KOC STANDARD

FOR
STAINLESS STEEL PIPE
(SEAMLESS AND WELDED)
DOC NO: KOC-MP-020

ISSUING AUTHORITY ':

STANDARDS DIVISION
 KOCSTANDARDFOR
STAINLESS STEEL PIPE
(SEAMLESS AND WELDED)

DOC NO : KOC-MP-020
DOC. NO. KOC-MP-020 Page 3 of 16 REV. 1

TABLE OF CONTENTS

PAGE NO.

SCOPE

GENERAL IAPPLICATION

TERMINOLOGY

REFERENCE CODES AND STANDARDS

ENVIRONMENTAL CONDITIONS

PROCESS OF MANUFACTURE & MATERIAL

CHEMICAL PROPERTIES

MECHANICAL PROPERTIES

NON-DESTRUCTIVE TESTING

DIMENSIONS, WEIGHTS, LENGTHS,

AND END FINISHES

REPAIR BY WELDING

INSPECTION

QUALITY ASSURANCE

DOCUMENTATION

MANUFACTURING PROCEDURE QUALIFICATION

MARKINGS

STORAGE, HANDLING AND SHIPPING

APPENDIX A:

STAINLESS STEEL PIPE FOR

SOURICHLORIDE SERVICE

APPENDIX B:

DATA SHEET 1 ORDERING INFORMATION

SCOPE:

The standard defines the minimum requirements for manufacture, testing

and supply of Seamless or Longitudinal Seam Welded Austenitic Stainless
steel pipe required for KOC facilities. Stainless Steel Pipe shall comply with
the requirements of ASTM A312 and ASTM A530. This Standard may also
be used for other Chromium-Nickel alloy pipes with additions and
modifications as indicated in this Standard.

This Standard is also applicable to duplex stainless steels. For "Sour

Environment" requirements of NACE Standard MR0175 shall be met.

GENERAUAPPUCATION :

Stainless Steel Pipe shall be used for high temperature and corrosion
resistant requirements relating to the following applications at KOC facilities:

i) Condensate Flare System

ii) Lube Oil
iii) Seal Oil
iv) Hydraulic Oil
v) Process Chemicals
vi) Inhibitors
vii) Process Condensate
viii) Wet Process Gas
ix) Chemical Injection Services
x Raw Sea Water

AlSl 300 series, type: 304, 316 stainless steel pipes shall be used for all of
the above applications unless otherwise specified.

Stainless steel pipe shall not be used for services such as:

i1 Hydrochloric acid
ii) Sulfuric acid
iii) Waste water and produced water
iv) Crude oil containing more than 25Oh water
v) Other corrosive water

Normally, seamless stainless steel pipe shall be used. However, welded pipe
may be accepted with appropriate NDT requirement.

Pipe shall be procured from manufacturers who possess valid ASTM licence
and who are capable of meeting the additional requirements of this
Standard.

This Standard shall be used in totality when the quantity is large enough to
make a mill run of the pipe. The clauses of this Standard shall be selectively
used for purchasing small quantities of out-of-stock line pipes.
3.0 TERMINOLOGY :

3.1 KOC Kuwait Oil Company (K.S.C.)

3.2 NDT Non-Destructive Testing

3.3 NPS . Nominal Pipe Size

3.4 Defect A flaw (imperfection or unintentional

discontinuity) of such size, shape, orientation,
location or properties as to be regarded
objectionable.

A condition of being imperfect, a departure of a

quality characteristic from its intended end
condition.

3.6 HIC Hydrogen Induced Cracking : Brittle Failure by

cracking under the action of corrosion with
presence of water and H2S.

3.7 SSC Sulphide Stress Cracking.

3.8 Sour
Environments Sour environments are defined as fluids
containing water as a liquid and hydrogen
sulphide (H2S) as a gas, at concentration and
pressure exceeding the limits defined in clauses
3.8.1, 3.8.2 and 3.8.3.

3.8.1 Sour Gas:

Materials shall be resistant to sulphide stress cracking (SSCC) if the

gas being handled is at a total pressure of 0.4 MPa (65 psia) or
greater and if the partial pressure of HS
, in the gas is greater than
0.0003 MPa (0.05 psia). For further clarification, refer to NACE
MR0175 and Appendix "A".

