aramco material specification

Previous Issue: 30 March 2005 Next Planned Update: 1 April 2010 of 21 Primary contact: Anezi, Mohammed Ali on 966-3-8746122

Copyright©Saudi Aramco 2007. All rights reserved.

Materials System Specification

01-SAMSS-333 3 July 2007 High Frequency Welded Line Pipe, Class C

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

Saudi Aramco DeskTop Standards Table of Contents 1 Scope………………........................................ 2 2 Normative References.......................…......... 2 3 Definitions.........................................….......... 4 4 Classification and Designation...................…. 4 5 Information to be Supplied by the Purchaser.................................... 4 6 Manufacturing................................................ 4 7 Requirements................................................ 7 8 Inspection.....................................……......... 9 9 Marking of the Pipes………………............... 14 10 Coating for Temporary Protection................ 15 Annex B - Manufacturing Procedure Qualification......................................... 16 Annex D - Non-Destructive Testing (NDT)......... 21

Document Responsibility: Materials and Corrosion Control 01-SAMSS-333 Issue Date: 3 July 2007 Next Planned Update: 1 April 2010 High Frequency Welded Line Pipe, Class C

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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 3183-3, which is a part of this specification. The text in each paragraph below is an addition to ISO 3183-3 unless it is noted as a modification. ISO 3183-3 paragraphs that are not listed below are adopted without modification.

1 Scope [Modification] This Specification only applies to high frequency welded pipe, outside diameter 114.3 mm (NPS 4) and larger, for use in Saudi Aramco Requirement Class C service (as defined in SAES-L-136). All pipe produced to this specification must be suitable for wet, sour service and meet 01-SAMSS-022 Class IV fracture toughness requirements.

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.

2 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 Sour, Wet Service Line Pipe


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01-SAMSS-022 Fracture Control Testing Procedures for Line Pipe

01-SAMSS-024 Pipe Handling and Nesting

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

Saudi Aramco Inspection Requirements

Form 175-010400 Pipe: High Frequency Welded Steel Line Pipe, Class C, NPS 4 and Larger

2.2 Industry Codes and Standards

American Petroleum Institute

API SPEC 5L Specification for Line Pipe

American Society for Nondestructive Testing, Inc.

ASNT SNT-TC-1A Recommended Practice for Personnel Qualification and Certification

ASNT CP-189 Standard for Qualification and Certification of Nondestructive Testing Personnel

American Society for Testing and Materials

ASTM D1141 Standard Practice for the Preparation of Substitute Ocean Water

ASTM E112 Estimating the Average Grain Size of Metals

ASTM E381 Standard Method for Macroetch Testing Steel Bars, Billets, Blooms, and Forgings

International Standardization Organization

ISO 3183-3 Petroleum and Natural Gas Industries – Steel Pipe for Pipelines – Technical Delivery Conditions – Part 3: Pipes of Requirement Class C

ISO 7438 Metallic Materials – Bend Test

ISO 7539-2 Corrosion of Metals and Alloys – Stress Corrosion Testing – Part 2: Preparation and Use of Bent-Beam Specimens

ISO 9764 Electric Resistance and Induction Welded Tubes for Pressure Purposes – Ultrasonic Testing of the Weld Seam for the Detection of Longitudinal Imperfections

ISO 10474 Steel and Steel Products – Inspection Documents


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ISO 11484 Steel Tubes for Pressure Purposes – Qualification and Certification of Non-destructive Testing (NDT) Personnel

ISO 11496 Seamless and Welded Steel Tubes for Pressure Purposes – Ultrasonic Testing of Tube Ends for the Detection of Laminar Imperfections

Pipeline Research Council International, Inc.

