REPSOL OIL OPERATIONS

NC-115 DEVELOPMENT PROJECT

DOCUMENT NO: 12/47/002
CONSULTANTS: TEKNICA (UK) LTD

API 5L X52 LINE PIPE MATERIAL SPECIFICATION

REFERENCES

API-5L Specification for Line Pipe

TEKNIKA (UK) LTD

A 4/12/96 Approval
APPROVED
01 29/11/96 Comment 1 Paul
Rev Date Issued for Originator Checked Eng Co-Ordinator PM Approved
 CONTENTS

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TITLE

INTRODUCTION

1.0 SCOPE

3.0 DEFINITIONS

5.0 PROCESS OF MANUFACTURE AND MATERIAL

6.0 MATERIAL REQUIREMENTS

7.0 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS AND FINISHES

8.0 COUPLINGS

9.0 INSPECTION AND TESTING

10.0 MARKING

11.0 COATING AND PROTECTION

12.0 DOCUMENTATION

13.0 SHIPPING

14.0 QUALITY ASSURANCE

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CONTENTS

APPENDIX
APPENDIX 1 MANUFACTURING PROCEDURE AND QUALIFICATIONS

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INTRODUCTION

This specification is supplementary to API Specification 5L: Line Pipe, 1995 Edition. The
numbering of the sections in this specification is the same as in API Specification 5L.

Insofar as only part of an API Specification section is changed the remainder of the section
shall be applicable. API Specification 5L sections and section paragraphs not mentioned in this
specification are fully applicable. Where requirements of this specification conflict with those
of API Specification 5L, this specification shall govern.

The Vendor shall submit a document specifying the manufacturing procedure of basic
materials and pipes for the approval of the Operator prior to qualification tests.

All communications, purchase orders, acceptances and certificates shall be written in the
English language.

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1.0 SCOPE

1.1 This specification defines the requirements for the manufacture, inspection,
testing, marking, coding, shipment and documentation of API 5L Grade X52
carbon steel line pipe, 16" OD and larger to be used in the construction of the
NC- 115 Field Development Project.

2
3.0 DEFINITIONS

'Operator' shall mean Repsol Oil Operations NC- 115 Development Project.

'Vendor' shall mean the manufacturer of pipe the subject of this specification.

'Inspector' shall mean any person, company or body appointed by the Operator to
exercise the functions entrusted to him under the Purchase Agreement
and notified by the Operator to the Vendor.

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5.0 PROCESS OF MANUFACTURE AND MATERIAL

5.1 This specification applies to pipes equal to or greater than 16" outside diameter.
They shall be manufactured by longitudinal seam or helical seam welding using the
automatic submerged arc-welding process, with at least two weld passes, one of
which shall be on the inside of the pipe, or shall be seamless.

5.2 Pipe may be cold-expanded for sizing purposes only, to a maximum of 1. 5 % greater
than the original diameter. The Vendor should state whether pipe is cold-expanded and
the degree of cold expansion.

5.6 Prior to production commencing full technical details of the manufacturing process
shall be submitted for the Operator's approval.

5.7 A manufacturing procedure specification for the pipe shall be submitted with the
proposal for the Operator's approval. The Operator reserves the right to witness all
pipe manufacturing procedures including qualification testing.

Should a change to the manufacturing procedure be required, it shall be subject to

prior approval by the Operator. The Operator reserves the right to request
re-qualification of the manufacturing process. Any change in pipe size, thickness or
source of steel supply shall be considered sufficient cause for re-qualification.

5.8 The manufacturing procedures shall be qualified during the first day's production as
specified in Appendix 1.

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4
6.0 MATERIAL REQUIREMENTS

-Ni + MO + V + 5B
60 15 10

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2
6.1 Chemical Composition

Chemical composition of steel shall be as defined in the table below:

Table 1

Element Symbol Ladle Analysis Max % Check Analysis Max %

Carbon c 0.14 0.15

Manganese Mn 1.50 1.55

Silicon si 0.35 0.35

Phosphorus p 0.025 0.025

Sulphur S 0.02 0.02
Aluminium AI 0.06 0.06
Copper Cu 0.25 0.25
Nickel Ni 0.35 0.35
Chromium Cr 0.15 0.15

Molybdenum mo 0.08 0.08

Nitrogen N 0.014 0.014

(a) Maximum nitrogen content up to 0.014% is acceptable if the ratio AL/N is

equal to or greater than 2.

