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TABLE OF CONTENTS

1. GENERAL .................................................................................................................................................................. 4
1.1. INTRODUCTION............................................................................................................................................................. 4
1.2. PURPOSE..................................................................................................................................................................... 4
1.3. DEFINITIONS ................................................................................................................................................................ 4
2. CODES AND STANDARDS.......................................................................................................................................... 4
3. REFERENCE DOCUMENTS ......................................................................................................................................... 6
4. DOCUMENT PRECEDENCE ........................................................................................................................................ 6
5. SPECIFICATION DEVIATION/CONCESSION CONTROL ................................................................................................ 6
6. QUALITY ASSURANCE/QUALITY CONTROL ............................................................................................................... 7
7. PLATE MANUFACTURE ............................................................................................................................................. 7
7.1. GENERAL REQUIREMENTS ............................................................................................................................................... 7
7.2. ROLLING TECHNIQUE - HEAT TREATMENT .......................................................................................................................... 7
7.3. CHEMICAL COMPOSITION ............................................................................................................................................... 8
8. PLATE ULTRASONIC EXAMINATION .......................................................................................................................... 9
9. PROCESS OF MANUFACTURE ................................................................................................................................... 9
9.1. GENERAL ..................................................................................................................................................................... 9
9.2. MANUFACTURING PROCEDURE...................................................................................................................................... 10
9.3. WELDING .................................................................................................................................................................. 11
10. MECHANICAL PROPERTIES ................................................................................................................................. 13
10.1. TEST FREQUENCY .................................................................................................................................................... 13
10.2. TENSILE TEST ......................................................................................................................................................... 13
10.3. GUIDED BEND TESTS ............................................................................................................................................... 13
10.4. TOUGHNESS TESTS .................................................................................................................................................. 14
10.5. MACRO/MICRO PLUS HARDNESS AND METALLOGRAPHIC TESTS ..................................................................................... 14
10.6. DROP WEIGHT TEAR TESTS ....................................................................................................................................... 15
11. HYDROGEN INDUCED CRACKING TESTS .............................................................................................................. 15
12. SULFIDE STRESS CRACKING TESTS ...................................................................................................................... 15
13. WELDABILITY TESTS............................................................................................................................................ 15
13.1. GENERAL ............................................................................................................................................................... 15
13.2. WELDING SPECIFICATIONS ........................................................................................................................................ 16
14. FIRST DAY PRODUCTION TEST ............................................................................................................................ 16
15. HYDROSTATIC TESTING ...................................................................................................................................... 16
16. NON DESTRUCTIVE INSPECTION ......................................................................................................................... 17
16.1. GENERAL ............................................................................................................................................................... 17
16.2. MAGNETIC PARTICLE INSPECTION............................................................................................................................... 17
16.3. BEVELING INSPECTION ............................................................................................................................................. 17
16.4. ULTRASONIC INSPECTION .......................................................................................................................................... 17
16.5. RADIOGRAPHY........................................................................................................................................................ 18
16.6. RESIDUAL MAGNETISM ............................................................................................................................................ 18

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17. DIMENSIONS, WEIGHTS, AND LENGTHS ............................................................................................................. 19


17.1. LENGTH ................................................................................................................................................................ 19
17.2. WALL THICKNESS .................................................................................................................................................... 19
17.3. DIAMETER ............................................................................................................................................................. 19
17.4. OUT-OF-ROUNDNESS .............................................................................................................................................. 19
17.5. STRAIGHTNESS ....................................................................................................................................................... 19
17.6. MISALIGNMENT OF PLATE EDGES .............................................................................................................................. 20
17.7. BEVELS ................................................................................................................................................................. 20
17.8. JOINTERS ............................................................................................................................................................... 20
18. WORKMANSHIP, VISUAL INSPECTION, AND REPAIR OF DEFECTS ....................................................................... 20
18.1. INSPECTION ........................................................................................................................................................... 20
18.2. WORKMANSHIP ...................................................................................................................................................... 20
18.3. REPAIRS ................................................................................................................................................................ 21
19. MARKING COATING AND BEVEL PROTECTION .................................................................................................... 21
20. RECORDS, TEST REPORTS AND ADDITIONAL INFORMATION .............................................................................. 22
21. SHIPPING AND HANDLING.................................................................................................................................. 22
22. GUARANTEE ....................................................................................................................................................... 23
APPENDICES .................................................................................................................................................................. 24
APPENDIX A: CHARPY V-NOTCH IMPACT REQUIREMENTS (1) (2) .................................................................................................... 24
APPENDIX B: HYDROGEN INDUCED CRACKING (HIC) SENSITIVITY TESTS ............................................................................................. 25
APPENDIX C: TESTING AND INSPECTION ...................................................................................................................................... 28
FIGURES ......................................................................................................................................................................... 30
FIGURE 1: CHARPY IMPACT SPECIMEN LOCATIONS ................................................................................................................... 30
FIGURE 2: HARDNESS SURVEY.............................................................................................................................................. 31

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1. GENERAL
1.1. Introduction
This specification gives the minimum requirements for the purchase of Submerged Arc Welded Line
Pipes for use in gas and liquid hydrocarbon service in sour and non-sour environment for the ABU
DHABI GAS INDUSTRIES LTD (GASCO).
Pipe supplied to this specification shall meet or exceed all the requirements of API 5L and the
additional provisions of this specification.
1.2. Purpose
This specification supplements the requirements for the manufacture of line pipe in accordance with
the API Specification 5L, Forty- Fourth Edition & its subsequent addendums. The Submerged Arc
Welded (SAW) line pipe manufactured to this specification shall conform to product specification
level (PSL) -2 and to the grade of API Specification 5L line pipe specified in the Purchase Order.
1.3. Definitions
Where used in this specification, the following terms shall have the meanings indicated below
unless otherwise clearly indicated by context of their use.

COMPANY: ABU DHABI GAS INDUSTRIES LTD. (GASCO)

CONCESSION REQUEST: A deviation requested by the CONTRACTOR or VENDOR, usually after


receiving the contract package or purchase order. Often, it refers to an authorization to use, repair,
recondition, reclaim, or release materials, components, or equipment already in progress or
completely manufactured but which does not comply with project requirements. A CONCESSION
REQUEST is subject to COMPANY approval.

CONTRACTOR: The party(s) which carries out all or part of the design, engineering, procurement,
construction, commissioning or management of the Project.

MANUFACTURER/VENDOR/SUPPLIER: The party(s) which manufactures and/or supplies the


material/equipment, and provides technical documents/drawings and services to perform the duties
specified by COMPANY/CONTRACTOR.

SUBCONTRACTOR/SUBVENDOR/SUBSUPPLIER: The party(s) which carries out all or part of the


design, procurement, installation and testing of the System(s) as specified by the
CONTRACTOR/VENDOR.

PROJECT: To be defined.

PROJECT MANAGEMENT TEAM (PMT): COMPANY authorized party responsible for overall day-
to-day execution of the PROJECT. PMT Is to serve as the liaison between COMPANY and
CONTRACTOR on the PROJECT.
SHALL: The word ‘Shall’ indicates a mandatory requirement.

SHOULD: The word ‘Should’ indicates a strong recommendation to comply with the requirements of
this document.

2. CODES AND STANDARDS


The following codes and standards, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a code or standard, the latest edition in force at the time of
contract award shall apply.