PR-15-9306 Susceptibility of Modern ERW Pipe to Selective Weld Seam Corrosion in Wet Environments, Catalog L51775, (www.prci.com)

3 Definitions 3.2.8 Continuous Electronic Process Control (CEPC), Level 3

For the purpose of this specification, CEPC shall be a minimum of Level 3, hereby defined as continuous monitoring, recording, and feedback regulation of welding heat input and weld seam heat treating variables (voltage, current, line speed, temperature) with alarm and automatic pipe marking for conditions exceeding the qualified process limits (See Annex B.4, Fig. 10). In addition, squeeze roll force or another variable directly related to variations in distortion angle (see Figure 9a and 9b) shall be monitored and recorded and used for feedback regulation.

4 Classification and Designation [No Modifications]

5 Information to be Supplied by the Purchaser 5.1 Mandatory information [modification]

f) Impact requirements are per 01-SAMSS-022 Class IV. The required impact energy value is specified in the purchase order.

5.2 Other information

• Applicable Saudi Aramco Material System Specifications (SAMSS)

• If pipe must be suitable for internal coating it shall be so stated in the purchase order.

6 Manufacturing 6.1 General

6.1.1 A manufacturer not previously qualified to bid on this specification, before being technically qualified to be awarded an order, shall:

1) submit at least one complete qualified Manufacturing Procedure (see Annex B) with all test results and supporting documents for approval.


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2) after submission of a manufacturing procedure, submit to an ERW Pipe Mill Evaluation of the specific plant that will produce the pipe. The audit criteria shall be defined by the Saudi Aramco Consulting Services Department/Materials Engineering & Corrosion Control Division, who shall accept or reject the mill based upon the audit, the Manufacturing Procedure Qualification, and the Track Record submittals. 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.

3) submit documentation of a successful process control track record as described below.

Track Record. Candidate manufacturer shall submit documentation, including quality control and process control records, of successful production on a total of 200,000 feet of pipe manufactured to 01-SAMSS-332, or equivalent production for other major oil companies of high quality pipe for severe wet, sour service. At least two different pipe diameters shall be represented in the production records.

On orders subsequent to the initial qualification, the specific manufacturing procedure shall be qualified for that job. (See Annex B) A procedure must be qualified and approved for each set of essential variables. (See B.1 and B.4.).

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 require approval of a waiver. See Introduction, Conflicts and Deviations.

At the conclusion of production, the manufacturer shall submit a Postproduction Process Control Report to the Saudi Aramco Consulting Services Department/Materials Engineering & Corrosion Control Division. This report shall be in electronic spreadsheet format (email submittal is acceptable). The report shall include a summary of pipe quality control tests and details relevant to any rejects. The report shall also include all of the results for tests required in 8.2.2.4, 8.2.3.6, 8.2.3.7 and 8.2.3.8. For each metal distortion angle measurement, the associated metal flow factor (distortion angle ÷ girth reduction at squeeze roll per Annex B.4.2.b) and heat input factor shall be reported.

6.1.2 NDT personnel shall be qualified to ISO 11484 Level 2 or ASNT SNT-TC-1A Level 2. The primary Level 3 employee shall be certified in accordance with ASNT CP-189.


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6.1.3 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 Steelmaking

6.2.2 The steels shall be treated by calcium addition for sulfide inclusion shape control. See also paragraph 7.2.2.

6.3 Pipe manufacturing

6.3.1 This specification applies to HFW pipe only. [modification]

6.3.3 Strip shall be rolled from continuously cast slabs that are no less than 150 mm in thickness as cast. Slit slabs or 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. Slit strip shall also be capable of passing sour service testing in accordance with 01-SAMSS-016 using Solution A. For all pipe produced to this specification, the strip edges shall be milled or machined before welding. Automatic seam tracking/position control shall be used for the heat treatment and NDT stages. [modification]

Process Control [addition]

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.4.

2. During production, verify maintenance within process limits by Continuous Electronic Process Control (CEPC), Level 3 (See 3.2.8):

For every pipe length, welding heat input shall be continuously monitored and shown to be within the qualified process limits (See Figure 10) by electronic data acquisition. Metal distortion flow angle shall also be verified metallographically in accordance with 8.2.3.8.2. CEPC shall immediately identify and segregate for rejection individual pipe lengths whose qualified process limits have been exceeded.