(b) Alloying elements Niobium, Vanadium, Titanium may be added to a combined

total not exceeding 0. 15 %.

(c) The weld crack susceptibility (Pcm) shall be derived from the following
formula:

PCM = C + -Si + Mn + Cu + Cr +
30 20

5
 Pcm maximum shall not be greater than 0. 19 on ladle analysis nor 0.20 on
check analysis.

The Operator's normal requirement of Carbon Equivalent (CE), by check

analysis, shall not exceed 0.35 as calculated by the following formula:

+ Ni + CU
15

CE = C + Mn + Cr + MO +V
6 5

6.1.1 The steel shall be produced by the basic oxygen or electric furnace,
continuous cast, process and shall be fully-killed and made to fine grain
practice.

6.1.4 Rare earth additions may not be made without the written approval of the
Operator, which will be based on submission of full details covering the type
and amount of rare earths added, how and where they are added and means of
analysis and control.

6. 1.5 Welded pipe shall be made from plate or coiled strip, and seamless pipe shall
be made from billets.

6.1.6 The longitudinal edges of plate or strip to be used in fabrication of welded pipe
shall be 100% ultrasonically tested. No laminations exceeding 15 mm in length
shall be present within 25 mm from the edge of the plate.

6.1.7 The plate or strip surface shall be automatic ultrasonically tested for
laminations along a sinusoidal pattern or alternative approved method along
parallel lines spaced 200 mm (8 inches) maximum.

6. 1. 8 Isolated laminations in the body of the plate shall not exceed 100 mm in any
direction.

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6
 6.1.9 Plates, coils and billets shall be correctly marked and stored to avoid any
confusion between heats of steel.

6.2 Mechanical Properties

6.2.1 All the relevant tests, specified in API Specification 5L Section 6 and the
paragraphs of this section, shall be carried out on a sample cut from one end of
a pipe randomly selected. The number and frequency of tests shall be as
specified in section 9 of API Specification 5L unless otherwise stated. See also
Appendix 1, 2. 1 (c) Production Tests.

The ultimate tensile and yield strengths shall conform to the minimum
requirements listed in Table 3 of API Specification 5L for X52 grade pipe.
Material stress-strain curves shall be recorded. The tests shall be carried out on a
pipe from each lot of 50 or less produced from each heat. The ratio of yield
strength to ultimate tensile strength in the finished pipe shall not exceed 0.85.

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7
7.0 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS AND END FINISHES

7.5 The pipe joints shall be in nominal lengths of 12.2 m with lower and upper bounds
of 11.6 m and 12.8 m respectively.

7.1 Pipe dimensions and tolerances, except as stated in this specification, shall be in
accordance with API Specification 5L. Tolerances of pipe end dimensions shall be
based on pipe outside diameters and wall thicknesses.

7.2 Outside diameter tolerances shall not exceed the tolerances specified in table 7 of API
Specification 5L.

The outside diameter checks on the body of the pipe shall be made at the mill with a
diameter tape on a random basis, but not less than three measurements per pipe joint.

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 7.3 The tolerance on wall thickness shall be in accordance with API Specification 5L,
excepting that under-thickness tolerance shall be maximum 5%. Ultrasonic testing
shall be employed to show that the minimum wall thickness is maintained.

7.4 The pipe shall be weighed as required by Table 6C of API Specification 5L.

7.6 In addition to the straightness requirements of paragraph 7 of API Specification 5L,

the local deviation from a straight line shall not exceed 1.5 mm per metre of length.

The surface condition of finished pipe shall be such that is fully compatible with
requirements for subsequent cleaning and application of protective coatings.

7.7 Mill jointers are not acceptable.

7.8 Workmanship, visual inspection and repair of defects shall conform to API
Specification 5L, sections 7.8 and 9.0 as qualified in this specification.
 7.8.1 All dents, with or with out a sharp bottom gouge, and all sharp gouges (deeper
than 0.8 mm) shall be considered defects. Repair of dents and gouges in dents
is not permitted.

Individual cases of pipe repair by grinding may be approved by the Inspector.

