chromate Treatment The procedure to apply the chromate treatment shall be in accordance with therecommendations of the manufacturer. Working solution preparation,maintainingconcentration, application procedure including method of spreading,spreading rate, drying times, etc. depending upon the temperature of theincoming pipe and the line speed shall be established. Temperature of thechemical, pipe pre‐ heat temperature vs. line speed, pipe heating afterchromating and time limit within which the pipe to be heated, testing &control,certificatory measures, shall be clearly established during PQT. 7.4.5 Coating Application The COMPANY Representative will check the correctness of each coatingapplication operation, values of the main parameters of each operation,preheating pipe surface temperature prior to epoxy powder applicationtemperature, line speed, fusion bonded epoxy curing time, temperature and flowrate of co‐polymer adhesive and polyethylene, etc. and the same shall berecorded. These values shall be complied with during regular production. 7.5 Qualification of Applied Coating 7.5.1 Tests on pipe coated partly with epoxy and partly with epoxy & adhesiveLayers a. Degree of Cure Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipeand the samples shall be taken for cure test using Differential ScanningCalorimetry (DSC) procedure. Care shall be taken to remove the samples offull film thickness avoiding inclusion of steel debris. Glass transitiontemperature differential (ΔTg) and % cure (ΔH) shall comply with thespecified requirements. b. Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9and 12 o'clock positions. The thickness shall comply with the specifiedthickness requirements. c. Adhesive layer Thickness Adhesive layer thickness shall be checked at every one metre spacing at 3,6, 9 and 12'o clock positions. The thickness shall comply with the specifiedthickness requirements d. Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall beset to exceed 5 v/micron of epoxy thickness specified for the portion coatedonly with epoxy layer. e. Adhesion Test
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HRC
i. Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coatedpipe. Test method, no. of test specimen and acceptance criteria shall complyCSA Z.245,20‐98, Table 4. ii. Adhesion of FBE shall also be separately determined at ambient temperatureat two locations by the "St Andrews Cross" method and the test shall complywith the specified requirements. f. 2.5° Flexibility Test 2.5° Flexibility test shall be carried out on the epoxy coated pipe at testtemperature of 0°C. Test method, no. of test specimen and acceptancecriteria shall comply CSA Z.245,20‐98, Table 4. g. Cross‐section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on theepoxy coated pipe. Test method, no. of test specimen and acceptancecriteria shall comply CSA Z.245,20‐98. Table 4.
7.5.2 Tests on pipes coated with all three layers a. Bond Strength: Three test pipes shall be selected for bond strength tests. On each of theselected pipes, three bond strength test shall be performed for eachspecified temperature I.e. one at each end and one in the middle of the pipeand specified requirements shall be complied with, i.e. bond strength as wellas mode of separation. Length of peel shall be minimum 65 mm. None ofthese samples shall fail. b. Impact Strength: Three test pipes shall be selected for impact strength test and the test shallmeet the specified requirements. c. Indentation Hardness: Two samples for both temperatures from all pipes shall be taken. If any oneof these samples fail to satisfy the specified requirements, then the test shallbe repeated on four more samples. In this case, none of the samples shallfail. d. Elongation at failure: Six samples each from three coated pipes i.e. 18 samples In all shall betested and the test shall comply the specified requirement. Only one sampleper pipe may fail. e. Cathodic Disbondment Test: Two CD tests shall be carried out for the total lot of test pipes having all threelayers. One test shall be carried out for 30 days duration and another test for48 hours duration. The tests shall comply the specified requirement.Whenever Procedure Qualification is necessitated for different pipe size withsame coating material combination, 48 hours test only be conducted. 30days CD test is not mandatory in this case.
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f. Holiday Inspection:
All the pipes shall be subject to holiday inspection. The test voltage shall beas specified in para 10.4, (b). g. Coating Thickness Measurement: All pipes shall be subject to coating thickness measurements. Acceptancecriteria shall be as per para 10.3. h. Air Entrapment: One sample each from pipe body and on weld (if applicable) shall be takenfrom all four coated pipes and the specified requirements shall be compliedwith. i. Degree of Cure: Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped fromone coated pipe and the samples shall be taken for cure test usingDifferential Scanning Calorimetry (DSC) procedure. Care shall be taken toremove the samples of full film thickness avoiding inclusion of steel debris.Glass transition temperature differential (ΔTg) and % cure (ΔH) shall complywith the specified requirements.