3. CEPC, Level 3 shall also be employed for the weld seam heat treatment temperature control. SPC, as described in 01-SAMSS-332, paragraph 8.2.3.7.2 and Appendix F, shall be used to control the ID heat treat width and centering.


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4. 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, assure, and maintain adequate welding power control.

6.4 Delivery condition [modification]

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 8.2.3.8.2 are met. Commentary Note:

Advanced weld seam heat treatment capability, such as full body heat treatment or multiple in-line heat treatments, is desirable and may be necessary in order to meet the acceptance criteria in 8.2.3.8.2.

7 Requirements 7.2 Chemical composition [modification]

7.2.2 Product Analysis – For all orders, Table 4 applies as modified below:

Element Maximum % Notes

Carbon 0.08 Table 4, Note (a) applies. Silicon 0.30 Manganese 1.40 Table 4, Note (a) applies. Sulfur 0.002 Phosphorus 0.015 Copper 0.20 See 01-SAMSS-016. Calcium 0.005 Modifies Table 4 Note d. Ca/S 0.7 to 3.0 Modifies Table 4 Note d. Nb+V+Ti 0.12 Modifies Table 4 Note h.

7.3 Mechanical and technological properties

7.3.1 General requirements [modification]

If pipe is cold expanded or cold reduced, the source strip shall meet the minimum specified yield and tensile requirements.

Tables 6, 7, 8, and 9 are not applicable. Fracture control testing shall be in accordance with 01-SAMSS-022 Class IV, except that frequency of testing and sampling conditions shall be per ISO 3183-3 (See Table 19).

For the weld area impact tests required to qualify the Manufacturing Procedure (B.3) and the Process Limits (B.4), sets of six specimens shall be tested instead of the usual sets of three specimens. For the impact tests during pipe production, sets of three specimens shall be used. In all cases,


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the average absorbed energy shall not be less than the value specified in the purchase order for the pipe body. The lowest individual reading shall not be lower than 75% of the specified value and shall not be lower than 40 J. Macroetching of specimens shall be used to insure accurate placement of the V-notch at the seam.

7.3.2 Special requirements for sour service.

7.3.2.1 Acceptance criteria for HIC resistance shall be in accordance with 01-SAMSS-016. [modification]

7.3.2.3 The results of the tests at 0.90 of actual yield strength (See 8.2.3.10) shall be described and reported pass/fail, but for information only. The following acceptance criteria shall be applied to the specimens tested at 0.80 of actual yield strength and all three specimens must pass:

After removal from the solution, the specimen shall be stressed to more than actual yield strength. The specimen shall not break and no cracks shall be visible at 10X magnification.

7.3.3 Special requirements for grooving corrosion resistance.

A test for grooving corrosion resistance shall be performed as part of the manufacturing procedure qualification (See Annex B). The test method shall be that described in Section 2 of the PRCI Final Report for PR-15-9306 "Susceptibility of Modern ERW Pipe to Selective Weld Seam Corrosion in Wet Environments." (See www.prci.com) The test environment shall be room temperature synthetic seawater (ASTM D1141) in equilibrium with 30 psia CO2. The acceptance criterion is that the grooving factor GF (weldline corrosion/general corrosion, see Figure 8) shall not exceed 1.5.

d2

ad1

original surface

Figure 8

GF = d1/d2 = 1 + a/d2 Commentary Note:

Figures 1 through Figure 7 are in the base specification, ISO 3183-3.


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7.5 Surface conditions, imperfections and defects

The pipe external surface and the internal surface, if it is to be 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

7.6.3.4 Length

7.6.3.4.1 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.