No more than ten repaired areas per pipe length will be permitted. After repair
the wall thicknesses shall still comply with this specification. Cosmetic
grinding, (ie grinding-out that does not reduce the wall thickness by more than
0.8 mm) is not a repair within the meaning of this clause. Repair by welding is
not permitted.

7.9 Pipe Ends

7.9.1 Ends of pipe shall be cut square at 90 degrees to the pipe axis within tolerance
of 1.2 mm across any diameter. The method of checking the squareness shall
be subject to agreement with the Operator and specified in the Vendor's
procedures.

7.9.3 The pipe ends shall be machine-bevelled in accordance with API Specification
5L, paragraph 7.9.3 or as may be otherwise specified on the purchase order.
Any bevelled ends deviating from the dimensions specified shall be
re-machined. No internal taper shall be created in the removal of any burrs.
Filing or hand-grinding is not permitted.

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9
8.0 COUPLINGS

8.1 The use of couplings is not permitted.

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9.0 INSPECTION AND TESTING

Test Temperature: 0 C.

Energy requirements: minimum average: 48J

minimum individual: 37J.

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9.2.1 Heat Analysis

A ladle analysis shall be made for each heat including the CE and Pcm values and
shall comply with the requirements of Table 1 of this specification and paragraph 6. 1.

The Vendor shall furnish full certificates of each ladle analysis. All elements listed
above, and intentionally-added elements agreed to but not stated above, shall be
determined and reported for ladle and check analysis.

9.2.2 Product Analysis

The Vendor shall furnish a report of the check analyses made on the finished pipe
including CE and Pcm values. Two samples shall be tested for each lot of 100 pipes or
heat, if fewer than 100 for any particular heat, and shall comply with the requirements
of Table 1 of this specification.

9.3.5 Charpy V-notch impact testing shall be performed in accordance with API
Specification 5L and ASTM A-370.

Longitudinal specimens may be used. For both types of specimen the notched axis
shall be perpendicular to the pipe surface.

Temperature and energy requirements for full size specimens shall be as follows:

11
 Per cent shear and lateral expansion behind the notch to be reported for
information purposes.

Full size 10 mm x 10 mm cross-section specimens should be used if possible.

For small specimens the maximum possible size must be used, and absorbed
energy acceptance levels are reduced as follows:

Specimen Cross-section Energy Factor

1.0

0.8

0.7.

10 mm X 10 mm

10 mm x 7.5 mm

10 mm x 5.0 mm

9.3.6 A Charpy transition curve should be provided for the materials, derived by
testing of three specimens at 20 C intervals from -60'C to +WC for each 10
heats produced.

9.3.7 The ends of the finished pipe shall be tested for hardness using the Vickers
method with a 10-kg load.

The hardness tests may be carried out on the samples cut from the ends of the
pipes for the other mechanical tests. The hardness as measured shall not exceed
a value of 250 HVIO and shall be based on individual values from indentations
at 1 mm from each surface and at the centre of the cross-section. Values for
base metal, heat-affected zone, fusion line and weld metal shall be recorded.

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12
9.4 Hydrostatic Tests

9.4.1 The test pressure for all pipe shall be held for not less than 10 seconds. The
serial number of the pipe being tested shall be legibly recorded on the pressure
recording chart. Copies of the chart shall be presented to the Operator.

Should a failure of a pipe occur during hydrostatic testing, a written report shall
be submitted to the Operator detailing the cause and extent of the failure.

9.4.3 Each joint of finished pipe shall be hydrostatically tested to a pressure

equivalent to 95% SMYS, based on nominal wall thickness. Supplementary
requirement SR14 may be used for calculation of the test pressure should this
be considered to be necessary.

9.6 Ample fluorescent lighting, both overhead and at pipe ends (for internal inspection),
shall be provided at the Inspector's table. The possibility of rolling each pipe joint for
inspection shall be provided. The Vendor shall have ultrasonic or other suitable
equipment available for use by the Inspector to examine remaining wall thickness after
defects are ground out. No pipe wall may be ground below the specified wall thickness
less the minus tolerance.

9.6.1 If the Inspector has repeatedly rejected more than 10% of the pipes for any
recurring cause, this shall be sufficient reason to refuse any more pipes for
final examination until the cause has been determined and corrected.