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AMERICAN PETROLEUM INSTITUTE (API)


API SPECIFICATION 5L Specification for Line Pipe
API RP 5L1 Recommended Practice for Railroad Transportation of Line Pipe
API RP 5LW Recommended Practice for Transportation of Line Pipe on Barges and
Marine Vessels
API RP 5L3 Recommended Practice for Conducting Drop - Weight Tear Tests
on Line Pipe
API 1104 Welding of Pipelines and Related Facilities

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)


ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of
Steel Products
ASTM E23 Standard Test Methods for Notched Bar Impact Testing of Metallic
Materials
ASTM E384 Standard Test Method for Knoop and Vickers Hardness of Materials
ASTM E112 Standard Test Methods for Determining Average Grain Size
ASTM E709 Standard Guide for Magnetic Particle Testing
ASTM E1268 Standard Practice for Assessing the Degree of Banding or Orientation
of Microstructures
ASTM G39 Standard Practice for Preparation and Use of Bent-Beam Stress-
Corrosion Test Specimens
ASTM E94 Standard Guide for Radiographic Examination
ASTM F21 Standard Test Method for Hydrophobic Surface Films by the Atomizer
Test

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)


ASME B 31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
ASME B 31.8 Gas Transmission and Distribution Piping Systems

ASME BOILER AND PRESSURE VESSEL CODE


Section V Non-destructive Examination
Section IX Qualification Standard for Welding and Brazing Procedures, Welders,
Brazers, and Welding and Brazing Operators.

NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)


NACE MR0175/ISO15156 Materials for use in H 2 S containing environments in Oil and Gas
Production -
Part-1: General principles for selection of cracking-resistant materials
Part- 2: Cracking- resistant carbon and low alloy steels, and the use of
cast irons.
Part -3: Cracking-Resistant CRAs (Corrosion-resistant alloys) and
other Alloys.
NACE TM0284 Evaluation of Pipeline and Pressure Vessel Steels for Resistance to
Hydrogen-Induced Cracking
NACE TM0177 Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking
and Stress Corrosion Cracking in H2S Environments

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EUROPEAN COMMITTEE FOR STANDARDIZATION (CEN)


EN 10204 Metallic products - Types of inspection documents
EN 1011 Welding - Recommendations for Welding of Metallic Materials

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)


ISO 9000 Quality management and quality assurance standards
ISO 9001 Quality Management Systems – Requirements
ISO 9004 Managing for the sustained success of an organization — A quality
management approach
ISO 9712 Non destructive testing qualification and certification of personnel

DEUTSCHES INSTITUT FUR NORMUNG


DIN SEL 072 Stahl-Eisen-Lieferbedingungen 072 - Ultrasonically Tested Heavy
Plate, Technical delivery.

3. REFERENCE DOCUMENTS
The following reference documents, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a document, the latest edition in force at the time of the
contract shall apply.
Design General Specifications:
DGS 6300-004 Pipeline Welding
DGS 9530-001 Factory Hot Bends

4. DOCUMENT PRECEDENCE
It shall be the CONTRACTOR’s responsibility to be knowledgeable of the requirements of the
referenced Codes and Standards.
The CONTRACTOR shall notify the COMPANY of any conflict between this specification, the
related data sheets, the Codes and Standards and any other specifications noted herein.
Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before
proceeding with the design or manufacture.
In case of conflict, the order of precedence shall be:
• National and / or Local Regulations
• Purchase Order or Contract including Project Datasheets and Specifications
• Design General Specifications
• Industry Codes and Standards

5. SPECIFICATION DEVIATION/CONCESSION CONTROL


Deviations from this specification are only acceptable where the CONTRACTOR has listed in his
quotation the requirements he cannot, or does not wish to comply with, and the COMPANY has
accepted in writing the deviations before the order is placed.
In the absence of a list of deviations, it will be assumed that the CONTRACTOR complies fully with
this specification.

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Any technical deviations to the Specifications and its attachments including, but not limited to, the
Data Sheets and Narrative Specifications shall be obtained by the CONTRACTOR only through
CONCESSION REQUEST format. CONCESSION REQUESTS require COMPANY’s
review/approval prior to implementation of the proposed changes. Technical changes implemented
prior to COMPANY approval are subject to rejection.

6. QUALITY ASSURANCE/QUALITY CONTROL


The CONTRACTOR shall have in effect at all times, a QA/QC program which clearly establishes
the authority and responsibility of those responsible for the quality system. Persons performing
quality functions shall have sufficient and well defined authority to enforce quality requirements that
initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness
of the corrective action.
CONTRACTOR’s Quality Management Systems shall comply with all the requirements of ISO 9001
“Quality Management Systems – Requirements” and ISO 9004 “Managing for the sustained
success of an organization — A quality management approach”.
A copy of the CONTRACTOR’S QA/QC program shall be submitted to the COMPANY with its
quotation for review and concurrence prior to award. If CONTRACTOR’S QA/QC program is ISO
9000 certified, then only a copy of the ISO 9000 certificate is required. In addition, if
CONTRACTOR’S facility is ISO certified, QA audit requirements will be waived in favor of ISO 9000
registrar audits, unless the COMPANY’s trend analysis program indicates areas of concern.
The CONTRACTOR shall identify in documents to its MANUFACTURERS, SUPPLIERS,
VENDORS and subcontractor’s all applicable QA/QC requirements imposed by the COMPANY, and
shall ensure compliance. CONTRACTOR shall provide objective evidence of its QA/QC
surveillance for all levels of its activity.

7. PLATE MANUFACTURE

7.1. General Requirements


Plate Manufacturer requires prior approval from COMPANY. Plate shall be supplied with material
certification according to EN 10204, Type 3.2.
The steel shall be manufactured by the electric arc furnace process or basic oxygen furnace
(B.O.F.) process and shall be fully killed and made to fine grain practice. Line pipe in sour service
application shall be calcium treated and vacuum degassed.
The grain size shall be ASTM N° 7 or finer as defined in ASTM E 112. The ferrite grain size shall be
determined on one pipe per heat. The specimen shall be prepared and etched for metallographic
examination at 100 X magnification. Grain size shall be reported on the mill test certificate.
Photomicrographs (100 X) shall be provided for each grain size test.
Steel manufacturer shall submit at bid stage for Company approval the methods, standard practices
for preventing center line segregation as well as the associated stereological procedures for
assessing the degree of banding or orientation of microstructures as described in ASTM E1268.
In addition, oxygen analysis shall be requested for information for checking effectiveness of
deoxydation practice.

7.2. Rolling Technique - Heat Treatment


Plates shall be manufactured by thermo mechanical controlled rolled process (M) or supplied in the
normalized (N) or quenched and tempered condition (Q) for grade X52 and above. Grade lower
than X52 may be supplied in the normalized condition (N) unless otherwise stated. The material
supplied must be suitable for induction forming into bends.

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If the CONTRACTOR wishes to supply material manufactured by the thermo-mechanical controlled


rolled process, then supporting data shall be submitted at the bid stage showing that the material
proposed can be hot formed in accordance with the Specification for Factory Hot Bends (DGS
9530-001) and still retain the tensile, charpy and hardness properties defined in this specification.

7.3. Chemical Composition


The CONTRACTOR shall provide a report to the COMPANY, giving the heat analysis of each heat
of steel used in the manufacture of pipe furnished on the purchase order.
The CONTRACTOR shall provide the COMPANY a certified product analysis of the finished pipe.
The product analysis shall include all elements listed in clause 7.3.1 and any other intentionally-
added elements, and shall be performed on two pipes per heat.
If the product analyses fail to meet the criteria specified in clause 7.3.1, then recheck analyses shall
be carried out. Recheck analysis requirement and acceptance criteria shall conform to API 5L,
except that In the event a recheck analysis fails to meet the criteria and the CONTRACTOR elects
to test the remaining pipe, lengths individually, the analysis shall be made for all elements listed in
clause 7.3.1.