3.8.2 Sour Oil & Multiphase:

- Materials shall be resistant to SSCC if:

i) total system pressure exceeds 1.8 MPa (265 psia) and if partial
pressure of H2S is greater than 0.0003 MPa (0.05 psia), or

ii) , exceeds 0.07 MPa (10 psia) in the

if partial pressure of HS
gas phase, or
 iii) if the H,S content is greater than 15% in gas phase. For
further clarification. refer t o Appendix "An and NACE MR-
0175.

mole% of H,S x total system pressure

H,S Partial Pressurn
100

REFERENCE CODES AND STANDARDS :

In the event of conflict between this Standard and the codes referenced
herein. the most stringent requirement shall apply, unless otherwise
specified.

Any exceptions or deviations from this standard, along with their merits &
justification, shall be brought to the attention of KOC8s Controlling
Department for their review, consideration and amendment b y the Standards
Division (if required).

List of applicable codes and standards (latest revision with addendum shall
be applicable):

INTERNATIONAL STANDARDS

ASME B36.19M Stainless Steel Pipe

ASTM A312 Seamless and Welded Austenitic Stainless Steel Pipe.

ASTM A370 Standard test methods and definitions for mechanical testing
of steel products.

ASTM A530 Standardspecificationfor general requirementsfor specialized

carbon and alloy steel pipe.

ASTM A700 Practicesfor packaging, marking and loading method for steel
products for domestic shipment.

ASTM A790 Standard specification for seamless and welded

ferriticlaustenitic stainless steel pipe.

ASME Sec.lX Welding and Brazing Qualifications.

ASME B31.3 Chemical Plant and Petroleum Refinery Piping.

ASME B31.4 Liquid Transportation .System for Hydrocarbon, LPG.

Anhydrous Ammonia and Alcohols.

ASME B31.8 Gas Transmission and Distribution Piping System.

API RP 5LW Recommended Practice for Transportation of Line Pipe on

Barges and Marine Vessels.
DOC. NO. KOC-MP-020 1 Page 7 of 16 1 REV. 1
I

BS 3605 Austenitic stainless steel pipes and tubes for pressure

purposes.

Part 1. Specification for seamless tubes.

BS 3605 Austenitic stainless steel pipes and tubes for pressure

purposes.

Part 2. Specification for longitudinally welded tubes.

NACE MR0175 Sulphide Stress Corrosion Cracking Resistant Metallic

Materials for Oil Field Equipment.

ENVIRONMENTAL CONDITIONS :

The environment of Kuwait is severe on all equipment and must be

considered carefully before procurement of plant and equipment. It must be
assumed that, unless otherwise specified, equipment may be subjected to
sand and fine particle dust storms, sand laden winds, chemical contaminants
and extreme temperatures.

KOC Standard for Basic Design data, KOC-G-007, provides the detailed
design information regarding the environmental, site, and utility supply
conditions prevailing throughout the KOC facilities.

PROCESS OF MANUFACTURE AND MATERIAL :

The pipes shall be manufactured from steel produced by an electric process.

Pipe furnished to this standard shall be as per ASTM A312 requirements,

unless otherwise specified.

Material furnished under this Standard shall conform to general requirements

and applicable specification as per ASTM A450 or A530.

Welded pipes shall be manufactured from flat rolled strip longitudinally

welded across the abutting edges by a continuous automatic welding
process without the addition of filler metal, unless otherwise specified.

Electric resistance welding shall not be used.

All pipe shall be furnished in the heat treated condition as per ASTM A312,
unless otherwise specified.

Finished pipe shall not include transverse butt welds.

Pipe shall be furnished with plain ends upto 1H" size, 2" and above shall be
bevelled ends, unless otherwise specified.

Surface imperfections which encroach on the minimum wall thickness shall

be considered defects.
The ends shall be cut nominally square with the axis of the pipe and shall be
free from excessive burrs.

Where direct sour service, sour environment, or CO, services are applicable,
the selection of material shall be based on NACE Standard MR0175.