8 Inspection 8.1 Types of inspection and inspection documents

Saudi Aramco Form 175-010400 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

A semi-guided root bend test per 8.2.3.6, with the root of the weld in tension, shall be substituted for each flattening test with weld at 12 o'clock that is required by 8.2.1 and Annex B.4.3

In addition, one flattening test (weld at 3 o'clock) per 8.2.3.7 and one root bend test per 8.2.3.6 shall be performed on specimens from the middle pipe of each coil.

8.2.2 Selection and preparation of samples and test pieces

8.2.2.4 Charpy V-notch impact test pieces [modification]

01-SAMSS-022 applies. Full size specimens (10 mm x 10 mm) shall be used 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.


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8.2.3.6 Bend test [modification]

An ISO 7438 Para. 4.1 (bending device with supports and a mandrel) bend test shall be applicable to HFW weld samples as described in 8.2.1. The test may be performed on the test pieces depicted in ISO 3183-3 Figure 6 or the test may be performed on a full ring of pipe as shown below in Figure 6-B. The full wall thickness is tested – no machining of the O.D. or I.D. face shall be done. The mandrel diameter shall be as specified in ISO 3183-3 Table 5, for example 5T for Grade X60 (L415). Fractures or cracks caused by weld defects shall be cause for rejection of the representative coil and shall not be discarded and retested.

Mandrel Diameter (D)

PipeSample

Figure 6-B

8.2.3.7 Flattening test

8.2.3.7.2 [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:

D/t H/D

>48 0.3

35-48 0.4

<35 0.5

where

D = specified outside diameter

t = specified wall thickness

H = distance between flattening plates

All values in the same unit.

8.2.3.8 Macrographic and metallographic examinations


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8.2.3.8.2 Weld microstructure and hardness tests

Frequency: One test per 50 lengths for items a), b), c), d), e), below and the microhardness tests. At least one pipe from each cast (heat) shall be tested. Item f), the metal distortion angles Θ , shall be measured metallographically at least three times per shift and correlated with the distortion angle parameter (i.e., squeeze roll load) that is being monitored and recorded as part of the CEPC Level 3 process.

Preparation: For each pipe tested, at least one transverse specimen of the weld area shall be polished to metallographic quality and shall be etched to provide grain boundary contrast.

Acceptance criteria: Using a metallurgical microscope or metallograph, the transverse specimen shall be examined at a magnification sufficient to easily measure grain size per ASTM E112.

a) The normalized zone shall extend through the wall and completely overlap the original weld line.

b) The weld seam microstructure shall contain no untempered martensite or bainite and no inclusions at the fusion line.

c) The grain sizes of the weld seam area and the parent metal shall be determined per ASTM E112. Weld seam grain size shall not exceed parent metal grain size by more than one ASTM grain-size unit.

d) A balanced uniform forged structure shall be present as depicted in Figure 9a and 9b.

e) Fusion line must be perpendicular with the pipe surfaces to within ± 5° (A) for any pipe wall greater than 7.9 mm (0.312 in.) and ± 10° for pipe with wall thicknesses equal to or less than 7.9 mm (0.312 in.).

f) The distortion angle Θ of the metal flow due to squeeze roll forging pressure must be within the qualified limits (Annex B.4, Figure 10), as measured with respect to the pipe wall centerline (B1 & B2), perpendicular to the fusion line. The metal distortion angle shall be determined (four locations) near a position equivalent to one-fourth wall thickness (¼ x wt) and three-fourths wall thickness (¾ x wt) from the O.D. surface on both sides of the weld seam. See Figure 9a and 9b. During qualification and production of a particular line item (same grade, O.D., w.t.), the OD and ID distortion angles shall always be measured at the same distance (L) from the fusion centerline, as established during qualification for average OD and ID metal distortion angles. The location of L for angle measurement shall be at the outer region of the welding heat tint zone, with a tolerance of ± 3% of the wall thickness. The distance LOD for the OD angles ΘOD may be


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different from the distance LID for the ID angles ΘID, but each shall be identified in the qualification report.