7.3.1. Composition

PRODUCT ANAYSIS PRODUCT ANALYSIS


ELEMENT MAXIMUM MAXIMUM WEIGHT MAXIMUM WEIGHT
WEIGHT PERCENT PERCENT
(Non Sour Service) (Sour Service)
C 0.16 (Note-1) 0.16 (Note-1)
Mn 1.60 1.40
Si 0.45 0.40
S 0.01 0.002
P 0.025 0.015
Ca 0.006 0.006
Nb 0.050 0.050
V 0.08 0.08
Ti 0.04 0.04
Al 0.05 0.05
Cu 0.35 0.35
Ni 0.30 0.30
Mo 0.10 0.10
Cr 0.20 0.20
N 0.012 0.012
B 0.0005 0.0005
Sn 0.015 0.015
Sb 0.010 0.010
Bi 0.005 0.005
Pb 0.005 0.005
As 0.005 0.005

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Notes:
1) For Thermo mechanical controlled process, Carbon content shall not exceed 0.12% for Non
Sour service and 0.10% for Sour Service
2) The sum of Nb+V+Ti shall not exceed 0.15 percent.
3) The sum of Cu+Cr+Ni+Mo shall not exceed 0.6 percent.
4) The total Al:N ratio shall not be less than 2:1.
For Sour Service application, for sulphur in the range of 0.0015 – 0.003%, calcium shall be two
times the sulphur content.
The carbon equivalent (CE) based on product analysis and calculated by the following formulas
shall not exceed the indicated percentages:
Mn Cr + Mo + V Ni + Cu
CE = C + + + ≤ 0.39
6 5 15
Pcm = C + Si + Mn + Cu + Cr + Ni + Mo + V + 5B < 0.21
30 20 60 15 10

8. PLATE ULTRASONIC EXAMINATION


Plates used for the manufacture of pipe shall be scanned ultrasonically for laminations detection
according to German Standard, Stahl-Eisen-Lieferbedingungen - SEL-072. A band 50mm wide
measured from the final cut edge of the plate shall be subject to a 100% scan. The remainder of
the plate shall be scanned along parallel, equispaced lines, such that a minimum 25% of the plate
is inspected.
The acceptance criteria shall be based on the lamination size and frequency according to the
classification of SEL-072 as described below:

LOCATION SEL - 072 LAMINATION ACCEPTANCE LEVELS

Plate/Coil body Table 1 Class 1

Plate/Coil edges Table 2 Class 1

9. PROCESS OF MANUFACTURE
9.1. General
The pipe shall conform to the grade of API Specification 5L line pipe as specified by COMPANY,
and as modified by these supplemental requirements.
The pipes shall be manufactured from plates by cold forming (UOE or JCO or 3-Roll Bending
process) and mechanical expansion and shall have one longitudinal seam made by the Automatic
Submerged Arc Welding Process. The longitudinal weld seam shall include at least one pass made
on the inside and at least one pass made on outside in accordance with API Specification 5L. The
joint efficiency factor shall be 1.
After execution of the longitudinal seam, the run-on and run-off tabs shall be removed only by flame
cutting or sawing.
The pipes shall be cold expanded at a permanent straining rate in the range 0.8% to 1.5%. The
expansion ratio shall be recorded on 3 pipes minimum per shift.

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A higher grade of API 5L pipe shall not be substituted for the grade of pipe specified on the
purchase order without the approval of the COMPANY in writing.
The pipe manufacturer shall conduct all tensile, guided-bend, fracture toughness, drop weight tear
test and hardness tests described in this specification. Results of all tests shall be recorded and
provided to the COMPANY. The test results must conform to the requirements of this specification
and API Specification 5L for acceptance. For sour service application, Hydrogen Induced Cracking
(HIC) sensitivity and Sulfide Stress Cracking (SSC) tests shall be conducted as described in this
specification.
9.2. Manufacturing Procedure
A Manufacturing Procedure Specification (MPS) shall be submitted by the pipe mill along with the
list of documents given below at least two weeks prior to the pre-manufacturing meeting (PMM)
which shall be attended by the COMPANY and CONTRACTOR. In addition to the MPS, an
Inspection and Testing Plan (ITP) for steel making and pipe production shall be submitted to the
CONTRACTOR and COMPANY for review. The ITP for steel making and pipe production shall list
all the key activities in a sequential manner and shall specify the personnel responsible, reference
document, acceptance criteria, test report and inspection involvement of the MANUFACTURER for
each activity. ITP shall also include inspection involvement of CONTRACTOR and its third party
inspection agency. ITP shall be submitted for CONTRACTOR and COMPANY review/approval.
COMPANY Third Party Inspection involvement where applicable will be advised by the COMPANY
during review of the ITP.
• Steelmaker, and plant at which steel is produced.
• Steelmaking process and nominal weight of each heat.
• Target chemical composition together with minimum and maximum working limits for heat and
product analysis.
• Technique proposed for sulphide shape control.
• Casting technique, and size and weight of ingots, slabs or skelps
• Slab soaking, holding and plate finish working temperatures (with tolerances and method of
control
• Rolling reductions and working temperatures (with tolerances and method of control).
• Any cooling rate limitation
• Heat treatment on rolled plates.
• Ultrasonic plate testing techniques, coverage and acceptance criteria.
• Plate edge preparation (weld joint design) and final machined width of plate (with tolerances).
• Method of controlling thickness of finished plate.
• Method of forming pipe shape from plate and of degreasing weld bevel.
• Method of tack welding and spacing of tack welds (if any).
• Methods and stages, of fixing and removal of run-on/run-off plates.
• Results of HIC and SSC corrosion tests on similar grade pipe.
• Full details of all welding procedures and repair procedures including submerged arc welding
sequence, number of wires, welding parameters, electrical characteristics, speed, sequence,
dimensions and number of weld passes and methods of guiding welding heads.
• Method of calibrating plate ultrasonic equipment and frequency of calibration.
• Methods of weld defect removal and repair welding procedures.
• Types, sizes and brand names of all welding consumables.

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• Full details of ultrasonic procedure for the longitudinal weld, including a statement of the weld
length at the pipe ends not scanned by all probes, methods of marking defects and indicating
loss of coupling, and calibration procedures.
• Method of measuring pipe wall thickness, including sensitivity and calibration technique.
• Full details of radiographic testing equipment, including film type.
• Techniques for wet magnetic particle inspection.
• Histograms of mechanical test results from previous orders of the same grade pipe in the same
or similar sizes.
• Details of method and procedures for cold expansion and hydrostatic testing.

9.3. Welding

9.3.1. Welding Processes


The welding process for the longitudinal seam shall be confined to the automatic Submerged Arc
Welding (SAW) process.
The maximum height of outside and inside weld bead shall not be more than 3mm. All pipes shall
be checked for weld bead height using a template having a cutout for the weld bead and shall be
measured and recorded three times per shift.
Gas Metal Arc Welding (GMAW) process may be used for tack-welding only provided that the weld
is completely remelted by the Submerged Arc Welding process.
Weld repair shall be carried out by SAW process or manual Shielded Metal Arc Welding (SMAW)
process using low hydrogen electrodes.
Each welding procedure shall be fully detailed in Welding Procedure Specification (WPS) form
previously approved by the COMPANY with the necessary Procedure Qualification Record (PCR)
back-up.

9.3.2. Welding Consumables


a) The weld deposits obtained from the consumables shall satisfy chemical composition the
impact toughness and hardness requirements of this specification and shall have tensile
properties that are equal to or slightly higher than those of the base metal. Weld metal shall not
overmatch the max UTS of the base metal by more than 20%.
b) Nickel contents in consumables for sour service application shall not exceed 1%. The
molybdenum contents in consumable shall not exceed 0.5 % and shall not be deliberated
added.
c) All welding consumables shall conform to ASME Boiler and Pressure Vessel Code, Section IIC
(AWS) or approved equivalent.
d) The CONTRACTOR shall obtain manufacturer’s test certificates (3.1 certificates according to
EN10204) for each batch of consumables used on the job.
e) Coated electrodes shall be of the low hydrogen type (i.e. maximum hydrogen content of 10 ml
per 100 gram of weld metal).
f) Low hydrogen coated electrodes and welding fluxes shall be stored and used according to the
recommendations of their manufacturers. If there are no written recommendations from the
manufacturers of consumables the following instructions shall be applied.
• Low hydrogen coated electrodes shall be oven dried for at least two hours at 350°C. A
lower temperature for a longer holding time is not acceptable. Immediately upon
withdrawal from their hermetically sealed container or drying oven, the electrodes shall be
kept in a holding oven at approximately 100°C before use.