CHEMICAL PROPERTIES :

The manufacturer shall furnish material test certificates and chemical

analysis report giving the heat analysis of each heat of steel used in the
manufacture of pipe. This report shall also list the pipe numbers of those
pipes made from the heat of steel, for final certification and shipment.

The pipe manufacturer shall furnish the results of product analysis per ASTM
A31 2 Table 1. The number of samples to be taken shall be one per heat.
The samples shall be taken either from the test pieces used for the
verification of the mechanical properties or from the pipe at the same
location as for the mechanical test samples.

MECHANICAL PROPERTlES :

Mechanical properties shall be as per ASTM A312 and as specified here

under.

Pipe may be supplied either hot finished or cold finished but shall be free of
scale and contaminating iron particles and other foreign matter.

-
Transverse or longitudinal tension test Tensile tests and acceptance criteria
for seamless and welded pipes shall be carried out in accordance with ASTM
A530 and A370.

8.3.1 The number of pipe on which mechanical test at room temperature

are to be performed shall be 2% of the pipe from each heat.

8.3.2 Test samples shall be cut from the pipe in the final supply condition
with same size, grade and heat treatment conditions. The strip test
piece shall not include the weld.

-
Flattening or Bend Test A t the option of the manufacturer, either a
flattening or a bend test shall be carried out for both types of pipes.

8.4.1 Flattening Test:

The flattening test shall be based on description as per ASTM A450.

It shall meet testing procedures and requirements as per ASTM A340
and ASTM A530.
 8.4.2 Bend Test:

The Bend Test shall be as per ASTM A31 2 and test description ASTM
A370.

8.5 Macroscopic examination (welded pipes only)

8.5.1 A sample for the flattening or weld bend test shall be macroscopically
examined before testing. The edge of the sample for a distance of at
least 25mm on each side of the weld and it shall be ground to at least
a 600 grit finish and etched in a suitable reagent to reveal the weld
structure.

8.5.2 When examined at a magnification of x10, the weld shall be free from
defects such as cracks, porosity, slag and undercutting, and shall
exhibit complete fusion with the parent metal through the full
thickness of the pipe.

9.0 NON-DESTRUCTIVE TESTING:

9.1 Hydrostatic Testing:

Every pipe shall be tested at the manufacturer's works as per ASTM A530
requirements.

9.2 All non-destructive tests, if specified on the data sheet, shall be carried out
after completion of manufacture, heat-treatment and hydrostatic testing.

10.0 DIMENSIONS, WEIGHTS. LENGTHS, AND END FINISHES :

10.1 Dimensions, size, weights, wall thickness selection, pipe threads as per
ASME B36.19M.

10.2 Pipe straightness, end conditions, tolerance and variations shall be as per
ASTM A312, A530.

10.3 Workmanship, finish and appearance shall be as per ASTM A312.

11.0 REPAIR BY WELDING:

11.1 Welding repairs shall not be allowed, unless otherwise specified.

12.0 INSPECTION:

12.1 Manufacturer shall furnish all sample test certificates as per Sect 23 of
ASTM A530.

12.2 Third party inspection if required, shall be specified in the purchase order.
Following will be the scope of third party but not necessary limited to:
 Verify actual manufacturing procedure as approved by KOC.
Identify raw material against steel mill certificates.
Monitor edge preparation for welding (welded pipe).
Monitor weld procedures and qualification records (welded pipe)
Monitor weld macro sampling for welded pipe.
Verify reference standards for ultrasonic testing.
Witness calibration runs for NDE and verify their frequency.
Monitor NDE examination and review records.
Surveillance of heat treatment operations.
Verify calibration of hydrostatic test recording equipment.
Monitor hydrostatic testing and review records.
Verify sampling of test specimens.
Witness mechanical tests.
Visual and dimensional checks of finished pipes.
Verify complete traceability, from heat to finished pipe.
Check final markings.
Sign and stamp all reports.

12.3 Nondestructive Testing when specified in the Data Sheet, stainless steel
pipe shall be subject to ultrasonic non-destructive testing in accordance with
ASTM A312 (Sect 9.5) practice to maintain quality control during
manufacture. Method of test, calibration standards, checking equipment,
and acceptance as per ASTM E-213 or for short, abrupt type discontinuities,
the Eddy Current Testing (ET) may be applied as per ASTM E426.

