01-SAMSS-332

Materials System Specification 01-SAMSS-332

3 July 2007

High Frequency Welded Line Pipe, Class B Materials and Corrosion Control Standards Committee Members Anezi, Mohammed Ali, Chairman Rumaih, Abdullah Mohammad, Vice Chairman Abdul Hadi, Abdul Latif Ibrahim Bannai, Nabeel Saad Buraiki, Iyad Abdulrazzak Burgess, Brian Wayne Cruz, Czar Ivan Tecson Kermad, Abdelhak Lobley, Graham Russel Mehdi, Mauyed Sahib Moore, Mark Andrew Mugbel, Wajdi Mohammad Nasri, Nadhir Ibrahim Niemeyer, Dennis Charles Nuaim, Tareq Abdulaziz Omari, Ahmad Saleh Rao, Sanyasi Tems, Robin Douglas

Saudi Aramco DeskTop Standards Table of Contents 1 2 3 4 5

Scope............................................................. 2 Normative References................................... 3 Definitions...................................................... 4 Classification and Designation....................... 4 Information to be Supplied by the Purchaser.................................... 4 6 Manufacturing................................................ 5 7 Requirements................................................. 8 8 Inspection...................................................... 9 9 Marking of the Pipes..................................... 15 10 Coating for Temporary Protection................ 15 Previous Issue: 30 March 2005

Next Planned Update: 1 April 2010 Page 1 of 24

Primary contact: Anezi, Mohammed Ali on 966-3-8746122 Copyright©Saudi Aramco 2007. All rights reserved.

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Table of Contents (Cont'd) Annex B - Manufacturing Procedure Qualification......................................... Annex B.3 - Qualification of Welding Conditions.............................. Annex D - Non-Destructive Testing (NDT)......... Annex F - Statistical Process Control.................

16 18 21 22

Introduction Conflicts and Deviations 1)

Any conflicts between this Specification and other applicable Saudi Aramco Engineering Procedures (SAEPs), Saudi Aramco Engineering Standards (SAESs), Saudi Aramco Materials System Specifications (SAMSSs), Saudi Aramco Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2)

Direct all requests to deviate from this Specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

The following paragraph numbers refer to International Standard ISO 3183-2, which is a part of this specification. The text in each paragraph below is an addition to ISO 3183-2 unless it is noted as a modification. ISO 3183-2 paragraphs that are not listed below are adopted without modification. 1

Scope [Modification] This Specification only applies to high frequency welded (HFW) pipe, outside diameter 114.3 mm (NPS 4) and larger, for use in Saudi Aramco Requirement Class B. Commentary Note: Requirement Class B services are defined by Saudi Aramco Engineering Standards (i.e., SAES-L-136) and typically include sweet and sour liquid hydrocarbons and dry sweet hydrocarbon gas transportation.

Unless stated to the contrary in the purchase requisition and the purchase order, pipe manufactured to this specification must be suitable for external coating with fusion bonded epoxy at a later date by the Purchaser. If the pipe will be internally coated, it shall be so stated in the purchase requisition and the purchase order. Page 2 of 24

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

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01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Normative References The following additional references apply to the implementation of this specification: 2.1

Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standard SAES-L-136

Pipe Selection and Restrictions

Saudi Aramco Materials System Specifications 01-SAMSS-016

Qualification of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking

01-SAMSS-022

Fracture Control Testing Procedures for Line Pipe

01-SAMSS-024

Pipe Handling and Nesting

Saudi Aramco Inspection Requirements Form 175-010300 2.2

Pipe: Plain End Electric Resistance or Electric Induction Welded Steel Pipe

Industry Codes and Standards American National Standard Institute ANSI/ASQC Z1.4

Sampling Procedures and Tables for Inspection by Attributes

American Petroleum Institute API SPEC 5L

Specification for Line Pipe

American Society for Testing and Materials ASTM E112

Estimating the Average Grain Size of Metals

ASTM E381

Standard Method of Macrotech Testing Steel Bars, Billets, Blooms, and Forgings

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

International Organization for Standardization

3

ISO 3183-2

Petroleum and Natural Gas Industries - Steel Pipe for Pipelines - Technical Delivery Conditions Part 2: Pipes of Requirement Class B