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• Electrodes withdrawn from the holding oven shall be used within 2 hours after withdrawal.
If unused they shall be re-dried for 2 hours at 350°C as above.
• Fluxes shall be dry and free from any foreign matter. The fluxes shall be kept in a drying
oven at approximately 120°C before use.
• For SAW process, basic flux shall be used. Details of slag basicity should be provided from
the flux manufacturer. The flux should be non-active, i.e. all the major elements such as Mn
and Si should be added from the wire and not the flux.
g) The suppliers’ consumables traceability and flux re-cycling/re-conditioning procedure shall be
approved by the COMPANY before commencement of production welding.
h) All welding consumables shall be submitted to inspection by the COMPANY. The mill
inspection certificates for each batch and lot of consumables shall be available for that purpose.
These documents shall certify the consumables meet the requirements of the relevant
standards for classification and grade.

9.3.3. Qualification Of Manual Welders


Welders who have performed a satisfactory welding procedure qualification test are thereby
qualified.
Other welders shall be qualified by visual and radiographic examinations and side bend tests as
follows:
100% visual examination.
100% radiographic examination
4 guided side bend tests at location selected by the COMPANY representative for sour service
application.

9.3.4. Longitudinal Weld Qualifications


The welding procedure for longitudinal weld shall be qualified together with the first day production
tests (see Appendix C ) based on the submitted W.P.S.

9.3.5. Repair Weld Qualifications


All repairs shall include a minimum preheat of 100°C, unless the qualification test shows that a
higher temperature is necessary.
Each welding repair shall be qualified on a pipe section under realistic conditions in accordance
with API Specification 5L Appendix D and this specification.
Unless otherwise agreed with COMPANY, the following two repair types are to be qualified by tests.
a. One mid-thickness repair (or one 2/3 thickness repair) simulating a defect located on fusion
line. The mid-thickness repair shall be subject to the following tests:
− Charpy tests in accordance with clause 10 but with sets removed from the following
locations:-
• repair weld centre line
• fusion line between repair weld and original weld
• fusion line between repair weld and parent material.
− 1 macro/hardness test in accordance with clause 10 of this specification
− The tests required by API Specification 5L Appendix D
− 100% UT and Radiography in accordance with clause 16 of this specification.

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b. One shallow repair with 2 weld passes minimum simulating a defect located at weld toe.
The shallow repair shall be subject to:
− 1 macro/hardness test in accordance with clause 10 of this specification.
− 100% MPI in accordance with clause 16 of this specification.

9.3.6. Production Welding


The welding conditions used for the longitudinal weld and repair welds shall not depart from those
of the related procedure qualification test.
However, the following variations are acceptable, if the variations in the welding parameters result
in an increase or decrease of 10% in heat input; if outside this parameter the welding procedure
shall be re-qualified with additional Charpy Impact tests:
• Amperage : + 10%
• Voltage : + 7%
• Travel speed : + 10%
• Preheating interpass temperature : -0°C, +50°C (provided that max.
interpass temperature of 250°C is
not exceeded)

10. MECHANICAL PROPERTIES

10.1. Test Frequency


Tensile testing shall be carried out on two pipes per heat. Macro/micro plus hardness, guided-bend
and Charpy tests shall each be carried out on one pipe per batch. A batch is defined as up to 100
pipes from the same heat, with the same grade, nominal diameter and wall thickness that have
been heat treated together. A summary of requirements is given in Appendix C.

10.2. Tensile Test


The tensile tests and properties shall conform to the requirements of API Specification 5L (Table-7
for Non Sour Service and Table H.2 for Sour Service) for the grade of pipe specified on the
purchase order.
The tensile, yield and elongation properties of the base metal shall be determined.
Frequency of weld tensile tests shall be as per appendix C of this specification.
The actual yield strength of the pipe shall not exceed the specified minimum yield strength as
required for the API 5L grade specified by more than 18,850 psi (130 MPa).
The minimum required elongation shall be determined in accordance with the formula given in the
footnote of Table-7 (Non Sour Services) & Table H.2 (Sour services) in API Specification 5L, but
shall not be less than 20 percent for a gauge length of 50mm.
Tensile properties shall be determined from specimens removed from pipe in its final Condition (i.e.
after mechanical expansion). Tensile test specimen orientation shall be as shown in Fig.5 (b) of API
Specification 5L. The testing procedure shall be in accordance with ASTM A 370.
The ratio of yield strength to tensile strength in base metal shall not exceed 0.90.

10.3. Guided Bend Tests


Guided bend tests shall be conducted in accordance with API Specification 5L.

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10.4. Toughness Tests


The fracture toughness of the pipe shall be determined by the use of Charpy V-notch impact tests in
accordance with API Specification 5L and as modified by these supplemental requirements.
Charpy test specimens shall be full-size (10 mm x 10 mm) transverse specimens whenever
possible. If pipe size (geometry) does not permit extraction of a full size specimen, the largest
obtainable sub-size specimen shall be used.
Sub-size specimens shall be in accordance with Appendix A of this Specification.
When one-half size transverse specimens are not obtainable due to pipe size, longitudinal
specimens may be substituted after the approval of the COMPANY.
Charpy specimens shall be taken from the same test ring as the tensile specimens. One set of
three specimens shall be taken from each of the following positions:
• Pipe body at 90 degrees to the weld
• Weld centerline
• Fusion line
• Fusion line + 2 mm
• Fusion line + 5 mm
Charpy test specimens shall be located at mid-thickness of the pipe with the axis of the notch
perpendicular to the pipe surface. Specimen locations and notch positions for weldments are
shown in Figure 1.
The Charpy V-notch energy requirements shall be in accordance with Appendix A of this
Specification. A full Charpy transition curve shall be established as part of the first day production
tests and subsequently for one pipe per 10 heats as shown in Appendix- C of this specification.
The Charpy V – Notch Test Temperature for all specimens shall be in accordance with the following
table:

0
Specified Wall Thickness (T), mm Test Temperature, C

T≤ 16 TD
16 < T≤ 25 TD-10
25 < T TD-20
TD=0º C or the minimum design temperature, whichever is the lower.

The percent shear area shall be reported for all Charpy test specimens. The minimum average (set
of three test specimens) shear fracture area for each test shall be ≥ 85 percent.

10.5. Macro/Micro Plus Hardness And Metallographic Tests


The weld shall be evaluated by removing a pipe cross section containing the weld. The section
shall include the weld fusion line, H.A.Z. and parent metal on both sides of the weld and shall be
polished and etched for examination. The weld shall have complete penetration and fusion. The
geometry, including plate edges inside and outside weld profile shall be within the tolerances
specified in the manufacturing procedure specification. There shall be no evidence of defects.
Vickers hardness testing with a 10 kg load shall be conducted on the weld cross sections in
accordance with Figure 2. Three hardness traverses shall be made across the weld area, two (2)
millimeters from each pipe surface and one in the middle of the pipe wall thickness. Testing shall
include parent metal (each side) heat affected zone (each side) and weld fusion line. The Spacing
between the hardness impressions shall be 0.75mm in HAZ. The hardness impressions nearest the
fusion line shall be within 0.5mm of the fusion line. A minimum of 3 readings on parent material
either side of the Weld in all location to be performed.

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The hardness shall not exceed 230 HV 10 and 300 HV 10 for sour service and non sour service
application respectively. Macrographic, micrographic and hardness examination shall be required
as per Appendix C of this specification. The metallographic examination shall verify that no
untempered martensite remains on weld seam.

10.6. Drop Weight Tear Tests


Drop weight tear tests (DWTT) shall be performed on pipe equal to or greater than 16 in (406 mm)
O.D. in accordance with API Specification 5L and API RP 5L3.
Two transverse specimens shall be taken from one length of pipe from each heat supplied on the
purchase order.
For each test (of a set of two test specimens), the average shear fracture area shall be ≥ 85%. The
DWTT shall be conducted at 0 degree C or the minimum design temperature, whichever is lower,
for wall thickness 19mm and less. For wall thickness above 19mm, test temperature shall be in
accordance with API RP 5L3.
Test specimen and test procedure shall be in accordance with API RP 5L3.
A full transition curves shall be established as part of the first day production tests, and
subsequently for one pipe per ten heats as per Appendix – C of this specification.