13.0 OUAUTY ASSURANCE:

The manufacturer shall operate a quality system which ensures that the
requirements of this Standard are achieved. The quality system shall
preferably be based on the IS0 9000 series of standards and the
manufacturer shall demonstrate compliance by providing a copy of the
accredited certificate on the manufacturer's quality manual. Verification of
the manufacturer's quality system is normally part of the pre-qualification
procedure, and is therefore not detailed in the core text of this Standard.

14.0 DOCUMENTATION:

14.1 Manufacturing Procedure Specification:

The manufacturer shall submit with their quotation a manufacturing

procedure, which shall include the.following:

Steel maker and plant at which steel is produced.

Steel making process.
a Limits on heat and product analysis
Casting techniques, ingots or billet soaking, holding and billet finish,
working temperatures and control methods.
Ingot or billet piercing pipe shape techniques.
Method of controlling the thickness of finished platesipipes.
Method of forming pipe shape from plate for welded pipe.
 Automatic welding procedure. (For welded pipe)
Method of heat treatment details on finished pipes, if any.
Pipe end ultrasonic testing techniques and acceptance criteria.
Details of automatic testing equipment and calibration.
Procedure of mechanical testing including type of test and expected
ranges.
Method of measuring pipe wall thickness, pipe length, diameter.
Hydrostatic testing procedure and methods of recording.
Pipe traceability and identification scheme.

(The above requirements may be selectively waived at the discretion

of KOC for the manufacturer who has prior experience with the
Company.)

14.2 A t least one copy of material certification, tally sheets (pipe number list) and
release documentation shall be dispatched with the pipes to facilitate goods
receiving inspection.

14.3 Final dossiers shall include the following:

Manufacturing Procedure Specification (if applicable)

Manufacturing Procedure Qualification Records (if applicable)
Concessions (as applicable)
Original stamped or embossed, all certificates and reports as per
clause (12.0) of this Standard
Tally Sheets

14.4 All correspondence, drawings, instructions, data sheet, and any other
written information shall be in English language. All dimensions, units of
measurement, physical constants, etc shall be in SI units, unless otherwise
specified.

15.0 MANUFACTURING PROCEDURE QUALIFICATION:

I f specified in Data Sheet, Manufacturing procedure qualification shall be

carried out based on the procedure submitted by the manufacturer and that
approved by KOC. Test shall be witnessed by KOC's representativelthird
party inspection. First length of pipe produced representing each nominal
wall thickness, material grade and steel source shall be examined and tested
as per requirements of this Standard and ASTM A312 to include the
-following:-

Chemical composition
Tensile properties
Final heat treatment
Flattening or bend test
Metallographic examination (for welded pipe)
Hydrostatic test
Visual inspection for surface defects and dimensional tolerances
Ultrasonic examinations.
 Reports shall be approved by KOC prior to commencement of regular
production.

Procedure qualification shall be repeated upon any change in the

manufacturing procedure as deemed necessary by KOC representativelthird
party inspector.

Appendix "A" details requirements for Sour Service or Sour Environment.

16.0 MARKINGS:

In addition to the marking specified in ASTM A312, each pipe length shall
be marked with a paint stencilled only. Manufacturer shall also ensure
marking of pipe numbers on both ends to verify pipe traceability with the
reports and the requirements of ASTM A312. The word "Sour" shall be
included in the pipe marking for sour service application, and colour codes
can be applied in the field, if required. Also, refer to KOC Standard KOC-G-
004 for packing, marking and documentation.

17.0 STORAGE, HANDLING AND SHIPPING:

17.1 All handling, and storage shall be done with care to avoid any
mechanical damage to the pipe. Loading and shipping shall be as per
ASTM A700 IAPI RPIILW, unless otherwise specified.

-
17.2 Protective Coating Pipe shall be supplied uncoated, unless specified
otherwise.
18.0 APPENDIX "A" -
STAINLESS STEEL PIPE FOR SOUIUCHLORIDE SERVICE

A.l SCOPE:

The following KOC supplementary requirements shall apply only when

specified on the purchase order Data Sheet. The supplementary
requirements are in addition to the requirements stipulated in General
Specification, for extra testing or inspection for service in sour
environments.