ISO 8258

Shewhart Control Charts

ISO 9764

Electric Resistance and Induction Welded Tubes for Pressure Purposes - Ultrasonic Testing of the Weld Seam for the Detection of Longitudinal Imperfections

ISO 11496

Seamless and Welded Steel Tubes for Pressure Purposes - Ultrasonic Testing of Tube Ends for the Detection of Laminar Imperfections

Definitions 3.2.8

Continuous Electronic Process Control (CEPC), Level 2 For the purpose of this specification, CEPC, if used, shall be a minimum of Level 2, hereby defined as continuous monitoring and recording of heat input variables (voltage, current, line speed) and seam annealing variables (annealing power input and line speed) with alarm and automatic pipe marking for upset conditions outside of the qualified process limits (See Annex B.3, Figure 8). In addition, it is highly desirable to extend CEPC to monitor squeeze roll force or another variable directly related to metal distortion angle (see Figure 7).

4

Classification and Designation [No Modifications]

5

Information to be Supplied by the Purchaser 5.1

Mandatory information [modification] 8)

5.2

Impact requirements are per 01-SAMSS-022 Class I or Class IV. For Class IV, impact energy value is specified in the purchase order.

Other information •

Applicable Saudi Aramco Materials System Specifications (SAMSS)

•

Service, including "sour" or "non-sour"

•

If pipe must be suitable for internal coating, it shall be so stated.

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01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Manufacturing 6.1

General

6.1.1

The quality system shall be subject to approval by Saudi Aramco Inspection Department/Vendor Inspection Division when the manufacturer is surveyed for consideration as a qualified supplier and the quality system shall be assessed periodically thereafter.

6.1.2

NDT personnel shall be qualified to ISO 11484 Level 2 or ASNT SNT-TC1A Level 2. The primary Level 3 employee shall be certified in accordance with ASNT CP-189.

6.1.3

A manufacturer, not previously qualified to bid on this specification, shall submit at least one complete Manufacturing Procedure (see Annex B) for approval prior to award of any Purchase Order and the manufacturer and bid shall not be considered technically acceptable until approved as described in Annex B. Once qualified, a manufacturer may qualify additional procedures after award of the Purchase Order(s), as described below. A specific manufacturing procedure shall be qualified for the job (see Annex B). A procedure must be qualified and approved for each set of essential variables (see B.0 and B.3.) Minor exceptions to this specification may be addressed in the Manufacturing Procedure approval process (Annex B). In these cases, formal waivers are not required, but intended exceptions and Saudi Aramco approval must be in writing. Major deviations from this specification shall be submitted in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran. A postproduction report shall be submitted to the Company or Buyer Representative demonstrating adequate process control during the entire production run for the purchase order. Commentary Note: The postproduction report shall include complete production test data such as SPC charts, hardness, flattening tests, load cell readings, anneal width, etc.

6.2.1

For sour service, the steel shall be treated by calcium addition for sulfide inclusion shape control. See also paragraph 7.2.1.

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

6.3

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Pipe manufacturing This specification applies to HFW pipe only. [modification] Strip shall be rolled from continuously cast slabs that are no less than 100 mm in thickness as cast. Slit strip shall not be used unless the Manufacturing Procedure documents that the strip is capable of meeting the C2; R2; S2 rating after macroetching with ammonium persulfate in accordance with ASTM E381, or an equivalent procedure approved by Saudi Aramco. Such slit strip (regardless of service) shall also be capable of passing sour service testing in accordance with 01-SAMSS-016 using Solution A. Process Control, Option 1 Verifiable control of process variables is required for all pipe produced. The welding process shall also be qualified prior to production, in accordance with this specification. Basic process control requirements for welding are: 1.

Qualify the process limits in accordance with Annex B.3.

2.

During production, verify maintenance of acceptable welding conditions and adequate process control. Either of three methods is acceptable for use: a.

Continuous Electronic Process Control (CEPC), Level 2. (see 3.2.8). For every pipe length, heat input variables (voltage, current, line speed) and seam annealing variables (annealing temperature and line speed) shall be continuously monitored and shown to be within the qualified process limits (See Figure 8) by electronic data acquisition. Metal distortion angle shall be verified metallographically in accordance with 8.2.3.7.2. If squeeze roll force or another parameter proven to have direct correlation with flow angle is measured as part of CEPC, then the metal distortion angle shall be measured metallographically at least once per shift. CEPC methods shall not require Statistical Sampling and Statistical Process Control (SPC) methods for control of voltage, current, line speed, and metal distortion angle. CEPC shall immediately identify and segregate individual pipe lengths whose qualified process limits (Annex B.3) have been compromised.

b.