11. HYDROGEN INDUCED CRACKING TESTS


For sour service application, Hydrogen Induced Cracking (HIC) tests shall be performed in
accordance with Appendix B of this specification.

12. SULFIDE STRESS CRACKING TESTS


For line pipes of grade X-52 and higher in sour service application, Sulphide Stress Cracking (SSC)
tests (four point bend tests as per ASTM G39) shall be conducted as per method B of NACE
Standard TM0177 using test solution A. For acceptance, no cracking shall be observed in 720 hours
with a constant load equivalent to 90% of the actual yield strength of the pipe. Specimens shall be
located across the Weld seam as close to the pipe inside surface as possible. The SSC test shall
be a part of the first day production testing. A detailed procedure shall be submitted for approval to
COMPANY.

13. WELDABILITY TESTS

13.1. General
Weldability tests shall be carried out for pipes of Grade X60 and X-65 using a procedure similar to
that used in the field girth welding.
Two 500mm long pieces, taken from the first day’s production shall be welded together in
accordance with the requirements given below.
The weld shall be made with cellulosic electrodes matching the strength of the material (i.e. E7010-
G for X60 and E8010-G for X65) and capable of meeting the charpy acceptance criteria as per
DGS 6300-004 ‘Pipeline Welding’.
• Welding position 5G, vertical down.
• Bevel in accordance with API 5L.
• Heat input 1kJ/mm ± 0.1 kJ/mm
• Preheat shall be calculated in accordance with EN 1011.
• PWHT shall not be carried out for LSAW Pipes unless specified.
• Welders shall be qualified in accordance with DGS 6300-004 ‘Pipeline Welding’.

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In case CONTRACTOR intends to use automatic welding in the field, additional. Weldability test
shall be conducted with Automatic Welding using equipments intended to be used in the field.
Weldability test shall be carried out for the heaviest wall thickness of each diameter/material
grade/pipe making process combination for each mill. The manufacturer shall guarantee that all
remaining pipes would also pass these tests

13.2. Welding Specifications


The contractor shall submit a Weld Procedure Specification (WPS) outlining his proposals to the
company for approval prior to welding the test pieces.
The test weld shall be subject to 100% Radiography, ultrasonic testing, such those areas containing
defects are found and excluded from test pieces.
The test weld shall be subject to the following mechanical tests:
• Two transverse tensile tests taken from the 2 o’clock, and 8 o’clock positions. The UTS shall
meet the requirements as per DGS 6300-004 ‘Pipeline Welding’.
• Charpy tests in accordance with DGS 6300-004 ‘Pipeline Welding’, with specimens taken from
the 3 o’clock position with additional sets at root for FL, FL +2 and Weld metal.
• Macro/hardness test in accordance with DGS 6300-004 ‘Pipeline Welding’.
• SSCC tests for sour service welds.

14. FIRST DAY PRODUCTION TEST


During the first day production testing, the tests shall include all Mechanical, Non-Destructive,
corrosion testing, etc as listed in Appendix C of this specification.
Three of the completely finished pipes of the first day production shall be selected at random for
testing to verify that the submitted manufacturing procedure results in fully acceptable pipe. If more
than one heat is used in the first day production at least two heats shall be represented by the test
pipes.
If any of the first day production tests fail, production shall be halted and all pipes produced shall be
identified and rejected. The reason for the failure shall be identified to the satisfaction of the
COMPANY. The manufacturing procedure shall be amended. A new set of tests shall be
conducted on the first day’s production to the new procedure.
MANUFACTURER shall submit to COMPANY results of all tests of first day production together with
macrographs of weld cross sections and micrographs confirming microstructure of plate. First day
production testing shall apply to each mill and each pipe dimension.

15. HYDROSTATIC TESTING


Hydrostatic testing of the pipe shall be in accordance with API 5L and the following:
Each length of pipe shall withstand, without leakage, a hydrostatic test pressure such that the hoop
stress, calculated on the basis of minimum specified wall thickness and including stresses from end
loading, is at least 95 percent of the specified minimum yield strength. If applicable, the end load
compensation factor as determined by the formula given in Clause 10.2.6.6 of API Specification 5L
shall be used.
The test pressure shall be held for not less than 10 seconds, during which time the full length of the
weld seam shall be inspected for leaks.
The hydrostatic test equipment shall be equipped with a recording gauge that will record the test
pressure and duration of test applied to each length of pipe. Hydrostatic test records shall be made
available to the COMPANY Representative.

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16. NON DESTRUCTIVE INSPECTION

16.1. General
All NDT examinations shall be performed by personnel qualified by a third party in accordance with
ASNT Recommended Practice SNT-TC-1A, Level II. Personnel interpreting results of any non-
destructive testing shall be qualified by a third party to SNT-TC-1A Levels II or III. For UT at least
one level III qualified inspector shall be available to the mill (on call) for overall supervision.
All NDT shall be performed in accordance with written procedures. These procedures shall have the
prior approval of COMPANY.
When grinding repairs are made because of imperfections found by nondestructive testing the
section of the pipe containing such repairs shall be subjected to additional nondestructive testing
using the same nondestructive testing techniques, and magnetic particle testing after the grinding
operation.
All nondestructive inspection equipment shall be checked at least twice per eight (8) hour working
shift to demonstrate effectiveness of calibration and operational procedure.
Such inspection equipment shall also be checked immediately following any equipment failure or
equipment adjustment. These equipment checks shall either be regularly scheduled, or with
enough notice so that the COMPANY’s Representative may witness equipment checks each time.
All sensitivity adjustments shall be carried out dynamically. The dynamic calibration on the first day
production pipe shall be witnessed by the COMPANY Inspector.

16.2. Magnetic Particle Inspection


All finished beveled pipe ends shall be examined by Magnetic Particle Inspection (MPI), bevels
showing linear indication exceeding 3 mm shall require re-beveling.
MPI shall be conducted in accordance with ASTM E709. Direct magnetization techniques including
prods and clamps are not acceptable. AC techniques are preferred.

16.3. Beveling Inspection


After beveling, the complete circumference of the pipe ends shall be ultrasonically tested from the
inside for laminations. This inspection shall cover a width which includes the entire bevel.
Alternately, the pipe ends may be tested from the outside prior to beveling and in such cases, a
band at least 25 mm wide, which shall include the eventual beveled areas, shall be tested.
Laminations are not acceptable in this area.

16.4. Ultrasonic inspection


The weld seam shall be ultrasonically tested after hydrostatic testing. Acceptance criteria for weld
discontinuities shall be in accordance with API Specification 5L, Annexure-K (applicable for both
Sour and Non-sour service).
Submerged arc welds shall be inspected over their entire length, for both longitudinal and
transverse defects, using ultrasonic examination in accordance with API Specification 5L,
Annexure-K (applicable for both Sour and Non-sour service).
Calibration of ultrasonic equipment may be based upon either notches or holes; however, reference
standards shall contain both notches and holes. The manufacturer shall furnish, for COMPANY
approval, a complete description of their proposed procedures, including a description of the
equipment; the number, size, angle, frequency, mode, and location of the transducers; continuity
checking; scanning speed; method of weld tracking; defect marking methods; operator qualification;
calibration reference standards, and acceptance limits. During the first day of production, the
Manufacturer shall demonstrate to the satisfaction of the Company Representative, the
effectiveness of this equipment and procedures, using an API 5L reference standard approved by
the COMPANY’s representative.

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The equipment for ultrasonic examination shall be fitted with an automatic paint spray system for
marking areas giving ultrasonic indications and areas of loss of ultrasonic coupling with the pipe.