7.5.3 Inspection of all test pipes All pipes shall be subject to the following Inspections: a. Surface cleanliness, surface roughness measurements and dust controlimmediately after second abrasive blast cleaning and salt test immediately afterDe‐ionized water wash. b. pH of pipe surface before and after phosphoric acid wash. c. visual inspection of chromate coating. d. Visual inspection of finished coating, cut back dimension, internal/externalcleanliness, end sealing and bevel inspection. Acceptance criteria for all inspection and testing shall be as specified in thisspecification. 7.6 After completion of the qualification tests and inspection as per para 7.4 and 7.5above, the CONTRACTOR shall prepare and Issue to COMPANY for approval adetailed report of the above tests and inspection including testreports/certificates of all materials and coatings tested. Only upon writtenapproval from COMPANY, CONTRACTOR shall commence production coating. 7.7 On successful completion of PQT, coating of all five (5) test pipes shall beremoved and completely recycled as per the approved coating procedurespecification, at CONTRACTOR'S expense. Remaining pipes will be acceptedby COMPANY provided they meet the requirements of this specification andneed not be stripped and re‐cycled.
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7.8
HRC
The CONTRACTOR shall re‐establish the requirements of qualification and in amanner as stated before or to the extent considered necessary by COMPANY,in the event of, but not limited to, the following:
• • • • • 7.9
8.0 8.1 8.2
8.3
8.4
Every time there is a change in the previously qualified procedure. Every time there is a change in the manufacturer and change in formulation of any of the raw materials and change in location of raw materialmanufacture. Every time the coating yard is shifted from one location to the other or everytime the critical coating equipments (induction heater, epoxy spray system,extruder, etc) are shifted. Any change In line speed during coating application Any time when in COMPANY'S opinion the properties are deeded to besuspect during regular production tests.
COMPANY reserves the right to conduct any or all the test required forqualification through an independent laboratory or agency at the cost ofCONTRACTOR when in COMPANY's opinion, the results are deemed suspect.COMPANY's decision shall be final. PIPE SURFACE PREPARATION Unless specified otherwise, the pipes shall be supplied free from mill applied oilsbut may be subject to contamination occurring during transit. Prior to cleaning operation, CONTRACTOR shall visually examine the pipes andshall ensure that all defects, flats and other damages have been repaired orremoved. The CONTRACTOR shall also remove marking stickers, if any,present within the pipe. Record shall be kept of such marking on the stickers toensure traceability of pipe after coating. Any oil, grease, salt or other contaminants detrimental to the formation of a goodcoating bond or coating quality shall be removed prior to coating application.Contaminants may be removed by the use of non‐oily solvents. Gasoline orkerosene shall not be used for this purpose. Visible oil and grease spots shall beremoved by solvent wiping. Solvent cleaning shall be in accordance with SSPCSP1.Steel surface shall be allowed to dry before abrasive cleaning. All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasiveblast cleaning. The external surface of the pipe shall be cleaned using 2 no. dryabrasive blast cleaning units to achieve the specified surface cleanliness andprofile. After first abrasive blast cleaning, chemical pre‐ treatment withphosphoric acid solution as per para 8.6 shall be carried out prior to secondabrasive blast cleaning. However at the option of CONTRACTOR, chemical pretreatmentwith phosphoric acid solution as per para 8.6 may be carried out afterthe second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection systemto ensure total removal of dust generated during blast cleaning from the pipesurface. The equipment used for abrasive blast cleaning shall meet the specifiedrequirements and shall be free from oil, water soluble salts and other forms ofcontamination to ensure that the cleaning process is not impaired. Traps,separators and filters shall be checked for condensed water and oil at the startof each shift
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8.5
HRC
and emptied and cleaned regularly. During abrasive blast cleaning,the metallic abrasive shall be continuously sieved to remove "fines" and"contaminants" and the Quality checked at every four hours. Abrasives used forblast cleaning shall comply ISO‐11124 Suitable plugs shall be provided at both pipe ends to prevent entry of anyshot/grit into the pipe during blast cleaning operations. These plugs shall beremoved after blast cleaning. Alternatively the CONTRACTOR may link thepipes suitably together to prevent the entry of any shot/grit into the pipe.