Statistical Process Control (SPC)

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

If CEPC methods are not used, physical sampling for SPC of all process variables is required. In this case, the manufacturer shall submit his proposed SPC procedure for approval along with the Manufacturing Procedure (Annex B and Annex B.2). Annex F contains guidelines for an SPC procedure that would be satisfactory to Saudi Aramco. SPC methods shall identify and segregate each lot that may contain pipe manufactured with process variables outside of the qualified process limits (Figure 8 and Annex B.3) in accordance with ISO 8258 using control limits specified in Annex B.3.5. c.

Combination of CEPC and SPC If CEPC is used to control heat input process variables, but not metal distortion angle, SPC can be used to control metal distortion angle in accordance with the frequency described in 8.2.3.7.2. The average of the tests required for each lot shall represent one sub-group to be charted by SPC in accordance with ISO 8258 using control limits as specified in Annex B.3.5.

3.

Qualification of welding conditions shall verify that the primary power line voltage to the mill, and within the mill, does not fluctuate significantly. The mill must demonstrate and assure maintenance of adequate weld power control.

Process Control, Option 2 Verifiable control of process variables is required for all pipe produced. A manufacturer may submit its own proprietary process control procedures for review. The information shall be treated as confidential by Saudi Aramco. The proprietary process control system must meet the intent of this specification to define relevant process variables, relate these variables to production of acceptable pipe, and maintain process control during production. Deviations from Option 1 requirements (above) must be very well supported with detailed procedure descriptions, a large amount of production data, and appropriate statistical analysis. 6.4

Heat treatment condition The full width and thickness of the weld seam shall be heat treated after welding so that the weld microstructure and hardness requirements in paragraph 8.2.3.7.2 are met. Full body normalizing is optional. CEPC, Level 2, when employed shall be used to assure the ID heat treat width and centering by monitoring annealing temperature and line speed as related to temperature control. In the absence of CEPC, SPC shall be used for the Page 7 of 24

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

sample frequency described in 8.2.3.7.2. Failure or abnormal operation of the seam heat treatment equipment shall trigger an alarm and automatic pipe marking. Failure to control the ID heat treat width, and centering, by SPC shall cause the lot in question to be rejected. 7

Requirements 7.2

Chemical composition [modification]

7.2.1

Cast analysis (heat analysis) Element

7.2.2

7.3

Maximum %

Silicon

0.35

Manganese

1.40 (Table 3 note applies)

Sulfur (sour service)

0.003

Sulfur (non-sour service)

0.006

Copper

0.20 if 01-SAMSS-016 specified

Calcium

0.006

Ca/S (sour service)

> 1.5 when S > 0.0015%

Product analysis (see ISO 3183-2 Table 3, Note 4) Wall thickness, mm

Maximum CEV

< 11.1

0.42

11.1 – 12.6

0.41

12.7 – 15.8

0.40

> 15.8

0.39

Mechanical and technological properties [modification] Table 6 and 7 are not applicable. Fracture control testing shall be in accordance with 01-SAMSS-022.

7.5

Surface conditions, imperfections and defects Pipe that is to be externally and/or internally coated shall be free of scabs, slivers, laps, seams, and other conditions that would impair coating, including, but not limited to, oil, grease, tape, lacquer, and varnish.

7.6

Dimensions, masses, and tolerances

7.6.3.3

Length Page 8 of 24

Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

7.6.3.3.2

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01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Random length group "r2" shall be delivered except as specified below or otherwise specified in the Purchase Order. 1)

No pipe lengths less than 10.0 m will be accepted.

2)

Pipe lengths less than 11.6 m can not exceed 2% of the total line item quantity.

3)

If the pipe is identified in the Purchase Order as being intended for subsequent internal coating, the maximum length of any individual pipe is 12.8 m.

Inspection 8.1

Types of inspection and inspection documents Saudi Aramco Inspection Requirements Form 175-010300 specifies the inspection and testing requirements. The certificates/data to be provided are of the ISO 10474 Type 3.1.B and shall be reported in the English language.