Figure 9a

Figure 9b

B1 - Angle of metal flow distortion (Theta in fig. 9a) on OD side B2 - Angle of metal flow distortion on ID side A - Angle of fusion line measured from perpendicular to OD surface WT - Pipe wall thickness Note: Various techniques can be used for revealing and measuring metal flow distortion.

Some methods that have proven successful individually or in combination include: 1) saturated picric acid etchant in distilled water, 2) taking specimens from a small pipe sample in which the seam has not been heat treated, 3) use of an optical comparator or profile projector.

Hardness Tests Frequency and sample preparation for hardness tests shall be as described above. The same samples can be used for both the weld microstructure tests and the hardness tests. Vickers hardness testers shall be used.


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Hardness traverses shall be made 1.5 mm ± 0.5 mm from the I.D. and O.D. surfaces and at the mid-wall. Each traverse shall consist of at least the following: one indentation in the center of the weld area, one indentation located not more than 1.0 mm on each side of the central indentation, and one indentation in the parent metal outside of the normalized zone on each side of the weld. (Total of 5 indentations in each traverse.) For each traverse, the middle three measurements should be in the normalized zone and encompass the weld seam.

The maximum hardness measured shall not exceed 240 HV (Vickers Hardness using a 10 kg load) and the average hardness of the middle three I.D. measurements shall be at least 5 HV lower than the average hardness of the corresponding three O.D. measurements as shown by a statistical t-test of data from two samples with unequal variances for a 95% confidence level.

8.2.3.9 Hydrogen-induced cracking (HIC) test [modification]

Testing for HIC resistance shall be in accordance with 01-SAMSS-016.

8.2.3.10 Sulfide stress cracking (SSC) test

Three samples shall be tested and all three shall meet the acceptance criterion in 7.3.2.3. Either Method 1 or Method 2 below may be used.

Method 1:

Method 1 is the TM0177-96 Method C test (C-ring) with the I.D. surface placed in tension. Test solution A shall be used. Three samples shall be tested at 0.80 of the actual measured yield strength and three samples shall be tested at 0.90 of the actual measured yield strength. See 7.3.2.3 for the acceptance criteria. The deflection is calculated according to the equation:

tE4 S 2t)-(d t)-(d πD =

where D = deflection across bolt holes

t = specimen thickness

d = specimen outer diameter

S = desired inner fiber stress

E = modulus of elasticity

Method 2:

Method 2 is the four point bend test per ISO 7539-2 with machined specimens. The standard requirements in ISO 3183-3 Paragraph 8.2.3.10 apply except that three samples shall be tested at 0.80 of the actual measured yield strength and three samples shall be tested at 0.90 of the actual measured yield strength. See 7.3.2.3 for the acceptance criteria.


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8.2.3.11 Hardness test

8.2.3.11.3 Hardness surveys may be as specified in 8.2.3.8.2 above [modification]

8.2.3.12 Hydrostatic test

The seam shall be positioned in the upper quadrant (approximately 12:00 o'clock) prior to the application of pressure. Any pipe whose seam is not in the upper quadrant during pressure testing shall be re-tested. At least one inspection observer shall be present during pressurizing to observe the weld seam, from a safe location, for leaks that may not register an obvious pressure drop on the test gauge. Any failing or leaking pipes shall be rejected and the cause investigated and corrective actions documented.

8.2.3.12.1 The hydrostatic test pressure shall be calculated in accordance with 8.2.3.12.2, but shall be calculated so that a stress of 100% SMYS is reached. If the manufacturing procedure qualification demonstrates plastic deformation in the pipe, the pressure may be reduced enough to prevent deformation. Also, note that if the hydrostatic seal is on the end face of the pipe by means of a ram, Method B in ISO 3183-3 Para. 8.2.3.12.2 b) provides for appropriate end load compensation.