16.4.1. Reference Standards


The reference standards shall be made from a pipe manufactured as production pipe for the order.
The length of the reference standard shall be sufficient for the standard defects to be inspected
while the equipment is travelling at its normal inspection speed. The standard defects shall consist
as a minimum, of the following:
The width of the notch shall not exceed 1.0 mm.
The reference level shall be the lowest of the signals produced from any of the above specified and
the trigger/alarm level shall be set on 100 % of this reference level.
16.4.2. The reference pipe shall also contain two 1.6 mm dia drilled holes located 4 mm from weld toes
(one on each side of weld seam) for checking the ultrasonic gate width (gate setting).

16.4.3. Acceptance Limits


Any imperfection which produces a signal of height exceeding the reference level defined above
shall be considered an unacceptable defect. Any imperfection found by the automatic ultrasonic
system shall be further investigated by radiography.

16.5. Radiography
Each end of the weld seam in SAW pipe shall be examined radiographically for a distance of at
least 200 mm from the end of the pipe in accordance with API Specification 5L, Annexure-K
(applicable for both Sour and Non-sour service).
X-ray radiography using ultra fine grain film only shall be permitted. Film types are subject to
COMPANY approval.
Acceptance standard for radiography shall be in accordance with API Specification 5L, Annexure-K
(applicable for both Sour and Non-sour service) except that incomplete penetration and lack of
fusion shall not be accepted.
The penetrameter used shall be of the wire type in accordance with API Specification 5L, Annexure-
K (applicable for both Sour and Non-sour service).

16.6. Residual Magnetism


Pipe shall be checked subsequent to any inspection that uses a magnetic field, handling with any
electromagnetic equipment and prior to shipment from the mill.
Pipe ends shall be checked for residual magnetism as follows:
• Measurements shall be made on the root face using a Hall-effect gaussmeter or other type of
instrument approved by the Company. However, in the case of dispute, measurements with the
Hall-effect gaussmeter shall govern. The gaussmeter shall be operated in accordance with
written instructions demonstrated to produce accurate results. The accuracy shall be verified at
least once each day that the gaussmeter is used.
• Measurements shall be made on each end of at least 10 percent of the pipes per working shift.
As a minimum, one pipe shall be taken from the beginning of the shift, one from near the
middle, and one from the end of the shift.
• As a minimum, four readings shall be taken approximately 90 degrees apart around the
circumference of each end of the pipe. No reading shall exceed 20 gauss when measured with
a Hall-effect gaussmeter, or equivalent values, with other types of instruments.
• Any pipe that does not meet the above requirements shall be considered defective.

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• In addition, all pipe produced between the defective pipe and the last acceptable pipe shall be
measured. Alternately, if the pipe production sequence is documented, pipe may be measured
in reverse sequence beginning with the pipe produced prior to the defective pipe until at least
three (3) consecutive pipes meet the requirements. Pipe produced prior to the three
consecutive acceptable pipes need not be measured. Pipe produced after the defective pipe
shall also be measured until at least three (3) consecutive pipes meet the acceptance
requirements.
• All defective pipe shall be degaussed full length and remeasured or permanently rejected.

17. DIMENSIONS, WEIGHTS, AND LENGTHS


Dimensions, lengths, weights, and straightness of pipe shall comply with API Specification 5L and
the following:

17.1. Length
The pipe shall be supplied to the following length requirements unless otherwise specified on the
Purchase Order.
• A minimum of 95 % of pipes shall be between 11.00 to 12.5 m
• No pipe shall be less than 9.00 m.

17.2. Wall Thickness


Pipe wall thickness at any point shall not deviate from the specified wall thickness by more than
plus 10 percent or minus 5 percent.

17.3. Diameter

17.3.1. Pipe Body

17.3.2. The outside diameter of the pipe body as determined by taping the circumference shall not deviate
more than +/-3 mm from the values given in table 9 of API Specification 5L.

17.3.3. Pipe Ends


For a length of 100mm from each pipe end, the internal diameter shall not deviate from nominal
internal diameter by more than +/- 1.5mm. Internal diameter shall be measured using internal
gauge or measuring tape inside the pipe. The method and equipment used shall be approved by
Company. Nominal internal diameter is defined as nominal outside diameter given in metric table
minus 2 times the nominal wall thickness.

17.4. Out-Of-Roundness
The out-of-roundness of the outside diameter of the pipe at any point along its length shall not
exceed the following:
Max. O.D. - Min. O.D. ≤ 1.0 percent
Nom. O.D.

17.5. Straightness
Straightness shall not exceed 0.20 percent of the pipe length. Measurements shall be made using
a taut string or wire from end to end along the side of the pipe measuring the greatest deviation.

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17.6. Misalignment Of Plate Edges


The radial offset of edges (misalignment) for pipe with specified wall thickness shall be as per the
following table.

Maximum permissible radial


Specified wall thickness (T), mm
offset, mm
T ≤ 10 1.0
10 < T ≤ 20 0.1T
T > 20 2.0

The offset shall be measured and recorded on the macros for the hardness specimen one pipe per
batch.

17.7. Bevels
Pipe ends shall be beveled in accordance with API Specification 5L unless otherwise specified by
the COMPANY.

17.8. Jointers
Jointers shall not be supplied.

18. WORKMANSHIP, VISUAL INSPECTION, AND REPAIR OF DEFECTS

18.1. Inspection
All first-day production tests will be witnessed by the CONTRACTOR and COMPANY’s
Representative. In addition, all pipes will be subject to inspection by the COMPANY/CONTRACTOR
Representative. MANUFACTURER shall give sufficient notice (14 days) and ahead of the time
when pipe production is to begin.
The company’s representatives shall have free entry at all times to all parts of the manufacturer’s
works which concern the manufacture, testing, inspection, quality control, and shipping of the pipe
ordered, including the steel mill, the plate or strip mill and the pipe mill.
The pipe mill and steel mill shall make available to the company’s representative without charge, all
reasonable facilities to inspect, measure, and test the pipe in all stages of production including, for
example, ultrasonic equipment for wall thickness measurements after grinding repairs.
The company’s representatives shall have the option to examine all materials rejected for any
reason. The causes for rejection shall be brought to the attention of the company representative
and all affected materials shall be retained until examined by the company’s representative.

18.2. Workmanship
The manufacturer shall take all reasonable precautions to ensure that the pipe surface is free from
imperfections that might interfere with the efficient application of an external coating. In addition,
the metal surfaces shall be sufficiently clean and smooth to permit non-destructive examination. All
loose scale shall be removed, and pitting and rough surfaces shall be removed by grinding. Pipe
shall have a workmanlike finish, and the manufacturer shall remove by grinding, mechanical marks
and abrasions, such as cable marks, scores, etc. Imperfections such as scabs, seams, laps, tears,
and slivers shall also be removed. The remaining wall thickness shall be within the specified wall
thickness tolerances.
The pipe shall contain no dents which affect the curvature of the pipe at the longitudinal weld or at
the pipe ends. Pounding out or jacking out dents is prohibited.

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All cold-formed dents with a sharp bottom gouge and all sharp gouges, without dents, deeper than
one mm shall be considered defects which require repair or rejection. Repair shall only be
permitted with the approval of the company representative.

18.3. Repairs

18.3.1. Body of pipe


Repairs by welding are not permitted. The jacking out of dents is not permitted.
Surface defects in the pipe outside the welded seam and not encroaching upon the required
minimum thickness may be removed by grinding, provided a smooth curved surface is maintained,
and the final thickness after grinding is not less than the required minimum thickness as confirmed
by ultrasonic testing. Apart from minor cosmetic grinding as approved by the COMPANY
Representative, all repairs shall be carried out before cold expansion and hydrostatic test.