9.6.2 In the event that defective pipe is detected during additional investigations by
the Inspector, the Vendor and the Operator shall mutually agree on additional
inspection requirements. In such a case, the cost of additional inspection shall
be borne by the Vendor as his responsibility for the quality of the finished
pipe.

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13
 In all cases where the Inspector has rejected pipes, the burden of proof that
the rejected pipes meet the requirements lies solely with the Vendor.

9.7 Non-destructive Inspection

9.7.3 Radiographic examination of at least 20 cm (8 inches) on each end of welded

pipe shall be made after the hydrostatic test.

9.7.4 Before hydrostatic testing, all seamless pipe shall be ultrasonically inspected
full length for longitudinal defects and laminations in accordance with API
Specification 5L, SR4.

The weld of each welded pipe shall be 100% ultrasonic tested after hydrostatic
testing, and all suspected indications shall be radiographed.

9.7.4.2 Dynamic calibration of the NDT equipment should be conducted to

demonstrate the reliability of the test methods and interpretation.

9.7.4.3 Before bevelling, the full circumference of each pipe end shall be
ultrasonically tested for laminations over a length of 75 mm. No
laminations within this 75-mm band width shall be accepted.

The acceptance reference limit for checking of pipe ends for

laminations shall have the approval of the Operator, but the height of
the signal shall not be greater than 20% of the reference standard,
back-wall echo, full screen height.

9.7.5 All completed pipe bevel ends are to be magnetic particle inspected for
laminations and defects, which shall be cause for rejection or cropping of the
pipe end. Any laminar defects exceeding 3 mm in length shall be rejected.

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9. 10.1 Re-check Analyses

If any of the product analyses fail to conform to the specified requirements,

re-check analyses may be carried out in accordance with API Specification 5L,
except that the testing shall include analyses for all the elements of the original
specification.

9.10.7 Re-tests for acceptance are permitted in accordance with API Specification 5L
Section 9.3 Tensile Tests and Guided Bend Tests, and in accordance with API
Specification 51- SR5, paragraph SR5B.4 for Charpy impact tests.

9. 10. 8 For each lot of pipes to be accepted all the tests must be successful.

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15
10.0 MARKING

10.1 All pipe shall be marked by the Vendor in accordance with API Specification 5L,
section 10, as modified by this specification.

10.2 Markings shall be paint-stencilled on the outside surface of both ends of each pipe or
cold-die stamped on both end-weld bevels. Imperial units shall be used for pipe size
dimensions and metric units for lengths etc. The pipe number and wall thickness shall
also be marked on the inside at one end of each pipe.

10.3.1 Painted markings shall be in white block capitals with a minimum height of 25
mm.

10.5 Markings shall include pipe wall thickness and pipe length. The latter to the nearest
hundredth of a metre. In addition, the purchase order number, heat number and pipe
identification number (joint number) are to be marked on each pipe. All pipe shall be
colour-coded in accordance with API Specification 5L SR3.

10.11 Should pipe be manufactured in more than one mill, the pipe numbers shall be selected
so that each mill's production numbers run consecutively without duplication of
numbers used by other mills.

10. 12 Pipe shall be shipped free from dirt, scale, grease or oil.

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16
11.0 COATING AND PROTECTION

11.1 Pipe shall be supplied bare unless otherwise specified on the purchase order.

17
12,0 DOCUMENTATION

12.1 All test documentation shall show the witness and approval of the Inspector.
12.2 All test documentation shall be retained by the Vendor until the Operator agrees to its
disposal subject to a limit of five years.
12.3 The original plus three copies of the following documents shall be supplied to the
Operator within five days of shipment.
12.3.1 Mill test certificates including the following information:
ladle analysis including carbon equivalent (CE and Pcm)

check analysis including carbon equivalent (CE and Pcm)

full mechanical test results

hydrostatic test pressure

Vendor's statement of full compliance with this specification

final heat treatment condition.

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 12.3.2 A pipe control sheet which shall contain the following information:

purchase order number

pipe joint number

heat number

batch number

pipe size, wall thickness, length and weight.

12.4 NDT reports.

12.5 Hydrostatic test records.

12.6 Details of all pipe repairs excluding cosmetic grinding.

12.7 NDE operator's qualification certificates.

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19
13.0 SHIPPING

13.1 Unless otherwise qualified in the purchase order, shipment of all pipe sizes shall be in
accordance with the current edition of API Specification 5L: Recommended Practice
for Railroad Transportation of Line Pipe or API RP 5L5: Recommended Practice for
Marine Transportation of Line Pipe, whichever is applicable.