8.2

Specific inspection and testing

8.2.1

Type and frequency of tests For certain environments, such as wet, sour crude oil, the Purchase Order may specify 01-SAMSS-016, which contains the Saudi Aramco requirements for hydrogen induced cracking (HIC) testing.

8.2.2

Selection and preparation of samples and test pieces

8.2.2.2.3

Charpy V-notch impact test pieces [modification] 01-SAMSS-022 applies. Full size specimens (10 mm x 10 mm) shall be use whenever possible and the pipe sample may be flattened before machining to obtain as close as possible to a full size specimen. Subsize specimens shall only be allowed when the pipe wall thickness is insufficient to provide full size specimens. In these cases the largest possible subsize specimens, obtainable by flattening or use of tapered ends, shall be used.

8.2.3.6

Flattening test

8.2.3.6.1

[modification] Besides the two test pieces taken from both end-of-coil locations, one test piece shall also be taken from two random, but not identical, locations

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

through the remaining length of the coil and tested with the weld at the 3 o'clock position. Commentary Note: One coil may produce 12-34 pipe lengths depending on size and thickness. The intent is to get 4 tests evenly spaced throughout the coil length. Ideally, 4 separate pipes in the coil length are to be sampled.

8.2.3.6.2

[modification] In the first step of the flattening test, no weld opening shall occur when the pipe is flattened as follows, and continue flattening to report the height when a weld opening does occur or until opposite walls of the pipe meet:

where,

D/t

H/D

>50

0.4

30-50

0.5

3.0, the process must be requalified after process improvements have been made.

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

6.

7.

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

c)

Determine the average overall metal distortion angle for all ID angles combined. This calculated value is defined as X-barQID.

d)

Determine the standard deviation for all ID angles combined. This calculated value is defined as SQID. If SQID > 3.0 the process must be requalified after process improvements have been made.

e)

Determine, for the additional single pipe from coil A, the average OD and ID angles with their associated standard deviations. These values (XbarAOD, X-barAID, SAOD, and SAID) are defined as approximations of the true process means and standard deviations and shall appear in the qualification report. If SAOD or SAID are greater than SQOD or SQID, respectively, requalification shall be required after significant process improvement.

The final process capability curve (Figure 8) represents the qualified process limits for the Manufacturing Procedure and combination of essential welding variables. Any operation shown to be outside of the Qualified Process Limits will require evaluation by CSD or requalification, and any pipe produced outside this qualified boundary must be either rejected or held for further evaluation. a)

For pipe manufactured with full CEPC, level 2, (see 6.3.2.a) the CEPC system shall control process variables within the area bounded in Figure 8 in accordance with 6.3.2.a.

b)

For pipe manufactured without any CEPC (see 6.3.2.b) adequate SPC sampling must be accomplished in accordance with Annex F to assure the maintenance of the Qualified Process Limits in Figure 8 with a 95% confidence level.

c)

For pipe manufactured to 6.3.2.c the distortion metal angle tests taken in accordance with 8.2.3.7.2 shall be SPC charted in accordance with ISO 8258. A production lot shall be rejected if the sub-group plot falls outside of the UCL or LCL.

The pipe used for qualification may be included in the production order provided that each coil is sampled and tested as described in B.3.3 above. Any coil that does not pass all of the tests shall be rejected.

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Annex D – Non-Destructive Testing (NDT) D.2

General NDT requirements and acceptance criteria D.2.2 Timing of NDT operations Ultrasonic examination of the weld seam shall be carried out after hydrostatic testing. Means shall be provided to mark the pipe when the ultrasonic inspection equipment indicates an imperfection is present so that defective areas can be identified. D.2.4 Laminar imperfections at the pipe ends Verification shall be carried out in accordance with ISO 11496. Also, the seam weld area of the bevels shall be examined by dye penetrant, magnetic particle, or shear wave ultrasonic inspection; the choice of inspection techniques is at the mill's option. No laminations or cracklike indications extending into the face of the bevel are acceptable. If any defects are found at the pipe ends, the pipe shall be cut back to remove such defects.