18.3.2. Seam Weld


All repairs shall be carried out before cold expansion and hydrostatic test to procedures approved
by the COMPANY. The repair shall be made either by automatic submerged arc welding or by
manual metal arc using low hydrogen electrodes to a qualified procedure.
Repairs to the welded seam shall be limited to three per pipe. The cumulative length of repair
welding shall not exceed 5% of the total weld length on each pipe. The repair of pipe with defects in
excess of these limits shall only be permitted with the prior approval of the COMPANY. Any
evidence of cracking in the weld shall be cause for rejection and subsequent investigation.
All areas repaired by welding shall be radiographed, MPI tested and manually ultrasonic tested in
accordance with section 15 of this specification.
The repair procedure shall be qualified to API Specification 5L, Appendix C & D with the following
additional tests:
a) X-Ray in accordance with API Specification 5L.
b) Macro hardness of weld and HAZ per clause 10 of this specification.
c) Transverse charpy test to clause 10 of this specification.
Acceptance criteria shall be to this specification.
Repair welder’s performance tests shall be assessed solely by X-Ray inspection against the
requirement of repair weld procedures prepared by the MANUFACTURER for approval.

19. MARKING COATING AND BEVEL PROTECTION


Pipe shall be furnished bare and free of all mill coating.
Each pipe shall be low-stress die-stamped with its unique pipe number on the weld bevel at each
end. No die stamping, hot or cold shall be permitted on pipe body.
The pipe shall be paint stenciled, at both ends, in accordance with API Specification 5L on the
inside surface of the pipe within 200 mm of the ends. Internal Pipe markings shall show name or
mark of the manufacturer, API Specification 5L, outside diameter, wall thickness, pipe steel grade
with sour or non-sour, PSL-2, type of pipe, length, weight, unique pipe number, heat number and
batch number, hydrostatic test pressure. Sizes, weights, lengths, and pressures shall be given in
metric units. Outside diameter marking shall include diameter, wall thickness, length and grade at
one end only.
Detailed marking procedure shall be submitted to COMPANY for approval prior to Pipe production.
Locating Weld seam to be marked inside each pipe with 50 mm Daub Heat resistant paint.

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Bevel protectors or end caps shall be installed on all pipe ends. The end caps shall be hookable
type, which shall allow the use of end hooks without the need for their removal during pipe
handling. The bevel protector/end caps shall be the re-usable type. The details of the bevel
protector/end caps shall be furnished to COMPANY for approval prior to start of the production.
Pipes of the same diameter but of different wall thicknesses or material shall, in addition to any
other requirements be color coded to provide visual identification. The proposals for the color
coding shall be provided to COMPANY for approval.

20. RECORDS, TEST REPORTS AND ADDITIONAL INFORMATION


Unless otherwise specified, certificates shall be of type 3.2 as per European Standard EN 10204.
The following records and test reports shall be furnished by the CONTRACTOR to COMPANY at no
cost to COMPANY.
Certified chemical analysis and all mechanical test results from qualification and production (tensile
test: charpy V-notch impact tests, hardness test, DWTT).
• HIC and SSCC test results and photographs for sour services line pipes.
• Non destructive examination reports
• Hydrostatic test certificates.
• Weldability test report and Manufacturer’s recommendations or guide for welding of pipes
• List of pipes showing pipe numbers, heat numbers individual length and weight
• Approved Concession requests
Contractor shall also provide line pipe tracking data in electronic file. The specific data and file
format shall be agreed with COMPANY prior to the start of work and shall include but not limited to
the following:
− Marking information
− Date of plate and pipe manufacture
− Heat Number
− All mechanical properties and test results.
− All dimensional records.
− Final inspection and release date.
− Descriptions and disposal of repairs.
− Load out data/despatch date
Approved final ITP, manufacturing procedure specifications & procedures stated in section 9.2, mill
certificates, pipe traceability and identification procedures shall be submitted to the COMPANY in
an electronic format (CD-ROM) in addition to hard copies as part of the deliverables at the time of
pipe delivery.

21. SHIPPING AND HANDLING


All pipes shall be handled, loaded and shipped in accordance with API RP 5L1, Recommended
Practice for Railroad Transportation of Line Pipe, and API RP 5LW, Recommended Practice for
Transportation of Line Pipe on Barges and Marine Vessels.
MANUFACTURER/SUPPLIER shall submit loading instructions and diagrams for COMPANY
approval for all pipe shipped by rail, truck, or vessel. However, approval of these documents shall
not relieve the MANUFACTURER/SUPPLIER of its responsibility for damage during shipment.

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All dimensional tolerances and pipe surface conditions specified herein and in API Specification 5L
shall apply to the pipe as received by the COMPANY at the shipping destination. Line pipes shall
not be shipped in the upper deck.

22. GUARANTEE
MANUFACTURER shall bear all costs to seek, find, and repair all leaks and/or ruptures which occur
during field hydrostatic testing, and which result from defects traceable to the manufacture of the
pipe. The field test will not exceed a pressure that will cause a circumferential fiber stress greater
than 100 percent of the specified minimum yield strength of the pipe. The COMPANY may elect to
raise and lower the field test pressure one or more times either as part of a planned testing routine,
or as a consequence of a failure in the pipeline, or in the testing equipment; however, these
pressure cycles shall in no way relieve the MANUFACTURER of its obligations.

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APPENDICES

Appendix A: Charpy V-Notch Impact Requirements (1) (2)

Pipe Grade Minimum Average Minimum Individual


Value (Joules) Value (Joules)
B 27 22
X-42 27 22
X-52 55 45
X-60 57 50
X-65 60 53

Notes:
1) Minimum absorbed energy requirements for full size (10 mm X 10 mm) transverse specimens.
2) For other specimen sizes and orientations, the above values shall be multiplied by the following
factors:

Size (mm) Orientation Factor


10 X 10 Longitudinal 1.5
10 X 7.5 Transverse 0.75
10 X 7.5 Longitudinal 1.125
10 X 5.0 Transverse 0.5
10 X 5.0 Longitudinal 0.75

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Appendix B: Hydrogen Induced Cracking (HIC) Sensitivity Tests

B.1 General
The Manufacturer shall perform HIC sensitivity tests in accordance with NACE TM0284 with the
following additional requirements and amendments.

B.2 Sampling
One pipe from each of the first three heats of pipe produced shall be tested. One pipe out of every
subsequent ten heats shall be tested. The pipes for testing shall be selected by the COMPANY’S
Representative from the heats exhibiting the higher sulfur contents.
Two coupons shall be selected and tested for each pipe. Each coupon shall be sectioned into three
specimens. One coupon shall be cut from the pipe opposite the weld seam parallel to the rolling
direction. The other coupon shall be cut from the pipe transverse to the weld.

B.3 Qualification Of Test Method


Before commencement of the order, the Manufacturer shall provide the Purchaser with a detailed
procedure for the testing, metallographic preparation and evaluation of HIC specimens. The
Manufacturer shall qualify his test method using samples from a steel of known crack sensitivity. All
tests shall be witnessed by the Purchaser.

B.4 Test Method


The test method shall comply with NACE TM0284 with the following clarifications:
Initially the specimen shall be rough ground on a belt grinder or by surface grinding. This shall be
followed by final grinding to a 320 grit finish, using silicon carbide papers. The specimens shall then
be degreased in acetone. The effectiveness of degreasing shall be demonstrated by using the
atomizer test of ASTM F21. Thereafter, extreme care must be taken not to contaminate the
specimens.
One set of specimens from both the seam weld and base pipe material shall be tested, without
applied stress, in the test solution. Tests shall be carried out with specimens that are not coated in
any way before exposure in the test environment.

B.5 Test Solution


The test shall be performed in test solution A of NACE TM 0177, i.e. 0.5% acetic acid + 5% NaCl
saturated with H2S. The testing shall be performed in glass vessels.
The solution shall be deaerated by bubbling nitrogen through it at a rate of at least
100mL/minute/Liter for one hour. The specimens shall be immersed in the solution with the face of
100 mm x 20 mm in the vertical position and the lower face raised from the cell bottom on bars of
Teflon or glass. When stacked, the specimens shall also be separated by similar bars.
Nitrogen bubbling shall be continued for a further one hour after which the solution shall be
saturated by bubbling H2S at the rate of at least 200mL/minute/Liter for one hour through an open-
ended tube with a 5 mm internal diameter. Upon reaching saturation, the H2S flow rate may be
reduced to 100mL/minute, for a 10 liter solution or pro rata, and maintained at this rate for the test
period. The H2S purity shall be 99.5 vol% or better.
A small positive pressure of H2S should be maintained in the test cell by the use of an outlet trap to
prevent oxygen contamination from the air.