8.2.3.13 The lighting in the hydrostatic test area and the area for visual examination shall provide a minimum illumination of 500 lux. [modification]

9 Marking of the Pipes [Modification] Marking of pipes shall be in accordance with API SPEC 5L (2004) Section 10 with the additional requirements listed below. The marking "Spec. 3183-3" shall be used in place of "Spec. 5L" and the symbol "ERW" shall be substituted for the symbol "E" as the Process of Manufacture. The grade number shall first be that from API SPEC 5L followed by the equivalent grade, in parenthesis, from ISO 3183-2.

The size of the lettering shall be commensurate with the diameter of the pipe, but in no case less than 21 mm in height for API standard markings and 13 mm in height for shipping markings. Paint stencil marks with white alkyd enamel or equivalent.

Each pipe shall be marked with the port designation as well as the Purchase Order number and item number.

Example: Saudi Aramco/Dammam Saudi Aramco D-518-01-3000/Item No. 2.

Each pipe shall be marked with the Saudi Aramco Material System (SAMS) Catalog designated stock number (SAP 9CAT number). For pipe purchased for which there is no assigned SAMS 9CAT stock number, the pipe shall be marked "01-SAMSS-333."


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10 Coating for Temporary Protection Pipe shall be supplied without mill coating unless specified otherwise in the Purchase Order. Varnish coating of the markings is acceptable provided that the varnish is hard drying with a maximum dry film thickness of 0.050 mm.

Revision Summary 30 March 2005 Revised the "Next Planned Update". Reaffirmed the contents of the document, and

reissued with minor changes. 3 July 2007 Editorial revision to delete Section 11.


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Annex B – Manufacturing Procedure Qualification B.1 Introductory Note (modified)

All pipe must be manufactured using a qualified Manufacturing Procedure that has been approved by Saudi Aramco Consulting Services Department/Materials Engineering & Corrosion Control Division (ME&CCD). Procedure submittals include B.2, B.3, and B.4 requirements. The Manufacturing Procedure shall be qualified prior to start of main production and submitted no later than five days after start of main production. Fax or email submittals are acceptable. Final acceptance of pipe is contingent upon successful qualification of a procedure and approval by ME&CCD, plus evidence that the pipe was manufactured within the limits of the Manufacturing Procedure.

The manufacturer may use a previously qualified Manufacturing Procedure if the new product falls within a set of previously qualified essential variable groups listed below. In this case, the submittal should be in the form of a Manufacturing Procedure Specification with simplified B.2 information and without the detailed supporting test data that was previously submitted. The manufacturing procedure shall be requalified any time there is a change in the essential variables. If the essential welding variables (Annex B.4) change, but the essential manufacturing variables are unchanged, then only the welding conditions (Annex B.4) must be requalified.

Essential manufacturing variables:

a) Pipe grade

b) Outside diameter group

1) Up to and including 323.9 mm (NPS 12)

2) Over 323.9 mm (NPS 12)

c) Wall thickness group

1) 6 mm to 11 mm

2) Over 11 mm

d) Strip coils from same steelmaker/specification/grade.

B.2 Characteristics of the Manufacturing Process

In addition to all of the base specification Annex B.2 requirements, manufacturer shall identify the primary steel producer, the reroller, if applicable, and the strip mill, and shall state the thickness, and split width if applicable, of the slab from which the strip was rolled and the method for controlling segregation during casting. In addition to the list of required information, the pipe making equipment should be described with particular attention to


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equipment and processes that may not meet the intent of this specification. Completely describe the strip edge milling, automatic seam tracking, and weld seam heat treatment process and equipment. Commentary Note:

Advanced weld seam heat treatment capability, such as full body heat treatment or multiple in-line heat treatments, is desirable.