8.6 Chemical Pre‐treatment with Phosphoric Acid Solution 8.6.1 All pipes shall be provided chemical pre‐treatment with phosphoric acid solution.10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used toremove all soluble salts and other soluble contaminants. The CONTRACTOR shall provide data sheets and supporting documentation forthe phosphoric acid to be used. The documentation shall verify that thephosphoric acid is suitable for the treatment of line pipe prior to the applicationof the specific fusion bonded epoxy powder being applied and the final coatingwill meet fully the requirements of this specification. 8.6.2.1 The pipe temperature immediately prior to the phosphoric acid treatment shall be in the range of 450 to 750C. Phosphoric acid treatment shall be followedimmediately by washing with de‐ionized water. De‐ionized water used shall conform to the following requirements: SI. No. Properties Unit Requirement a. Turbidity NTU 1 max. b. c. d. e. f. g.
8.6.3
8.6.4
Conductivity Hardness Total Alkalinity as CaC03 Chloride as CI" Sulphate as SO4 pH
μmho/cm ‐ mg/l mg/l mg/i ‐
5 max. Nil 2 to 3 1 max. 1 max. 6.5 to 7.5
Tests to determine the above properties shall be carried out in accordance with"Standard Methods for the Examination of Water and Wastewater" publishedjointly by American Public Health Association, American Water WorksAssociation and Water Pollution Control Federation. Quality of the de‐ionized water shall be monitored at the start of each shift and atevery four hours interval. Non‐compliance of de‐ionized water wrt the aboverequirements shall cause for stoppage of the operations. The pH of the pipe surface shall be determined both before and after the de‐ionizedwater rinse initially on each pipe and in case of consistent results, thefrequency may be relaxed to once per hour at the discretion of COMPANYRepresentative. The measured pH shall be as follows: Before de‐ionized water wash : 1 to 2 After de‐ionized water wash : 6 to 7 After the de‐ionized water wash, the pipe shall be dried with dry air and preheatedto a temperature of 65°C to 85°C.
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HRC
8.6.5 The salt tests shall be carried out after de‐ionized water rinse. One test shall becarried out at one end of each pipe. The acceptance criteria shall be 2g/cm2. Anapproved salt meter (SCM 400 or equivalent) shall be used to carry out salttests and shall be calibrated in accordance with the equipment manufacturer'srecommendations. 8.7 Abrasive cleaning carried out shall be such that the resultant surface profile Isnot dished and rounded when viewed with 30X magnification. The standard offinish for cleaned pipe shall conform to near white metal finish to Sa 2 ½ ofSwedish Standard SIS 055900 latest edition. Surface of pipe after abrasive blastcleaning shall have an anchor pattern of 50 to 70 microns (Rz), This shall bemeasured for each pipe by a suitable instrument such as surface profile depthgauge. In addition the pipe surface after blast cleaning shall be checked for thedegree of cleanliness (Sa 2 ½), degree of dust and shape of profile. Degree ofdust shall comply the requirements of ISO 8502 ‐ 3. Acceptance limit shall beeither quality rating 2 or Class 2. 8.8 All pipes shall be visually examined for presence of any shot/grit/loose materialleft inside the pipe during blast cleaning. Suitable mechanical means (stiff brush)shall be employed to remove the same before the pipes are processed further.In addition, inside surface of the pipe shall also be visually inspected forpresence of any foreign material or shots and grit (free or embedded/sticking topipe inside surface). The pipe inside surface shall be examined using sharpfloodlight focused at the middle of the pipe at one end while inspection is carriedout visually from other end. Any foreign material or shots/grit present in the pipeshall be completely removed by mechanical brush, high pressure air jets, bytilting of pipe, etc. 8.9 At no time shall the blast cleaning be performed when the relative humidityexceeds 85%. The CONTRACTOR shall measure the ambient conditions atregular intervals during blast cleaning and coating operations and keep recordsof prevailing temperature, humidity and dew point. 