13.2 Bevel protectors of a type approved by the Operator shall be supplied and installed
by the Vendor before stock-piling or transportation of the pipe takes place.

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20
14.0 QUALITY ASSURANCE

adequate identification and suitable handling of items.

14.1 General

All certification, test results or any other documentation submitted to the Operator
relative to the inspection system and results of inspections shall be in the English
language.

The Vendor shall establish and maintain a fully documented quality control system to
ensure:

(a) adequate, effective inspection and objective evidence that items conform to
contract requirements; and

(b)

(c) Where applicable, any verification of quality carried out by the Operator
which requires verification of selected characteristic of any item or process

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 by the Operator beyond which the work shall not proceed unless released.

(d) The Vendor shall detail in the manufacturing procedure the lines of
responsibility to ensure continuous supervision and maintenance and
inspection procedure throughout the duration of the work. Full QA/QC
procedures shall be provided to the Operator for review and approval.

14.2 Inspection Plan

Prior to the commencement of the work, the Vendor shall prepare a written inspection
plan which describes the inspection to be carried out on each contract or product. The
inspection plan, reference procedures and changes thereto are subject to the approval
of the Operator.

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 The inspection shall include:

(a) A flow chart illustrating each inspection point and its relative location in the
procedure cycle where conformance of characteristics is verified. The Vendor may
include additional inspection points for its own verification of quality which will not
be subject to Operator acceptance.

Copies of specific forms used by the Vendor to record the results of each
inspection.

(b) The characteristic to be inspected at each inspection point from incoming

inspection to shipping inspection, the procedures and acceptance criteria to
be used. The procedures shall be provided to the Operator's representative
as requested.

(c)

14.3 Special Process Procedures

The Vendor shall establish and maintain control of all special processes which are essential to
production, inspection or safety. Equipment, processing environment and the Vendor's
personnel shall be subject to appropriate qualifications or certification to the satisfaction of the
Operator's representative.

The Operator's representative shall be afforded unrestricted opportunity to perform verification

of inspection. The Vendor shall make available its inspection equipment for reasonable use by
the Operator's representative to verify the conformance of items to contract requirements. The
Vendor's personnel shall be made available for the operation of inspection equipment as
required.

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 APPENDIX I

MANUFACTURING PROCEDURE AND QUALIFICATIONS

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 APPENDIX I

steel-making process and detail of all heat treatments inclusive of ladle analysis on
each heat produced

pipe manufacturing process and the preparation of plates or billets

percentage of cold expansion

details of mechanical testing, non-destructive testing and quality control procedures

hydrostatic testing procedures

welding procedure and details of type, size and grade of filler materials, speed of
welding, joint design, number of weld passes, dimensions and depth of fusion,
dimension of finished weld, method of grinding

MANUFACTURING PROCEDURE AND QUALIFICATIONS

In order to qualify the manufacturing procedure the following shall be submitted for approval of the
Operator:

1.0 Manufacturing Procedure Specification

The Vendor shall submit a document specifying the manufacturing procedure to the Operator
for approval, prior to qualification tests.

The procedure specification shall include, but shall not be limited to, the following
information:

(a)

(b)

(c)

(d)

(e)

(f)

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 (g) method of forming

(h) details of NDT techniques and equipment.

2.0 Manufacturing Procedure Qualification Tests

2.1 The first completely finished pipe on each wall thickness, each diameter and each
grade of steel made at the beginning of normal production or after any change in the
fabrication or welding procedure, shall be visually inspected for compliance with
dimensional tolerances of pipe wall thickness, diameter, out-of-roundness,
straightness, weld contour, surface inspections etc.

Qualification Tests

(a) After visual inspection and acceptance, the said first pipe shall be tested as
follows:

Welded Pipe

(i) The entire weld shall be radiographed and ultrasonically examined.

(ii) Four transverse weld bend test specimens shall be removed from points
selected at random.