D.4

NDT of HFW pipe D.4.1 Nondestructive testing of the weld seam D.4.1.1 Pipe for liquid service shall be inspected to ISO 9764 acceptance Level L3 (N10 notch) and pipe for gas service shall be inspected to acceptance Level L2 (N5 notch). D.4.2 Laminar imperfections in the pipe body Verification of compliance shall be carried out. Inspection may be on the flat form prior to welding or full-body inspection after welding, at the discretion of the manufacturer.

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Annex F – Statistical Process Control of Heat Input Variables SAMPLING:

Establish a physical sampling plan for each lot of 100 lengths in accordance with ANSI/ASQC Z1.4 and the table below using an AQL of 0.65. Sample Size Normal

20

Tightened

32

Reduced

8

Lot Reject no.

1

STATISTICAL PROCESS CONTROL (SPC) METHODS: 1.

When CEPC methods are not used, follow the sampling plan for metallurgical structure and record the appropriate welding conditions representing voltage, current, line speed, and if possible squeeze roll pressure or other value related to metal distortion angle.

2.

Construct SPC charts in accordance with ISO 8258 for appropriate values representing Process Variables as identified in Annex B.3.2, "Qualification of Welding Conditions."

3.

Monitor and maintain process control of essential process variables, with SPC charts described above in accordance with ISO 8258.

4.

Any single sample group, or process variable, represented by one value plotted outside of the constructed Upper and Lower Control Limits (UCL and LCL) shall be rejected and evaluated for a possible assignable cause. Corrective action shall be implemented, where appropriate, and associated lot(s) rejected.

5.

Any two consecutive sample sub-groups represented by two consecutive values plotted outside of the constructed UCL and LCL shall be identified for assignable cause. Associated lots shall be rejected and production halted until effective corrective action has been achieved.

STATISTICAL PROCESS CONTROL OF METALLURGICAL STRUCTURE: 6.

Sampling Plan for manufacturing without CEPC methods. The sampling plan is not required for any other testing required by this specification unless required by 6.3, 6.4 or 8.2.3.7.2.

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Document Responsibility: Materials and Corrosion Control Issue Date: 3 July 2007 Next Planned Update: 1 April 2010

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

a.

The sampling plan required for metallurgical control is to be used after steady state production conditions have been achieved or verified. Steady state conditions are defined as changes in process variable settings that are still within the qualified process limits in Annex B.3, Figure 8.

b.

All pipes produced during non-steady state production conditions must be rejected, evaluated if appropriate for metal distortion angle, and the results, including process control chart recordings, reported to Saudi Aramco Consulting Services Department, Materials Engineering & Corrosion Control Division for decision as to disposition.

c.

The following sampling plan for metallurgical control is based upon ANSI/ASQC Z1.4, "Sampling Procedures and Tables for Inspection by Attributes".

d.

i)

Lot size, for process control, shall consist of 100 pipe lengths in any single pipe diameter / wall thickness / strength combination. Lot sizes of less than 100 pipe lengths shall be evaluated either the same as 100 pipe lengths, or added to the previous lot and the larger lot evaluated in accordance with Z1.4.

ii)

Sampling plans are selected for an AQL = 0.65. Refer to Z1.4 switching rules when appropriate for switching from normal inspection to either tightened or reduced inspection activity (Figure 9).

Attempt to sample non-sequential pipe lengths from each lot of 100. Evaluate the weld zone microstructure, or values representing such, in terms of the requirements in 8.2.3.7.2 of this document, and reject the lot if one specimen or sub-group fails.

7.

Rejected lots shall be re-inspected (8.2.4) by UT, metallographic section, mechanical testing, and re-hydrotested if appropriate. The results of process control for each rejected lot shall be reported to Saudi Aramco for disposition.

8.

Any product, by normal inspection, that results in the rejection of two out of five consecutive lots of pipe will require major mechanical maintenance, related to control of the essential variables, and switched to tightened inspection (see Figure 9 and the table above). Pipe production, under tightened inspection, that results in the rejection of ten sequential lots, shall require a halt in production, major mechanical and/or electrical maintenance, re-qualification of related welding conditions, and all ten lots produced shall require re-evaluation for an assignable cause for losing process control.

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9.

01-SAMSS-332 High Frequency Welded Line Pipe, Class B

Any product, by normal inspection, that results in the acceptance of 10 consecutive lots shall allow switching to reduced inspection (see Figure 9 and the table above).

Figure 9 – Statistical Process Control Cycle

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