B.3 Manufacturing Procedure Qualification Tests

Manufacturing procedure qualification test results to be submitted include:

a) All tests required in Section 8 of ISO 3183-3 and this specification. A complete series of tests shall be performed on at least one pipe from each coil described in B.4.3.c. If multiple welding lines will be used for production the same requirements shall apply to each pipe manufacturing line.

b) Results of 01-SAMSS-022 impact tests.

c) Results of 01-SAMSS-016 HIC tests.

d) Results of sulfide stress cracking tests.

e) Results of grooving corrosion tests.

f) Qualification of process limits (welding qualification) as specified in Annex B.4, attached.

g) Complete description of Continuous Electronic Process Control.

h) For the purpose of the first-time qualification only (Para. 6.1.1) the submittal may be based upon Annex B.1, B.2, mill historical production data, and the mill's own process control procedures. However, the quantity and quality of the information submitted must be sufficient to confirm compliance with the intent of this specification. If a purchase order is awarded on this basis, the specific qualification tests required by Annex B.3 and B.4 shall be performed prior to start of main production.

i) Postproduction Process Control Report (see 6.1.1) for a previous order, either a) the last order, or preferably b) the last order with the same essential welding variables (see Annex B.4).

B.4 Qualification of Process Limits

1. Essential welding variables:

a. Pipe grade

b. Nominal diameter

c. Specified wall thickness ± 1.0 mm

d. Operation within qualified process limits (Figure 10)


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e. Contact tip/roller alloy composition (HFERW only)

f. Induction coil configuration (HFI only)

g. Impeder configuration (HFI only)

2. Process variables:

a. Heat Input Factor (function of wall thickness, voltage, current, temperature, and line speed)

b. Metal Flow Factor (distortion angle ÷ girth reduction at squeeze roll)

c. Seam annealing power (related to temperature)

d. Seam anneal width at I.D. surface

3. Qualification Steps

a. Install chart recorders, or other appropriate devices, for electronic data acquisition to monitor and control the process variables listed above.

b. From the nominal settings for voltage, current, line speed, and metal flow factor (distortion angle ÷ girth reduction) identify, or calculate, the maximum and minimum limits for each and construct the preliminary process limits (see Figure 10). Note: the boundary limits may be based on experience (such as data from

a previous order), or calculated, or chosen arbitrarily.

c. Produce at least one coil at the nominal welding conditions and one coil at each of the chosen maximum and minimum limit points, determined in B.4.3.b above, and depicted in Figure 10.

i. Sample each coil at the front, middle, and end.

ii. Evaluate each sample for compliance with 7.3.1 and 8.2.3.3 (impact tests of weld samples only), 8.2.3.6 (bend test), 8.2.3.7 (flattening test) and 8.2.3.8 (metallographic examination).

iii. If any set of specimens fails to meet the requirements above, adjust the variable settings accordingly and produce another coil. If necessary continue adjustments until the desired limits of the process have been identified.

iv. Choose, at random, one additional pipe from coil A and remove at least 10 samples, at least one meter apart, for metallographic tests in accordance with 8.2.3.8.2.f.


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Figure 10

4. Perform the following calculations with the measurements made in 8.2.3.8.2.f for all five test coils.

a) Determine the average overall metal distortion angle for all OD angles combined. This calculated value is defined as X-barQOD.

b) Determine the standard deviation for all OD angles combined. This calculated value is defined as SQOD. If SQOD > 3.0, the process must be requalified after process improvements have been made.

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 (X-barAOD, 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.

5. The final process capability curve (Figure 10) represents the qualified process limits for the Manufacturing Procedure and combination of


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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. For all pipe manufactured, the CEPC system shall control process variables within the area bounded in Figure 10 in accordance with 6.3.3.

6. The pipe used for qualification may be included in the production order provided that each coil is sampled and tested as described in B.4.3.c above. Any coil that does not pass all of the tests shall be rejected.


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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.4.2 Nondestructive testing of the weld seam

Pipe shall be inspected to ISO 9764 acceptance level L2 (N5 notch).

D.4.3 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.