(iii) Two transverse weld and two transverse base materials tensile test
specimens shall be removed at random points, The transverse weld
specimens shall be tested for ultimate strength only. The transverse
base-metal specimens shall be tested for yield and ultimate strength and
percentage elongation. In addition, an all-weld tensile specimen shall be
extracted from the weld seam and tested. The properties shall be at least
equal to those of the parent plate.
121471002
(iv) Six weld macro-sections shall be removed from points selected by the
Operator's representative and polished and etched to show the
metallurgical structure. A hardness survey shall be made on each
section.

(v) From the pipe material at 90' to the seam weld, two impact test samples
shall be extracted (one from either end of the pipe) and subject to
impact testing at WC. One sample consists of three impact specimens.
The specimens shall be 10 mm x 10 mm, 10 mm x 7.5 mm or 10 mm x
5 mm depending on wall thickness. From the weld seam fusion line and
HAZ of the weld, samples shall be taken and submitted to impact
testing.

Seamless Pipe

(i) The entire pipe shall be ultrasonically examined for longitudinal

defects, laminations etc after all heat treatment, expansion and
hydrostatic testing operations.

(ii) Four longitudinal tensile specimens shall be removed from the pipe,
two from either end. The yield and tensile strength plus percentage
elongation shall be determined according to API 5LX, 9.3.1.3.

(iii) Two sets of three Charpy specimens shall be removed, one set at each
end of the pipe, and shall be tested at WC.

(iv) Two macro-sections shall be removed from each end of the pipe (10 em
from the end). They shall be polished and etched to show the
metallurgical structure. Six hardness values shall be determined on each
macro. The hardness shall not exceed 250 HV10.

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(b) Butt-welding Test (Weldability)

To prove the weldability of the pipe, the Vendor shall perform a weldability
test using two sections of pipe having the maximum carbon equivalent. This
test shall be performed on each pipe size and grade.

The Vendor shall use the vertical downhill manual welding process using
cellulosic electrodes. Radiographic acceptance and mechanical testing shall
conform to API1104.

The Vendor shall submit to the Operator the procedure qualifications reports
giving the results of all tests, micrographs, radiographic films etc.

(C) Production Tests

Tests on plate or billet shall be performed by either the Vendor or the plate
supplier.

The Vendor shall submit a certificate to the Operator certifying that the test
results conform to the specification.

The Vendor shall perform all tests described below and submit to the
Operator a report on each pipe test. The Operator reserves the right to select
the pipes to be tested and to witness the tests himself. A finished pipe shall
be selected from each lot of 100 pipes of size 16" OD or less and a finished
pipe from each lot of 50 pipes of size over 16" OD.

Tensile Tests

Two transverse (longitudinal on seamless pipe) tensile test specimens shall

be removed from the selected pipe. The test shall include yield strength,
tensile strength and elongation determinations.

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One specimen is to be tested, the second to be tested only if the first fails to
meet the requirements.

Tensile and Guided Bend Tests - Weld

One transverse weld tensile test specimen and two transverse weld bend test
specimens shall be removed from the selected pipe. The test on the transverse
weld tensile test specimens shall be for tensile strength determination only.
The tests on the transverse weld bend specimens shall be done by bending
one specimen on the face of the weld and the other on the reverse side. (Two
side bends shall be used when wall thickness exceeds 20 mm.)

Impact Tests

On the selected pipe, six impact test full-size specimens, where possible, (two
sets of three) shall be removed from the base material and three sets from the
longitudinal weld on welded pipe.

All specimens shall be 'V'-notch Charpies taken so that the axis of the notch is
perpendicular to the surface of the pipe. The base-metal specimens shall be
taken at 90' to the seam weld and at either end of the pipe.

Specimens extracted from the weld seam shall be tested in the (a) weld
material, (b) fusion line and (c) HAZ Charpies shall be determined by the
lowest impact values recorded in procedure testing.

Impact tests shall be carried out at WC and in accordance with the

requirements and procedures of ASTM A 370-71 and ASTM E 23-71.

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3.0 Manufacturing Procedure Acceptance

3.1 (a) It is intended that sulphur content should be significantly below the
permitted maximum value.
(b) In order for the manufacturing procedure to be considered qualified, all pipe
selected for testing shall meet all the requirements of this specification.

3.2 Failure in any test during qualification shall require an amendment to the procedure
to correct the cause, and full-repeat qualification testing shall be performed.

4.0 Reporting

The Vendor shall submit a report to the Operator giving the results of all of the
production procedure qualification test.

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