8.10 The blast cleaned surface shall not be contaminated with dirt, dust, metalparticles, oil, water or any other foreign material, nor shall the surface or itsanchor pattern be scarred or burnished. All blast cleaned pipe surface shall bekept in dust free enclosure prior to coating. After blast cleaning, all surfaces shallbe thoroughly inspected under adequate lighting to determine anchor pattern,quality of blasting and identify any surface defects prior to coating application. All surface defects such as slivers, scab, burns, laminations, welds spatters,gouges, scores, indentations, slugs or any other defects considered Injurious tothe coating Integrity made visible during blast cleaning shall be reported to theCOMPANY Representative and on permission from COMPANY Representative,such defects shall be removed by filing or grinding. After any grinding ormechanical repairs, the remaining wall thickness shall be checked andcompared with specified thickness. Any pipes having thickness less than 95% ofspecified thickness shall be kept aside and disposed off as per the instructionsof COMPANY Representative. The method employed to remove surface defectsshall not burnish or destroy the anchor pattern or contaminate the surface.Pneumatic tools shall not be used unless they are fitted with effective air/oil andwater traps. Where burnishing results in destruction of anchor pattern, theanchor pattern shall be restored by suitable means. Pipes which have damagesrepaired by grinding and have ground areas more than 50mm in diameter shall be re‐blasted. Any dust or loose residues that have been accumulated during blasting and/orduring filing/grinding operations shall be removed by vacuum cleaning.
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8.11
8.12
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If contamination of surface occurs, the quality of blast cleaning method andprocess shall be examined. If the surface roughness is outside the specifiedlimit, the blast cleaning material shall be checked and replaced. Upon Completion of the blasting operations, the quality control supervisor shallaccept the pipe for further processing or return for re‐blasting after removal ofdefects/imperfections. In case imperfections are considered detrimental to thecoating quality, the same shall be reported to COMPANY'S Representative forfinal decision on rejection or re‐blasting / removal of defects. Re‐ blasting /removal of defects or returning pipe to the yard shall be at the CONTRACTOR'Scost. COMPANY'S Representative, in additions, reserves the right to initiate any ofthe above actions during periodic inspections for oil, dust, salt, imperfections,surface defects, lack of white metal finish, etc. In order to ensure that pipe with defects are not processed further, provisionsshall be available to lift the pipes from inspection stand.
8.13 Chemical Pre‐treatment with Chromate Solution 8.13.1 Following completion of abrasive blast cleaning, all pipe surface shall bechemically pre‐treated with a10% strength chromate solution. 8.13.2 The CONTRACTOR shall provide data sheets and supporting documentation forthe chemical to be used. The documentation shall verify that the chemical issuitable for the treatment of line pipe prior to the application of the specific fusionbonded epoxy powder being applied and the final coating will meet fully therequirements of this specification. 8.13.3 The chemical pre‐treatment shall be applied fully in accordance with the chemicalsuppliers' Instructions and in a manner that ensures 100% uniform coverage ofthe pipe surface without introducing surface contamination. 8.13.4 The CONTRACTOR shall check that the concentration of the chemical pretreatmentsolution remains within the range recommended by the chemicalmanufacturer for the pipe coating process. The concentration shall be checkedat the makeup of each fresh solution and once per hour, using a methodapproved by the chemical manufacturer. The CONTRACTOR shall also ensurethat the chemical pre‐treatment solution remains free from contamination at alltimes. Recycling of chemical pre‐treatment solution is not permitted. 8.13.5 The CONTRACTOR shall ensure that the temperature of the substrate ismaintained between 40°C and 80°C and the chromate solution temperaturedoes not exceed 60°C or as recommended by the manufacturer. 8.13.6 The chromate coating shall be smooth, even, free from runs, drips or excessiveapplication and lightly adherent with no flaking of the coating. The chromatecoated steel must bethoroughly dried immediately after application and shall beachieved by boiling off any residual solution on the surface. 8.14 The total allowable elapsed time between completion of the blasting operationsand commencement of the pre‐coating and heating operations shall be such thatno detectable oxidation of the surface occurs. Relative humidity readings shallbe recorded every half an hour during the blasting operations
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in the immediatevicinity of the operations. The maximum elapsed time shall not exceed theduration given below: Relative Humidity % >80 70 to 80