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Test conditions shall be as follows:


0
Temperature 25 ± 3 C
H2S concentration (2300 - 3500 ppm) saturated condition
pH value - Initial 2.9 to 3.3
- Final 3.5 to 4.0
Test period 96 hours
The pH value of the solution shall be measured at the beginning and the end of the test and the
H2S concentration in the solution determined at the end by iodometric titration.

B.6 Evaluation Of Blistering And Hydrogen Induced Cracking

B.6.1 Blistering
The tendency to blister shall be reported after visual examination. Photographs shall be taken of the
two wide faces of each coupon to show any blistering. Where photography does not adequately
show blisters a dimensioned sketch may be substituted.

B.6.2 Hydrogen Induced Cracking


Specimens taken with their long axis (100 mm) parallel to the rolling direction shall be sectioned
transversely at three points.
Metallographic evaluation shall comply with NACE TM0284 with the additional requirement that all
faces shall be subjected to either wet magnetic particle testing or macroetching, before
metallographic polishing, in order to make an accurate assessment of whether any significant
cracks are present which may have become invisible due to smearing of the metal surface during
preparation.
The selections shall be mounted in epoxy resin, or an equivalent, and polished. To avoid the
possible obscuring of the cracks, the metallographic preparation shall entail polishing to a finish of 1
µm or less. Cracking shall then be estimated by micrographic examination at magnifications of X30
and X100.

B.6.3 Evaluation
For each crack observed, the length and extent of stepwise propagation shall be measured. For
each section containing cracks, one photograph shall be taken showing one of the complete
transverse sections with examples of cracking.
HIC is evaluated in terms of crack length ratio (CLR), crack thickness ratio (CTR) and crack
sensitivity ratio (CSR).
These values shall be reported for each section examined and as the average of three sections per
specimen. The results for each specimen, i.e. the average of the three sections examined, shall be
used for evaluating HIC susceptibility. In this evaluation, cracks associated with surface blistering
which have no part more than 1 mm from the specimen surface shall be disregarded.

B.6.4 Acceptance Criteria


The following acceptance criteria shall be met:
CLR 15 % maximum
CSR 1.5 % maximum
CTR 5 % maximum
The maximum individual crack length on any section shall not exceed 5 mm.

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If any specimen fails to meet the above acceptance criteria, the heat of steel represented by the
test shall be rejected. In addition, the Manufacturer may elect to make re-tests on two additional
test pipes, selected by the COMPANY’S Representative which represent two other heats from the
10 heat lot. If both the retests meet the above acceptance criteria, the 10 heat lot shall be accepted,
except for the heat which failed the initial test. If one or both of the retests fail, the entire 10 heat lot
shall be rejected.

B.7 Reporting
The test reports shall contain the following information:
• Results of cracking evaluation indicating CLR, CTR, and CSR for each section and also
averaged for 3 sections with test result (i.e. pass/fail).
• Photomicrographs of the specimens showing cracking together with photographs of adjacent
material:
− unetched; showing type of inclusions
− etched; showing microstructure of parent material
Banding index per ASTM E 1268 shall be recorded for information.
• The pH of H2S saturated solution at the start and end of the test, the H2S content and type of
solution.
• Photographs of specimens showing any blisters.
• Location and dimensions of specimens and if taken from the weld or body of the pipe.
• Complete chemical analysis of material tested.
• Mechanical properties of materials tested.

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Appendix C: Testing And Inspection

First Day Production Test During Production


Test/Inspection
Frequency Remarks Frequency Remarks
Visual Inspection (Surface All Pipes external All Pipes external
Defects) (plus internal if OD (plus internal if OD
>610 mm) >610 mm)
DIMENSIONS:
Length All Pipes All Pipes
Measurement and
Wall Thickness All Pipes All Pipes
Recording
Weight All Pipes All Pipes
OD of Pipe Body All Pipes 3 Pipes/Shift
ID of Pipe Ends of 100mm All Pipes 3 Pipes/Shift
Measurement and
OOR of Pipe Body All Pipes 3 Pipes/Shift
Recording
OOR of Pipe Ends All Pipes 3 Pipes/Shift Measurement and
OOR at weld location All Pipes 3 Pipes/Shift Recording (Note-1)
Pipe End Squareness All Pipes 3 Pipes/Shift
Straightness All Pipes 3 Pipes/Shift
All other Dimensions All Pipes 3 Pipes/Shift
ULTRASONIC EXAMINATION:
Plates All Plates All Plates
Longitudinal Weld All Pipes All Pipes
Pipe Ends All Pipes 25mm of Pipe Ends All Pipes 25mm of Pipe Ends
MAGNETIC PARTICLE INSPECTION (MPI):
Longitudinal Weld All Selected 100 % weld
Pipes
Pipe End Bevel All Pipes All Pipes
Weld repair Repair Shallow Weld
Procedure Repair
RADIOGRAPHY:
Longitudinal Weld All Selected 100 % weld All Welds End 200 mm
pipes
Deep Weld Repair Areas On All Weld Repairs All Deep Weld
Longitudinal Weld Repairs
PHYSICAL TESTS:
Tensile Test All Selected Two Pipes Per
Pipes Heat
Weld Tensile Test All Selected One Pipe Per
Pipes Batch
All Weld Tensile Test One Pipe
Charpy V-Notch Test All Selected Test Temperature 1 Pipe Per Batch Test Temperature as
Pipes as per clause 10.4 per clause 10.4 of
of this specification this specification
Full Charpy Transition Curve One Pipe One Pipe Per 10
Test heats
Drop Weight Tear Test All Selected Test Temperature 1 Pipe Per Batch Test Temperature as
Pipes as per clause 10.6 per clause 10.6 of
of this specification this specification

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First Day Production Test During Production


Test/Inspection
Frequency Remarks Frequency Remarks
Full DWTT Transition Curve One Pipe One Pipe Per 10
Test heats
Macro, Metallographic, micro Three Pipes (3 Radial Offset To Be One Pipe Per Radial Offset To Be
plus hardness Test specimens per Recorded Batch (3 Recorded
pipe) specimens per
pipe)
Guided Bend test One Pipe One Pipe Per
Batch
Hydrostatic Test All Pipes All Pipes
Cold Expansion All pipes 3 Pipes Per Shift

CHEMICAL COMPOSITION:
Heat Analysis One Per Heat One Per Heat
Product Analysis On Pipes Two Per Heat Two Per Heat

Product Analysis On Plate One Per Heat One Per Heat


Grain size One Per Heat One Per Heat
Hydrogen Induced Cracking First Three Heats One Pipe Per Ten
Test Heats
SSCC Test On One Selected Each Thickness
Pipe
Residual Magnetism All Pipes 10 % of Pipes
Weldability Qualification Test 1 Girth Seam Per
Procedure/Process
as per clause 13

Note-1: Dimensions for Pipe OD, ID, OOR, Straightness, end of Squareness etc. shall be measured and
recorded 3 Pipes/Shift. The dimension of remaining pipes shall be checked to confirm the requirement of clause
17 of this specification.

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FIGURES
Figure 1: Charpy Impact Specimen Locations

Charpy
Specimen

Fusion line
+ 5mm

Fusion line
+ 2mm
Weld Centre
line
Fusion line

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Figure 2: Hardness Survey

0.5mm 0.5mm
0.75mm typical
0.75mm typical

2.0mm

2,0mm

0.5mm 0.5mm

Broken lines denote location for hardness

Hardness indents shall be evenly spaced as follows:


Weld metal and parent metal 2mm

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