A.2 MATERIAL AND CHEMICAL COMPOSITION:

A.2.1 Materials shall be selected from those permitted in the NACE

Standard MR0175 for sour duty and shall take into account
resistance to general corrosion. Also, the pH value of the
process stream and the presence or absence of corrodents
such as oxygen, carbon dioxide, chlorides etc shall be
considered in the final selection of material.

Acceptable specifications shall be as per ASTM A789, and

A790 or equivalent.

A.2.2 Austenitic stainless steels shall be in the solution annealed

condition.

A.2.3 Heat-treatment shall be mandatory and procedures shall meet

the requirements of NACE MR0175.

A.3 KOC SUPPLEMENTARY REQUIREMENTS:

(Only when specified on Data Sheet)

1. Intergranular Corrosion Test:

The intergranular corrosion test shall be carried out when specified on

the Data Sheet. The number of pieces on which the test shall be
carried out shall be 1% of the number of pipes in each batch. The
tests shall be carried out and evaluated in accordance with ASTM
A262. .

2. Radiographic Examination Tests:

Radiographic examination shall be performed in accordance with

paragraph UW-51 of ASME section VIII, Division 1.
3. Additional nondestructive Testing:

KOC shall have the option to specify additional non-destructive tests

e.g those required for the detection of transverse and laminar defects.
Methods of Test and the basis of acceptance shall be as per ASTM
A530.

When examined at a magnification of x 10, the weld shall be free

from defects such as cracks, porosity, slag and under-cutting, and
shall exhibit complete fusion with the parent metal through the full
thickness of the pipe.
DOC. NO. KOC-MP-020 1 Page 15 of 16 I . REV. 1

APPENDIX @ -
19.0 DATA SHEET 1 ORDERING INFORMATION
SpedRcadan 0 ASTM A312 Duplex Steel (Specify) Grade
NPS In Owntity Meteis Feet

Nomind Wdl Thidcness In mm Schedule

Length (SpedficlRandom) 0 m 0 others (Spedfy) m

End Finish 0 Pldn Ends 0 other (spedfy)

Dhcnsiond Tdermces & Strdghmess as per ASTM A530 Yes 0 No
Non-Destructive In Testing ASTM A312 0 Yes 0 No
Certificates of Tests and Inspection Cl Yes as per ASTM A530 0 Others(specify1
Radiographic Examination 0 Yes 0 No other (specify)
Weld Repairs 0 Yes 0 No
Heat Treatment (specify)

Alternate Mill hydrostatic test required 0 Yes 0 No

(If yes.spedfy1
Flow Medium Composition (Service)

Sour Environment 0 Yes 0 No

Maximum Design Pressure kPa P&J

Maximum Design Temp. OC Min. Design Temp. OC

Installation 0 Above ground 0 Underground
Third Party Inspection 0 Yes 0 No

Special Coating & Protection 0 Yes 0 No

(If yes, specify)

End Protection 0 Yes 0 No

(If yes, specify)

Marking 0 As per ASTM A31 21A530

Special Marking OYes O N o
(if yes. specify)
Additiond Documentation OYes O N o
(If yes. specify)

Additiond Requirements 0 Yes 0 No

(ifyes. specify)

Manufacturing Procedure Spec. Required Cl Yes No

Manufacturing Procedure Qualification 0 Yes 0 No

Required.
DOC. NO. KOC-MP-020 1 Page 16 of 16 1 REV. 1

DATA SHEET (Cont.)

KOC SUPPLEMENTARY REQUIREMENTS

For Sour Sedce/Per Project Specifications

Intergranular Corrosion Test 0 Yes 0 No

Radiographic Examination 0 Yes 0 No
(Welded Pipe)

Additional Non-Destructive Test . 0 Yes [7 No

(Transverse + Lamination defects)

Ultrasonic Testing 0 Yes 0 No

(Longitudinal Imperfections)

Macroscopic Examination 0 Yes No

(Welded Pipe)

Eddy Current Test 0 Yes 0 No

(Short, abrupt discontinuity)